CN115427364A

CN115427364A - System and method for separating glass substrates

Info

Publication number: CN115427364A
Application number: CN202180030368.0A
Authority: CN
Inventors: 陈信霖; 彭志钦; 王逸群
Original assignee: Corning Inc
Current assignee: Corning Inc
Priority date: 2020-03-12
Filing date: 2021-02-25
Publication date: 2022-12-02
Also published as: TW202206384A; WO2021183291A1; JP2023516498A; KR20220152305A

Abstract

A method for separating a glass sheet, the method comprising the steps of: engaging a first surface of a glass sheet with a scoring wheel, the glass sheet defining the first surface and a sheet thickness; moving the scoring wheel along the glass sheet at a scoring rate of at least 35 meters per minute; applying a force on the glass sheet with the scoring wheel; maintaining the force within a predetermined force of 1.0 newtons; and forming, with the scoring wheel, a median crack extending along a length of the first surface and into the glass sheet, the median crack defining a crack depth extending into the glass sheet, wherein the crack depth extending into the glass sheet varies by less than 2.0% along the length of the median crack on the first surface.

Description

System and method for separating glass substrates

This application is filed in accordance with the patent statutes with the benefit of priority from U.S. provisional patent application No. 62/988,606, filed on 12/3/2020, the entire contents of which are the basis of this application and are incorporated herein by reference in their entirety.

Technical Field

The present specification relates generally to methods and systems for separating glass substrates, and in particular to a method and system for forming a median crack in a glass substrate.

Background

Thin flexible glass substrates can be used in a variety of applications, including so-called "electronic paper", color filters, photovoltaic cells, displays, OLED lighting, and touch sensors. The glass used for such substrates can be relatively thin. The processing of the substrate may be performed on an individual glass sheet basis, or by transporting the substrate as a long glass web, which may be wound on rolls or reels. In either case, individual glass sheets or discrete portions of the glass web may be cut into glass sheets for further processing or ready for installation into a final product.

Disclosure of Invention

To cut the glass sheet or glass web, the glass sheet or glass web may be scored, for example, with a scoring wheel, to form a crack along the glass sheet or glass web. Tension may then be applied to the glass sheet or web to separate the glass sheet or web along the crack. Variability in crack depth can lead to undesirable separation and/or breakage of the glass sheet or glass web, thus increasing defects and manufacturing costs. Accordingly, it is desirable to maintain a consistent crack depth, and there is a need for apparatus and methods for forming a consistent median crack in a glass sheet to promote desirable separation along the median crack.

In a first aspect A1, a method for separating a glass sheet according to the present disclosure includes the steps of: engaging a first surface of a glass sheet with a scoring wheel, the glass sheet comprising a second surface opposite the first surface and a sheet thickness between the first surface and the second surface; moving the scoring wheel along the first surface of the glass sheet with a scoring rate of at least about 35 meters per minute; applying and maintaining a force on the first surface of the glass sheet with the scoring wheel while the scoring wheel is moved along the first surface of the glass sheet, the force being within a predetermined force of about 1.0 newton; and forming a median crack with the scoring wheel, the median crack extending along a length of the first surface and into the glass sheet, the median crack defining a crack depth extending into the glass sheet, the crack depth being less than the sheet thickness and varying by less than about 2.0% along the length of the median crack on the first surface.

In a second aspect A2, the present disclosure provides method aspect A1, wherein applying the force comprises the steps of: a position of the scoring wheel in a first direction transverse to the first surface of the glass sheet is maintained with a cylinder coupled to the scoring wheel.

In a third aspect A3, the present disclosure provides the method of aspect A2, further comprising the steps of: the rod of the cylinder is restrained from movement with a linear motion guide engaged with the rod of the cylinder, wherein the linear motion guide permits movement of the rod in the first direction and restrains movement of the rod in a direction transverse to the first direction.

In a fourth aspect A4, the present disclosure provides the method of any one of aspects A2 or A3, wherein applying the force comprises the steps of: the position of the scribing wheel in the first direction is maintained with a first actuator coupled to the scribing wheel through the cylinder.

In a fifth aspect A5, the present disclosure provides the method of any one of aspects A1-A4, wherein the fracture depth of the median fracture varies by less than about 1.5% along the length of the median fracture on the first surface.

In a sixth aspect A6, the present disclosure provides the method of any one of aspects A1-A5, wherein the fracture depth of the median fracture varies by less than about 1.0% along the length of the median fracture on the first surface.

In a seventh aspect A7, the present disclosure provides the method of any one of aspects A1-A6, wherein the scoring rate is at least about 40 meters per minute.

In an eighth aspect A8, the present disclosure provides the method of any one of aspects A1-A7, wherein the scoring rate is at least about 45 meters per minute.

