PRIORITY CLAIM AND CROSS-REFERENCE

[0001] This application claims the benefit of priority under 35 U.S.C. § 119 of U.S. Provisional Serial No. 63/540722 filed on September 27, 2023 and U.S. Provisional Serial No. 63/411345 filed on September 29, 2022, the contents of which are relied upon and incorporated herein by reference in their entireties.

FIELD

[0002] The disclosure relates to roll-to-sheet glass assembly apparatuses and related methods.

BACKGROUND

[0003] Glass production may include the production of continuous ribbons or webs of glass material. Such production methods may include the storage or accumulation of the ribbons of glass material on spools. The spools of glass material may be stored and/or transported to different locations or to other production equipment where the spools of glass material may be unwound and/or separated into individual glass pieces or sheets. The individual glass sheets may then be further processed for various end uses.

[0004] Ultra-thin glass (UTG) may be produced in this manner in which the glass ribbon is produced and wound onto a spool. Existing and/or traditional apparatuses and methods of unwinding the glass material and/or separating the glass ribbon into individual sheets suffers from various drawbacks. Existing and/or traditional apparatuses and methods may be slow, result in high rates or incidents of poor glass quality, have high costs, require large footprints in manufacturing facilities, and may result in low yields of glass sheets that are acceptable for the end use. There exists a need, therefore, for improved apparatuses and methods for producing glass sheets from continuous glass ribbons. SUMMARY

[0005] The present disclosure provides apparatuses and methods for producing glass sheets from spools of flexible glass ribbon. The glass ribbon may be ultra-thin glass (UTG) that is collected on spools after forming and is subsequently separated into separate glass sheets for further processing. The apparatuses and methods of the present disclosure provide integrated controlled removal of the glass ribbon from the spools, collection of the interleaf layer that may be located between the layers of glass ribbon, and separation of the glass ribbon into separate glass sheets. The glass ribbon can be measured, monitored and controlled during movement of the glass ribbon for improved accuracy, reduced cost, improved cycle times, improved quality and other improvements over existing and traditional apparatuses and methods.

[0006] In some embodiments of the present disclosure, an apparatus includes a spool unwinder configured to accept a spool of glass ribbon and an interleaf rewinder configured to collect interleaf. The apparatus may also include a separation assembly configured to separate a glass sheet from the glass ribbon and a controller coupled to the spool unwinder, the interleaf rewinder, and the separation assembly. The controller may be configured to control movement of the glass ribbon from the spool unwinder to the separation assembly. [0007] In one aspect, the spool unwinder may include an unwinder shaft coupled to an unwinder motor. The unwinder motor may be coupled to the controller.

[0008] In another aspect, the interleaf rewinder may include an interleaf shaft coupled to an interleaf motor and the interleaf motor is coupled to the controller.

[0009] In another aspect, the apparatus may include at least two edge sensors configured to determine a position of the glass ribbon at a position downstream of the spool unwinder.

[0010] In another aspect, the at least two edge sensors may be coupled to the controller and the controller is configured to adjust a position of the spool unwinder when the position of the glass ribbon does not align with a predetermined location of the glass ribbon. [0011] In another aspect, the at least one edge roller may be positioned at an edge of the glass ribbon and the at least one edge roller is coupled to the controller and configured to move the glass ribbon.

[0012] In another aspect, the at least one edge roller may be obliquely angled relative to a longitudinal direction of the glass ribbon and configured to apply a longitudinal force and a lateral force to the glass ribbon. [0013] In another aspect, the controller may be configured to adjust the angle of the at least one edge roller relative to the longitudinal direction of the glass ribbon.

[0014] In another aspect, the interleaf rewinder may include an interleaf roller. The interleaf roller may include openings coupled to a vacuum source and the interleaf roller is configured to move the interleaf away from the glass ribbon toward the interleaf rewinder. [0015] In another aspect, the spool unwinder may include a spool diameter detector.

[0016] In another aspect, the spool unwinder may include a spool pressure roller positioned radially outward from a center of the spool. The spool pressure roller may be configured to apply a force to the glass ribbon.

[0017] In another aspect, the apparatus may include a free roller positioned downstream of the spool unwinder. The free roller may be configured to maintain the glass ribbon in a predetermined curved shape during unwinding.

[0018] In another aspect, the apparatus may include a free loop sensor positioned between the spool unwinder and the free roller. The free loop sensor may be coupled to the controller and configured to determine a position of the glass ribbon in the predetermined curved shape.

[0019] In another aspect, the apparatus may include a stress zone positioned downstream of the spool unwinder. The stress zone may include a first free roller, a second free roller, and a pressure roller. The pressure roller may be coupled to the controller and configured to apply a force to the glass ribbon between the first free roller and the second free roller.

