WO2016081398A1 - Packages, methods of handling a stack of glass sheets and methods of fabricating a support frame - Google Patents

Packages, methods of handling a stack of glass sheets and methods of fabricating a support frame Download PDF

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Publication number
WO2016081398A1
WO2016081398A1 PCT/US2015/060971 US2015060971W WO2016081398A1 WO 2016081398 A1 WO2016081398 A1 WO 2016081398A1 US 2015060971 W US2015060971 W US 2015060971W WO 2016081398 A1 WO2016081398 A1 WO 2016081398A1
Authority
WO
WIPO (PCT)
Prior art keywords
sheets
stack
support frame
package
vibration
Prior art date
Application number
PCT/US2015/060971
Other languages
French (fr)
Inventor
Adam James Ellison
Sangku Moon
Nicholas James Smith
Edward ZHMAYEV
Original Assignee
Corning Incorporated
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Corning Incorporated filed Critical Corning Incorporated
Priority to JP2017526838A priority Critical patent/JP2017536305A/en
Priority to CN201580073473.7A priority patent/CN107207151A/en
Priority to KR1020177016502A priority patent/KR20170085099A/en
Publication of WO2016081398A1 publication Critical patent/WO2016081398A1/en

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65GTRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G49/00Conveying systems characterised by their application for specified purposes not otherwise provided for
    • B65G49/05Conveying systems characterised by their application for specified purposes not otherwise provided for for fragile or damageable materials or articles
    • B65G49/06Conveying systems characterised by their application for specified purposes not otherwise provided for for fragile or damageable materials or articles for fragile sheets, e.g. glass
    • B65G49/063Transporting devices for sheet glass
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D85/00Containers, packaging elements or packages, specially adapted for particular articles or materials
    • B65D85/30Containers, packaging elements or packages, specially adapted for particular articles or materials for articles particularly sensitive to damage by shock or pressure
    • B65D85/48Containers, packaging elements or packages, specially adapted for particular articles or materials for articles particularly sensitive to damage by shock or pressure for glass sheets
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65GTRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G49/00Conveying systems characterised by their application for specified purposes not otherwise provided for
    • B65G49/05Conveying systems characterised by their application for specified purposes not otherwise provided for for fragile or damageable materials or articles
    • B65G49/06Conveying systems characterised by their application for specified purposes not otherwise provided for for fragile or damageable materials or articles for fragile sheets, e.g. glass
    • B65G49/062Easels, stands or shelves, e.g. castor-shelves, supporting means on vehicles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65GTRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G2201/00Indexing codes relating to handling devices, e.g. conveyors, characterised by the type of product or load being conveyed or handled
    • B65G2201/02Articles
    • B65G2201/0214Articles of special size, shape or weigh
    • B65G2201/022Flat

Definitions

  • the present disclosure relates generally to packages, methods of handling a stack of glass sheets and methods of fabricating a support frame and, more particularly, to a packages that tune a natural frequency of deflection of a stack of glass sheets to include a first mode of vibration greater than 10 Hz.
  • the disclosure further relates to methods of handling a stack of glass sheets including the step of tuning the natural frequency of deflection of the stack of sheets to include a first mode of vibration greater than a predetermined frequency.
  • the disclosure also relates to methods of fabricating a support frame including the step of designing the support frame to tune a natural frequency of deflection of a stack of sheets supported by the support frame to include a first mode of vibration above a predetermined frequency.
  • a package comprises a support frame including a lattice of support elements defining a network of openings.
  • the package further includes a stack of sheets supported by the support frame and spanning over the network of openings, wherein the package tunes a natural frequency of deflection of the stack of sheets to include a first mode of vibration greater than 10 Hz.
  • the first mode of vibration is greater than 33 Hz.
  • the first mode of vibration is greater than 50 Hz.
  • the support frame defines at least one node of vibration of the stack of sheets.
  • the support frame is configured to support the stack of sheets at an angle of inclination relative to a direction of gravity.
  • the angle of inclination is within a range of from about 0° to about 90°.
  • the support frame comprises a curved support structure and sheets of the stack of sheets are substantially curved.
  • the package further comprises interleaf material positioned between adjacent sheets of the stack of sheets.
  • the package further comprises a securement device configured to maintain a position of the stack of sheets with respect to the support frame, wherein the securement device further tunes the natural frequency of deflection of the stack of sheets to include the first mode of vibration greater than 10 Hz.
  • the package further comprises a dampening device configured to tune the frequency of vibrations imposed on the package away from the natural frequency of deflection of the stack of sheets.
  • a method for handling a stack of sheets with a support frame including a lattice of support elements defining a network of openings.
  • the method includes the step of tuning a natural frequency of deflection of the stack of sheets to include a first mode of vibration greater than a predetermined frequency by supporting the stack of sheets with the support frame.
  • the predetermined frequency is greater than 10 Hz.
  • the predetermined frequency is greater than 33 Hz.
  • the predetermined frequency is greater than 50 Hz.
  • the step of tuning further includes pressing the stack of sheets against the support frame.
  • the method further comprises the step of designing the support frame to tune the natural frequency of deflection of the stack of sheets to include the first mode of vibration greater than the predetermined frequency.
  • the support frame defines at least one node of vibration of the stack of sheets.
  • after the step of tuning further comprising the step of transporting the package with a vehicle that transmits vibrations to the package.
  • a method of fabricating a support frame comprising the step (I) of providing a lattice of support elements defining a network of openings, wherein the lattice of support elements is configured to support a stack of sheets while the sheets span over the network of openings.
  • the method further includes the step (II) of designing the support frame to tune a natural frequency of deflection of a stack of sheets supported by the support frame to include a first mode of vibration above a predetermined frequency.
  • the predetermined frequency is 10 Hz.
  • the predetermined frequency is 33 Hz.
  • the predetermined frequency is 50 Hz.
  • step (II) of designing the support frame includes adjusting the stiffness of the support frame to tune the natural frequency of deflection of the stack of sheets.
