WO2011006089A2

WO2011006089A2 - Coated glass bottles, encapsulated compact fluorescent bulbs and articles and methods of manufacture

Info

Publication number: WO2011006089A2
Application number: PCT/US2010/041563
Authority: WO
Inventors: Gregory Caldwell
Original assignee: Greg Caldwell Company, Llc
Priority date: 2009-07-10
Filing date: 2010-07-09
Publication date: 2011-01-13
Also published as: WO2011006089A3

Abstract

The invention relates to articles coated with a shatterproof elastomeric overmold, such as including glass baby and drinking articles, as well as compact fluorescent lamps. The coated glass articles provide shock resistance to prevent breakage in many typical drops, or total glass containment with the elastomeric sleeve if the glass does break. The coating also provides thermal insulation to maintain the temperature of liquids disposed therein and keep the temperature of liquids in the container from migrating to the hand of the person handling the article. Additionally, the coated compact fluorescent lamp provides safety and containment while eliminating worries of broken glass and mercury exposure. Methods of manufacturing elastomer coated articles by dipping an article in a solvent dispersion of uncured elastomer to provide one or more layers is also provided, or a method for injection overmolding of a coating on the article.

Description

COATED GLASS BOTTLES, ENCAPSULATED COMPACT FLUORESCENT BULBS AND ARTICLES AND METHODS OF MANUFACTURE

[0001] This international patent application claims priority to and the benefit of U.S.

Provisional Application Serial Number 61/224,516 filed on July 10, 2009 and 61/332,510 filed on May 7, 2010, which are incorporated herein by reference.

TECHNICAL FIELD

[0002] The invention generally contemplates providing coated glass articles to facilitate preventing breakage or containing the glass upon breakage for various articles. For example, the invention generally contemplates providing new and improved glass articles such as baby bottles, drinking glasses or compact fluorescent bulbs, having an elastomer coating, such as silicone, and processes of manufacturing coated glass articles made from solvent dispersions which form a substantially uniform coating on the glass articles. The coating forms a containment system for the bottles, glasses or compact fluorescent lamps (CFLs). In the case of CFLs, this containment system will provide containment of mercury, phosphorous and glass that is exposed if breakage occurs.

BACKGROUND

[0003] The varying uses for having an elastomer coating on articles such as baby bottles, drinking glasses and CFLs arose from differing backgrounds.

[0004] For example, in recent years, baby bottles and other such articles have been produced of plastic materials, particularly polycarbonate plastics which include the chemical bisphenol A (BPA). Bisphenol A is an organic compound with two phenol functional groups. It is a difunctional building block of several plastics and plastic additives, and a monomer used in the production of polycarbonate. Polycarbonate plastic is a clear and nearly shatter-proof material, which was found attractive for use in making a variety of common products including baby and water bottles as well as other articles. Recently, the chemical BPA is suspected of being hazardous to humans, and concerns about the use of BPA in consumer products has been targeted as being unsafe. Particularly susceptible are infants fed with liquid formula from a BPA containing bottle, which have been found to have significant exposure. For example, babies fed formula from polycarbonate bottles can consume up to 13 micrograms of BPA per kg of body weight per day. Infants may be particularly susceptible to BPA's endocrine-disrupting potential. New research from the US suggests that people who drink from bottles made of polycarbonate plastic, such as that used to make hard-plastic drinking bottles and baby bottles, have a considerably higher level of the chemical BPA in their bodies compared to when they do not.

[0005] The finding confirms concerns expressed by consumer groups and public health experts, that polycarbonate plastic bottles are an important source of the BPA that finds its way into the human body. BPA has been shown to interfere with reproductive development in animals, and has been linked to cardiovascular disease and diabetes in humans, among other things. Studies have shown that BPA can leach from the container into the liquid, and thereby result in a corresponding increase of intake into the body. If such bottles are heated, as is the case with baby bottles, the levels of leaching can be considerably higher. Hard plastic polycarbonate bottles are often used as refillable containers by others, such as people when working out, athletes, students, and others. It has also been found that drinking cold liquids from

polycarbonate bottles increases the BPA levels ingested.

[0006] At the same time, glass articles which avoid the BPA issues are subject to breakage if dropped, which is particularly problematic with baby bottles or other articles such as beer glasses. There is also the potential for thermal shock to cause breakage of the glass container, such as when the glass article is placed into boiling water from being in the refrigerator or freezer for example, or having a cold beverage poured into it when hot. Between harmful plastics and glass breakage, there is a need for baby or other bottles, beer glasses and glass articles that alleviate these issues.

[0007] Another use of the invention, for coating CFLs, arose from a different background. Developed in the 1970' s the compact fluorescent lamp (CFL) has gained popularity over the years and especially in recent years with energy conservation becoming a global necessity. Units manufactured worldwide are currently close to 4 billion annually and production continues to increase exponentially combined with a global initiative to phase out the traditional incandescent bulb. The CFL bulb utilizes mercury in its components to create energy savings, but when the bulbs break mercury exposure and contamination create health and safety hazards.

[0008] CFL sales have been increasing due to government action. For example, in 2007,

Australia became the first country to ban the sale of incandescent bulbs, and sales there will be phased out entirely by 2009. The European Union, Ireland, and Canada have since announced plans to ban incandescent bulbs. The United States has also passed legislation increasing the efficiency standard required for light bulbs, which will effectively phase out incandescent bulbs. In total, more than 40 countries have announced plans to follow suit. CFL bulbs are lighting more homes than ever before, and the United States Environmental Protection Agency (EPA) is encouraging Americans to use and recycle CFL bulbs safely. Carefully recycling CFL bulbs prevents the release of mercury into the environment and allows for the reuse of glass, metals and other materials that make up fluorescent lamps. The EPA is continually reviewing its cleanup and disposal recommendations for CFLs to ensure that the Agency presents the most up-to- date information for consumers and businesses. Maine's Department of Environmental Protection released a CFL breakage study report on February 25, 2008. The EPA has conducted an initial review of this study and, as a result of this review, it has updated its CFL cleanup instructions.

[0009] Pending the completion of a full review of the Maine study, the EPA will determine whether additional changes to the cleanup recommendations are warranted. The agency plans to conduct its own study on CFLs after thorough review of the Maine study.

[0010] In the Maine study, experimental trials where compact fluorescent lamps (CFLs) were broken in a small/ moderate sized room were conducted. Broken lamps were either not cleaned up, cleaned up using Maine Department of Environmental Protection (DEP) pre-study cleanup guidance, vacuumed, or cleaned up using variations of the pre-study cleanup guidance. The mercury concentrations at the five foot height (adult breathing zone) and one foot height (infant/toddler breathing zone) above the study room floor were continuously monitored. A notable finding of the study was how variable the results can be depending on the type of lamp, level of ventilation and cleanup method.

[0011] The pre-study cleanup guidance was generally found to be sound, including the advice to not vacuum as part of the cleanup. However as a result of this study, the cleanup guidance was modified.

[0012] Mercury concentration in the study room air often exceeds the Maine Ambient

Air Guideline (MAAG) of 300 nanograms per cubic meter (ng/m³) for some period of time, with short excursions over 25,000 ng/m³, sometimes over 50,000 ng/m³, and possibly over 100,000 ng/m³ from the breakage of a single compact fluorescent lamp. A short period of venting can, in most cases, significantly reduce the mercury air concentrations after breakage. Concentrations can sometimes rebound when rooms are no longer vented, particularly with certain types of lamps and during/after vacuuming. Mercury readings at the one foot height tend to be greater than at the five foot height in non vacuumed situations.

[0013] Although following the pre-study cleanup guidance produces visibly clean flooring surfaces for both wood and carpets (shag and short nap), all types of flooring surfaces tested can retain mercury sources even when visibly clean. Flooring surfaces, once visibly clean, can emit mercury immediately at the source that can be greater than 50,000 ng/m³. Flooring surfaces that still contain mercury sources emit more mercury when agitated than when not agitated. This mercury source in the carpeting has particular significance for children rolling around on a floor, babies crawling, or non mobile infants placed on the floor.