[0020] In some embodiments in accordance with the present disclosure, a method for producing glass sheets from a glass ribbon is provided. The method may include unwinding glass ribbon from a glass ribbon spool and comparing a position of the glass ribbon to a predetermined glass ribbon position. The method may also include automatically adjusting the position of the glass ribbon when the position of the glass ribbon deviates from the predetermined glass ribbon position by more than a predetermined amount and separating a glass sheet from the glass ribbon.

[0021] In one aspect, an unwinding speed of the glass ribbon is automatically controlled to remain in a predetermined unwinding speed range.

[0022] In another aspect, the step of comparing the position of the glass ribbon to the predetermined ribbon position may include obtaining position information from at least two edge position sensors positioned at different longitudinal positions relative to the glass ribbon. [0023] In another aspect, the step of automatically adjusting the position of the glass ribbon may include adjusting a rotational speed of at least one edge roller.

[0024] In another aspect, the method may include automatically adjusting a longitudinal tension of the glass ribbon to maintain the longitudinal tension of the glass ribbon in a predetermined longitudinal tension range.

[0025] In another aspect, the method may include automatically adjusting a lateral tension of the glass ribbon to maintain the lateral tension of the glass ribbon in a predetermined lateral tension range.

[0026] In another aspect, the step of automatically adjusting the lateral tension of the glass ribbon comprises adjusting an angle of at least one edge roller relative to a longitudinal direction of the glass ribbon.

[0027] In some embodiments in accordance with the present disclosure, an apparatus for separating a glass sheet from a glass ribbon is provided. The apparatus may include an upper isolator configured to contact the glass ribbon and a lower isolator positioned downstream from the upper isolator and configured to contact the glass ribbon. The apparatus may also include a backer positioned between the upper isolator and the lower isolator and configured to contact the glass ribbon and apply a force to create stress in the glass ribbon at a predetermined separation position and an initiator configured to contact the glass ribbon and create a flaw in the glass ribbon at the predetermined separation position. [0028] In one aspect, the backer may be configured to apply the force to the glass ribbon before the initiator contacts the glass ribbon.

[0029] In another aspect, the apparatus may include a spool unwinder positioned upstream from the upper isolator. The spool unwinder may be configured to remove the glass ribbon from a spool.

[0030] In another aspect, the backer may include a bar extending laterally across a width of the glass ribbon.

[0031] In another aspect, the backer may include a groove extending laterally across a contact surface of the backer. The groove may be positioned opposite to the initiator.

[0032] In another aspect, the upper isolator may include a first pair of bars positioned on opposite sides of the glass ribbon, each of the first pair of bars configured to move toward the glass ribbon to clamp the glass ribbon therebetween.

[0033] In another aspect, the lower isolator may include a second pair of bars positioned on opposite sides of the glass ribbon, each of the second pair of bars configured to move toward the glass ribbon to clamp the glass ribbon therebetween. [0034] In another aspect, the apparatus may include a separation sensor positioned on an opposite lateral side of the glass ribbon from the initiator, the separation sensor configured to determine whether the glass sheet successfully separated from the glass ribbon.

[0035] In some embodiments in accordance with the present disclosure, a method of separating a separating a glass sheet from a glass ribbon is provided. The method may include clamping a glass ribbon using at least one isolator and applying a force to the glass ribbon in a direction substantially perpendicular to a longitudinal direction of the glass ribbon. The method may also include determining a position of at least one edge of the glass ribbon and automatically adjusting a position of an initiator to a predetermined separation position based on the position of the at least one edge of the glass ribbon. The method may also include initiating a flaw in the glass ribbon at the predetermined separation position.

[0036] In one aspect, the step of determining the position of the at least one edge of the glass ribbon is performed using at least two edge position sensors.

[0037] In another aspect, the step of applying the force to the glass ribbon is performed before the step of initiating the flaw in the glass ribbon.

[0038] In another aspect, the step of initiating the flaw in the glass ribbon is performed by contacting the glass ribbon at a position laterally inward of the at least one edge of the glass ribbon and moving the initiator laterally outward past the at least one edge of the glass ribbon.

[0039] In another aspect, the step of applying the force to the glass ribbon includes moving a backer against the glass ribbon on a side of the glass ribbon opposite to the initiator. [0040] In another aspect, the method may include moving the glass sheet away from the glass ribbon using a transport tool.

[0041] In another aspect, the force is continued to be applied to the glass ribbon until the glass sheet is moved a sufficient distance away from the glass ribbon to prevent contact between the glass sheet and the glass ribbon.