  • first embodiment, the second embodiment and the third embodiment can be provided alone or in combination with one or any combination of the embodiments discussed above.
  • FIG. 1 is a schematic side view of a package in accordance with aspects of the disclosure
  • FIG. 2 is a front view of the package taken at line 2-2 of FIG. 1;
  • FIG. 3 is a cross-sectional view of the package taken at line 3-3 of FIG. 2;
  • FIG. 4 is a cross-sectional view of another embodiment of a package
  • FIG. 5 is a cross-sectional view of the package taken at line 5-5 of FIG. 2;
  • FIG. 6 is front view of another embodiment of a package
  • FIG. 7 is a front view of a support frame of the package of FIG. 1;
  • FIG. 8 illustrates a first particle distribution pattern on a glass sheet
  • FIG. 9 illustrates a second particle distribution pattern on another glass sheet.
  • Glass sheets are commonly fabricated by a flowing molten glass to a forming body whereby a glass ribbon may be formed by a variety of ribbon forming processes, for example, slot draw, down-draw, fusion down-draw, or up-draw. Of course, glass ribbons may also be formed using other forming processes such as a float process. The glass ribbon from any of these processes may then be subsequently divided to provide sheet glass suitable for further processing into a desired display application.
  • the glass sheets can be used in a wide range of display applications, for example liquid crystal displays (LCDs), electrophoretic displays (EPD), organic light emitting diode displays (OLEDs), plasma display panels (PDPs), or the like.
  • LCDs liquid crystal displays
  • EPD electrophoretic displays
  • OLEDs organic light emitting diode displays
  • PDPs plasma display panels
  • glass sheets may need to be transported from one location to another. Typically, the glass sheets are transported with a conventional support frame designed to secure a stack of glass sheets in place.
  • FIGS. 8 and 9 illustrate particle distributions on two different glass sheets supported by two different support frames after unpacking and washing the transported glass sheets.
  • the hidden lines 801 of FIG. 8 illustrate the approximate location of the support elements in a first conventional support frame.
  • hidden lines 901 of FIG. 9 illustrate the approximate location of support elements of a second conventional support frame. As shown in FIGS.
  • particles were observed wherein 70-80% of the particles included a maximum dimension of from about 0.3 microns to about 5 microns. Not only was it surprising and unexpected that the particles existed, but it was still further surprising and unexpected that the particles appeared to be patterned in a halo configuration (e.g., see 803 in FIG. 8; 903 in FIG. 9) in the openings between the support elements 801, 901 of the respective support frames.
  • a halo configuration e.g., see 803 in FIG. 8; 903 in FIG. 9
  • a package can be provided that reduces deposition of particles (e.g., fibers) from the interleaf material on the major surfaces of the glass sheets.
  • a package 101 includes a plurality of glass sheets 109 that are arranged as a stack of sheets 105.
  • the stack of sheets can be various sizes, for example, a few hundred sheets at a time.
  • interleaf layer 107 such as paper, may be positioned between adjacent sheets 109 of the stack of sheets 105.
  • the package further includes a support frame 103 that may be formed from metal (e.g., aluminum), wood or other material that may effectively support the stack of glass sheets.
  • the support frame 103 includes a lattice of support elements 700 defining a network of openings 705.
  • the lattice of support elements 700 can include a plurality of horizontal support elements 701, 701b, 701c, 701d and a plurality of vertical support elements 703a, 703b, 703c.
  • the horizontal support elements are illustrated in a row of horizontal support elements where, as shown, a plurality of horizontal rows can be provided that are substantially parallel with respect to one another.
  • the plurality of vertical support elements are illustrated in a column of vertical support elements where, as shown, a plurality of vertical columns may be provided that are substantially parallel with respect to one another.
  • the support frame 103 can be configured to support the stack of sheets 105 at an angle of inclination "A" relative to a direction of gravity "G".
  • the angle of inclination "A" can be any angle within a range of from about 0° to about 90° such as from greater than 0° to less than 90°, such as from about 5° to about 45° such as from about 10° to about 25° although other angles may be provided in further embodiments.
  • the support frame 103 can further include a lower ledge 707.
  • the lower ledge 707 can support a weight of the stack of sheets 105 at a lower end 113 of the stack. More particularly, with an angle of inclination "A" greater than 0°, with reference to FIG. 7, outer faces 709 of the support elements 700 and an outer face 711 of the lower ledge 707 can act together support the weight of the stack of sheets 105.
  • the support elements 700 may comprise channel support elements that have the outer faces 709 that provide a support surface for the stack of glass sheets 105. Providing the support elements as a channel can reduce weight and material costs while still providing a relatively rigid support surface for the stack of glass sheets.
  • FIG. 3 illustrates the stack of glass sheets 105 being directly supported by the outer faces 709 with the understanding that an interleaf layer, a protective surface, or other feature may be provided to protect adjacent glass sheet from being damaged by the support frame 103.
  • a cushion layer 119 may be provided between the stack of sheets 105 and the outer faces 709 of the support elements 700 and the outer face 711 of the lower ledge 707.
  • the cushion layer 119 can help prevent scratching that may otherwise occur with relative movement between the stack of sheets 105 and the support frame 103.
  • the cushion layer may act as a damping device configured to tune the frequency of vibrations imposed on the package away from the natural frequency of deflection of the stack of sheets 105.
  • the damping device may help isolate the stack of glass sheets 105 from vibrations traveling through the support frame 103.
  • Such cushion layers 119 can be used to reduce or alter the frequency/amplitude imposed by the transportation and effectively raise the deflection frequencies to the desired range.
  • the cushion layer 119 can comprise a resilient foam, a resilient mat, or other cushion layer configuration.
  • damping devices such as strategic package wrapping, shocks, pads or other damping devises may be used to mitigate coupling of imposed frequencies into deflection.
  • the outer face 709 of the support elements 700 can provide a substantially flat planar support surface with a cross-section having a substantially straight profile as illustrated in FIG. 3.