[0014] Cleaning up a broken CFL by vacuuming up the smaller debris particles in an un- vented room can elevate mercury concentrations over the MAAG in the room and it can linger at these levels for hours. Vacuuming tends to mix the air within the room such that the one foot and five foot heights are similar immediately after vacuuming. A vacuum can become contaminated by mercury such that it cannot be easily decontaminated. Vacuuming a carpet where a lamp has broken and been visibly cleaned up, even weeks after the cleanup, can elevate the mercury readings over the MAAG in an un-vented room. [0015] In the coming years with energy conservation being a global initiative, the sales of

CFL bulbs and possible exposure to mercury becomes an ever-growing safety concern. With mercury exposure and possible poisoning there is a need for mercury and glass containment to alleviate these issues in association with CFLs. The containment will also allow for more effective recycling.

SUMMARY

[0016] The invention is directed to glass articles such as baby bottles, drinking bottles and glasses, or other glass articles and vessels such as, but not limited to beer glasses, wine bottles, beakers, pharmaceutical containers, fragrance containers or the like, or other articles that can be coated with an elastomer coating, such as a BPA free, shatterproof elastomer sleeve, such as formed of silicone. The coated glass baby bottles for example, provide peace of mind that parents seek when feeding their babies, and prevent the bottle from shattering or "exploding" if or when dropped. The coated glass articles according to the invention provide shock resistance to prevent breakage in many typical drops, or total glass containment with the elastomer sleeve if the glass article does break. The shatterproof silicone coated glass baby bottle and containment system is ideal for active parents who will accept nothing but the safest products for their young kids while eliminating all worries of BPA and glass breakage. The coating also provides thermal insulation to maintain the temperature of liquids disposed therein and keep the heat (or cold) of liquids in the glass article from migrating to the hand of the baby or other person handling the glass article, and prevents thermal shock from causing breakage. The coating may use FDA compliant silicone materials to form the sleeve that will contain the glass and any liquids, or other elastomeric or polymeric materials. The silicone sleeve is adhered directly to the glass baby bottle or glass article, providing better gripping characteristics, without slippage.

[0017] The use of curable elastomeric silicone compositions for coating glass articles such as baby bottles, drinking bottles and glasses, or other glass substrates according to the invention provides for increased tensile strength in the coated article. In examples, the coating may be clear or employ a large spectrum of colors, embossed or other designs or the like, while allowing viewing of the contents. The coating is chemically stable at higher temperatures and the glass articles can be machine washed, microwaved, boiled or the like. The coating has a long shelf life without degradation, and bonds to the glass substrate. The coating may be applied and cured at relatively cool temperatures, and the coating is formed so as to be substantially free of encapsulated bubbles.

[0018] There are also provided methods of producing the coated glass articles, including a dipping process. Such a method provides for use of apparatus for coating one or more glass articles with a protective material by dipping the glass articles into the protective material which is in a dip tank. A fixture for holding a plurality of glass articles is provided and used in association with a computer-controlled two or three axis automatic dipping unit. The dipping system may allow dipping recipes to be developed for different glass articles, and precise dipping steps employed and operated by computer. The system may have one or more extended mounting arms for receiving multiple holding fixtures for mounting the glass articles for dipping. A separate dip tank may be used which includes automatic temperature, viscosity, level and mixing controls to provide a dipping solution having the desired characteristics which is uniform over multiple dipping cycles. A dip tank shuttle may be used to allow multiple dipping cycles to be performed quickly using multiple mounting arms. The dipping system may be contained in an enclosure to allow control of and evacuation and treatment of evaporated solvents. A programmable laminar flow drying system may be provided in association with the dipping system to facilitate higher production capabilities.

[0019] In another example, the coated glass articles are produced using an injection molding process. For example the glass baby bottle may be formed by injection molding wherein the glass bottle is held in a fixture in association with a mold, to prevent breakage of the bottle when clamped in the mold, and the liquid silicone is injected around the bottle and cured to form the coated bottle configuration.

[0020] Other configurations, such as incorporating a temperature sensing device in conjunction with the glass article, providing decoration such as by embossing, or other configurations are contemplated. [0021] This invention described herein is also directed to encapsulated compact fluorescent lamp (CFL) bulbs or other like articles. The encapsulated CFL bulb will provide peace of mind and safety by preventing exposure to harmful mercury, phosphorus and glass released when CFL bulbs break. The encapsulation prevents shattering or exploding if or when dropped. The encapsulation on the bulb also provides shock resistance to prevent breakage in many typical drops or total containment with the silicone encapsulation if the bulb does break. The shatterproof silicone encapsulated CFL bulb and containment system is ideal for consumers and business including but not limited to hotels, schools, offices and public and private institutions, who have limited knowledge of the recommended cleanup procedure if a CFL bulb breaks.

[0022] The use of curable elastomeric silicone compositions for encapsulating CFL bulbs or articles of the like according to the invention provides for increased tensile strength in the encapsulated article. In examples, the encapsulation maybe clear with minimal color, lumen or Kelvin scale value changes or may employ a large spectrum of colors to change the color, lumens or Kelvin scale value of the bulb. The coating is stable at higher temperatures and will not yellow, crack or peel. The silicone has a long shelf life without degradation, and bonds to the CFL bulb envelope. The silicone may be applied and cured at relatively cool temperatures, and the coating is formed so as to be free of encapsulated bubbles during manufacturing.

[0023] There are also provided methods of producing the encapsulated CFL bulbs by a dipping process. The method provides for use of an apparatus for encapsulating one or more CFL bulbs with a protective material by dipping the CFL bulb into the protective material in a dip tank. A fixture for holding a plurality of CFL bulbs is provided and used in association with a computer controlled two or three axis automatic dipping unit. The dipping system may allow different dipping recipes to be developed for different glass articles, and for precise encapsulating steps to be employed and operated by the computer. The system may have one or more extended mounting arms for receiving multiple holding fixtures for mounting the CFL bulbs for dipping. A separate dip tank may be used which includes automatic temperature, viscosity, level and mixing controls to provide a dipping solution having the desired characteristics which is uniform over multiple dipping cycles. A dip tank shuttle may be used to allow multiple dipping cycles to be performed quickly using multiple mounting arms. The dipping system may be contained in an enclosure to allow control of and evacuation and treatment of evaporated solvents. A programmable laminar flow drying system may be provided in association with the dipping system to facilitate higher production capabilities.

[0024] The coated compact fluorescent lamp provides the benefits of shatter resistance and full containment of the glass, mercury and phosphorus if the bulb does break. The coated glass bulb provides piece of mind that a consumer seeks when being conscious of safety and mercury exposure and prevents the bulb from "exploding" and releasing mercury and phosphorus if or when dropped or broken. The shatterproof silicone coated compact fluorescent bulb and containment system is ideal for consumers who will accept nothing but the safest products for their home and businesses.

[0025] These and other aspects of the present invention will be apparent to one skilled in the art from the following description.

BRIEF DESCRIPTION OF THE DRAWINGS

[0026] FIG. 1 is a cross sectional view of a baby bottle with a coating provided thereon according to an example of the invention;

[0027] FIG. 2 is a cross sectional view of a glass bottle with a coating provided thereon according to an example of the invention;

[0028] FIG. 3 is a cross sectional view of a drinking glass with a coating provided thereon according to an example of the invention;

[0029] FIG. 4 is a flow chart of a method according to an example of the invention;

[0030] FIG. 5 is a side elevation showing the a dipping system for a plurality of glass articles;

[0031] FIG. 6 is a cross sectional view of an injection molding arrangement for producing the coated glass article according to an example; and [0032] FIG. 7 is an alternate example of a coated glass article with a temperature sensor associated therewith according to an example.

[0033] FIG. 8 is a side elevation of the spiral compact fluorescent bulb showing encapsulation according to an example of the invention.

[0034] FIG. 8A is a cross sectional view of the spiral compact fluorescent bulb of Fig. 8 with a coating provided and key strength points revealed to show an example of the invention.

[0035] FIG. 9 is a flow chart of a method according to an example of the invention.

