HALF-MARBLE

The present invention relates to a device and method for manufacturing decorative elements from glass and/or ceramic marbles. The invention also relates to decorative elements manufactured with the method, and to a method for decorating products using the decorative element .

In the distant past marbles were made from wood, clay, marble or stone. From 1870 marbles were mass produced from clay. In 1870 a marble factory was set up in Lauscha, Germany. Most marbles are made nowadays from glass in Mexico using a marble manufacturing machine. The glass is first melted in a furnace. The liquid glass is then pressed through a small hole so that a long strand of liquid glass is created. The long strand is cut into small pieces which are finally rolled through a mill, whereby the marbles acquire their round shape. During or after the marble production process paint can be arranged in or on a marble so that the marble is decorated.

Marbles are usually sold as toy for children. The use of marbles for decorative purposes is very limited even though marbles do in fact have the most diverse, attractive manifestations. The present invention has for its object to provide a decorative means which can be used universally and which has the appearance of a marble.

This object is achieved with a method for manufacturing decorative elements from glass and/or ceramic marbles, wherein the method comprises steps for: - providing at least one marble;

- fixing the marble in a fixing member for the purpose of fixation of each marble during a sawing process;

- positioning the marble relative to a sawing member by means of the fixing member;

- sawing through the marble using the sawing member .

Sawing through a marble creates two spheres which are flat on one side, referred to below as half-marbles. Because a half-marble has a flat surface on one side, it can be readily arranged for decorative purposes on all kinds of products. Because of the surprisingly attractive manifestation of the half-marble, the product is called Marble Miracle. It is noted that the marbles do not have to be sawn precisely through the middle, it being possible to envisage other divisions of the marble. What is important is that the appearance of a marble is retained.

In one embodiment a plurality of marbles are arranged in a manner such that during the sawing process material of at least one marble is always in contact with the sawing member.

In one embodiment the marble has a diameter of between 0.5 cm and 10 cm, preferably 0.5 cm - 2.5 cm, more preferably 0.8 cm - 2 cm. Typical sizes of the marbles are 12, 14, 16, 17, 22, 25, 30, 35, 42 and 50 mm.

In a further embodiment the marble comprises a decoration which is preferably arranged internally.

In a further embodiment the sawing member comprises a diamond saw. In a further embodiment the fixing member comprises a pair of clamping elements, each provided with openings adapted to receive less than half the marble,

wherein the step for fixing the marble in a fixing member comprises the step of:

- clamping the marble in the openings, wherein during clamping of the marble a determined distance is maintained between the clamping elements at the position of the marble.

In a further embodiment the spaces are arranged in a conveyor adapted to transport and clamp the marble.

In a further embodiment the determined distance depends on the diameter of the marble and/or a thickness of a saw blade of the sawing member. A typical thickness of the saw blade varies between 1.5 and 2 mm.

In a further embodiment the fixing member comprises a deformable material. Through the use of deformable material the marbles can be well fixed with a determined force, and vibrations are discharged through the material during the sawing process.

The deformable material preferably comprises polyurethane and/or rubber. A clamping element can be made in relatively simple manner with these materials.

In a further embodiment the deformable material comprises polyurethane with a shore hardness between 70 and 90, and preferably with a shore hardness of 80. Said values have given good results in which little damage was caused to the marbles, such as splintering.

In a further embodiment the method further comprises of drilling through the decorative element using a drill. Use can preferably be made here of the fixing member to support or fix the half-marble. Drilling through the half-marble one or more times makes it suitable to serve as jewellery or for instance as button. In a specific embodiment the half-marble is drilled through and

then provided with a handle so that a game piece is created which can be used in a game.

The invention also relates to a decorative element manufactured with the above stated method. The invention also relates to a method for decorating products using the above stated decorative element, wherein the method comprises of:

- arranging the decorative element on or in the product; - attaching the decorative element onto or into the product by means of adhesive and/or by heating the decorative element.

The invention also relates to a device for manufacturing decorative elements from glass and/or ceramic marbles, comprising:

- a fixing member for fixing at least one marble in fixation positions;

- a sawing member for sawing through the marble. In one embodiment a number of fixing members are comprised in a conveyor. Continuous and automatic operation is possible by driving the conveyor and fixing the marbles in the openings, and this increases productivity.