  • the support frame 401 can alternatively include a curved support structure. Indeed, as shown, the support frame 401 can include support elements 402 defining a substantially curved support surface 403 with a cross-section having a substantially curved profile as illustrated in FIG. 4. As the stack of glass sheets 105 conforms to the shape of the support structure, the stack of glass sheets 105 includes a curved stack of sheets that conform to the curved shape of the support surface 403.
  • Providing the glass sheets with a curved configuration can increase the stiffness of the stack of glass sheets and also help strengthen the glass sheets against flexing, thereby raising the natural frequency of the deflection of the stack of sheets 105 when transporting the package 101.
  • a damping device similar to the cushion layer 119 can be provided by including a curved shape to conform to the curved shape of the support surface 403.
  • the curved cushion layer may increase the effective stiffness of the stack of sheets to raise the deflection frequencies to the desired range.
  • the support frame 103 can also include a stand 115 that can help support the support elements 700 in a proper orientation.
  • frame members 117 can attach the support elements 700 and/or the lower ledge 707 to the stand 115.
  • the package 101 can also comprise a securement device 111 configured to maintain a position of the stack of sheets 105 with respect to the support frame 103.
  • the securement device can include a plurality of press bars 121.
  • the press bars 121 may each be pulled against the stack of glass sheets 105 by straps 123 to clamp portions 501 of the stack of glass sheets 105 between a lower surface 503 of the press bars 121 and the outer face 709 of the support elements 700.
  • a protective interleaf or other material may be provided between the press bars 121 and the stack of glass sheets 105 to avoid scratching, cracking or otherwise damaging the glass sheets.
  • the clamped portions 501 are immobilized by the clamping action between the press bars 121 and the support elements 700.
  • the support frame also provides the network of openings 705 with portions of the stack of sheets 105 spanning over the network of openings.
  • the support frame 103 can define at least one node of vibration of the stack of sheets 105 wherein vertical movement of spanning portions 505 across the openings 705 may flex in directions 507a, 507b.
  • the stack of sheets 105 can include a first mode of vibration greater than a predetermined frequency such as greater than 10 Hz, greater than 33 Hz or greater than 50 Hz depending on the expected vibrations the package will be exposed to during transport.
  • a predetermined frequency such as greater than 10 Hz, greater than 33 Hz or greater than 50 Hz depending on the expected vibrations the package will be exposed to during transport.
  • the method can include the step of providing the lattice of support elements 700 defining the network of openings 705. As shown in the figures, the lattice of support elements 700 is configured to support the stack of sheets 105 while the sheets span over the network of openings 705. The method can further include the step of designing the support frame 103 to tune a natural frequency of deflection of a stack of sheets 105 supported by the support frame 103 to include a first mode of vibration above a predetermined frequency.
  • the support frame 103 can be fabricated to accommodate a particular stack of glass sheets with known stiffness, and other vibrational characteristics. Likewise, a frequency or range of vibrational frequencies to be avoided can be determined from a vibrational frequency distribution of expected vibrational frequencies likely to be encountered on a predetermined travel arrangement. With the known characteristics of the stack of glass sheets and the known expected vibrational frequencies to be encountered on the predetermined travel arrangement, the support frame 103 can be custom designed to tune a natural frequency of deflection of a stack of sheets supported by the support frame to include a first mode of vibration above the predetermined frequency expected during the travel arrangement.
  • the support frame 103 may be custom designed to tune the natural frequency of deflection of the stack of sheets 105 supported by the support frame 103 to include a first mode of vibration above 10 Hz, such as above 33 Hz such as above 50 Hz.
  • the support frame 103 may be custom designed to tune the natural frequency of the stack of sheets.
  • the support frame may be designed to tune the natural frequency of the stack of sheets by adjusting the stiffness of the support frame.
  • the stiffness of the support frame 103 may be increased by adding optional additional frame members 118 (shown in broken lines). Increasing the stiffness of the support frame 103 by adding the optional additional frame members 118 can raise the resonant frequency distribution to avoid high energy frequency vibrations typical of the expected transportation route.
  • optional additional support elements 706 shown in broken lines
  • vibrational nodes can be increased as well as the stiffness of the support frame 103 to desensitize the package from expected vibrations along predetermined transportation routes.
  • the securement device can facilitate tuning of the natural frequency of deflection of the stack of sheets 105 to include the first mode of vibration greater than 10 Hz, such as greater than 33 Hz, such as greater than 50 Hz.
  • the number of press bars and/or the configuration of press bars may be changed to tune the natural frequency of the stack of sheets.
  • vertical press bars 601 may link together the horizontal press bars 121 to tune the natural frequency of the stack of sheets.
  • an edge-constraint system or wrapping can also be provided to further modify the frequency distribution through node design.
  • the horizontal press bars 121 may be strategically located to counteract deflection modes imposed by the support frame 103.
  • one or more of the horizontal press bars 121 may be positioned along the dashed lines 715a, 715b, 715c to span across the openings 705 to help counteract the deflection modes imposed by the support frame 103.
  • methods are provided for handling the stack of sheets 105 with the support frame 103 including the lattice of support elements 700 defining the network of openings 705.
  • the method includes the step of tuning the natural frequency of deflection of the stack of sheets 105 to include a first mode of vibration greater than a predetermined frequency (e.g., greater than 10 Hz, greater than 33 Hz, or greater than 50 Hz) by supporting the stack of sheets 105 with the support frame 103.
  • a predetermined frequency e.g., greater than 10 Hz, greater than 33 Hz, or greater than 50 Hz
  • the step of tuning can include pressing the stack of sheets 105 against the support frame 103.
  • the press bars 121 may be pressed against the stack to press the stack against the support frame.
  • Different press bar configurations can be designed to help adjust the natural frequency of defection of the stack of sheets 105 without necessarily changing other characteristics of the support rack. For instance, if there is a desire to further tune the stack, a different press bar configuration may be selected (e.g., see FIG. 6) to tune the natural frequency of deflection of the stack of sheets 105.
  • the method can also include the step of designing the support frame to tune the natural frequency of deflection of the stack of sheets to include the first mode of vibration greater than the predetermined frequency.