[0036] FIG. 10 is a side elevation showing a dipping system for a plurality of CFL bulbs.

[0037] FIG. 11 is a side elevation of the encapsulated tube compact fluorescent bulb.

[0038] FIG. 1 IA is a is a cross sectional view of the tube compact fluorescent bulb with a coating provided and key strength points revealed to show an example of the invention.

DETAILED DESCRIPTION OF THE DRAWINGS

[0039] With reference now to the drawings, and in particular to Fig. 1, a baby bottle 10 coated with a BPA free, shatterproof silicone sleeve 12 is shown. The bottle 10 generally has a concave bottom surface 18. The coating 12 extends to a lip 14 below the level of threads used to secure a cap 16 thereon. The coated glass bottle 10 provides peace of mind that a parent seeks when feeding their babies, and prevents the bottle 10 from shattering or "exploding" if or when dropped. The coating 12 on the bottle 10 provides shock resistance to prevent breakage of the glass bottle 10 in many typical drops, such as from a high chair, stroller, table or the like. If the bottle 10 does break, the sleeve 12 provides total glass containment within the silicone sleeve, and also fully contains any liquid, to prevent the mess that would occur otherwise if the bottle does break. The shatterproof silicone coated glass baby bottle and containment system is ideal for active parents who will accept nothing but the safest products for their young kids while eliminating all worries of BPA and glass breakage. The coating 12 according to an example uses FDA compliant silicone materials to form the sleeve 12, that are safe and durable. The silicone sleeve 12 is adhered directly to the glass baby bottle, to prevent slippage, and provide better gripping characteristics for the parent or child, without slippage. The coating 12 is transparent or translucent to allow the contents contained therein to be seen. Additionally, branding or decoration may be applied to the bottle 10 prior to coating, which may then be seen behind the coating 12. The coating 12 may also have color, sparkles or other decorative features incorporated therein to provide aesthetic appeal. As the coating 12 is directly adhered to the bottle 10, it may be machine washed, such as in a dishwasher, without degradation, or water ingress behind the coating, and at high temperature for disinfecting. The coated bottle is also microwavable without degradation of the coating 12. The coating 12 also provides thermal insulation to maintain the temperature of liquids disposed therein and keep the heat (or cold) of liquids in the bottle from migrating to the hand of the baby or other person handling the bottle 10. Other glass bottles, such as drinking bottles may be coated similarly, or other glass articles such as beakers or the like. The coating 12 may be easily applied to different size or shape glass articles. The coated glass articles provide the benefits of having a BPA free drinking bottle or glass articles for other purposes, while providing shatter and shock resistance and/or full containment of the glass (and liquid using a top) if the bottle or article does break.

[0040] In this example, the protective material of coating or sleeve 12 is formed of a

FDA food contact approved silicone material, such as Elastosil® products from Wacker Chemical Co. or Silastic® products from Dow Corning, but other suitable silicone materials may be used, or other suitable materials such as natural rubber. This material is crystal clear, nontoxic, and allows application via dipping and/or injection molding for example. The coating 12 is formed to have a thickness of between 0.3 mm to 1.5 mm, or for many baby bottle configurations, between about 0.5 to 1.2 mm, but other thicknesses may be suitable depending on the application. Thicknesses of up to ¹A inch are possible for example, and different thicknesses are easily achieved in manufacture. The thickness of the coating 12 is designed to resist tearing, such as if the glass does break, and thus to retain any glass and liquid therein. The coating 12 may have a durometer of 20A to 80A for example, with durometer adjustable for the application.

[0041] Figure 2 shows another example of the invention, wherein a glass bottle 160, such as a baby bottle, is coated with BPA free, shatterproof silicone sleeve coating 162. The bottle 160 is generally made from glass 161 and has a generally rounded bottom surface 164 with a protective bumper 166. The protective bumper may be formed as a separate member as shown, or may be formed from the coating 162 itself. The bottom surface 164 may be more rounded, such as somewhat spherical, which may also facilitate providing additional impact strength and shock resistance.

[0042] The coating 162 extends to a lip 168 immediately below the threads 169 used to secure a cap (not shown) thereon. The bumper 166 may be a separate member, as shown, and in this event, the coating 162 also encompasses the protective bumper 166. The protective coating 162 helps prevent the coated glass bottle 160 from shattering or "exploding" if or when dropped. The coating 162 on the bottle 160 provides shock resistance to prevent breakage of the glass bottle 160 in many typical drops. Further, the form of the bottle 160 with a rounded bottom may be simpler to produce, and the use of a bumper 166 (formed as a separate member or of coating 162), allows a flat bottom to be formed on the bottle 160 to facilitate having it stand upright on a surface. The bumper 166 also provides shock resistance upon dropping, as many drops will involve the bottom area of the bottle 160. If the glass 161 of the bottle 160 does break, the protective coating 162 provides total glass containment within the silicone sleeve 162, and also fully contains any liquid, to prevent the mess that would occur otherwise if the bottle 160 does break. The optional protective bumper 166 is operatively attached to the bottom surface 164 of the glass 161 forming the glass bottle 160 and is within the protective coating 162. The protective bumper 166 adds additional protection to the glass bottle 160 in the event of a typical drop. The small additional weight of the protective bumper 166 will have additional feature of tending to orient the glass bottle 160 in free-fall with the bottom surface 164 of the glass bottle 160 pointing toward the ground. The protective bumper 160 is formed of shock absorbent material such as silicone, rubber, polymer compound or other like material allowing the impact of the bottle 162 hitting the ground to be absorbed by the protective bumper 166. It has been found that the provision of the coating 162 provides greatly increased performance in preventing glass breakage in drop tests, and the further provision of a bumper 166 also provides much increased performance if the article is dropped in a manner that the bumper 166 receives at least some of the impact.

[0043] The coating 162 according to an example uses FDA compliant silicone materials to form the coating 162, that are safe and durable. The silicone coating 162 is adhered directly to the glass bottle 160. Having the silicone coating 162 adhere directly to the glass bottle 160 improves the gripability of the glass bottle 160, reducing slippage when holding bottle 160. The coating 162 may be transparent or translucent to allow the contents contained in the glass bottle 160 to be seen. Additionally, branding or decoration may be applied to the glass 161 of the bottle 160 prior to coating, which may then be seen behind coating 162. The coating 162 may also have color, sparkles or other decorative features incorporated therein to provide aesthetic appeal. As coating 162 is adhered to the glass 161 of bottle 160, the bottle 160 may be machine washed, such as in a dishwasher, without degradation, or water ingress behind the coating 162, and at high temperatures for disinfecting. The coated bottle 160 is also microwaveable without degradation to coating 162. The coating 162 also provides thermal insulation to maintain the temperature of the contents of the glass 160 and keep the heat (or cold) of the contents of the glass 160 from migrating to the hand of the holder of the bottle 160. An additional advantage of coating 162 is the added strength and impact resistance it provides to glass bottle 160, allowing for a reduced thickness of glass 161 being required to form the glass bottle 160. Using a reduced thickness of glass 161 simplifies the manufacturing process and reduces the weight and cost of the glass 161 used to make the bottle 160.

[0044] The protective bumper 166 has the additional advantage of being able to forego any necessity of having to incorporate a heavy glass bottom into the glass 161 forming the glass bottle 160. Thus allowing for a uniform thickness for glass 161 along the lower portion of the glass bottle 160 below the lip 168. Glass 161 having a uniform thickness allows for a simplified manufacturing process where the lower portion of the glass 161 below the lip 168 cools down at a uniform rate once it has been formed, decreasing the time needed to cool the glass, reducing the complexity and cost of the manufacturing process and reducing the potential for cracking during cooling. Decreasing the thickness of the glass 161 allows for an increase in the flexibility of glass 161 making glass 161 more resistant to shattering and breaking due to dropping, and also from thermal expansion and contraction, for example, while heating in a microwave or washing in hot water.