In a ninth aspect A9, the present disclosure provides the method of any one of aspects A1-A8, wherein the fracture depth varies by less than about 5 microns along the length of the median fracture on the first surface.

In a tenth aspect a10, the present disclosure provides the method of any one of aspects A1-A9, wherein the sheet thickness is less than about 0.5 millimeters.

In an eleventh aspect a11, the present disclosure provides the method of any one of aspects A1-A9, wherein the sheet thickness is about 0.30 millimeters.

In a twelfth aspect a12, the present disclosure provides the method of any one of aspects A1-a11, wherein applying the force on the first surface of the glass sheet with the scoring wheel further comprises the steps of: the force is maintained within about 0.2 newtons of the predetermined force.

In a thirteenth aspect a13, the present disclosure provides a glass cutting system comprising: a scribing wheel; a regulator; a cylinder coupled to the scribe wheel and in communication with the regulator; a second actuator coupled to the cylinder; and a controller communicatively coupled to the regulator and the second actuator, the controller comprising a processor and a memory, the memory comprising a set of computer-readable and executable instructions that, when executed by the processor, cause the processor to: directing the regulator to apply and maintain a force on the first surface of the glass sheet with the scoring wheel using the air cylinder, the force being within a predetermined force of about 1.0 newton; and directing the second actuator to move the scoring wheel along the glass sheet with a scoring rate of at least about 35 meters per minute, thereby forming a median crack extending along a length of the first surface and into the glass sheet, the median crack defining a crack depth extending into the glass sheet, the crack depth being less than a sheet thickness of the glass sheet and varying on the first surface along the length of the median crack by less than about 5 microns.

In a fourteenth aspect a14, the present disclosure provides the system of aspect a13, further comprising the steps of: a second actuator coupled to the cylinder.

In a fifteenth aspect a15, the present disclosure provides the system of aspect a14, wherein the first actuator is communicatively coupled to the controller, and wherein the set of computer-readable and executable instructions, when executed by the processor, further cause the processor to direct the first actuator to move the cylinder toward the first surface of the glass sheet.

In a sixteenth aspect a16, the present disclosure provides the system of any one of aspects a13-a15, further comprising: a linear motion guide engaged with the rod of the cylinder, wherein the linear motion guide allows movement of the rod in a first direction and restricts movement of the rod in a direction transverse to the first direction.

In a seventeenth aspect a17, the present disclosure provides the system of any one of aspects a13-a16, wherein the set of computer-readable and executable instructions, when executed by the processor, cause the processor to direct the second actuator to move the scoring wheel along the glass sheet with a scoring rate of at least about 40 meters per minute.

In an eighteenth aspect a18, the present disclosure provides the system of any one of aspects a13-a17, wherein the set of computer-readable and executable instructions, when executed by the processor, further cause the processor to direct the adjuster to utilize the air cylinder to apply and maintain the force with the scoring wheel on the first surface of the glass sheet, the force being within about 0.2 newtons of the predetermined force.

In a nineteenth aspect a19, the present disclosure provides the system of any one of aspects a13-a18, wherein the fracture depth of the median fracture varies by less than about 1.5% along the length of the median fracture on the first surface.

In a twentieth aspect a20, the present disclosure provides the system of any one of aspects a13-a19, wherein applying the force on the first surface of the glass sheet with the scoring wheel comprises the steps of: maintaining the force within about 0.2 newtons of the predetermined force.

Additional features and advantages of the embodiments 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 as 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 in and constitute a part of this specification. The drawings illustrate various embodiments described herein and, together with the description, serve to explain the principles and operations of the claimed subject matter.

Drawings

Fig. 1 schematically depicts a perspective view of a glass cutting system according to one or more embodiments shown or described herein;

FIG. 2 schematically depicts a control diagram of the glass cutting system of FIG. 1, in accordance with one or more embodiments shown or described herein;

FIG. 3 schematically depicts the glass cutting system of FIG. 1 and a glass sheet according to one or more embodiments shown or described herein;

FIG. 4 schematically depicts the glass sheet of FIG. 3 having a median crack extending into the glass sheet, in accordance with one or more embodiments shown or described herein;

FIG. 5A schematically depicts a perspective view of the glass sheet and median crack of FIG. 4, in accordance with one or more embodiments shown or described herein;

FIG. 5B schematically depicts a glass sheet having a non-uniform median crack; and

fig. 5C schematically depicts another glass sheet having a non-uniform median crack.

