The present specification generally relates to systems for separating glass sheets from glass ribbons and glass manufacturing apparatuses comprising the same.
Continuous glass ribbons may be formed by processes such as the fusion draw process or other, similar downdraw processes. The fusion draw process yields continuous glass ribbons which have surfaces with superior flatness and smoothness when compared to glass ribbons produced by other methods. Individual glass sheets sectioned from continuous glass ribbons formed by the fusion draw process can be used in a variety of devices including flat panel displays, touch sensors, photovoltaic devices and other electronic applications.
Various techniques for separating discrete glass sheets from a continuous glass ribbon may be used. These techniques generally including clamping a portion of the continuous glass ribbon while the ribbon is scored and a discrete glass sheet is separated from the continuous glass ribbon by applying a bending moment about the score line.
While such techniques are effective for separating a discrete glass sheet from a continuous glass ribbon, a need exists for alternative apparatuses for separating discrete glass sheets from continuous glass ribbons.
According to one embodiment, a glass separation system for separating a glass substrate from a continuous glass ribbon may include an A-surface nosing bar positioned on a first side of a glass conveyance pathway. A long axis of the A-surface nosing bar may be substantially orthogonal to a conveyance direction of the glass conveyance pathway. The A-surface nosing bar may be pivotable about an axis of rotation parallel to the conveyance direction of the glass conveyance pathway. The glass separation system may further comprise a B-surface nosing bar positioned on a second side of the glass conveyance pathway and opposite the A-surface nosing bar. A long axis of the B-surface nosing bar may be substantially orthogonal to the conveyance direction of the glass conveyance pathway. The B-surface nosing bar may be pivotable about an axis of rotation parallel to the conveyance direction of the glass conveyance pathway.
According to another embodiment, an apparatus for forming a glass substrate from a glass ribbon may comprise a forming vessel, a glass conveyance pathway, a glass separation system, and a scoring apparatus. The forming vessel may include a first forming surface and a second forming surface converging at a root. The glass conveyance pathway may extend from the root in a downward vertical direction. The glass separation system may be positioned downstream of the forming vessel and may include an A-surface nosing bar and a B-surface nosing bar. The A-surface nosing bar may be positioned on a first side of the glass conveyance pathway and include a first A-surface nosing actuator coupled to a first end of the A-surface nosing bar and a second A-surface nosing actuator coupled to a second end of the A-surface nosing bar. The B-surface nosing bar may be positioned on a second side of the glass conveyance pathway opposite the A-surface nosing bar and may include a first B-surface nosing actuator coupled to a first end of the B-surface nosing bar, and a second B-surface nosing actuator coupled to a second end of the B-surface nosing bar. The scoring apparatus may be positioned on a first side of the glass conveyance pathway downstream from the A-surface nosing bar. The first end of the A-surface nosing bar may be opposite the first end of the B-surface nosing bar and the second end of the A-surface nosing bar may be opposite the second end of the B-surface nosing bar. The glass separation system may include a clamping mode and an adjustment mode wherein, in the adjustment mode, an actuation stroke length of the first A-surface nosing actuator and an actuation stroke length of the second A-surface nosing actuator are independent of one another and an actuation stroke length of the first B-surface nosing actuator and an actuation stroke length of the second B-surface nosing actuator are independent of one another.
According to another embodiment, a method of separating a glass sheet from a glass ribbon may include conveying a continuous glass ribbon in a conveyance direction on a glass conveyance pathway. The glass conveyance pathway may extend through a glass separation system comprising an A-surface nosing bar positioned on a first side of the glass conveyance pathway and a B-surface nosing bar positioned on a second side of the glass conveyance pathway. The method may further include pivoting the A-surface nosing bar about an A-surface axis of rotation and pivoting the B-surface nosing bar about a B-surface axis of rotation. After the pivoting, the A-surface nosing bar and the B-surface nosing bar may be parallel with the major surfaces of the continuous glass ribbon. Thereafter, the A-surface nosing bar and the B-surface nosing bar may be advanced towards the continuous glass ribbon such that the continuous glass ribbon is clamped between the A-surface nosing bar and the B-surface nosing bar. A score line may then be formed in the continuous glass ribbon and a glass sheet may be separated from the continuous glass ribbon at the score line.
Additional features and advantages of the glass separation systems described herein will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the embodiments described herein, including the detailed description which follows, the claims, as well as the appended drawings.