[0042] In another aspect, the method may include determining whether the glass sheet has separated from the glass ribbon using a separation sensor positioned on a lateral side of the glass ribbon from the initiator.

BRIEF DESCRIPTION OF THE DRAWINGS

[0043] The present disclosure is best understood from the following detailed description when read in conjunction with the accompanying drawings. It is emphasized that, according to common practice, the various features of the drawings are not necessarily to scale. On the contrary, the dimensions of the various features are arbitrarily expanded or reduced for clarity. Like reference numerals denote like features throughout specification and drawings.

[0044] FIG. l is a flow chart illustrating an example method of producing glass substrates in accordance with various embodiments of the present disclosure.

[0045] FIG. 2 is an illustration of an example glass substrate that can be separated from a glass ribbon using one or more apparatuses or methods of the present disclosure.

[0046] FIG. 3 is a side view of an example roll-to-sheet glass production apparatus in accordance with various embodiments of the present disclosure.

[0047] FIG. 4 is a front view of the roll-to-sheet glass production apparatus of FIG. 3.

[0048] FIG. 5A is a block diagram of an example roll-to-sheet apparatus in accordance with various embodiments of the present disclosure.

[0049] FIG. 5B is a front view of an example roll-to-sheet production apparatus that may be controlled using the elements of the apparatus of FIG. 5 A.

[0050] FIG. 6 is an isometric view of another example roll-to-sheet production apparatus in accordance with various embodiments of the present disclosure.

[0051] FIG. 7 is a side view of another example roll-to-sheet production apparatus in accordance with various embodiments of the present disclosure.

[0052] FIG. 8 is a side view of another example roll-to-sheet production apparatus in accordance with various embodiments of the present disclosure.

[0053] FIG. 9 is a perspective side view of an example glass separation apparatus in accordance with various embodiments of the present disclosure.

[0054] FIG. 10 is a side view illustration of another example glass separation apparatus in accordance with various embodiments of the present disclosure.

[0055] FIG. 11 is a side view illustration of another example glass separation apparatus in accordance with various embodiments of the present disclosure.

[0056] FIG. 12 is a side view illustration of another example glass separation apparatus in accordance with various embodiments of the present disclosure.

[0057] FIG. 13 is a side view of a portion of an example roll-to-sheet glass production apparatus in accordance with various embodiments of the present disclosure.

[0058] FIG. 14 is a front view of the portion of the roll-to-sheet glass production apparatus of FIG. 13.

[0059] FIG. 15 is an illustration of a method of glass ribbon separation using the apparatus of FIG. 13. [0060] FIG. 16 is a side view of an example glass singulation detection showing a satisfactory separation in accordance with some embodiments of the present disclosure. [0061] FIG. 17 is a side view an of the glass singulation detection of FIG. 16 showing an unsatisfactory separation in accordance with some embodiments of the present disclosure.

[0062] FIG. 18 is an illustration of an example pre-tensioning bar and notch that can be used on various example roll-to-sheet glass production apparatuses of the present disclosure.

[0063] FIG. 19 is an illustration of an example glass substrate handling apparatus showing various stages of glass separation in accordance with various embodiments of the present disclosure.

[0064] FIG. 20 is an illustration of another glass substrate handling apparatus showing various stages of glass separation in accordance with various embodiments of the present disclosure.

[0065] FIG. 21 is an example layout of an example packing apparatus in accordance with various embodiments of the present disclosure.

[0066] FIG. 22 is an illustration of an stack of example glass sheet trays in accordance with some embodiments of the present disclosure.

[0067] FIG. 23 is an illustration of an example tray being loaded with a glass sheet in accordance with some embodiments of the present disclosure.

[0068] FIG. 24 is an illustration of the tray of FIG. 23 loaded with multiple glass sheets.

[0069] FIG. 25 is a side view of another example glass separation apparatus in accordance with various embodiments of the present disclosure.

[0070] FIG. 26 is a graph showing stress in a glass ribbon during glass separation processes under various process conditions in accordance with various embodiments of the present disclosure.

[0071] FIG. 27 is a side view of an example glass separation apparatus performing an example glass separation process in accordance with various embodiments of the present disclosure.

[0072] FIG. 28 is a graph showing results of an example glass separation process under various process conditions in accordance with various embodiments of the present disclosure. DETAILED DESCRIPTION

[0073] This description of the exemplary embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. In the description, relative terms such as “lower,” “upper,” “horizontal,” “vertical,”, “above,” “below,” “up,” “down,” “top” and “bottom” as well as derivative thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description and do not require that the apparatus be constructed or operated in a particular orientation. Terms concerning attachments, coupling and the like, such as “connected” and “interconnected,” refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise.