Detailed Description

Reference will now be made in detail to embodiments of an apparatus and method for separating glass sheets. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. A glass cutting system according to embodiments described herein generally includes a scoring wheel and an air cylinder that maintains the position of the scoring wheel in a first direction transverse to the glass sheet. In detail, the air cylinder may maintain the position of the scoring wheel in the first direction such that the scoring wheel may maintain a constant or nearly constant force on the glass sheet to form a median crack in the glass sheet. By maintaining a constant or nearly constant force on the glass sheet, the variation in crack depth of the median crack can be minimized. By minimizing the variation in the depth of the crack, undesirable and/or unpredictable separation of the glass sheet along the median crack may be minimized, thereby reducing chipping and reducing manufacturing costs. These and other embodiments will be described in more detail herein with particular reference to the drawings.

The phrase "communicatively coupled" is used herein to describe the interconnectivity of various components of the glass cutting system, and means that the components are connected by wires, optical fibers, or wirelessly so that electrical, optical, and/or electromagnetic signals can be exchanged between the components.

Referring now to fig. 1, an example glass cutting system 100 is schematically depicted. In an embodiment, the glass cutting system 100 generally includes a cutting member, depicted as a scoring wheel 140. As described in more detail herein, the glass cutting system 100 is operable to move the scoring wheel 140 in a first direction (i.e., in the y-direction as depicted) toward or away from the glass sheet. The glass cutting system 100 is also operable to move the scoring wheel 140 at least in a second direction (i.e., in the x-direction as depicted) and/or in a third direction (i.e., in the z-direction as depicted), the second direction and the third direction being transverse to the first direction. In an embodiment, scoring wheel 140 comprises a wheel having a suitably selected geometry to induce controlled mechanical damage to the glass sheet. Scribing wheel 140 may comprise an abrasive scribing wheel such as a saw tooth scribing wheel, a diamond scribing wheel, or the like.

In the embodiment depicted in fig. 1, the glass cutting system 100 can include a cylinder 120 coupled to a score wheel 140. The cylinder 120 may generally include a body 122 and a rod 124 movably engaged with the body 122. In detail, the rod 124 may be extended outwardly from the body 122 or drawn toward the body 122, thereby moving the rod 124. In an embodiment, the cylinder 120 is in communication with a regulator 115 that can regulate the pressure of air supplied to the cylinder 120. By adjusting the air pressure supplied to the air cylinder 120, the rod 124 may be moved relative to the body 122 and the position of the rod 124 relative to the body 122 may be maintained (e.g., maintained in the first direction). Because the scoring wheel 140 is coupled to the lever 124, the position of the scoring wheel 140 in the first direction may be maintained by maintaining the position of the lever 124 relative to the body 122 via the adjuster 115. As described in more detail herein, the cylinder 120 and the regulator 115 can assist in maintaining the position of the score wheel 140 to apply a force to the glass sheet with the score wheel 140.

In some embodiments, the glass cutting system 100 can include one or more sensors that detect the position of the score wheel 140. For example, in the embodiment depicted in fig. 1, the glass cutting system 100 includes a displacement sensor 117 structurally configured to detect the position of the cutting wheel 140 in a first direction (i.e., in the y-direction as depicted). Although in the embodiment depicted in fig. 1, the glass cutting system 100 includes the displacement sensor 117, it should be appreciated that the glass cutting system 100 may also include any suitable sensor for detecting the position of the cutting wheel 140 in the first direction, such as, and not limited to, hall effect sensors, eddy current sensors, inductive sensors, laser sensors, piezoelectric sensors, and the like.

In some embodiments, the glass cutting system 100 can include a linear motion rail 130 that engages the rod 124 of the cylinder 120. The linear motion guide 130 generally allows movement of the rod 124 in a first direction (i.e., in the y-direction as depicted) while limiting movement of the rod 124 in a direction transverse to the first direction (e.g., a second direction and/or a third direction (i.e., the x-direction and the z-direction as depicted), respectively). As described in more detail herein, by limiting movement of the lever 124 in a direction transverse to the first direction, the linear motion guide 130 can help minimize movement of the score wheel 140 in other directions (i.e., in the x-direction and the z-direction, respectively, as depicted) as the score wheel 140 moves along the glass sheet.

In some embodiments, the air cylinder 120 can be coupled to a first actuator 110 operable to move the air cylinder 120 toward or away from the glass sheet. For example, in the embodiment depicted in fig. 1, the cylinder 120 may be coupled to a cylinder plate 114, which may be coupled to the actuator plate 112. In an embodiment, the actuator plate 112 may be engaged with the first guide 116 and movable along the first guide 116. The first actuator 110 is coupled to the actuator plate 112 and is generally operable to move the actuator plate 112, and thus the cylinder plate 114 and the cylinder 120. By moving the cylinder 120 in a first direction (i.e., in the y-direction as depicted), the first actuator 110 can position the cylinder 120, and thus the score wheel 140, on the glass sheet. For example, the first actuator 110 may be operable to move the scoring wheel 140 to engage the glass sheet, while the air cylinder 120 may assist in maintaining contact between the scoring wheel 140 and the glass sheet as the scoring wheel 140 moves along the glass sheet. For example, the air cylinder 120 may allow the scoring wheel 140 to move in a first direction (i.e., in the y-direction as depicted) to accommodate changes in the glass sheet in the first direction so that contact between the scoring wheel 140 and the glass sheet is maintained as the scoring wheel 140 moves along the glass sheet.