It is to be understood that both the foregoing general description and the following detailed description describe various embodiments and are intended to provide an overview or framework for understanding the nature and character of the claimed subject matter. The accompanying drawings are included to provide a further understanding of the various embodiments, and are incorporated into and constitute a part of this specification. The drawings illustrate the various embodiments described herein, and together with the description serve to explain the principles and operations of the claimed subject matter.
Reference will now be made in detail to various embodiments of glass separation systems, examples of which are illustrated in the accompanying drawings. Whenever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts. One embodiment of a glass separation system is schematically depicted in
Ranges can be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.
Directional terms as used herein—for example up, down, right, left, front, back, top, bottom—are made only with reference to the figures as drawn and are not intended to imply absolute orientation.
Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order, nor that with any apparatus specific orientations be required. Accordingly, where a method claim does not actually recite an order to be followed by its steps, or that any apparatus claim does not actually recite an order or orientation to individual components, or it is not otherwise specifically stated in the claims or description that the steps are to be limited to a specific order, or that a specific order or orientation to components of an apparatus is not recited, it is in no way intended that an order or orientation be inferred, in any respect. This holds for any possible non-express basis for interpretation, including: matters of logic with respect to arrangement of steps, operational flow, order of components, or orientation of components; plain meaning derived from grammatical organization or punctuation, and; the number or type of embodiments described in the specification.
As used herein, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a” component includes aspects having two or more such components, unless the context clearly indicates otherwise.
Referring now to
The delivery vessel 225 supplies the molten glass 226 to the forming apparatus 241 through a downcomer 230. The forming apparatus 241 comprises an inlet 232, a forming vessel 235, and a pull roll assembly 240. In the embodiment depicted in
As the continuous glass ribbon 204 is drawn along the glass conveyance pathway 300 and into the glass separation system 100, the continuous glass ribbon 204 may rotate or twist such that the continuous glass ribbon 204 is no longer within or even parallel to the plane of the glass conveyance pathway 300 as it enters the glass separation system 100. This condition is schematically depicted in
Specifically referring to
The glass conveyance pathway 300 comprises a conveyance direction 306 which, in the embodiment shown in
The A-surface nosing bar 102 is positioned on a first side 302 of the glass conveyance pathway 300 and generally comprises an A-surface nosing member 104 positioned adjacent to the glass conveyance pathway 300. A long axis 106 (indicated by a double arrow showing the direction of the long axis 106) of the A-surface nosing bar 102 is substantially orthogonal to the conveyance direction 306 of the glass conveyance pathway 300. That is, the long axis 106 of the A-surface nosing bar 102 is generally transverse to the conveyance direction 306 of the glass conveyance pathway 300. In the embodiments described herein, the A-surface nosing bar 102 is pivotable about an A-surface axis of rotation 108 that is substantially parallel to the conveyance direction 306 of the glass conveyance pathway 300. That is, the A-surface nosing bar 102 is pivotable about a substantially vertical axis of rotation such that an orientation of the A-surface nosing bar 102 can be adjusted in a horizontal plane (i.e., the X-Y plane in the coordinate axes depicted in
Similarly, the B-surface nosing bar 112 is positioned on a second side 304 of the glass conveyance pathway 300 opposite the A-surface nosing bar 102 and generally comprises a B-surface nosing member 114 positioned adjacent to the glass conveyance pathway 300. A long axis 116 (indicated by double arrow showing the direction of the long axis 116) of the B-surface nosing bar 112 is substantially orthogonal to the conveyance direction 306 of the glass conveyance pathway 300. That is, the long axis 116 of the B-surface nosing bar 112 is generally transverse to the conveyance direction 306 of the glass conveyance pathway 300. In the embodiments described herein, the B-surface nosing bar 112 is pivotable about a B-surface axis of rotation 118 that is substantially parallel to the conveyance direction 306 of the glass conveyance pathway 300. That is, the B-surface nosing bar 112 is pivotable about a substantially vertical axis of rotation such that an orientation of the B-surface nosing bar 112 can be adjusted in a horizontal plane (i.e., the X-Y plane in the coordinate axes depicted in