[0074] For purposes of the description hereinafter, it is to be understood that the embodiments described below may assume alternative variations and embodiments. It is also to be understood that the specific articles, compositions, and/or processes described herein are exemplary and should not be considered as limiting.

[0075] In the present disclosure the singular forms “a,” “an,” and “the” include the plural reference, and reference to a particular numerical value includes at least that particular value, unless the context clearly indicates otherwise. When values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. As used herein, “about X” (where X is a numerical value) preferably refers to ±10% of the recited value, inclusive. For example, the phrase “about 8” preferably refers to a value of 7.2 to 8.8, inclusive. Where present, all ranges are inclusive and combinable. For example, when a range of “1 to 5” is recited, the recited range should be construed as including ranges “1 to 4”, “1 to 3”, “1-2”, “1-2 & 4-5”, “1-3 & 5”, “2-5”, and the like. In addition, when a list of alternatives is positively provided, such listing can be interpreted to mean that any of the alternatives may be excluded, e.g., by a negative limitation in the claims. For example, when a range of “1 to 5” is recited, the recited range may be construed as including situations whereby any of 1, 2, 3, 4, or 5 are negatively excluded; thus, a recitation of “1 to 5” may be construed as “1 and 3-5, but not 2”, or simply “wherein 2 is not included.” It is intended that any component, element, attribute, or step that is positively recited herein may be explicitly excluded in the claims, whether such components, elements, attributes, or steps are listed as alternatives or whether they are recited in isolation. [0076] The present disclosure provides apparatuses and methods for preparing, packing and/or separating glass substrates from a spool of glass material. In some examples, the glass substrates are made of ultra-thin glass (UTG). The apparatuses and methods may include apparatuses that can unwind the spool of glass material and separate the glass material into separate glass substrates and/or package the separated glass substrates for further processing.

[0077] Unless expressly indicated otherwise, the terms “glass substrate,” “glass article” or “glass” used herein are understood to encompass any object made wholly or partly of glass. Glass articles include monolithic substrates, or laminates of glass and glass, glass and non-glass materials, glass and crystalline materials, and glass and glass-ceramics (which include an amorphous phase and a crystalline phase).

[0078] The glass article or glass substrate may be transparent or substantially transparent. As used herein, the term “transparent” is intended to denote that the article, at a thickness of approximately 1 mm, has a transmission of greater than about 85% in the visible region of the spectrum (400-700 nm). For instance, an exemplary transparent glass panel may have greater than about 85% transmittance in the visible light range, such as greater than about 90%, greater than about 95%, or greater than about 99% transmittance, including all ranges and subranges therebetween. According to various embodiments, the glass article may have a transmittance of less than about 50% in the visible region, such as less than about 45%, less than about 40%, less than about 35%, less than about 30%, less than about 25%, or less than about 20%, including all ranges and subranges therebetween. In certain embodiments, an exemplary glass panel may have a transmittance of greater than about 50% in the ultraviolet (UV) region (100-400 nm), such as greater than about 55%, greater than about 60%, greater than about 65%, greater than about 70%, greater than about 75%, greater than about 80%, greater than about 85%, greater than about 90%, greater than about 95%, or greater than about 99% transmittance, including all ranges and subranges therebetween.

[0079] Exemplary glasses can include, but are not limited to, aluminosilicate, alkalialuminosilicate, borosilicate, alkali-borosilicate, aluminoborosilicate, alkali- aluminoborosilicate, and other suitable glasses. Non-limiting examples of glasses that may be processed using the apparatuses and methods of the present disclosure include WILLOW® glasses from Corning Incorporated. The glass article may be optionally strengthened. In some embodiments, the glass article may be strengthened mechanically by utilizing a mismatch of the coefficient of thermal expansion between portions of the article to create a compressive stress region and a central region exhibiting a tensile stress. In some embodiments, the glass article may be strengthened thermally by heating the glass to a temperature above the glass transition point and then rapidly quenching. In some other embodiments, the glass article may be chemically strengthening by ion exchange.

[0080] The apparatuses and methods of the present disclosure can be used to produce glass substrates made of ultra-thin glass (UTG). For purposes of the present disclosure, ultrathin glass (UTG) is flexible glass that can be bent and/or wound into spools or rolls. In some examples, the UTG can have a thickness in a range of about 40 micrometers to about 100 micrometers. The apparatuses and methods of the present disclosure can be used to unwind glass that has been rolled onto spools and then separate the glass ribbon into separate glass substrates or glass sheets. The apparatuses and methods of the present disclosure are improvements over existing and traditional apparatuses and methods. For example, the apparatuses and methods of the present disclosure can be performed more quickly, at reduced costs, with less manufacturing floor space or footprint, with improved production yield, and with improved quality over existing or traditional apparatuses and methods.