In some embodiments, the first actuator 110 may include any actuator suitable for moving the cylinder 120, such as, and not limited to, a Direct Current (DC) motor, an Alternating Current (AC) motor, and the like, and may be a servo motor including a positioning encoder. Although in the embodiment depicted in fig. 1, the glass cutting system 100 includes the actuator plate 112 and the cylinder plate 114, this is merely an example. In embodiments, the first actuator 110 may be coupled to the cylinder 120 in any suitable manner to allow the first actuator 110 to move the cylinder 120, and thus the score wheel 140.

In some embodiments, the glass cutting system 100 further includes one or more linear actuators operable to move the cylinder 120, and thus the score wheel 140, in the second and third directions (i.e., in the x and y directions, respectively). In the embodiment depicted in fig. 1, the glass cutting system 100 includes a second actuator 111 coupled to a cylinder 120 and/or a first actuator 110. The second actuator 111 is operable to move the cylinder 120, and thus the scribing wheel 140, at least in a second direction (i.e. in the x-direction as depicted). In some embodiments, the glass cutting system 100 further includes a third actuator 113 operable to move the cylinder 120, and thus the score wheel 140, in a third direction (i.e., in the z-direction as depicted). The second actuator 111 and the third actuator 113 may comprise any suitable actuator to move the cylinder 120, and thus the scoring wheel 140. For example and without limitation, the second actuator 111 and the third actuator 113 may each be a linear actuator including a DC motor, an AC motor, or the like, and may each be a servo motor including a positioning encoder. In the embodiment depicted in fig. 1, the second actuator 111 and the third actuator 113 are coupled to the cylinder 120 by an actuator plate 112 and a cylinder plate 114, however, this is merely an example. In embodiments, the second actuator 111 and the third actuator 113 may be coupled to the cylinder 120 in any suitable manner to move the cylinder 120 and the score wheel 140.

Referring to FIG. 2, a control diagram of the glass cutting system 100 is schematically depicted. In an embodiment, the glass cutting system 100 includes a controller 160 that includes a processor 162, a data storage component 164, and/or a memory component 166. The memory component 166 may be configured as volatile and/or non-volatile memory, and thus may include random access memory (including SRAM, DRAM, and/or other types of RAM), flash memory, secure Digital (SD) memory, cache, compact Disc (CD), digital Versatile Disc (DVD), and/or other types of non-transitory computer-readable media. Depending on the particular embodiment, these non-transitory computer-readable media may be located within the controller 160 and/or external to the controller 160.

The memory component 166 may store operating logic, analysis logic, and communication logic in the form of one or more sets of computer-readable and executable instructions. The analysis logic and communication logic may each include a plurality of different logic segments, each of which may be implemented as a computer program, firmware, and/or hardware, for example. A local interface is also included in the controller 160 and may be implemented as a bus or other communication interface to facilitate communication among the components of the controller 160.

Processor 162 may include any processing component operable to receive and execute instructions (e.g., from data storage component 164 and/or memory component 166). Although the components in fig. 2 are depicted as being located within the controller 160, this is merely an example, and in some embodiments, one or more of the components may be located external to the controller 160. Further, although the controller 160 is depicted as a single component, this is also an example, and the controller 160 may include any suitable number of components.

In an embodiment, the controller 160 is communicatively coupled to one or more components of the glass cutting system 100. For example, in the embodiment depicted in fig. 2, the controller 160 is communicatively coupled to the first actuator 110, the second actuator 111, the third actuator 113, and the regulator 115. In an embodiment, the controller 160 can direct the first actuator 110, the second actuator 111, the third actuator 113, and the cylinder 120 (directed via the regulator 115) to move such that the glass cutting system 100 forms a crack in the glass sheet, as described in more detail herein.

For example, and referring to fig. 3, a side view of the glass cutting system 100 and glass sheet 200 is schematically depicted. In the embodiment depicted in fig. 3, glass sheet 200 defines a first edge 206 and a second edge 208 positioned opposite first edge 206. Although in the embodiment depicted in fig. 3, the glass sheet 200 is a discrete sheet defining the first edge 206 and the second edge 208, this is merely an example, and the glass sheet 200 may be a continuous web.