In one embodiment the fixing member comprises a number of openings which can be arranged opposite each other in pairs for the purpose of clamping in each pair one of the marbles to be sawn through. The marbles are here almost wholly enclosed, this providing for optimum clamping. In a further embodiment the fixing member comprises two annular clamping elements arranged coaxially or adjacently. An endless conveyor belt is hereby created

enabling automatic operation with a relatively simple device.

In a further embodiment the fixation positions are ordered such that during sawing the sawing member is in continuous material engagement with material of at least one marble. Because the saw is always in contact with the material of at least one marble, the saw, and also the fixing member, will undergo a gradual transition of force when cutting one marble after another. This prevents a jolting movement, thereby preventing splintering of the marbles. Furthermore, a complex placing control is not necessary.

Further advantages, features and details of the present invention will be further elucidated on the basis of a description of several embodiments with reference to the accompanying figures, in which:

- Figure 1 shows an embodiment of a clamping element with a number of holes;

- Figure 2 shows part of a first embodiment of a device for manufacturing decorative elements;

- Figure 3 shows a part of a device for manufacturing decorative elements according to a second embodiment of the invention;

- Figure 4 shows an example of a half-marble as manufactured with the method according to the invention;

- Figure 5 shows an example of a vase decorated with half-marbles;

- Figure 6 shows a half-marble in which a hole has been arranged; - Figure 7 shows an example of a game piece 70 manufactured from a half-marble according to one embodiment .

In the method according to a preferred embodiment according to the invention glass marbles are first fixed in a fixing member. Figure 1 shows an embodiment of a clamping element 10 comprising a number of openings 11. Openings 11 (referred to below as holes) are of a size such that slightly less than half of a marble 12 is received in holes 11. In one embodiment the clamping element 10 consists of a beam 10 comprising deformable material such as polyurethane. Holes 11 are arranged on one side in deformable block 10. Holes 11 can be of cylindrical shape, although other shapes are also possible. What is important is that the opening in the holes is of a size such that only a part of a marble 12 is received in the holes. When sufficient marbles 12 have been received in clamping element 10, a second clamping element (not shown in figure 1) is arranged against first clamping element 10 so that the other side of marbles 12 is also enclosed. A distance is however preferably left between the two clamping elements. This distance is defined such that space is available for the saw blade.

Once marbles 12 have been fixed between the two clamping elements 10, the whole fixing member is positioned relative to a circular saw 21. Figure 2 shows part of an embodiment of a device 20 for manufacturing half-marbles. Circular saw 21 is driven by for instance an electric motor so that it begins to rotate. The circular saw preferably comprises a diamond saw. A diamond saw is found to be highly suitable for sawing through glass marbles when these latter are properly fixed. Cooling takes place during the sawing using cooling water, so that the saw and the marble do not become too hot.

Clamping elements 10 are now moved along circular saw 21, each on one side of circular saw 21, over a workbench 22 in a direction as indicated in figure 2. During this movement a pressure is exerted on both fixing members so that marbles 12 are pressed fixedly between the two fixing members 10. Marbles 12 remain in place as a result of this force being exerted. If an elastic fixing member is used, friction in the holes will prevent the marbles beginning to rotate when circular saw 21 makes contact with the marbles. Vibrations which occur during sawing are moreover absorbed by the elastic fixing member. Good results have been achieved with a fixing member made of polyurethane with a shore hardness between 50 and 110, preferably 60 and 100, more preferably 70 and 90. The flexible fixing member more preferably has a shore hardness of about 80.

It is noted that the invention is not limited by the use of an elastic fixing member. What is important is that the marbles are properly fixed before they come into contact with the blade of the saw.

The example of figure 2 shows that the holes 11 are ordered in a specific manner. The upper row of holes is offset to some extent relative to the lower row of holes so that the outer edge of circular saw 21 always remains in contact with at least one marble. This prevents the two clamping elements 10 moving forward in uncontrolled manner after sawing through a marble 12 as a result of a continuously exerted pressure in the direction of forward movement. The movement can here even extend to a position in which the following marble is contacted by the periphery of circular saw 21, whereby damage by means of splintering can occur.

Figure 3 shows a part of a device 30 for manufacturing half-marbles according to a second embodiment of the invention. Device 30 comprises two clamping elements 31, 32, each consisting of an annular elastic belt with a row of holes (not visible in figure 3) . Clamping elements 31, 32 are arranged around shafts 33, 34 respectively which are driven and transmit the rotating movement to clamping elements 31, 32 respectively. In figure 3 arrows indicate the direction in which clamping elements 31, 32 rotate. Marbles 35 are fed using a feed device 36 such that a marble 35' drops at regular intervals into a hole of lower clamping element 31. Marble 35' is carried to a circular saw 25 and, having arrived at the position of marble 35", will make contact with circular saw 25.