  • stiffness of the support frame 103 may be increased by adding optional additional support elements 706 (shown in broken lines). Likewise, the stiffness of the support frame 103 may be reduced by reducing the number or arrangement of existing support elements 700.
  • any of the methods can include providing active vibration to cancel the undesired vibrations during transport.
  • vibrations can be introduced out-of-phase with the driving vibrations to minimize deflection in any of the modes present that can nevertheless become excited during transport.
  • the method can also include the step of transporting the package with a vehicle that transmits vibrations to the package.
  • the vehicle can transmit significant energy to the package at a frequency less than 10 Hz with the natural frequency of deflection of the stack of sheets 105 supported by the support frame 103 to include a first mode of vibration above 10 Hz.
  • the vehicle can transmit significant energy to the package at a frequency less than 33 Hz with the natural frequency of deflection of the stack of sheets 105 supported by the support frame 103 to include a first mode of vibration above 33 Hz.
  • the vehicle can transmit significant energy to the package at a frequency less than 50 Hz with the natural frequency of deflection of the stack of sheets 105 supported by the support frame 103 to include a first mode of vibration above 50 Hz.
  • Tuning the stack of sheets to include a first mode of vibration above 10 Hz avoids resonating the stack of sheets with the most energetic applied disturbances typically experienced in the low frequency range (0-10 Hz), due to trucks passing over bumps and potholes in the road. Furthermore, tuning the stack of sheets to include a first mode of vibration above 33 Hz, such as above 50 Hz also avoids higher frequencies that may be encountered during transport. As such, the driving force of vibrations imposed during transport may be decoupled from the deflection modes defined by the support frame, thereby avoiding significant oscillation that may be otherwise experienced with a stack of sheets that is not properly tuned for transport.
  • Ranges can be expressed herein as from “about” one particular value, and/or to "about” another particular value. When such a range is expressed, embodiments include 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 aspect. 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. [0050] The terms “substantial,” “substantially,” and variations thereof as used herein are intended to note that a described feature is equal or approximately equal to a value or description.

Abstract

A package tunes a natural frequency of deflection of a stack of sheets to include a first mode of vibration greater than 10 Hz. In another embodiment, a method of handling a stack of sheets with a support frame includes the step of tuning a natural frequency of deflection of the stack of sheets to include a first mode of vibration greater than a predetermined frequency by supporting the stack of sheets with the support frame. In still another embodiment, a method of fabricating a support frame comprises the step of designing the support frame to tune a natural frequency of deflection of a stack of sheets supported by the support frame to include a first mode of vibration above a predetermined frequency.

Description

PACKAGES, METHODS OF HANDLING A STACK OF GLASS SHEETS AND METHODS OF FABRICATING A SUPPORT FRAME
[0001] This application claims the benefit of priority to U.S. Application No. 62/081906 filed on November 19, 2014 the content of which is incorporated herein by reference in its entirety.
BACKGROUND
[0002] Conventional packages are commonly used to handle a stack of glass sheets. The stack of sheets commonly includes interleaf material placed between adjacent sheets in the stack.
SUMMARY
[0003] The following presents a simplified summary of the disclosure to provide a basic understanding of some exemplary aspects described in the detailed description.
[0004] The present disclosure relates generally to packages, methods of handling a stack of glass sheets and methods of fabricating a support frame and, more particularly, to a packages that tune a natural frequency of deflection of a stack of glass sheets to include a first mode of vibration greater than 10 Hz. The disclosure further relates to methods of handling a stack of glass sheets including the step of tuning the natural frequency of deflection of the stack of sheets to include a first mode of vibration greater than a predetermined frequency. Still further, the disclosure also relates to methods of fabricating a support frame including the step of designing the support frame to tune a natural frequency of deflection of a stack of sheets supported by the support frame to include a first mode of vibration above a predetermined frequency.
[0005] In accordance with a first embodiment, a package comprises a support frame including a lattice of support elements defining a network of openings. The package further includes a stack of sheets supported by the support frame and spanning over the network of openings, wherein the package tunes a natural frequency of deflection of the stack of sheets to include a first mode of vibration greater than 10 Hz. In one embodiment, the first mode of vibration is greater than 33 Hz. In another embodiment, the first mode of vibration is greater than 50 Hz. In yet another embodiment, the support frame defines at least one node of vibration of the stack of sheets. In still another embodiment, the support frame is configured to support the stack of sheets at an angle of inclination relative to a direction of gravity. In one embodiment, the angle of inclination is within a range of from about 0° to about 90°. In a further embodiment, the support frame comprises a curved support structure and sheets of the stack of sheets are substantially curved. In still a further embodiment, the package further comprises interleaf material positioned between adjacent sheets of the stack of sheets. In another embodiment, the package further comprises a securement device configured to maintain a position of the stack of sheets with respect to the support frame, wherein the securement device further tunes the natural frequency of deflection of the stack of sheets to include the first mode of vibration greater than 10 Hz. In yet another embodiment, the package further comprises a dampening device configured to tune the frequency of vibrations imposed on the package away from the natural frequency of deflection of the stack of sheets.
[0006] In accordance with a second embodiment, a method is provided for handling a stack of sheets with a support frame including a lattice of support elements defining a network of openings. The method includes the step of tuning a natural frequency of deflection of the stack of sheets to include a first mode of vibration greater than a predetermined frequency by supporting the stack of sheets with the support frame. In one embodiment, the predetermined frequency is greater than 10 Hz. In another embodiment, the predetermined frequency is greater than 33 Hz. In still another embodiment, the predetermined frequency is greater than 50 Hz. In a further embodiment, the step of tuning further includes pressing the stack of sheets against the support frame. In still a further embodiment, the method further comprises the step of designing the support frame to tune the natural frequency of deflection of the stack of sheets to include the first mode of vibration greater than the predetermined frequency. In yet a further embodiment, the support frame defines at least one node of vibration of the stack of sheets. In another embodiment, after the step of tuning, further comprising the step of transporting the package with a vehicle that transmits vibrations to the package. [0007] In accordance with a third embodiment, a method of fabricating a support frame comprising the step (I) of providing a lattice of support elements defining a network of openings, wherein the lattice of support elements is configured to support a stack of sheets while the sheets span over the network of openings. The method further includes the step (II) of designing the support frame to tune a natural frequency of deflection of a stack of sheets supported by the support frame to include a first mode of vibration above a predetermined frequency. In one embodiment, the predetermined frequency is 10 Hz. In another embodiment, the predetermined frequency is 33 Hz. In still another embodiment, the predetermined frequency is 50 Hz. In another embodiment, step (II) of designing the support frame includes adjusting the stiffness of the support frame to tune the natural frequency of deflection of the stack of sheets.