In an embodiment, the glass sheet 200 defines a first surface 202 and a second surface 204 positioned opposite the first surface 202, and the glass sheet 200 defines an estimated sheet thickness St between the first surface 202 and the second surface 204. As depicted and referred to herein, the first direction (i.e., the y-direction) is transverse to the first surface 202 of the glass sheet 200. In some embodiments, the sheet thickness St is less than 0.5 millimeters. In some embodiments, sheet thickness St is between 0.25 millimeters and 0.5 millimeters, inclusive of the endpoints and all ranges therebetween. In some embodiments, the sheet thickness St is about 0.25 millimeters. In some embodiments, the sheet thickness is about 0.30 millimeters. In some embodiments, the sheet thickness St is about 0.4 millimeters. In some embodiments, the sheet thickness St is about 0.5 millimeters.

To separate portions of the glass sheet 200, the scoring wheel 140 of the glass cutting system 100 engages the first surface 202 of the glass sheet 200. For example, and referring to fig. 1-3, in some embodiments, the controller 160 directs the regulator 115 to move the cylinder 120 to move the scoring wheel 140 toward the first surface 202 to engage (e.g., contact) the first surface 202 of the glass sheet 200.

In some embodiments, the controller 160 additionally or alternatively directs the first actuator 110 to move the cylinder 120 toward the first surface 202 of the glass sheet 200. For example, in some embodiments, the controller 160 can direct the first actuator 110 to move the cylinder 120 toward the first surface 202 of the glass sheet 200 such that the scoring wheel 140 engages the first surface 202 of the glass sheet 200.

With the scoring wheel 140 engaged with the first surface 202 of the glass sheet 200, the scoring wheel 140 is moved along the first surface 202 of the glass sheet 200 at a scoring rate. For example, in an embodiment, the controller 160 directs the second actuator 111 and/or the third actuator 113 to move the cylinder 120, and thus the score wheel 140, along the first surface 202 of the glass sheet 200.

In some embodiments, the second actuator 111 and/or the third actuator 113 moves the score wheel 140 along the first surface 202 of the glass sheet 200 with a score rate of at least about 35 meters per minute. In some embodiments, the second actuator 111 and/or the third actuator 113 move the scribing wheel 140 between about 35 meters per minute and about 60 meters per minute, including the endpoints and including all ranges therebetween. In some embodiments, the second actuator 111 and/or the third actuator 113 moves the score wheel 140 along the first surface 202 of the glass sheet 200 with a score rate of at least about 40 meters per minute. In some embodiments, the second actuator 111 and/or the third actuator 113 moves the score wheel 140 along the first surface 202 of the glass sheet 200 at a score rate of between about 40 meters per minute and about 60 meters per minute, including the endpoints and including all ranges therebetween. In some embodiments, the second actuator 111 and/or the third actuator 113 moves the score wheel 140 along the first surface 202 of the glass sheet 200 with a score rate of at least about 45 meters per minute. In some embodiments, the second actuator 111 and/or the third actuator 113 moves the score wheel 140 along the first surface 202 of the glass sheet 200 at a score rate of between about 45 meters per minute and about 60 meters per minute, including the endpoints and including all ranges therebetween.

As the scoring wheel 140 moves along the first surface 202 of the glass sheet 200, the scoring wheel 140 exerts a force on the first surface 202 of the glass sheet 200. For example, in an embodiment, the controller 160 directs the cylinder 120 (via the regulator 115) and/or the first actuator 110 to maintain the position of the scoring wheel 140 such that the scoring wheel 140 applies a force to the first surface 202 of the glass sheet 200. In an embodiment, the scoring wheel 140 maintains the force on the first surface 202 of the glass sheet 200 within a predetermined force of 1.0 newtons as the scoring wheel 140 is moved along the first surface 202 of the glass sheet 200. In some embodiments, the scoring wheel 140 maintains the force on the first surface 202 of the glass sheet 200 within a predetermined force of about 0.75 newtons as the scoring wheel 140 is moved along the first surface 202 of the glass sheet 200. In some embodiments, the scoring wheel 140 maintains the force on the first surface 202 of the glass sheet 200 within a predetermined force of about 0.5 newtons as the scoring wheel 140 is moved along the first surface 202 of the glass sheet 200. In some embodiments, the scoring wheel 140 maintains the force on the first surface 202 of the glass sheet 200 within a predetermined force of about 0.2 newtons as the scoring wheel 140 is moved along the first surface 202 of the glass sheet 200.