[0081] An example glass production method 100 is shown in FIG. 1. As shown, the method 100 may begin at step 102 at which glass forming is performing. The ingredients for the glass can be deposited into a suitable container, melted, and formed into a glass ribbon. The glass ribbon may have a predetermined size, width, and/or thickness. In some examples, the glass ribbon may be formed using a down draw process. In other examples, a suitable float glass production method may be used to form the glass. In a preferred example, the glass ribbon is formed using a fusion draw glass production method. In other examples, other glass production methods may be used. The glass that is formed at step 102 may be an UTG product such that the glass can be flexed, bent, rolled, or spooled without breaking or failure of the glass.

[0082] At step 104 of method 100, the glass ribbon may be spooled. In this step, the glass ribbon may be wound around a circular support structure like a spool. During such a process, the glass ribbon may be re-oriented to a horizontal orientation over one or more sets of rollers. During such process, the glass ribbon may be cooled in a controlled manner to manage stresses in the ribbon and optimize attributes of the glass. The ribbon may be moved away from the ribbon forming assemblies and then spooled (i.e., rolled) onto a roll with a protective interleaving material, such as an elongated resin film. The spool of glass ribbon is prepared with the interleaving protective material positioned between the adjacent layers of the glass in the spool to protect the surface of the glass. [0083] After a spool of glass ribbon is prepared, the spool can be moved to a protective region of a manufacturing facility so as not to expose the spool of glass material to a non-clean room environment. The spools may be loaded, in some examples, into protective enclosures that are sealed from outside contamination. The spools and/or the protective enclosures can then be transferred, moved, or otherwise transported to other regions, facilities or locations where the spools of glass ribbon can be further processed into glass substrates or sheets.

[0084] At step 106 of method 100, the spools of glass ribbon can be unspooled. During unspooling, the glass ribbon can be unwound from the spools. The protective interleaving material can also be removed from the glass ribbon. After the glass ribbon is removed, the glass ribbon can be manipulated into a linear orientation by rollers or other tools.

[0085] At step 108, the glass ribbon can be separated into individual sheets or substrates of glass material. The glass ribbon can be cut using suitable cutting or singulation techniques, as will be further described. After the glass sheets are separated from the glass ribbon, the glass sheets can be moved to packaging station.

[0086] At step 110, the glass sheets can be packed into a suitable tote or container for transportation for further processing. In some examples, the glass sheets can be stacked and can be interleaved with protective material or packing elements positioned between adjacent glass sheets.

[0087] In various examples of the present disclosure, step 106 and step 108 can be performed by a roll-to-sheet glass assembly apparatus. Such apparatuses can process a spool of glass ribbon into cut, singulated glass sheets for further processing.

[0088] Turning now to FIG. 2, an example glass sheet 200 is shown. The glass sheet 200 can be produced, for example, from a continuous glass ribbon. The glass ribbon may be rolled onto a spool and then unspooled prior to separation of the glass ribbon into multiple glass sheets 200. The glass sheet 200 may have a predetermined size. The glass sheet may have an overall width XI and an overall height Yl. A margin portion 204 of the glass sheet may be located around a quality area 202 of the glass sheet 200. The margin portion 204 can be a border that is positioned on either lateral side and a top and bottom of the glass sheet 200. The margin portion may have a width X2 that is located on either side of the quality area 202. The margin portion may also have a height Y2 that is located above and below the quality area 202. The margin portion 204 may be used to handle the glass sheet during manufacturing processes. For example, rollers, articulators, grippers, cutters, or other tools may contact the glass sheet during manufacturing. It is desirable, however, that no contact is made to the quality area 202 of the glass sheet during manufacturing. By limiting contact to the quality area 202, contamination, defects and other quality issues in the quality area 202 of the glass sheet 200 can be minimized.

[0089] The margin area 204 and/or the quality area 202 of the glass sheet 200 may have various sizes as may be needed for a particular product or a particular application. In one example, the glass sheet 200 may be made of an ultra-thin glass (UTG). The UTG may have a thickness of about 40 micrometers to about 100 micrometers. The glass sheet 200, in such an example, may have an overall width XI of about 472.5 mm. In a preferred example, the glass sheet 200 may have an overall width XI of about 472.5 ± 12.5 mm. The glass sheet 200 may have an overall height of about 580 mm. The margin may have a width X2 of about 55 mm and a height Y2 of about 25 mm. The quality area may have a size of about 350 mm wide by about 530 mm in height. In other examples, the glass sheet 200 may have other sizes with other sizes of the margin portion 204 and/or the quality area 202.