[0008] Of course, the first embodiment, the second embodiment and the third embodiment can be provided alone or in combination with one or any combination of the embodiments discussed above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] These and other features, aspects and advantages of the present disclosure can be further understood when read with reference to the accompanying drawings:
[0010] FIG. 1 is a schematic side view of a package in accordance with aspects of the disclosure;
[0011] FIG. 2 is a front view of the package taken at line 2-2 of FIG. 1;
[0012] FIG. 3 is a cross-sectional view of the package taken at line 3-3 of FIG. 2;
[0013] FIG. 4 is a cross-sectional view of another embodiment of a package;
[0014] FIG. 5 is a cross-sectional view of the package taken at line 5-5 of FIG. 2;
[0015] FIG. 6 is front view of another embodiment of a package;
[0016] FIG. 7 is a front view of a support frame of the package of FIG. 1;
[0017] FIG. 8 illustrates a first particle distribution pattern on a glass sheet; and
[0018] FIG. 9 illustrates a second particle distribution pattern on another glass sheet.
DETAILED DESCRIPTION [0019] Apparatus and methods will now be described more fully hereinafter with reference to the accompanying drawings in which embodiments of the disclosure are shown. Whenever possible, the same reference numerals are used throughout the drawings to refer to the same or like parts. However, this disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein.
[0020] Glass sheets are commonly fabricated by a flowing molten glass to a forming body whereby a glass ribbon may be formed by a variety of ribbon forming processes, for example, slot draw, down-draw, fusion down-draw, or up-draw. Of course, glass ribbons may also be formed using other forming processes such as a float process. The glass ribbon from any of these processes may then be subsequently divided to provide sheet glass suitable for further processing into a desired display application. The glass sheets can be used in a wide range of display applications, for example liquid crystal displays (LCDs), electrophoretic displays (EPD), organic light emitting diode displays (OLEDs), plasma display panels (PDPs), or the like. Frequently, glass sheets may need to be transported from one location to another. Typically, the glass sheets are transported with a conventional support frame designed to secure a stack of glass sheets in place. Moreover, interleaf material is commonly placed in between each sheet of glass to help prevent contact and therefore preserve the pristine surfaces of the glass sheets.
[0021] There can also be a benefit to not only preventing damage to the surfaces but also minimizing or preventing contamination of the pristine surfaces from debris such as small particles that may otherwise interfere with processing or performance of the glass sheets as display substrates. The presence, size(s), and location(s) of small contaminant particles are typically evaluated using scanning particle inspection equipment. Capabilities often exist to inspect for particles down to 0.3 μιη in size, though many specifications only require inspection for particles down to 1.0 μιη. In this regard, applicant unexpectedly discovered that when inspecting the surfaces of glass sheets with a particle counter at the panel-making facility, the interleaf material had contaminated the surfaces of the glass sheets with very small particles in the range of 0.3- 1.0 μιη range (outside of the usual range of inspection, which at this facility was for particles greater than 1.0 μιη). Indeed, FIGS. 8 and 9 illustrate particle distributions on two different glass sheets supported by two different support frames after unpacking and washing the transported glass sheets. The hidden lines 801 of FIG. 8 illustrate the approximate location of the support elements in a first conventional support frame. Likewise, hidden lines 901 of FIG. 9 illustrate the approximate location of support elements of a second conventional support frame. As shown in FIGS. 8 and 9, particles were observed wherein 70-80% of the particles included a maximum dimension of from about 0.3 microns to about 5 microns. Not only was it surprising and unexpected that the particles existed, but it was still further surprising and unexpected that the particles appeared to be patterned in a halo configuration (e.g., see 803 in FIG. 8; 903 in FIG. 9) in the openings between the support elements 801, 901 of the respective support frames.
[0022] Based on the surprising visual evidence observed, it was found that small but significant deflection of glass sheets can substantially impact glass surface quality. Indeed, movement of the glass sheets at frequencies lower than a predetermined frequency where jostling is imposed on the package during routine transport was found to cause the glass to rub against the interleaf paper. Rubbing of the glass sheets against the interleaf paper can cause releasing and adhering of paper particles and impact surface quality of the glass product. Moreover, rubbing the particles against the glass sheet can result in increased adhesion of the paper particles to the glass sheet. The increased adhesion can make subsequent removal of the particles (e.g., by washing) less effective. Consequently, rubbing of the glass sheet against the interleaf paper can adversely impact practical yield of product since customers rely on pristine glass surfaces without contamination.
[0023] It was discovered that particle deposition can be reduced, thereby enhancing the quality of the glass sheets after transportation, by tuning the natural frequency of the stack of sheets to avoid low vibration modes commonly associated with typical transportation methods.
[0024] In one embodiment of the disclosure, a package can be provided that reduces deposition of particles (e.g., fibers) from the interleaf material on the major surfaces of the glass sheets. For instance, referring to FIG. 1, a package 101 includes a plurality of glass sheets 109 that are arranged as a stack of sheets 105. The stack of sheets can be various sizes, for example, a few hundred sheets at a time. As shown, in some embodiments, interleaf layer 107, such as paper, may be positioned between adjacent sheets 109 of the stack of sheets 105.