[0045] Figure 3 shows a further example of the invention, wherein a drinking glass 170, such as a beer glass, is coated with BPA free, shatterproof silicone sleeve coating 172. The drinking glass 170 is generally made from glass 171 and has a generally flat bottom surface 174. Optionally, drinking glass 170 may have a generally rounded bottom surface 174. In this example, there also may be provided a molded protective bumper 176, formed as a separate member as shown or of the coating 172 itself. The coating 172 extends to the rim 178 of the drinking glass 170, or if desired, to a position slightly below the rim so the user feels the glass portion upon drinking. The coating 172 may also encompasses the bottom surface 174, and the protective bumper 176 if provided as a separate member. The protective coating 172 helps prevent the coated glass drinking glass 170 from shattering or "exploding" if or when dropped. The coating 172 on the drinking glass 170 provides shock resistance to prevent breakage of the glass drinking glass 170 in many typical drops. If the glass 171 of the drinking glass 170 does break, the protective coating 172 provides glass containment within the silicone sleeve 172. The bumper 176 may be formed as a separate protective bumper 176 which is operatively attached to the bottom surface 174 of the glass 171 forming the glass drinking glass 170 and is within the protective coating 172, or as a thickened portion of the coating 172. The protective bumper 176 adds additional protection to the glass drinking glass 170 in the event of a typical drop. The small additional weight of the protective bumper 176 will have the additional feature of tending to orientate the glass drinking glass 170 in free-fall with the bottom surface 174 of the glass drinking glass 170 pointing toward the ground. The protective bumper 170 is formed of shock absorbent material such as silicone, rubber, polymeric compound or other similar material, allowing the impact of the drinking glass 172 hitting the ground to be absorbed by the protective bumper 176.

[0046] The coating 172 according to an example uses FDA compliant silicone materials to form the coating 172, that are safe and durable. The silicone coating 172 is adhered directly to the glass drinking glass 170. Having the silicone coating 172 adhere directly to the glass drinking glass 170 improves the gripability of the glass drinking glass 170, reducing slippage when holding. The coating also provides some insulation, and generally will minimize condensation on the outer surface of the glass 170 which may normally occur with just the glass. The coating 172 is transparent or translucent to allow the contents contained in the glass drinking glass 170 to be seen. Additionally, branding or decoration may be applied to the glass 171 of the drinking glass 170 prior to coating, which may then be seen behind coating 172. The coating 172 may also have color, sparkles or other decorative features incorporated therein to provide aesthetic appeal. As coating 172 is adhered to the glass 171 of drinking glass 170, then drinking glass 170 may be machine washed, such as in a dishwasher, without degradation, or water ingress behind the coating 172, and at high temperatures for disinfecting. The coated drinking glass 170 is also microwaveable without degradation to coating 172. The coating 172 also provides thermal insulation to maintain the temperature of the contents of the glass 170 and keep the heat (or cold) of the contents of the glass 170 from migrating to the hand of the holder of the drinking glass 170. An additional advantage of coating 172 is the added strength and impact resistance it provides to glass drinking glass 170, allowing for a reduced thickness of glass 171 being required to form the glass drinking glass 170. Using a reduced thickness of glass 171 simplifies the manufacturing process and reduces the weight and cost of the glass 171 used to make the drinking glass 170.

[0047] The optional protective bumper 176 has the additional advantage of being able to forego any necessity of having to incorporate a heavy glass bottom into the glass 171 forming the glass drinking glass 170, which is typically done with beer glasses for example. Thus allowing for a uniform thickness for glass 171 along the lower portion of the glass drinking glass 170 below the rim 178. Glass 171 having a uniform thickness allows for a simplified manufacturing process where the lower portion of the glass 171 below the rim 178 cools down at a uniform rate once it has been formed, decreasing the time needed to cool the glass, reducing the complexity of the manufacturing process and reducing the potential for cracking during cooling. Decreasing the thickness of the glass 171 allows for an increase in the flexibility of glass 171 making glass 171 more resistant to shattering and breaking due to dropping, and also from thermal expansion and contraction, for example, while heating in a microwave or washing in hot water.

[0048] A person of ordinary skill in the art will appreciate that other examples of the invention include providing a coating and optionally a protective bumper, as described in the examples above, for other glass articles such as beakers, wine bottles, canning jars, pharmaceutical containers, syringes, fragrance bottles, and other such glass articles capable of being coated by a BPA free, shatterproof, silicone, coating. Different Food Grade coatings, such as plastic, PVB, HDPE, Plasti-Dip materials may also be usable to allow coating of the glass articles, such as by dipping in a manner similar to the silicone as described. As seen in Fig. 4 and 5, a first process for forming the coating 112 on glass articles 110 may be a dipping process which includes the steps of providing a liquid silicone dispersion using at least one solvent at 20 in a dip tank 272. The dispersion of base polymer in at least one solvent comprises about 30-65% by weight of base polymer. For example, the silicone rubber mixture may include multiple components, which in an example are Elastosil® A and Elastosil® B, in equal amounts of 25% each, along with at least one solvent to form a dispersion of silicone rubber. A cross-linking agent may be added to the dispersion at the time it is placed in the dipping tank. For example, the silicone rubbers which may be used to form the coating 112 have as a base elastomer or polymer an organopolysiloxane and may utilize either platinum, benzoyl peroxide, dichlorobenzoyl peroxide or other suitable vulcanization/curing systems. Fillers may also be used in the rubber composition to increase tensile strength and reinforcing silicone fillers which are inert to animal fluids and tissues when used as an integral part of the rubber formulation. Suitable silicone rubber base polymers are known to those skilled in the art. Contemplated solvents include any suitable pure or mixture of organic, organometallic or inorganic molecules that are volatilized at a desired temperature. The solvent may also comprise any suitable polar and non-polar compounds. In an example, the solvent comprises about 40% heptane and 8-10% D-limonene, but other amounts of these solvents may be used. Other solvents such as, toluene, pentane, hexane, cyclohexane, benzene, xylene, halogenated solvents such as carbon tetrachloride, and mixtures thereof or others may be suitable. The silicone dispersion may further include one or more colorants in an amount such as between about 1-2% and/or decorative materials such as sparkles in an amount such as 1-2%. A vacuum is applied at 22 to remove any entrained bubbles from the coating 112 by degassing. The silicone dispersion is maintained in a uniform mixture by vacuum pumping of the mixture in the tank through suitable filters, such as metal mesh filters, by a recirculating pump at 24. Other methods such as stirring may also be used. The laminar flowability of the mixture is maintained during one or more dipping cycles. The viscosity of the mixture is measured and maintained at 26 by the addition of constituents as needed between dipping cycles. The viscosity of the dispersion may be in the range of 2500 - 7900 centipoises, or according to an example, about 5000 - 5500 cp. The viscosity allows the desired thickness of the coating 112 to be obtained in one or more dipping cycles, and is set to allow any entrained bubbles to be effectively removed upon application of a vacuum or de-gassing step as described below. A plurality of glass articles 110 are positioned on a dipping fixture at 28, and lowered into the dip tank at a predetermined angle relative to the dispersion and at a predetermined speed at 30. The angle is generally between 5 - 20 degrees relative to the horizontal surface of the dispersion, depending, for example on the depth of a concave bottom surface of the glass article 110. In one example the glass articles 110 have a concave bottom surface, therefore the angled approach and removal eliminates any formation of a bubble at the concave bottom surface and ensures uniform coating thereof. If there is no concave bottom surface as in the examples of Figs. 2 and 3, the angling of the glass article 110 into the dispersion may not be necessary. The speed at which the glass articles 110 are dipped is generally substantially uniform and between about 50 to 100 mm/second, for example. The substantially uniform speed of dipping into and from dip tank 272 provides a substantially uniform thickness coating 112 on the glass articles 110. The glass articles 110 are dipped to the level of either the lip (see Fig. 1 and Fig. 2) or the rim (see Fig. 3) of the glass article 110 and may be rotated such that the level of the silicone rubber dispersion covers the entire portion of the glass article 110 below the lip or rim. Alternately, the dipping fixture may be rotated such that the glass article 110 is perpendicular to the silicone dispersion at the level of the lip or rim to fully coat the glass article 110 up to the lip or rim. In the event the bumper type configuration is to be provided by the coating itself, such as would be optional in the examples of Figs. 2 and 3, additional thickness of the coating at this area may be obtained by successive layers of the coating be applied in this area. One of ordinary skill in the art will appreciate and understand that any desired thickness of coating may be acquired. For a uniform coating, the glass article 110 is maintained in the dispersion for a predetermined time, such as 5 -10 seconds, to ensure even coating on the entire exterior surface of bottle 10, all the way to lip or rim(or other desired location). The glass articles 110 are then angled and removed from the silicone dispersion at a predetermined speed at 32 to provide an even coating over the entire outer surface of the glass articles 110. Multiple dipping cycles may be employed to gain the desired coating thickness. The movement of the glass articles 110 may be paused at the point that the glass article just exits the dispersion to allow any extra material to detach via the surface tension of the dispersion. Once removed from the dispersion, the coated glass articles 110 are flipped, such as 180 degrees at 264. The coated glass articles 110 may also be rotated after removal from the dispersion to substantially prevent movement of the coating by forces of gravity. The coating 110 on the glass articles 110 is then dried at 266, such as by heating and/or air circulation, until solvents are evaporated and curing/ polymerization of the coating is achieved. For example, an oven type arrangement may be used to facilitate curing of the silicone and evaporation of the solvent(s) therein.