The A-surface nosing bar 102 and the B-surface nosing bar 112 may be used to apply a clamping force to a continuous glass ribbon 204 drawn along the glass conveyance pathway 300 to facilitate securing the continuous glass ribbon 204 as the continuous glass ribbon 204 is scored in a direction transverse to the conveyance direction 306 and a discrete glass sheet is separated from the continuous glass ribbon 204. To facilitate application of the clamping force, the A-surface nosing bar 102 and the B-surface nosing bar 112 may be further coupled to actuators (not depicted in
In the embodiments described herein, the A-surface nosing bar 102 and the B-surface nosing bar 112 are positioned to apply a clamping force to the continuous glass ribbon 204 upstream (i.e., in +Z direction of the coordinate axes depicted in the drawings) of the location at which the continuous glass ribbon 204 is scored. Clamping the continuous glass ribbon 204 upstream of the scoring location assists in mitigating the upstream propagation of mechanical vibrations introduced into the continuous glass ribbon 204 during the scoring and separating operation. In turn, the mitigation of the upstream propagation of mechanical vibrations mitigates the disruption of the process of forming the continuous glass ribbon 204 with the forming vessel 235 (
When the A-surface nosing bar 102 and the B-surface nosing bar 112 apply a clamping force to the continuous glass ribbon 204, the continuous glass ribbon 204 is clamped between the A-surface nosing member 104 of the A-surface nosing bar 102 and the B-surface nosing member 114 of the B-surface nosing bar 112. As the A-surface nosing member 104 and the B-surface nosing member 114 directly contact the surface of the continuous glass ribbon 204, the A-surface nosing member and the B-surface nosing member are generally formed from materials which will not damage the surface of the continuous glass ribbon 204 when the clamping force is applied. In some embodiments, the A-surface nosing member 104 and the B-surface nosing member 114 are formed from polymeric materials, such as thermoplastics, thermosets, or thermoplastic elastomers, that have a Shore A durometer hardness from greater than or equal to about 50 to less than or equal to about 70. One non-limiting example of a suitable material from which the A-surface nosing member 104 and the B-surface nosing member 114 may be formed is silicone having a hardness from greater than or equal to about 50 to less than or equal to about 70 on the Shore A durometer scale. However, it should be understood that other materials are contemplated and possible.
As noted hereinabove, the A-surface nosing bar 102 and the B-surface nosing bar 112 are pivotable about respective A-surface and B-surface axes of rotation 108, 118 that are parallel to the conveyance direction 306 of the glass conveyance pathway 300. This facilitates adjusting the orientation of each of the A-surface nosing bar 102 and the B-surface nosing bar 112 to maintain a parallel relationship between the surfaces of the continuous glass ribbon 204 and the A-surface nosing bar 102 and the B-surface nosing bar 112, thereby mitigating the potential for damage to the continuous glass ribbon 204 as it is conveyed in the conveyance direction 306.
For example,
Referring now to
Referring now to
In embodiments, the glass separation system 100 may further comprise a scoring apparatus 150. In the embodiments described herein, the scoring apparatus 150 is positioned on a first side 302 of the glass conveyance pathway 300 (i.e., on the same side of the glass conveyance pathway 300 as the A-surface nosing bar 102) downstream of the A-surface nosing bar 102 (i.e., in the −Z direction relative to the A-surface nosing bar 102) such that the A-surface nosing bar 102 and the B-surface nosing bar 112 can apply a clamping force to the continuous glass ribbon 204 upstream of the scoring apparatus 150. The scoring apparatus 150 may generally comprise a scoring head 152, a scoring actuator 154, and a rail 156.
The rail 156 may be coupled to the carriage frame 120 and generally extends transverse to the conveyance direction 306 of the glass conveyance pathway 300. In embodiments, the scoring apparatus 150 is mounted on the rail 156 with the scoring actuator 154 which facilitates traversing the scoring apparatus 150 along the length of the rail 156.