In an embodiment, the predetermined force is associated with a predetermined cutting pressure. Without being bound by theory, the pressure applied to the first surface 202 of the glass sheet 200 by the scoring wheel 140 depends on the force applied to the first surface 202 and the geometry of the scoring wheel 140. In some embodiments, the predetermined force is associated with a predetermined cutting pressure of about 0.09 megapascals. In some embodiments, the predetermined force is associated with a predetermined cutting pressure of about 0.12 megapascals. In some embodiments, the predetermined force is associated with a predetermined cutting pressure of between about 0.09 and about 0.12 megapascals, including the endpoints and including all ranges therebetween. In some embodiments, the predetermined force is associated with a predetermined cutting pressure of between about 0.05 mpa and about 0.15 mpa, inclusive of the endpoints and inclusive of all ranges therebetween. In some embodiments, the predetermined force is associated with a predetermined cutting pressure of between about 0.05 megapascals and about 0.20 megapascals, including the endpoints and including all ranges therebetween. In some embodiments, the predetermined force is associated with a predetermined cutting pressure of between about 0.05 mpa and about 0.25 mpa, inclusive of the endpoints and inclusive of all ranges therebetween. In some embodiments, the predetermined force is associated with a predetermined cutting pressure of between about 0.05 mpa and about 0.30 mpa, inclusive of the endpoints and inclusive of all ranges therebetween.

As the scoring wheel 140 is forced by moving along the first surface 202 of the glass sheet 200 at the scoring rate, the scoring wheel 140 forms a median crack that extends into the first surface 202. For example, and referring to fig. 4, a side view of a glass sheet 200 is depicted having a median crack 210 formed in the glass sheet 200. The score wheel 140 forms a median crack 210 that extends along the length Le of the first surface 202 and into the glass sheet 200. Although in the embodiment depicted in fig. 4, the length Le is depicted as extending between and terminating at the first and second edges 206, 208, it should be understood that this is merely an example. For example, in some embodiments, median slit 210 may be confined between first edge 206 and/or second edge 208. Further, while in the embodiment depicted in fig. 4, the glass sheet 200 is depicted as including a first edge 206 and a second edge 208, it should be appreciated that the glass sheet 200 may be a continuous glass web and the median crack 210 may extend a length Le along the continuous glass web.

The median crack 210 defines a crack depth Cd extending into the glass sheet 200, and the crack depth Cd is less than the sheet thickness St. In some embodiments, the crack depth Cd is less than or equal to about 0.75St. In some embodiments, the crack depth Cd is less than or equal to about 0.5St. In some embodiments, the crack depth Cd ≦ 0.4St. In some embodiments, the crack depth Cd is less than or equal to about 0.3St. In some embodiments, the target fracture depth Td ≦ 0.25St. In some embodiments, the crack depth Cd is less than or equal to about 0.2St.

In an embodiment, the fracture depth Cd of the median fracture 210 varies (e.g., varies in the y-direction as depicted) along the length Le of the median fracture 210 by a variation v, which may be expressed as a percentage of the fracture depth Cd. In some embodiments, such as embodiments in which the sheet thickness St (fig. 3) is greater than or equal to 0.3 millimeters, the crack depth Cd varies by less than 2.0% across the length Le of the median crack 210 on the first surface 202 of the glass sheet 200. In an embodiment, such as an embodiment in which the sheet thickness St (fig. 3) is greater than or equal to 0.3 millimeters, the crack depth Cd of the median crack 210 varies by less than 1.5% along the length Le of the median crack 210 on the first surface 202 of the glass sheet 200. In an embodiment, such as an embodiment in which the sheet thickness St (fig. 3) is greater than or equal to 0.3 millimeters, the crack depth Cd of the median crack 210 varies by less than 1.0% along the length Le of the median crack 210 on the first surface 202 of the glass sheet 200.

Characterized in another way, in an embodiment, the variation in crack depth v is less than about 5 microns along the length Le of the median crack 210 on the first surface 202 of the glass sheet 200. In some embodiments, the variation in crack depth v is less than about 4 microns along the length Le of the median crack 210 on the first surface 202 of the glass sheet 200. In some embodiments, the variation in crack depth v is less than about 3 microns along the length Le of the median crack 210 on the first surface 202 of the glass sheet 200. In some embodiments, the variation in crack depth v is less than about 2 microns along the length Le of the median crack 210 on the first surface 202 of the glass sheet 200. In some embodiments, the variation in crack depth v is between about 2 microns and about 5 microns, inclusive, and all ranges therebetween, along the length Le of the median crack 210 on the first surface 202 of the glass sheet 200. By minimizing the variation in the crack depth Cd, undesirable separation of the glass sheet 200 along the median crack 210 may be minimized.

For example and with reference to fig. 5A, 5B, and 5C, perspective views of

glass sheets

200, 200', and 200", including

median slits

210, 210', and 210", respectively, are depicted. In the example depicted in fig. 5A, the median crack 210 defines a substantially uniform crack depth Cd extending into the first surface 202 of the glass sheet 200. Because the crack depth Cd is substantially uniform, separation of the glass sheet 200 along the median crack 210 will also be substantially uniform and undesirable breakage will be minimized.