[0049] The silicone dispersion in which the glass articles 110 are dipped is viscous and is circulated and filtered constantly in order to keep it from setting prematurely. As the dispersion is subjected to constant circulation and has a predetermined viscosity, uniform coating to the desired level on the bottles may be facilitated by control of the depth of the dispersion in the dip tank such as by providing a weir or dam over which the liquid dispersion flows to a recirculation pump. Other methods of maintaining the desired depth of dispersion may be used, such as depth sensors monitoring the surface of the dispersion to obtain a precise distance from the surface of the material to a fixed predetermined point. The dipping fixture will normally have only one type of glass article 110 engaged with it at any one time, and the position of the fixture can be precisely controlled via computer control, to accurately position the glass articles 110 relative to the dispersion. As shown in Fig. 5, the dipping system 270 may include a dip tank 272 and dipping fixture 54 is shown, with the dipping fixture 54 comprised of at least one work piece holding bar 56. The holding bar 56 may include holding one or more rows of glass article 110 therewith, which each row selectively dipped into the dip tank 52, to increase throughput. The holding bar 56 may be selectively pivoted at a desired entrance/removal angle, and to flip the coated glass articles 110 after coating, by a suitable pivoting/rotating system. The vertical elevation of the holding bar 56 is controlled very accurately as it dips into the tank 52 of coating solution. The vertical elevation of the silicone dispersion is also known very accurately. As noted previously, a weir or level sensor keeps the level of the dispersion in the tank 52 constant. If desired, the tank 52 may also be supported on suitable vertical movers 278, such as motor driven screw jacks or the like, to raise or lower the tank 52. Alternately, the level of the dispersion in the tank 52 may be monitored and the amount of movement of the holding bar may be adjusted accordingly to dip the glass articles 110 to the desired depth. The proper dip level may be established by running a test dip of the glass article 110 and then examining that test piece. If the level of the dip tank needs to be adjusted the level can be accurately adjusted using the dispersion depth measurement and/or level of the dip tank 52. The level of dispersion in the tank 52 may remain constant, and once the proper level is set, the production pieces may be quickly and easily dipped into the dispersion. If discrepancies develop during a production run, the level of the dip tank 52 may be adjusted automatically or manually during the production run. The dip tank 52 may be enclosed in a hood assembly 60 to allow evacuation of any evaporated solvents, and to allow the application of a vacuum after coating for removal of any bubbles. After coating, the dipped glass articles 110 may be removed from the dip tank hood assembly and may be moved to and/or through a drying system 62, such as an oven, air circulation system or the like.

[0050] In another example, the system may allow for coating of glass articles 110 with a protective silicone rubber material by dipping the glass articles 110 into the silicone dispersion provided in a dip tank 52 or by being sprayed, via a conveyor system for moving the glass articles 110 through the coating machine (not shown). A fixture supporting a plurality of glass articles 110 in an angled position relative to the surface of the silicone dispersion in said tank so that a predetermined area of each of the glass articles 110 is dipped into the protective silicone material as they are moved through the machine.

[0051] These methods of forming the coated glass articles 110 provides a seamless sleeve on the glass articles 110, that is adhered directly to the exterior surface of the glass articles 110, with a desired thickness. An automatic control system, well known in the art, may be used to control the rate of immersion and withdrawal as well as the period of submersion. The length of time of submersion and the number of submersions determines the thickness of the coating. The coating 112 on the glass articles 110 may be air or oven dried after one or more submersions or after each submersion, assuring that the at least one solvent is evaporated. For example, drying by air drying may be for about one hour for one coat depending on thickness, with additional drying time if multiple coats are used. Using heat to facilitate drying, the coated glass articles 110 may be placed into 100 degrees F for about 25 minutes for example, depending on thickness. The temperature in which the coated bottles may be dried may vary from about 100 to 200 degrees F for example, depending on the coating composition, solvents and solvent handling systems for example. Higher temperatures may be possible. The time may vary based upon the thickness of the coating, temperature or other factors. Other methods of drying may be utilized. If desired, immediately upon withdrawal, after the final dispersion dip, the coated glass articles 110 may be exposed within a high vapor content chamber, such as a steam saturated atmosphere with an ambient temperature of less than 120 degrees F., for about 30 seconds or until a fine, non-coalescing layer of condensate has been deposited over the surface of the uncured glass article coating. In an example, the uncured coated glass article 110 is then allowed to dry for 15 to 30 minutes before curing at about 300 degrees F. for approximately 25 minutes in a vented oven. This may form a grippable surface on the exterior of the coating 12 to facilitate use.

[0052] In another example, the coating 112 may be formed on the glass article 110 by an injection molding process. Referring to Fig. 6, an injection molding system 100 includes a liquid injection molding (LIM) machine 102, which for example may be a machine such as produced by Engel Austria GmbH, but other suitable machines may be used. The machine 102 is designed to handle the injection of liquid silicone, and may have a screw type or plunger type injection unit. In the example shown, a screw type injection unit is shown. The silicone may be melted for injection in the machine 102, and no solvents may be needed to form a liquid silicone for injection. A molding die 104 includes a cavity 106 having dimensions to form a desired thickness coating around the glass article 110 positioned therein, by overmolding of the silicone onto the exterior of the glass article 110. The glass article 110 is mounted via a mounting fixture 108, such as made of metal, which may be a cap-like member that the glass article 110 is screwed, or slotted into at one end of cavity 106. The mounting fixture alleviates any contact of the die with the glass article 110 upon being clamped into position for molding as shown in Fig. 6, and spaces the glass article 110 from the walls of cavity 106. In this manner, the glass article 110 is protected from breakage during the molding process. As an alternative, the glass article 110 may be filled with an incompressible liquid during the molding process to further withstand any forces acting on the glass article 110 during molding and prevent breakage. Upon actuation of the injection system of the molding machine 102, liquid silicone is forced into the space around glass article 110 to form coating 112 thereon. A vacuum may be applied and the liquid silicone may be cured in place within the mold, to remove any entrained bubbles and form a finished coated bottle product upon release from the mold.