[0025] The package further includes a support frame 103 that may be formed from metal (e.g., aluminum), wood or other material that may effectively support the stack of glass sheets. As shown in FIG. 7, the support frame 103 includes a lattice of support elements 700 defining a network of openings 705. Indeed, in one embodiment, the lattice of support elements 700 can include a plurality of horizontal support elements 701, 701b, 701c, 701d and a plurality of vertical support elements 703a, 703b, 703c. The horizontal support elements are illustrated in a row of horizontal support elements where, as shown, a plurality of horizontal rows can be provided that are substantially parallel with respect to one another. As further illustrated, the plurality of vertical support elements are illustrated in a column of vertical support elements where, as shown, a plurality of vertical columns may be provided that are substantially parallel with respect to one another.
[0026] In one embodiment, as shown in FIG. 1, the support frame 103 can be configured to support the stack of sheets 105 at an angle of inclination "A" relative to a direction of gravity "G". In some embodiments, the angle of inclination "A" can be any angle within a range of from about 0° to about 90° such as from greater than 0° to less than 90°, such as from about 5° to about 45° such as from about 10° to about 25° although other angles may be provided in further embodiments.
[0027] As further illustrated in FIGS. 1 and 7, the support frame 103 can further include a lower ledge 707. As shown in FIG. 1, the lower ledge 707 can support a weight of the stack of sheets 105 at a lower end 113 of the stack. More particularly, with an angle of inclination "A" greater than 0°, with reference to FIG. 7, outer faces 709 of the support elements 700 and an outer face 711 of the lower ledge 707 can act together support the weight of the stack of sheets 105.
[0028] As shown in FIGS. 3 and 5, the support elements 700 may comprise channel support elements that have the outer faces 709 that provide a support surface for the stack of glass sheets 105. Providing the support elements as a channel can reduce weight and material costs while still providing a relatively rigid support surface for the stack of glass sheets. FIG. 3 illustrates the stack of glass sheets 105 being directly supported by the outer faces 709 with the understanding that an interleaf layer, a protective surface, or other feature may be provided to protect adjacent glass sheet from being damaged by the support frame 103.
[0029] In one embodiment, as shown in FIG. 1, a cushion layer 119 may be provided between the stack of sheets 105 and the outer faces 709 of the support elements 700 and the outer face 711 of the lower ledge 707. The cushion layer 119 can help prevent scratching that may otherwise occur with relative movement between the stack of sheets 105 and the support frame 103. In further embodiments, the cushion layer may act as a damping device configured to tune the frequency of vibrations imposed on the package away from the natural frequency of deflection of the stack of sheets 105. For instance, the damping device may help isolate the stack of glass sheets 105 from vibrations traveling through the support frame 103. Such cushion layers 119 can be used to reduce or alter the frequency/amplitude imposed by the transportation and effectively raise the deflection frequencies to the desired range. The cushion layer 119 can comprise a resilient foam, a resilient mat, or other cushion layer configuration.
[0030] In addition or alternative to the cushion layer 119, other damping devices such as strategic package wrapping, shocks, pads or other damping devises may be used to mitigate coupling of imposed frequencies into deflection.
[0031] As further illustrated in FIG. 3, the outer face 709 of the support elements 700 can provide a substantially flat planar support surface with a cross-section having a substantially straight profile as illustrated in FIG. 3. In alternative embodiments, as shown in FIG. 4, the support frame 401 can alternatively include a curved support structure. Indeed, as shown, the support frame 401 can include support elements 402 defining a substantially curved support surface 403 with a cross-section having a substantially curved profile as illustrated in FIG. 4. As the stack of glass sheets 105 conforms to the shape of the support structure, the stack of glass sheets 105 includes a curved stack of sheets that conform to the curved shape of the support surface 403. Providing the glass sheets with a curved configuration can increase the stiffness of the stack of glass sheets and also help strengthen the glass sheets against flexing, thereby raising the natural frequency of the deflection of the stack of sheets 105 when transporting the package 101. In such applications, a damping device similar to the cushion layer 119 can be provided by including a curved shape to conform to the curved shape of the support surface 403. The curved cushion layer may increase the effective stiffness of the stack of sheets to raise the deflection frequencies to the desired range.
[0032] As further shown in FIG. 1, the support frame 103 can also include a stand 115 that can help support the support elements 700 in a proper orientation. In some embodiments, frame members 117 can attach the support elements 700 and/or the lower ledge 707 to the stand 115.
[0033] As further shown in FIGS. 1 and 2, the package 101 can also comprise a securement device 111 configured to maintain a position of the stack of sheets 105 with respect to the support frame 103. In one embodiment, as shown, the securement device can include a plurality of press bars 121. As shown in FIG. 5, the press bars 121 may each be pulled against the stack of glass sheets 105 by straps 123 to clamp portions 501 of the stack of glass sheets 105 between a lower surface 503 of the press bars 121 and the outer face 709 of the support elements 700. Although not shown, a protective interleaf or other material may be provided between the press bars 121 and the stack of glass sheets 105 to avoid scratching, cracking or otherwise damaging the glass sheets.
[0034] Referring to FIG. 5, as discussed above, the clamped portions 501 are immobilized by the clamping action between the press bars 121 and the support elements 700. The support frame also provides the network of openings 705 with portions of the stack of sheets 105 spanning over the network of openings. As such, the support frame 103 can define at least one node of vibration of the stack of sheets 105 wherein vertical movement of spanning portions 505 across the openings 705 may flex in directions 507a, 507b.
[0035] The stack of sheets 105 can include a first mode of vibration greater than a predetermined frequency such as greater than 10 Hz, greater than 33 Hz or greater than 50 Hz depending on the expected vibrations the package will be exposed to during transport.