In contrast to fig. 5B and with reference to fig. 5B, a perspective view of a glass sheet 200 'including a non-uniform median crack 210' is depicted. In fig. 5B, the median crack 210 'of the glass sheet 200' defines a pit 230 'that extends from the median crack 210' (i.e., extends in the y-direction as depicted). The pits 230 'may be formed, for example, by a change in the force applied by the cutting member (e.g., scoring wheel) to the glass sheet 200' (e.g., an undesirable increase in force). The pits 230 'interrupt the uniformity of the median crack 210' and may cause uneven or undesirable separation of the glass sheet 200 'along the median crack 210'.

Similarly and with reference to fig. 5C, a perspective view of another glass sheet 200 "including a non-uniform median crack 210" is depicted. In fig. 5C, the median crack 210 "of the glass sheet 200" defines a gap 232 "that extends from the median crack 210" (i.e., extends in the y-direction as depicted). The gap 232 "can be formed, for example, by a change in the force applied by the cutting member (e.g., score wheel) to the glass sheet 200" (e.g., an undesirable reduction in force). Similar to the crater 230' (fig. 5B), the gap 232 "interrupts the uniformity of the median crack 210" and can cause uneven or undesirable separation of the glass sheet 200 "along the median crack 210".

Referring again to fig. 1-4, by minimizing the variation in the crack depth Cd, the non-uniform separation of the glass sheet 200 can be minimized. As outlined above, variations in the crack depth Cd may be minimized by maintaining a consistent force on the glass sheet 200 with the scoring wheel 140, for example, by the air cylinder 120.

Also, by maintaining a consistent force with the scoring wheel 140, the scoring rate may be increased while maintaining acceptable crack depth Cd variation. In detail, as the scribing rate increases, the effect of the inconsistent force applied by the scribing wheel 140 on the crack depth Cd may be amplified, resulting in greater variation in the crack depth Cd. By maintaining a consistent force on the glass sheet 200 with the score-wheel 140, for example, using the air cylinder 120, the scoring rate of the score-wheel 140 can be increased while minimizing variations in the crack depth Cd. By increasing the score line rate, the glass sheet 200 can be separated more quickly, thereby increasing manufacturing throughput.

Thus, it should now be appreciated that a glass cutting system according to embodiments described herein generally includes a scoring wheel and an air cylinder that maintains the position of the scoring wheel in a first direction transverse to the glass sheet. In detail, the air cylinder may maintain the position of the scoring wheel in the first direction such that the scoring wheel may maintain a constant or nearly constant force on the glass sheet to form a median crack in the glass sheet. By maintaining a constant or nearly constant force on the glass sheet, the variation in crack depth of the median crack can be minimized. By minimizing the variation in crack depth, undesirable and/or unpredictable separation of the glass sheet along the median crack may be minimized, thereby reducing debris and reducing manufacturing costs.

It is noted that recitations herein of a component of the present disclosure being "configured" in a particular manner to embody a particular property or function in a particular manner are structural recitations as opposed to recitations of intended use. More specifically, references herein to the manner in which a component is "structurally configured" indicates the actual physical condition of the component and, as such, is to be taken as an exact recitation of the structural characteristics of the component.

It is noted that terms like "preferably," "commonly," and "generally" when used herein are not utilized to limit the scope of the disclosure or to imply that certain features are critical, essential, or even important to the structure or function of the claims. Rather, these terms are merely intended to identify particular aspects of embodiments of the present disclosure or to emphasize alternative or additional features that may or may not be utilized in a particular embodiment of the present disclosure.

For the purposes of describing and defining the present disclosure, the terms "substantially" and "about" are utilized herein to represent the inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement, or other representation. The terms "substantially" and "about" are also utilized herein to represent the degree by which a quantitative representation may vary from a stated reference without resulting in a change in the basic function of the subject matter at issue.

One or more of the following claims uses the term "wherein" as the transitional phrase. For the purposes of defining the disclosure, this term is introduced in the claims as an open-ended transition sentence that introduces recitations of a series of characteristics of structures, and should be interpreted in a manner similar to the more commonly used open-ended term "comprising".

Where the objects of the present disclosure have been described in detail and with reference to specific embodiments thereof, it is noted that even though specific components are depicted in each of the accompanying drawings that accompany the present specification, the various details disclosed herein should not be considered as implying that such details relate to components that are essential parts of the various embodiments described herein. Further, it will be understood that modifications and variations are possible without departing from the scope of the disclosure, including but not limited to the embodiments defined in the appended claims. More specifically, although some aspects of the present disclosure are identified herein as preferred or particularly advantageous, it is contemplated that the present disclosure is not necessarily limited to these aspects.