Just before marble 35" comes into contact with circular saw 25, marble 35" is fixed by clamping elements 31 and 32 such that a sufficiently great force can be exerted on marble 35" by circular saw 25 in order to saw through marble 35". It is possible here to envisage clamping elements 31, 32 being temporarily halted, after which circular saw 25 is moved relative to the fixed marble 35" such that a channel is sawn into marble 35". Alternatively, saw 25 can remain in a fixed stationary position, wherein clamping elements 31, 32 continue to rotate in optionally regular manner.

Because clamping elements 31 and 32 rotate, two half-marbles 37, 38 will be created after the sawing action which, as shown in figure 3, drop out of the respective fixing members 31, 32 or are removed from the fixing members. This removal is possible for instance by applying an overpressure in the holes from the interior of

fixing members 31, 32. Half-marbles 37, 38 are caught in a tray 39, 40 respectively. The half-marbles are collected in trays 39, 40, after which they can be further processed. Further processing can for instance consist of polishing the flat sides of the half-marbles.

In one embodiment of the method according to the invention the half-marble is provided with a through-bore following manufacture thereof. This through-bore can be made by means of a drill which is preferably placed on the flat side of the half-marbles. The fixing member is preferably used here as support/fixation for the half- marble.

Figure 4 shows an example of a half-marble 37 as manufactured with the above stated method. Half-marbles 37 can now be attached in simple manner to for instance a vase, a bathroom tile, a window, a shower door etc. Figure 5 shows an example of a vase 50 which is decorated with half-marbles 51. Attaching the half-marbles 51 to vase 50 can be performed with types of adhesive suitable for this purpose and known to the skilled person. Vase 50 can be already fired and polished beforehand, after which the half-marbles are arranged. Because the marbles have a flat contact surface, the half- marbles can also be readily arranged on for instance windows and tiles. The field of application of half- marbles as decorative means is in principle unlimited. Instead of using adhesive, the half-marble can also be attached to a product by heating the half-marble, whereby it wholly or partially melts. The half-marble can hereby be used as decoration of for instance glass windows. In one embodiment of the method marbles with a diameter of 1- 10 cm are used. Most commercially available marbles have a size in this range.

Figure 6 shows a half-marble 60 in which a hole 61 is arranged. The hole can be drilled completely through, but also partially through. In one embodiment a handle is arranged in hole 61 so that a game piece is created. An example of a game piece 70 is shown in figure 7. Game piece 70 comprises a half-marble 71, a handle 72 and a pin 73. Pin 73 runs wholly or partially through the hole arranged in half-marble 71. In the example of figure 7 game piece 70 also comprises a flat round magnet 74 on the underside of game piece 70. If game piece 70 is used together with a board of a board game (not shown) on which for instance metal rings are arranged, magnet 74 will ensure that game piece 70 remains attached to the board. Game piece 70 will hereby not be moved from its position if, accidentally or otherwise, the board is displaced.

In one embodiment marbles are used which already comprise a decorative element in their interior before they are sawn through. Owing to the method of the invention the decorative element inside the marble is not damaged. Nor when the decorative element is applied to the outer surface of a marble will damage be caused to the decorative element due to manufacture of half-marbles with the above stated method. No additional method step is hereby necessary to decorate the marbles themselves after the marbles have been sawn through. The marbles can be used directly as decoration on other objects, such as on the above-mentioned vases.

An important point of departure for the present invention is that marbles with their internal decoration can only be manufactured in a fully spherical form. In order to obtain a useful decorative element with the appearance of such a marble, a marble already manufactured

in spherical form is taken as starting point in the invention.

It will be apparent to the skilled person that it is not important for the invention that the marble be divided into two exactly equal parts. What is important is that the marble parts, optionally already with decoration, can be manufactured for the purpose of serving as decorative elements which can be easily arranged on objects . The present invention is described in the preceeding on the basis of several preferred embodiments. Different aspects of different embodiments are deemed described in combination with each other, wherein all combinations which can be made by a skilled person on the basis of this document must be included. These preferred embodiments are not limitative for the scope of protection of this document. The rights sought are defined in the appended claims .