[0090] Turning now to FIGs. 3 and 4, an example roll-to-sheet glass assembly apparatus 300 is shown. The roll-to-sheet apparatus 300 can perform, for example, steps 106 and 108 of the method 100. The roll-to-sheet apparatus 300 can accept a spool of rolled glass ribbon. The roll-to-sheet apparatus 300 can then unwind the glass ribbon, remove the interleaf, and separate the glass ribbon into glass sheets of a predetermined size. During such processing, the elements of the roll-to-sheet apparatus 300 do not contact and/or contaminate the quality area of the glass sheets to minimize risk of defects or contamination.

[0091] In the description of the roll-to-sheet apparatus 300 or other apparatuses of the present disclosure, the terms “upstream” and/or “downstream” may be used. Such terms are used to indicate a relative positions of elements and/or functionality of the roll-to-sheet apparatus or other apparatuses. The terms upstream and downstream are used relative to a direction of travel or processing of the glass ribbon. For example, the glass ribbon 330 may move in a downward direction as shown in the orientation of FIG. 3. The elements located above other elements on roll-to-sheet apparatus 300 are located upstream of such elements. Items located below other elements on the roll-to-sheet apparatus 300 shown in FIG. 3 are located downstream of such other elements.

[0092] In addition, the description below may use the terms “front” and/or “back” to describe opposite surfaces of the glass ribbon. The terms front and/or back are relative terms used to describe opposite sides of the glass ribbon and should not be interpreted to mean a particular side of a glass sheet, glass article, or other item that may include the glass sheet. The terms front and/or back or other relative terms do not mean that a particular side of the glass sheet is used on a front or back of a product that may incorporate the glass sheet. The term front is used in the present description to describe a side of the glass that faces outwardly from the spool of glass ribbon. The front side of the glass ribbon is denoted by the arrow marked “F” in FIG. 3. The term back is used in the present description to describe an opposite side of the glass ribbon than the front side. The back side of the glass ribbon is denoted by the arrow marked “B” in FIG. 3. These terms may be similarly used to describe the glass ribbon during descriptions of other embodiments or examples of the roll-to-sheet apparatuses of the present disclosure.

[0093] In addition, the terms longitudinal and lateral (or variations thereof) may be used to describe directions relative to the glass ribbon. As used in the present disclosure with reference to the glass ribbon, the lateral direction is a direction across a width of the glass ribbon. This direction is generally in a direction from left to right across the glass ribbon as shown in the view of FIG. 4. The longitudinal direction, as used in the present disclosure with reference to the glass ribbon, generally indicates a direction along a length or height of the glass ribbon. This direction is generally in a direction upwards and downwards along the glass ribbon as shown in the view of FIG. 4.

[0094] As shown, the roll-to-sheet apparatus 300 may include a spool unwinder 302 and an interleaf rewinder 304. The spool unwinder 302 operates to retain and control the unwinding of the glass ribbon that is contained on the spool. The spool unwinder 302 may include a shaft coupled to a motor that can spin the spool to unwind the glass ribbon that is contained on the spool. The spool unwinder 302 may also include a positioning mechanism (not shown). The positioning mechanism can allow the spool unwinder 302 to move the spool or the glass ribbon 330 laterally to control a lateral position of the glass ribbon 330 in the roll-to-sheet apparatus 300. The positioning mechanism can assist in positioning the glass ribbon 330 into a desired, targeted or predetermined position or alignment. The positioning mechanism may include a cylinder, solenoid, or other actuator that can laterally move the spool or the glass ribbon 330 that is located on the spool to the predetermined location. In other examples, the positioning mechanism can also position the glass ribbon 330 in a desired position in other directions in addition to the lateral direction. Such other directions may include a fore-aft position (i.e. in a direction left-to-right in the view shown in FIG. 3), or other directions.

[0095] The spool unwinder 302 and/or the elements thereof may be coupled to a controller, programmable logic controller (PLC) processing device or other control device to automatically operate the spool unwinder 302. The operating parameters of the spool unwinder 302 can be controlled or set to predetermined control limits that can be optimized and/or controlled. The operating parameters of the spool unwinder 302 may include a lateral position, unwinding speed, unwinding tension, and the like.

[0096] The interleaf rewinder 304 may be positioned downstream of the spool unwinder 302. The interleaf rewinder 304 operates to disengage the protective interleaf layer 332 from the glass ribbon 330. As previously described, the glass ribbon 330 that is collected on the spool includes the flexible glass ribbon with a layer of protective interleaf disposed between adjacent coils of glass ribbon 330. As the spool unwinder 302 uncoils the glass ribbon 330, the interleaf layer 332 is also uncoiled and the two layers (i.e., the glass ribbon 330 and the interleaf layer 332) are positioned adjacent to one another as they are uncoiled from the spool. The interleaf rewinder 304 can include an interleaf spool onto which the interleaf rewinder can accumulate the interleaf layer 332 as the interleaf layer 332 is removed from the glass ribbon 330.