[0053] Turning to Fig. 7, a further embodiment of the invention is shown, wherein the glass article 150 is provided with a temperature sensor 152 on an exterior surface of the glass article 150 and then having a coating 154 applied per the application of a silicone coating as described with reference to prior examples. The temperature sensor 152 may be of any suitable type, and sensors such as produced by American Thermal Instruments, Inc. may be suitable for example. Alternatively, micro-dot RFID temperature sensors and liquid crystal type temperature sensors may be used. For example, micro-dot RFID temperature sensors allow the temperature to be communicated to a separate receiver, such as a countertop device, to provide an indication of temperature to the user. The sensor 152 may read the actual temperature of the liquid contents or provide an indication if the liquid contents are above (or below) a predetermined temperature, to protect from burning a baby's mouth for example. The effect of the glass thickness may be accounted for in the calibration of the temperature sensor 152. The sensor 152 may be applied to the exterior surface of the glass article 150 where thermal conductivity through the glass will allow an accurate reading of the temperature of the liquid contents, with the exterior surface then coated with a silicone layer 154 to encapsulate the temperature sensor. The coating 154 will protect the temperature sensor 152, even in the washing machine or the like. The coating 154 may also provided with a thicker portion 156 at the location where the glass article 150 is generally handled to provide additional insulation from hot liquids, substantially preventing the heat (or cold) of a liquid in the bottle from migrating to the hand of the baby or other person handling the glass article 150.

[0054] As the invention pertains to CFLs, with reference now to the drawings, and in particular to Fig. 8, a compact fluorescent lamp 10 coated with a shatterproof elastomer coating 202, such as a silicone overmold, is shown. The coating 202 may be thick enough to the bulb 200 has a gas filled tube 206 connected to the magnetic or electronic ballast contained in the plastic base 208. The coating 202 extends onto the plastic base 208 to an extent at 204. The coating 202 on the bulb 200 may be thick enough to provide shock resistance to prevent breakage of the glass tube 206 in many typical drops, such as from a ladder, table, shelf or the like. The thickness may be between 0.3 mm to 2.5 mm for example, or for many CFL configurations, between about 0.5 to 1.5 mm, but other thicknesses may be suitable depending on the application or desired characteristics of the final product. For example, in some environments, it may be desired to have a thicker coating to provide enhanced protection against breakage or enhanced containment. It may also be desired to have a varying thickness coating on the bulb 200, for example with a thicker coating at the top or outer portions of the bulb 200, that are more likely to have impact forces exerted on them. The coating 202 provides shock resistance due to the nature of the coating itself, as well as the manner in which it contains the glass tube sections of the bulb 200. As seen in Figs. 8 and 8 A, in an example embodiment, the bulb 200 is overmolded in such a fashion that the once independent or separated glass tubes 206 are now connected to each other via connecting sections or webs 209 of the coating 202. These connecting sections 209 provide greatly increased structural strength of the bulb 200 and to each independent tube section 206, to greatly increase the tensile strength of the bulb 200 and therefore reducing the risk of breakage. The connecting portions 209 also allow for added performance and provide full containment, with the entire coating 202, of any broken glass, phosphorus, mercury or other materials. The connecting portions 209 also provide a reduced risk of breakage during installation and removal by counteracting a rotational force applied. This invention is especially beneficial and important for the consumer who does not understand that is not recommended to install compact fluorescent bulbs by holding the gas filled tube 206. In many common installation situations the fixture that the CFL bulb 200 is being installed into has insufficient room to install the bulb 200 correctly by holding the base 208 only, which are the manufacturers recommended installation practices due to the fragile glass tube 206. Thus, if the bulb 200 does break, the overmold 202 provides total glass and chemical containment within the silicone overmold, to prevent the mercury release or mess that would occur otherwise upon bulb breakage. The coating 202 U.S. Food and Drug Administration (FDA) compliant silicone materials to form the overmold 202, that are safe and durable. The silicone overmold 202 is adhered directly to the CFL envelope or glass tube 206 and base 208, to prevent breakage, contain mercury, phosphorus and glass and provide better gripping characteristics for installation and removal. The coating 202 may be transparent or translucent to minimize color, lumen or Kelvin scale changes to allow light to show through as if the coating were effectively not present, or the coating may employ a large spectrum of colors to change the color, lumens or Kelvin scale value of the bulb.. As the coating 202 is directly adhered to the bulb 200, it will be used in a normal fashion with no extra care or precaution for the consumer. As for other compact fluorescent bulbs, the coating 202 may be easily applied to different size or shape compact fluorescent bulbs or articles.

[0055] In this example, the protective material of coating or overmold 202 is formed of a

FDA food contact approved silicone material, such as Elastosil® products from Wacker Chemical Co. or Silastic® products from Dow Corning, but other suitable silicone materials may be used, or other suitable materials such as natural rubber. This material is crystal clear, nontoxic, and allows application via dipping and/or spraying for example. As mentioned previously, the coating 202 may have a desired and varying thickness, and such techniques may allow the desired coating thickness or varying thickness to be achieved. The material and thickness of the coating 202 is designed to resist tearing, such as if the bulb 200 does break, and thus to retain any glass, mercury and phosphorus (or other materials) therein. The coating 202 may have a durometer of 20A to 80A for example, with durometer adjustable for the application.

[0056] As seen in Fig. 9, a first process for forming the coating 202 on bulb 200 may be a dipping process which includes the steps of providing a liquid silicone dispersion using at least one solvent at 20 in a dip tank. The dispersion of base polymer in at least one solvent comprises about 30-65% by weight of base polymer. For example, the silicone rubber mixture may include multiple components, which in an example are Elastosil® A and Elastosil® B, in equal amounts of 25% each, along with at least one solvent to form a dispersion of silicone rubber. A cross- linking agent may be added to the dispersion at the time it is placed in the dipping tank. For example, the silicone rubbers which may be used to form the coating have as a base polymer an organopolysiloxane and may utilize either platinum, benzyl peroxide, dichlorobenzyl peroxide or other suitable vulcanization/curing systems. Fillers may also be used in the rubber composition to increase tensile strength and reinforcing silicone fillers which are inert to animal fluids and tissues when used as an integral part of the rubber formulation. Suitable silicone rubber base polymers are known to those skilled in the art.

[0057] Contemplated solvents include any suitable pure or mixture of organic, organo- metallic or inorganic molecules that are volatilized at a desired temperature. The solvent may also comprise any suitable polar and non-polar compounds. In an example, the solvent comprises about 40% heptane and 8-10% D-limonene, but other amounts of these solvents may be used. Other solvents such as, toluene, pentane, hexane, cyclohexane, benzene, xylene, halogenated solvents such as carbon tetrachloride, and mixtures thereof or others may be suitable.

[0058] A vacuum is applied at 252 to remove any entrained bubbles from the dip tank

272 by degassing. The silicone dispersion is maintained in a uniform mixture by vacuum pumping of the mixture in the tank through suitable filters, such as metal mesh filters, by a re- circulating pump at 254. Other methods such as stirring may also be used. The laminar flowability of the mixture is maintained during one or more dipping cycles. The viscosity of the mixture is measured and maintained at 256 by the addition of constituents as needed between dipping cycles. The viscosity of the dispersion may be in the range of 2500 - 7900 centipoises, or in a range of about 5000 - 5500 cp for example. The viscosity allows the desired thickness of the coating 202 to be obtained in one or more dipping cycles, and is set to allow any entrained bubbles to be effectively removed upon application of a vacuum or de-gassing step as described below.

[0059] A plurality of bulbs 200 are positioned on a dipping fixture at 258, and lowered into the dip tank at a predetermined angle relative to the dispersion and at a predetermined speed at 260. The angle is generally between 0 - 20 degrees relative to the horizontal surface of the dispersion, depending on the shape of the bulb 206 for example. As some bulbs 200 may have portions that may entrain bubbles, the angled approach eliminates any formation of any bubbles around the base 208 or portions of the glass tube sections 206, and ensures uniform or varied coating thereof. If there is no portions of the bulb 200 that entrain or create bubbles due to its configuration, the angling of the bulb 200 into the dispersion may not be necessary. The speed at which the bulbs 200 are dipped is generally substantially uniform and between about 50 to 100 mm/second, for example. The substantially uniform speed of dipping into and from the dip tank provides a substantially uniform thickness coating 202 on the bulb 200. If a varying thickness is desired, the speed of dipping may be altered to obtain the desired coating thicknesses on the corresponding portions of the bulb 200 as may be desired. The bulbs 200 are dipped to the level of base 204 (see Fig. 8) and may be rotated such that the level of the silicone rubber dispersion covers the entire portion of the bulb 200 above the base 204. Alternately, the dipping fixture may be rotated such that the bulb 200 is perpendicular to the silicone dispersion at the level of the base 204 to fully coat the bulb 200 up to the base 204. The bulb 200 is maintained in the dispersion for a predetermined time, such as 5 -10 seconds, to ensure even coating on the entire exterior surface of bulb 200, all the way to base 204, and to create the connecting portions 209. The bulbs 200 are then angled and removed from the silicone dispersion at a predetermined speed at 262 to provide an even coating over the entire outer surface of bulbs 200. Multiple dipping cycles may be employed to gain the desired coating thickness. The movement of the bulb 200 may be paused at the point that the bulb just exits the dispersion to allow any extra material to detach via the surface tension of the dispersion. Once removed from the dispersion, the coated bulbs 200 are flipped 180 degrees at 264. The coated bulbs 200 may also be rotated after removal from the dispersion to substantially prevent movement of the coating by forces of gravity. The coating 202 on bulbs 200 is then dried at 266, such as by heating and/or air circulation, until solvents are evaporated and curing/ polymerization of the coating is achieved. For example, an oven type arrangement may be used to facilitate curing of the silicone and evaporation of the solvent(s) therein.