[0036] In further embodiments of the disclosure, methods are provided for fabricating the support frame 103 that can tune the natural frequency of defection of the stack of glass sheets 105. For instance, the method can include the step of providing the lattice of support elements 700 defining the network of openings 705. As shown in the figures, the lattice of support elements 700 is configured to support the stack of sheets 105 while the sheets span over the network of openings 705. The method can further include the step of designing the support frame 103 to tune a natural frequency of deflection of a stack of sheets 105 supported by the support frame 103 to include a first mode of vibration above a predetermined frequency. In such cases, the support frame 103 can be fabricated to accommodate a particular stack of glass sheets with known stiffness, and other vibrational characteristics. Likewise, a frequency or range of vibrational frequencies to be avoided can be determined from a vibrational frequency distribution of expected vibrational frequencies likely to be encountered on a predetermined travel arrangement. With the known characteristics of the stack of glass sheets and the known expected vibrational frequencies to be encountered on the predetermined travel arrangement, the support frame 103 can be custom designed to tune a natural frequency of deflection of a stack of sheets supported by the support frame to include a first mode of vibration above the predetermined frequency expected during the travel arrangement.
[0037] In one embodiment, the support frame 103 may be custom designed to tune the natural frequency of deflection of the stack of sheets 105 supported by the support frame 103 to include a first mode of vibration above 10 Hz, such as above 33 Hz such as above 50 Hz.
[0038] Various aspects of the support frame 103 may be custom designed to tune the natural frequency of the stack of sheets. For instance, the support frame may be designed to tune the natural frequency of the stack of sheets by adjusting the stiffness of the support frame. In one embodiment, as shown in FIG. 1, the stiffness of the support frame 103 may be increased by adding optional additional frame members 118 (shown in broken lines). Increasing the stiffness of the support frame 103 by adding the optional additional frame members 118 can raise the resonant frequency distribution to avoid high energy frequency vibrations typical of the expected transportation route. In another embodiment, as shown in FIG. 7, optional additional support elements 706 (shown in broken lines) can be provided that reduce the span distance between support elements. For instance, vertical support elements can be installed to reduce the horizontal span distance from HI to H2. Likewise, horizontal support elements can be installed to reduce the vertical span distance from VI to V2. Consequently, the vibrational nodes can be increased as well as the stiffness of the support frame 103 to desensitize the package from expected vibrations along predetermined transportation routes.
[0039] In another embodiment, the securement device can facilitate tuning of the natural frequency of deflection of the stack of sheets 105 to include the first mode of vibration greater than 10 Hz, such as greater than 33 Hz, such as greater than 50 Hz. For instance, as shown in FIG. 6, the number of press bars and/or the configuration of press bars may be changed to tune the natural frequency of the stack of sheets. For instance, as shown vertical press bars 601 may link together the horizontal press bars 121 to tune the natural frequency of the stack of sheets. Although not shown, an edge-constraint system or wrapping can also be provided to further modify the frequency distribution through node design. Furthermore, the horizontal press bars 121 may be strategically located to counteract deflection modes imposed by the support frame 103. For instance, as indicated by dashed lines 715a, 715b, 715c in FIG. 7, one or more of the horizontal press bars 121 may be positioned along the dashed lines 715a, 715b, 715c to span across the openings 705 to help counteract the deflection modes imposed by the support frame 103.
[0040] In still further embodiments of the disclosure, methods are provided for handling the stack of sheets 105 with the support frame 103 including the lattice of support elements 700 defining the network of openings 705. The method includes the step of tuning the natural frequency of deflection of the stack of sheets 105 to include a first mode of vibration greater than a predetermined frequency (e.g., greater than 10 Hz, greater than 33 Hz, or greater than 50 Hz) by supporting the stack of sheets 105 with the support frame 103.
[0041] In one embodiment, the step of tuning can include pressing the stack of sheets 105 against the support frame 103. For instance, the press bars 121 may be pressed against the stack to press the stack against the support frame. Different press bar configurations can be designed to help adjust the natural frequency of defection of the stack of sheets 105 without necessarily changing other characteristics of the support rack. For instance, if there is a desire to further tune the stack, a different press bar configuration may be selected (e.g., see FIG. 6) to tune the natural frequency of deflection of the stack of sheets 105. [0042] The method can also include the step of designing the support frame to tune the natural frequency of deflection of the stack of sheets to include the first mode of vibration greater than the predetermined frequency. For instance, as mentioned previously optional additional frame members 118 (shown in broken lines) may be added or existing frame members 117 may be removed. In another embodiment, as shown in FIG. 7, the stiffness of the support frame 103 may be increased by adding optional additional support elements 706 (shown in broken lines). Likewise, the stiffness of the support frame 103 may be reduced by reducing the number or arrangement of existing support elements 700.
[0043] In still another embodiment, any of the methods can include providing active vibration to cancel the undesired vibrations during transport. For instance, vibrations can be introduced out-of-phase with the driving vibrations to minimize deflection in any of the modes present that can nevertheless become excited during transport.
[0044] After the step of tuning, the method can also include the step of transporting the package with a vehicle that transmits vibrations to the package. In some embodiments, the vehicle can transmit significant energy to the package at a frequency less than 10 Hz with the natural frequency of deflection of the stack of sheets 105 supported by the support frame 103 to include a first mode of vibration above 10 Hz. In another embodiment, the vehicle can transmit significant energy to the package at a frequency less than 33 Hz with the natural frequency of deflection of the stack of sheets 105 supported by the support frame 103 to include a first mode of vibration above 33 Hz. In still another embodiment, the vehicle can transmit significant energy to the package at a frequency less than 50 Hz with the natural frequency of deflection of the stack of sheets 105 supported by the support frame 103 to include a first mode of vibration above 50 Hz.
[0045] Tuning the stack of sheets to include a first mode of vibration above 10 Hz avoids resonating the stack of sheets with the most energetic applied disturbances typically experienced in the low frequency range (0-10 Hz), due to trucks passing over bumps and potholes in the road. Furthermore, tuning the stack of sheets to include a first mode of vibration above 33 Hz, such as above 50 Hz also avoids higher frequencies that may be encountered during transport. As such, the driving force of vibrations imposed during transport may be decoupled from the deflection modes defined by the support frame, thereby avoiding significant oscillation that may be otherwise experienced with a stack of sheets that is not properly tuned for transport.