In the embodiments described herein, the scoring head 152 is also mounted to the scoring actuator 154 as depicted in
In embodiments where the glass separation system 100 comprises a scoring apparatus 150, the B-surface nosing bar 112 further comprises an anvil nosing 122 positioned opposite the scoring head 152 of the scoring apparatus 150. That is, the anvil nosing 122 is positioned downstream of the B-surface nosing member 114 of the B-surface nosing bar 112. The anvil nosing 122 provides a support surface against which the continuous glass ribbon 204 is pressed during a scoring operation to facilitate formation of a score line and to prevent the scoring head 152 of the scoring apparatus 150 from piercing or breaking the continuous glass ribbon 204. In embodiments the anvil nosing 122 may be made from the same material as the A-surface nosing member 104 and the B-surface nosing member 114. That is, the anvil nosing 122 may be formed from polymeric materials, such as thermoplastics, thermosets, or thermoplastic elastomers which have a Shore A durometer hardness from greater than or equal to about 50 to less than or equal to about 70. One non-limiting example of a suitable material from which the anvil nosing 122 may be formed is silicone having a Shore A durometer hardness from greater than or equal to about 50 to less than or equal to about 70. However, it should be understood that other materials are contemplated and possible. In embodiments, the Shore A durometer hardness of the anvil nosing 122 may be greater than the Shore A durometer hardness of either the A-surface nosing member 104 or the B-surface nosing member 114.
In embodiments, the vertical distance between the upper most portion of the A-surface nosing member 104 that contacts the continuous glass ribbon 204 and the line of intersection between the scoring head 152 and the glass conveyance pathway 300 (referred to herein and illustrated
In embodiments, described herein the A-surface nosing bar 102 may further comprise at least one vacuum port 160 coupled to a vacuum line 162. The vacuum line 162 may be coupled to a vacuum pump (not depicted) which supplies a negative pressure to the vacuum line 162 and the at least one vacuum port 160. The vacuum port 160 may be positioned downstream of the of the A-surface nosing member 104 and upstream of the scoring apparatus 150. In the embodiment illustrated in
Still referring to
Referring now to
In embodiments, the control signals sent to the first A-surface nosing actuator 130, the second A-surface nosing actuator 132, the first B-surface nosing actuator 134, the second B-surface nosing actuator 136, and the scoring actuator 154 may be initiated by an input device 176 communicatively coupled to the controller 170, as schematically depicted in
Referring now to
Referring again to
In some embodiments of the clamping mode, the actuation stroke length of the first A-surface nosing actuator 130 and the actuation stroke length of the second A-surface nosing actuator 132 are independent of the actuation stroke length of the first B-surface nosing actuator 134 and the actuation stroke length of the second B-surface nosing actuator 136. That is, the actuators may be independently and individually operated such that the stroke length of a particular actuator may be varied from the remaining actuators. For example, and without limitation, the actuation stroke length of the first A-surface nosing actuator 130 and the actuation stroke length of the second A-surface nosing actuator 132 may be different than the actuation stroke length of the first B-surface nosing actuator 134 and the actuation stroke length of the second B-surface nosing actuator 136 In these embodiments, the actuation speed of the first A-surface nosing actuator 130 and the actuation speed of the second A-surface nosing actuator 132 are different than the actuation speed of the first B-surface nosing actuator 134 and the actuation speed of the second B-surface nosing actuator 136 such that the A-surface nosing member 104 of the A-surface nosing bar 102 and the B-surface nosing member 114 of the B-surface nosing bar 112 contact the continuous glass ribbon 204 at substantially the same time. For example, if the actuation stroke length of the first A-surface nosing actuator 130 and the actuation stroke length of the second A-surface nosing actuator 132 are longer than the actuation stroke length of the first B-surface nosing actuator 134 and the actuation stroke length of the second B-surface nosing actuator 136, then the actuation speed of the first A-surface nosing actuator 130 and the actuation speed of the second A-surface nosing actuator 132 may be greater than the actuation speed of the first B-surface nosing actuator 134 and the actuation speed of the second B-surface nosing actuator 136 such that the A-surface nosing member 104 of the A-surface nosing bar 102 and the B-surface nosing member 114 of the B-surface nosing bar 112 contact the continuous glass ribbon 204 at substantially the same time.
Referring now to
In some embodiments of the adjustment mode, the actuation direction of the first A-surface nosing actuator 130 and the actuation direction of the second A-surface nosing actuator 132 may be different to facilitate adjusting both the angular orientation of the A-surface nosing bar 102 as well as the spacing between the A-surface nosing bar 102 and a continuous glass ribbon 204 drawn in the conveyance direction 306 of the glass conveyance pathway 300. For example, the first A-surface nosing actuator 130 may be actuated in the +X direction of the coordinate axes illustrated in the figures while the second A-surface nosing actuator 132 may be actuated in the −X direction of the coordinate axes illustrated in the figures. Similarly, the actuation direction of the first B-surface nosing actuator 134 and the actuation direction of the second B-surface nosing actuator 136 may be different to facilitate adjusting both the angular orientation of the B-surface nosing bar 112 as well as the spacing between the B-surface nosing bar 112 and a continuous glass ribbon drawn 204 drawn in the conveyance direction 306 of the glass conveyance pathway 300.