Claims

1. A method for separating a glass sheet, the method comprising the steps of:

engaging a first surface of a glass sheet with a scoring wheel, the glass sheet comprising a second surface opposite the first surface and a sheet thickness between the first surface and the second surface;

moving the scoring wheel along the first surface of the glass sheet with a scoring rate of at least about 35 meters per minute;

applying and maintaining a force on the first surface of the glass sheet with the scoring wheel as the scoring wheel moves along the first surface of the glass sheet, the force being within a predetermined force of about 1.0 newton; and

forming a median crack with the scoring wheel, the median crack extending along a length of the first surface and into the glass sheet, the median crack defining a crack depth extending into the glass sheet, the crack depth being less than the sheet thickness and varying by less than about 2.0% along the length of the median crack on the first surface.

2. The method of claim 1, wherein the step of applying the force comprises the steps of: maintaining a position of the scoring wheel in a first direction transverse to the glass sheet with an air cylinder coupled to the scoring wheel.

3. The method of claim 2, further comprising the steps of: restricting movement of a rod of the cylinder with a linear motion guide engaged with the rod of the cylinder, wherein the linear motion guide permits movement of the rod in the first direction and restricts movement of the rod in a direction transverse to the first direction.

4. The method of claim 2, wherein the step of applying the force comprises the steps of: maintaining the position of the scoring wheel in the first direction with a first actuator coupled to the scoring wheel by the cylinder.

5. The method of claim 1, wherein the fracture depth of the median fracture varies by less than about 1.5% along the length of the median fracture on the first surface.

6. The method of claim 1, wherein the fracture depth of the median fracture varies by less than about 1.0% along the length of the median fracture on the first surface.

7. The method of claim 1, wherein the scoring rate is at least about 40 meters per minute.

8. The method of claim 1, wherein the scoring rate is at least about 45 meters per minute.

9. The method of claim 1, wherein the fracture depth varies by less than about 5 microns on the first surface along the length of the median fracture.

10. The method of claim 1, wherein the sheet thickness is less than about 0.5 millimeters.

11. The method of claim 1, wherein the sheet thickness is about 0.30 millimeters.

12. The method of claim 1, wherein the step of applying the force on the first surface of the glass sheet with the scoring wheel further comprises the steps of: maintaining the force within about 0.2 newtons of the predetermined force.

13. A glass cutting system comprising:

a scribing wheel;

a regulator;

a cylinder coupled to the scribe wheel and in communication with the regulator;

a second actuator coupled to the cylinder; and

a controller communicatively coupled to the regulator and the second actuator, the controller comprising a processor and a memory, the memory comprising a set of computer-readable and executable instructions that, when executed by the processor, cause the processor to:

directing the regulator to apply and maintain a force with the scoring wheel on the first surface of the glass sheet using the air cylinder, the force being within a predetermined force of about 1.0 newton; and

directing the second actuator to move the scoring wheel along the glass sheet with a scoring rate of at least about 35 meters per minute, thereby forming a median crack extending along a length of the first surface and into the glass sheet, the median crack defining a crack depth extending into the glass sheet that is less than a sheet thickness of the glass sheet and that varies on the first surface along the length of the median crack by less than about 5 microns.

14. The glass cutting system of claim 13, further comprising: a first actuator coupled to the cylinder.

15. The glass cutting system of claim 14, wherein the first actuator is communicatively coupled to the controller, and wherein the set of computer-readable and executable instructions, when executed by the processor, further cause the processor to direct the first actuator to move the cylinder toward the first surface of the glass sheet.

16. The glass cutting system of claim 13, further comprising: a linear motion guide engaged with a rod of the air cylinder, wherein the linear motion guide allows movement of the rod in a first direction transverse to the glass sheet and restricts movement of the rod in a direction transverse to the first direction.

17. The glass cutting system of claim 13, wherein the set of computer-readable and executable instructions, when executed by the processor, cause the processor to direct the second actuator to move the scoring wheel along the glass sheet with a scoring rate of at least about 40 meters per minute.

18. The glass cutting system of claim 13, wherein the set of computer-readable and executable instructions, when executed by the processor, further cause the processor to direct the adjuster to utilize the air cylinder to apply and maintain the force with the scoring wheel on the first surface of the glass sheet, the force being within about 0.2 newtons of the predetermined force.

19. The glass cutting system of claim 13, wherein the crack depth of the median crack varies by less than about 1.5% along the length of the median crack on the first surface.

20. The glass cutting system of claim 13, wherein applying the force on the first surface of the glass sheet with the scoring wheel comprises: maintaining the force within about 0.2 newtons of the predetermined force.