[0060] The silicone dispersion in which the bulbs 200 are dipped is viscous and is circulated and filtered constantly in order to keep it from setting prematurely. As the dispersion is subjected to constant circulation and has a predetermined viscosity, uniform coating to the desired level on the bulbs may be facilitated by control of the depth of the dispersion in the dip tank such as by providing a weir or dam over which the liquid dispersion flows to a recirculation pump. Other methods of maintaining the desired depth of dispersion may be used, such as depth sensors monitoring the surface of the dispersion to obtain a precise distance from the surface of the material to a fixed predetermined point. The dipping fixture will normally have only one type of bulb 200 engaged with it, and the position of the fixture can be precisely controlled via computer control, to accurately position the bulbs 200 relative to the dispersion.

[0061] As shown in Fig. 10, the dipping system 270 may include a dip tank 272 and dipping fixture 274 is shown, with the dipping fixture 274 comprised of at least one work piece holding bar 276. The holding bar 276 may include holding one or more rows of bulbs 200 therewith, which each row selectively dipped into the dip tank 272, to increase throughput. The holding bar 276 may be selectively pivoted at a desired entrance/removal angle, and to flip the coated bulbs 200 after coating, by a suitable pivoting/rotating system. The vertical elevation of the holding bar 276 is controlled very accurately as it dips into the tank of coating solution.

[0062] The vertical elevation of the silicone dispersion is also known very accurately. As noted previously, a weir or level sensor keeps the level of the dispersion in the tank 272 constant. If desired, the tank 272 may also be supported on suitable vertical movers 278, such as motor driven screw jacks or the like, to raise or lower the tank 272. Alternately, the level of the dispersion in the tank 272 may be monitored and the amount of movement of the holding bar may be adjusted accordingly to dip the bulbs to the desired depth.

[0063] The proper dip level may be established by running a test dip of the bulb 200 and then examining that test piece. If the level of the dip tank needs to be adjusted the level can be accurately adjusted using the dispersion depth measurement and/or level of the dip tank 272. The level of dispersion in the tank 272 may remain constant, and once the proper level is set, the production pieces may be quickly and easily dipped into the dispersion. If discrepancies develop during a production run, the level of the dip tank 272 may be adjusted automatically or manually during the production run. The dip tank 272 may be enclosed in a hood assembly 280 to allow evacuation of any evaporated solvents, and to allow the application of a vacuum after coating for removal of any bubbles. After coating, the dipped bulbs 200 may be removed from the dip tank hood assembly and may be moved to and/or through a drying system 282, such as an oven, air circulation system or the like.

[0064] In another example, the system may allow for coating of bulbs 200 with a protective silicone rubber material by dipping the bulbs 200 into the silicone dispersion provided in a dip tank or by being sprayed, via a conveyor system for moving the bulbs through the coating machine. A fixture supporting a plurality of bulbs in an angled position relative to the surface of the silicone dispersion in said tank so that a predetermined area of each of the bulbs 200 is dipped into the protective silicone material as they are moved through the machine.

[0065] These methods of forming the coated bulbs 200 provides a seamless overmold on the bulb 200, that is adhered directly to the exterior surface of the bulbs 200, with a desired thickness. An automatic control system, well known in the art, may be used to control the rate of immersion and withdrawal as well as the period of submersion. The length of time of submersion and the number of submersions determines the thickness of the coating 202. The coating 202 on the bulbs may be air or oven dried after one or more submersions or after each submersion, assuring that the at least one solvent is evaporated. For example, drying by air drying may be for about one hour for one coat depending on thickness, with additional drying time if multiple coats are used. Using heat to facilitate drying, the coated bulbs 200 may be placed into 100 degrees F for about 25 minutes for example, depending on thickness. The temperature in which the coated bulbs may be dried may vary from about 100 to 200 degrees F for example, depending on the coating composition, solvents and solvent handling systems for example. Higher temperatures may be possible. The time may vary based upon the thickness of the coating, temperature or other factors.

[0066] Other methods of drying may be utilized. If desired, immediately upon withdrawal, after the final dispersion dip, the coated bulbs 200 may be exposed within a high vapor content chamber, such as a steam saturated atmosphere with an ambient temperature of less than 120 degrees F, for about 30 seconds or until a fine, non-coalescing layer of condensate has been deposited over the surface of the uncured bulb coating. In an example, the uncured coated bulb is then allowed to dry for 15 to 30 minutes before curing at about 300 degrees F for approximately 25 minutes in a vented oven. This may form a gripable surface on the exterior of the coating 202 to facilitate use.

[0067] Alternate bulb configurations for a CFLs are shown in Figs. 11 and HA, and the features and characteristics of the coating 302 and 312 as described with reference to the example of Fig. 8 are maintained. In the configuration of CFLs 300 and 310 as shown in these Figs., the elastomer overmold 302 and 312 is shown. The coating 302 and 312 may be thick enough to provide advantages of impact resistance to make the bulbs 300 and 310 more shatterproof and for containment of glass, phosphorus and mercury if the bulb 300 or 310 breaks. The bulbs 300 and 310 have a gas filled tube 306 and 316 connected to the magnetic or electronic ballast contained in the base 308 and 318. The coating 302 and 312 extends onto the plastic base 308 and 318 respectively, to an extent at 304 and 314. The coating 302 and 312 may be thick enough to provide shock resistance to prevent breakage of the glass tube 306 and 316 in many typical drops, such as from a ladder, table, shelf or the like. The thickness may be between 0.3 mm to 2.5 mm for example, or for many CFL configurations, between about 0.5 to 1.5 mm, but other thicknesses may be suitable depending on the application or desired characteristics of the final product. For example, in some environments, it may be desired to have a thicker coating to provide enhanced protection against breakage or enhanced containment. It may also be desired to have a varying thickness coating on the bulb 300 or 310, for example with a thicker coating at the top or outer portions of the bulb 300 or 310, that are more likely to have impact forces exerted on them. The coating 302 or 312 provides shock resistance due to the nature of the coating itself, as well as the manner in which it contains the glass tube sections of the bulb 300 and 310. As seen in Figs. 11 and HA, in these example embodiments, the bulb 300 and 310 is overmolded in such a fashion that the once independent or separated glass tubes 306 and 316 of each bulb 300 and 310 are now connected to each other via connecting sections or webs 308 and 318 of the coating 302 and 312 respectively. These connecting sections 308 and 318 again provide greatly increased structural strength of the bulb 300 and 310 and to each independent tube section 306 and 316 of the bulbs 300 and 310, to greatly increase the tensile strength of the bulbs and therefore reducing the risk of breakage. The connecting portions 308 and 318 also again allow for added performance and provide full containment within the coating 302 and 312 of any broken glass, phosphorus, mercury or other materials, and provide a reduced risk of breakage during installation and removal by counteracting a rotational force applied. The coating 302 and 312 further provide better gripping characteristics for installation and removal. As should be recognized, the coating of the bulb sections 306 and 316 may similarly be used with other possible configuration of compact fluorescent bulbs, with the coating easily applied to different size or shape compact fluorescent bulbs or articles.