[0097] The interleaf rewinder 304 may include a shaft coupled to a motor that can couple to the interleaf spool to spin the interleaf spool at a predetermined speed and position to collect the interleaf layer 332. The interleaf rewinder 304 may also include a positioning mechanism that can position the interleaf spool at a desired position relative to the glass ribbon 330 and/or the interleaf layer 332. The positioning mechanism may allow the interleaf rewinder 304 to move in a lateral, longitudinal, or other position relative to the glass ribbon 330. Furthermore, the interleaf rewinder 304 and/or the positioning mechanism may be coupled to a controller, programmable logic controller (PLC) processing device or other control device to automatically operate the interleaf rewinder 304. The operating parameters of the interleaf rewinder 304 can be controlled or set to predetermined control limits that can be optimized and/or controlled. The operating parameters of the interleaf rewinder 304 may include a position, rewinding speed, rewinding tension, and the like.

[0098] As further shown in FIGs. 3 and 4, the roll-to-sheet apparatus 300 may include one or more sets of guide rollers. A first set of guide rollers 308 may be positioned downstream of the spool unwinder 302. The guide rollers 308 may be positioned on either lateral side of the glass ribbon 330 and contact the margin portions of the glass ribbon 330 but not contact the quality area or center region of the glass ribbon 330. The guide rollers 308 may contact the glass ribbon 330 to move and/or guide the glass ribbon 330 in a predetermined position or orientation. [0099] In this example, the first set of guide rollers 308 are positioned on an opposite side of the glass ribbon 330 from one or more interleaf transfer rollers 338. The interleaf transfer rollers 338 may be positioned downstream of the spool unwinder 302 and proximate to the interleaf rewinder 304. The interleaf transfer rollers 338 may operate to guide or move the interleaf layer 332 away from the glass ribbon 330 and toward the interleaf rewinder 304. The interleaf transfer roller 338 may be across the lateral surface of the interleaf layer 332. The interleaf transfer roller 338 may span across the glass ribbon 330 but does not contact the glass ribbon since the interleaf layer 332 is positioned between the interleaf transfer roller 338 and the glass ribbon 330.

[00100] The interleaf transfer roller 338 may be configured as a cylindrical member to remove or separate the interleaf layer 332 from the glass ribbon 330. The interleaf transfer roller 338 may exert a force against the interleaf layer 332 to remove the interleaf layer 332 from the glass ribbon 330. In one example, the interleaf transfer roller 338 may be configured to electrostatically attract the interleaf layer 332 away from the glass ribbon 330. In another example, the interleaf transfer roller 338 may include one or more openings along its surface in communication with a vacuum source to draw the interleaf layer 332 away from the glass ribbon 330. In another example, a clean, dry air jet can be applied at a position between the interleaf layer 332 and the glass ribbon 330 to assist in the separation. The clean, dry air jet can be applied directly or via the Coanda effect in various examples. In still another example, the surface of the interleaf transfer roller 338 may be sticky or tacky to apply an adhesive force to the interleaf layer 332 to remove the interleaf layer 332 from the glass ribbon 330. In still other examples, other methods or configurations may be used to separate the interleaf layer 332 from the glass ribbon 330.

[00101] The position of the glass ribbon 330 and/or the position of the interleaf layer 332 can be determined using one or more position sensors located at various positions along the glass ribbon 330. The roll-to-sheet apparatus 300 can include multiple sensors located at different longitudinal locations along the glass ribbon 330. In the example shown, a first edge position sensor 310 may be located downstream of the guide roller 308 and the interleaf transfer roller 338. A second edge position sensor 316 can be located further downstream along the glass ribbon 330. In other examples, the roll-to-sheet apparatus 300 can include further sensors to determine a position of the edges of the glass ribbon 330 and/or a position of the center of the glass ribbon 330. The sensor 310 and the sensor 316 operate to determine a position of the glass ribbon 330 and can be configured as edge position sensors, photoelectric sensors, laser sensors, center position sensors or the like. The sensors 310 and the sensor 316 (or other sensors) can be coupled to the controller, programmable logic controller (PLC) processing device or other control device to automatically operate the roll- to-sheet apparatus 300. The operating parameters of the spool unwinder 302, interleaf rewinder 304, guide rollers 308, interleaf transfer roller 338, and/or other elements of the roll- to-sheet apparatus 300 can be controlled or set to predetermined control limits that can be optimized and/or controlled. The operating parameters may include positions, alignments, speeds, and the like.