[0046] By tuning and transporting the stack of sheets 105 in such a way, significant resonant vibration of the glass sheets can be avoided during transport, thereby minimizing significant movement of the spanning portions 505 across the openings 705 in directions 507a, 507b. As relative movement between the interleaf layers 107 and glass sheets 109 are reduced, particle shedding from the interleaf layers 107 can likewise be reduced to consequently reduce contamination of the pristine major surfaces of the glass sheets 109. Furthermore, adhesion strength of the particles on the major surface of the glass can be reduced since relative movement between the interleaf layers and the major surfaces of the glass sheets are reduced. As such, existing washing procedures of the glass sheets may be more effective in removing particles that are nonetheless shed on the glass sheet. Consequently, glass product yield can be increased for glass customers who rely on pristine glass surfaces for proper function.
[0047] Furthermore, proper tuning of the stack of sheets 105 about a predetermined frequency can allow the packages to be safely shipped to the customer over longer distances relative to existing packages that are not tuned to a frequency above a predetermined frequency. Still further, as resonant frequencies are avoided, less costly transportation methods that may involve significant vibrations may be available since the impact of the vibrations can be reduced or eliminated.
[0048] It is also to be understood that, as used herein the terms "the," "a," or "an," mean "at least one," and should not be limited to "only one" unless explicitly indicated to the contrary. Likewise, a "plurality" is intended to denote "more than one."
[0049] Ranges can be expressed herein as from "about" one particular value, and/or to "about" another particular value. When such a range is expressed, embodiments include 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 aspect. 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. [0050] The terms "substantial," "substantially," and variations thereof as used herein are intended to note that a described feature is equal or approximately equal to a value or description.
[0051] 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. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is no way intended that any particular order be inferred.
[0052] While various features, elements or steps of particular embodiments may be disclosed using the transitional phrase "comprising," it is to be understood that alternative embodiments, including those that may be described using the transitional phrases "consisting" or "consisting essentially of," are implied. Thus, for embodiment, implied alternative embodiments to an apparatus that comprises A+B+C include embodiments where an apparatus consists of A+B+C and embodiments where an apparatus consists essentially of A+B+C.
[0053] It will be apparent to those skilled in the art that various modifications and variations can be made to the present disclosure without departing from the spirit and scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this disclosure provided they come within the scope of the appended claims and their equivalents.

Claims

What is claimed is:
1. A package comprising:
a support frame including a lattice of support elements defining a network of openings; and
a stack of sheets supported by the support frame and spanning over the network of openings, wherein the package tunes a natural frequency of deflection of the stack of sheets to include a first mode of vibration greater than 10 Hz.
2. The package of claim 1, wherein the first mode of vibration is greater than 33 Hz.
3. The package of claim 2, wherein the first mode of vibration is greater than 50 Hz.
4. The package of claim 1, wherein the support frame defines at least one node of vibration of the stack of sheets.
5. The package of claim 1, wherein the support frame is configured to support the stack of sheets at an angle of inclination relative to a direction of gravity.
6. The package of claim 5, wherein the angle of inclination is within a range of from about 0° to about 90°.
7. The package of claim 1, wherein the support frame comprises a curved support structure and sheets of the stack of sheets are substantially curved.
8. The package of claim 1, further comprising interleaf material positioned between adjacent sheets of the stack of sheets.
9. The package of claim 1, wherein the package further comprises a securement device configured to maintain a position of the stack of sheets with respect to the support frame, wherein the securement device further tunes the natural frequency of deflection of the stack of sheets to include the first mode of vibration greater than 10 Hz.
10. The package of claim 1, wherein the package further comprises a dampening device configured to tune the frequency of vibrations imposed on the package away from the natural frequency of deflection of the stack of sheets.
11. A method of handling a stack of sheets with a support frame including a lattice of support elements defining a network of openings, the method comprising the step of: tuning a natural frequency of deflection of the stack of sheets to include a first mode of vibration greater than a predetermined frequency by supporting the stack of sheets with the support frame.
12. The method of claim 11, wherein the predetermined frequency is greater than 10 Hz.
13. The method of claim 12, wherein the predetermined frequency is greater than 33 Hz.
14. The method of claim 13, wherein the predetermined frequency is greater than 50 Hz.
15. The method of claim 11, wherein the step of tuning further includes pressing the stack of sheets against the support frame.
16. The method of claim 11, further comprising the step of designing the support frame to tune the natural frequency of deflection of the stack of sheets to include the first mode of vibration greater than the predetermined frequency.
17. The method of claim 11, wherein the support frame defines at least one node of vibration of the stack of sheets.
18. The method of claim 11, wherein after the step of tuning, further comprising the step of transporting the package with a vehicle that transmits vibrations to the package.
19. A method of fabricating a support frame comprising the steps of:
(I) providing a lattice of support elements defining a network of openings, wherein the lattice of support elements is configured to support a stack of sheets while the sheets span over the network of openings; and
(II) designing the support frame to tune a natural frequency of deflection of a stack of sheets supported by the support frame to include a first mode of vibration above a predetermined frequency.
20. The method of claim 19, wherein the predetermined frequency is 10 Hz.
21. The method of claim 20, wherein the predetermined frequency is 33 Hz.
22. The method of claim 21, wherein the predetermined frequency is 50 Hz.
23. The method of claim 19, wherein the step (II) of designing the support frame includes adjusting the stiffness of the support frame to tune the natural frequency of deflection of the stack of sheets.
PCT/US2015/060971 2014-11-19 2015-11-17 Packages, methods of handling a stack of glass sheets and methods of fabricating a support frame WO2016081398A1 (en)

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JP2017526838A JP2017536305A (en) 2014-11-19 2015-11-17 Package, method of handling a stack of glass plates, and method of manufacturing a support frame
CN201580073473.7A CN107207151A (en) 2014-11-19 2015-11-17 Package, the method that processing glass flake is stacked and the method for manufacturing support frame
KR1020177016502A KR20170085099A (en) 2014-11-19 2015-11-17 Packages, methods of handling a stack of glass sheets and methods of fabricating a support frame

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JP3224155U (en) * 2019-09-18 2019-11-28 Agc株式会社 Glass plate container
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