In some embodiments of the adjustment mode, an actuation direction of the first A-surface nosing actuator 130 is the same as an actuation direction of the second B-surface nosing actuator 136. Similarly, in this embodiment, an actuation direction of the second A-surface nosing actuator 132 is the same as an actuation direction of the first B-surface nosing actuator 134. In some of these embodiments, the actuation stroke length of the first A-surface nosing actuator 130 is substantially the same as the actuation stroke length of the second B-surface nosing actuator 136. Similarly, the actuation stroke length of the second A-surface nosing actuator 132 is substantially the same as the actuation stroke length of the first B-surface nosing actuator 134. Alternatively, in some of these embodiments of the adjustment mode, the actuation stroke length of the first A-surface nosing actuator 130 is different than the actuation stroke length of the second B-surface nosing actuator 136. Similarly, the actuation stroke length of the second A-surface nosing actuator 132 is different than the actuation stroke length of the first B-surface nosing actuator 134.
Referring now to
Once the orientation of the A-surface nosing bar 102 and the B-surface nosing bar 112 have been adjusted to correspond with the orientation of the continuous glass ribbon 204, a clamping mode of the glass separation system 100 may be used to apply a clamping force to the continuous glass ribbon 204 prior to separating a discrete glass sheet 205 from the continuous glass ribbon 204. In particular, the A-surface nosing bar 102 and the B-surface nosing bar 112 are advanced towards the continuous glass ribbon 204 until the continuous glass ribbon 204 is clamped between the A-surface nosing member 104 of the A-surface nosing bar 102 and the B-surface nosing member 114 of the B-surface nosing bar 112. The glass separation system 100 travels along the rails 124 in a downward vertical direction at the same speed that the continuous glass ribbon 204 is conveyed in the conveyance direction 306 as the clamping force is applied to the continuous glass ribbon 204.
Once the clamping force is applied to the continuous glass ribbon 204, as depicted in
Prior to, contemporaneous with, or after the continuous glass ribbon 204 is scored, a glass carriage 180 is attached to the B-surface of the continuous glass ribbon 204 downstream of the glass separation system 100. The glass carriage 180 may be maneuvered into place with a robotic arm (not depicted) and attached to the continuous glass ribbon 204, with, for example, suction cups. Once the continuous glass ribbon 204 has been scored, the glass carriage 180 is maneuvered with the robotic arm to apply a bending moment to the continuous glass ribbon 204 about the score line, thereby separating a glass sheet 205 from the continuous glass ribbon 204. After the glass sheet 205 is separated from the continuous glass ribbon 204, the A-surface nosing bar 102 and the B-surface nosing bar 112 are withdrawn from the continuous glass ribbon 204, thereby disengaging the A-surface nosing member 104 of the A-surface nosing bar 102 and the B-surface nosing member 114 of the B-surface nosing bar 112 from the continuous glass ribbon 204.
Based on the foregoing, it should now be understood that the glass separation systems described herein may be used to compensate for variations in the orientation of a continuous glass ribbon relative to a glass conveyance pathway and conveyance direction, thereby mitigating the risk of damage to the continuous glass ribbon. In particular, the glass separation systems described herein include A and B-surface nosing bars which may be pivoted about an axis of rotation such that the A and B-surface nosing bars are substantially parallel with the surfaces of the continuous glass ribbon, thereby compensating for variations in the orientation of the continuous glass ribbon with respect to the glass conveyance pathway.
It will be apparent to those skilled in the art that various modifications and variations can be made to the embodiments described herein without departing from the spirit and scope of the claimed subject matter. Thus it is intended that the specification cover the modifications and variations of the various embodiments described herein provided such modification and variations come within the scope of the appended claims and their equivalents.
This application claims the benefit of priority under 35 U.S.C. § 119 of U.S. Provisional Application Ser. No. 62/629,829 filed on Feb. 13, 2018, the content of which is relied upon and incorporated herein by reference in its entirety.
Filing Document | Filing Date | Country | Kind |
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PCT/US2019/016655 | 2/5/2019 | WO | 00 |
Number | Date | Country | |
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62629829 | Feb 2018 | US |