[0068] Although the invention has been shown and described in conjunction with examples thereof, the same are considered as illustrative and not restrictive, and that all changes and modifications that come within the spirit of the invention described by the following claims are within the scope thereof.

Claims

What is claimed is:

1. A coated glass baby bottle comprising,

a glass baby bottle substrate;

at least one layer of a BPA free, shatterproof silicone material having a predetermined thickness such that the coating provides shock resistance to normal dropping of the baby bottle to facilitate preventing the bottle from shattering or "exploding" if or when dropped, and total glass containment within the silicone coating if the bottle does break.

2. The coated glass baby bottle of claim 1, wherein the coating further provides thermal insulation to maintain the temperature of liquids disposed therein and keep the heat (or cold) of liquids in the bottle from migrating to the hand of the baby or other person handling the bottle.

3. The coated glass baby bottle of claim 1, wherein the coating is formed of FDA compliant silicone materials.

4. The coated glass baby bottle of claim 1, wherein the coating increasing the tensile strength in the coated article.

5. The coated glass baby bottle of claim 1, wherein the coating includes one or more colors, while allowing viewing of the contents.

6. The coated glass baby bottle of claim 1, wherein the coating is chemically stable at higher temperatures to allow the bottle to be machined washed, microwaved or boiled without degradation of the coating, or the like.

7. The coated glass baby bottle of claim 1, wherein the coating bonds to the glass substrate.

8. The coated glass baby bottle of claim 1, wherein the coating is formed so as to be substantially free of encapsulated bubbles.

9. A method of manufacture of a coated glass article comprising

providing an apparatus for coating one or more articles with a protective material by dipping the bottles into the protective material in a dip tank, including a fixture for holding at least one glass article,

formulating a silicone dispersion in the dip tank,

removing encapsulated bubbles from the dispersion,

recirculating and filtering the dispersion in the dip tank,

measuring the viscosity of the dispersion and maintaining a predetermined viscosity, positioning at least one article on the fixture,

dipping the at least one article into the dispersion at a predetermined speed,

removing the at least one article from the dispersion at a predetermined speed, flipping the at least one article upon removal from the dispersion and curing the coating on the at least one article.

10. A coated glass article comprising,

a glass vessel substrate;

at least one layer of BPA free, shatterproof material having a predetermined thickness such that the coating provides shock resistance to normal dropping of the coated glass vessel to facilitate preventing the coated glass vessel from shattering if or when dropped, and providing glass containment within the silicone coating if the coated glass vessel does break.

11. The coated glass vessel of claim 10, wherein the coating further provides thermal insulation to maintain the temperature of liquids disposed therein and keep the temperature of the liquids in the vessel from migrating to the hand of the person handling the vessel.

12. The coated glass vessel of claim 10, wherein the coating is formed of FDA compliant silicone materials.

13. The coated glass vessel of claim 10, wherein the coating increasing the tensile strength in the glass vessel.

14. The coated glass vessel of claim 10, wherein the coating includes one or more colors, while allowing viewing of the contents of the vessel.

15. The coated glass vessel of claim 10, wherein the coating is chemically stable at higher temperatures to allow the vessel to be machined washed, microwaved or boiled without degradation of the coating, or the like.

16. The coated glass vessel of claim 10, wherein the coating bonds to the glass substrate.

17. The coated glass vessel of claim 10, wherein the coating is formed so as to be substantially free of encapsulated bubbles.

18. The coated glass vessel of claim 10, wherein the glass vessel further comprises a protective bumper operatively connected to its bottom surface for substantially reducing the shock to the glass vessel in the event of a typical drop.

19. An encapsulated compact fluorescent bulb comprising, at least one gas filled glass tube joined to a base containing a ballast, wherein the at least one gas filled glass tube includes an amount of mercury and phosphorus, and having at least one layer of silicone material having a predetermined thickness which substantially prevents the glass tube from shattering or breaking to thereby prevent the release of phosphorus and mercury if or when the bulb is dropped or other impact or force is imposed on the at least one glass tube, and wherein the at least one layer of silicone material provides for total glass and content containment within the silicone layer if the at least one glass tube does break.

20. The coated compact fluorescent bulb of claim 19, wherein the at least one layer of silicone provides for grip and structural reinforcement when installing and removing the bulb from a fixture.

21. The coated compact fluorescent bulb of claim 19, wherein the at least one layer of silicone is formed using liquid silicone materials.

22. The coated compact fluorescent bulb of claim 19, wherein the at least one glass filled tube includes at least two adjacent sections and the at least one layer of silicone includes a connecting portion that extends between the at least two adjacent sections that increases the tensile strength of the at least one glass tube by connecting the at least two adjacent sections of the at least one glass tube to one another.

23. The coated compact fluorescent bulb of claim 22, wherein the at least one glass tube is comprised of straight tube members with a longitudinal axis substantially parallel to the principal axis of the fluorescent lamp and the adjacent tube members being connected to each other in series to form a continuous arc path, and the tube members being arranged substantially at equal distance from the principal axis of the fluorescent lamp and from each other.

24. The coated compact fluorescent bulb of claim 22, wherein the glass tube arrangement is comprised of a single tube with substantially straight end sections and an intermediate portion between the end sections and the end sections being at one end of the tube arrangement and in proximity to each other and the intermediate portion having a coiled configuration wound about the principal axis of the lamp to provide the at least two sections.

25. The coated compact fluorescent bulb of claim 19, wherein the at least one layer of silicone is substantially void of color and crystal clear in appearance preventing decrease of lumen output from the bulb.

26. The coated compact fluorescent bulb of claim 19, wherein the at least one layer of silicone is chemically stable at the temperatures at which the bulb operates to allow the bulb to operate indefinitely without degradation of coating.

27. The coated compact fluorescent bulb of claim 19, where in the at least one layer of silicone provides a coating which bonds to the glass tube and the base forming a continuous layer over the connection therebetween that provides for containment of glass and the amounts of mercury and phosphorous in the event of breakage of the glass tube.

28. The coated compact fluorescent bulb of claim 19, wherein the at least one layer of silicone forms a coating which is substantially free of encapsulated bubbles.

29. The coated compact fluorescent bulb of claim 19, wherein the at least one layer of silicone forms a coating that provides for containment of glass and the amounts of mercury and phosphorous in the event of breakage of the glass tube and eliminates EPA recommended cleanup procedures in the event of breakage.

30. The coated compact fluorescent bulb of claim 19, wherein the at least one layer of silicone forms a coating that provides containment of glass and the amounts of mercury and phosphorous in the event of breakage of the glass tube to allow for safe transportation and storage to a recycling facility.

31. A method of manufacturing a coated fluorescent bulb comprising, a gas filled glass tube joined to a base containing a ballast wherein the gas filled glass tube includes an amount of mercury and phosphorus, comprising:

providing an apparatus for coating at least one fluorescent bulb with a protective material by dipping the bulbs into the protective material in a dip tank, including a fixture for holding the at least one fluorescent bulb,

formulating a silicone dispersion in the dip tank,

removing encapsulated bubbles from the dispersion,

recirculating and filtering the dispersion in the dip tank,

measuring the viscosity of the dispersion and maintaining a predetermined viscosity, positioning at least one fluorescent bulb on the fixture,

dipping the at least one fluorescent bulb into the dispersion at a predetermined speed, removing the at least one fluorescent bulb from the dispersion at a predetermined speed to form a coating on the fluorescent bulb,

flipping the at least one fluorescent bulb upon removal from the dispersion,

curing the coating on the at least one fluorescent bulb.

32. The method of claim 31, wherein the glass tube includes at least two adjacent sections and the coating increases the tensile strength in the coated glass tube by connecting the at least two sections of the glass tube to one another.

33. The method of claim 31, wherein the coating bonds to the glass tube and the base, forming a continuous layer over the connection therebetween that provides for containment of glass and the amounts of mercury and phosphorous in the event of breakage of the glass tube.