[00102] The roll-to-sheet apparatus 300 may also include one or more sets of air ionizer assemblies. A first air ionizer assembly 340 may include ionizer structures, air knives or nozzles that can utilize high voltages to ionize air molecules at localized regions proximate the air ionizer assembly 340. The air ionizer assembly 340 can reduce local air or environmental contamination near the glass ribbon 330 (and interleaf layer 332) and prevent or minimize contamination of the glass by particles in the air. The first air ionizer assembly 340 may be located at or near the guide roller 308 and the interleaf transfer roller 338.

[00103] The roll-to-sheet apparatus 300 may include additional air ionizer assemblies in addition to the first air ionizer assembly 340. The additional air ionizer assemblies may be configured similarly to the first air ionizer assembly 340 previously described. For example, a second air ionizer assembly 306 may be located at or near the spool unwinder 302. A third air ionizer assembly 342 may be located downstream of the first air ionizer 340. A fourth air ionizer assembly 344 may be located downstream of the third air ionizer assembly 342. A fifth air ionizer assembly 346 may be located downstream of the fourth air ionizer assembly 344. The fourth air ionizer assembly 344 and the fifth air ionizer assembly 346 may each be located at opposite longitudinal ends sides of a glass separation assembly 350 (further described below).

[00104] In addition to guide rollers 308, the roll-to-sheet apparatus 300 may include additional guide rollers positioned at other locations along the glass ribbon 330. For example, the roll-to-sheet apparatus 300 may include guide rollers 312. Guide rollers 312 may be positioned downstream of guide rollers 308. The guide rollers 312 may be similar to the guide rollers 308 previously described. The guide rollers 312 may be configured and positioned to contact an edge or margin portion of the glass ribbon 330 so as not to contact a quality area of the glass ribbon located at the center of the glass ribbon 330. The guide rollers 312 (as well as the guide rollers 308 or other guide rollers that may be used) are configured to drive the glass ribbon 330 in a desired direction in a controlled manner. The guide rollers 312 (and other guide rollers) may be operated at a predetermined speed to maintain a predetermined tension and speed of the glass ribbon 330. In some examples, the guide rollers 312 may be skewed or angled relative to the longitudinal direction of the glass ribbon 330. As shown in FIG. 4, the guide rollers 312 may be obliquely angled such that an upstream portion of the guide rollers 312 is located closer to a center of the glass ribbon 330 than a downstream portion of the guide rollers 312. Such an angled alignment of the guide rollers 312 can be used to maintain a tensile force on the glass ribbon 330 to improve stability of the conveyance. In some examples, the angle of the skew of the guide rollers 312 can be changed to maintain a predetermined tension on the glass ribbon 330. In some examples, the guide rollers 312 can be, automatically or via operator interaction, controlled as tensile force, position, speed or other information is obtained from sensors and processed by the PLC, processing device, or other controller that may be coupled to the roll-to-sheet apparatus 300. [00105] As further shown, the roll-to-sheet apparatus 300 may include a separation assembly 350. The separation assembly 350 may operate to cut, singulate, separate, or otherwise produce individual glass sheets from the glass ribbon 330. The glass sheets may have the dimensions and configuration of the glass sheet 200 (FIG. 2) previously described. The glass sheets may have other sizes and configurations as may be desired for various end products and uses.

[00106] The separation assembly 350 may include a backer 320, an initiator 322, a first isolator 318, and a second isolator 324. The separation assembly 350 may engage both a front side and a back side of the glass ribbon 330 when a sufficient length of the glass ribbon 330 has extended past the separation assembly 350. The separation assembly 350 may engage the glass ribbon to cut or separate the glass sheet from the glass ribbon. Such engagement may occur in a margin portion of the glass sheet so that the quality area of the glass sheet is not contacted by the separation assembly 350. This further reduces a likelihood of contamination to the quality area of the glass sheet.

[00107] The separation assembly 350 is positioned downstream of the spool unwinder 302 and the interleaf rewinder 304 as well as downstream of the sensors 310, 316 and guide rollers 308, 312. In this position, the glass ribbon 330 is positioned and guided in stable manner past the separation assembly 350. When the glass ribbon has moved to the predetermined position, the separation assembly may engage the glass ribbon 330. The first isolator 318 and the second isolator 324 may engage the glass ribbon by engaging both the front side and the back side of the glass ribbon 330. The first isolator 318 and the second isolator 324 may be a cylinder, bar, or other elongated member that can move toward and away glass ribbon 330 in a controlled manner. The first isolator 318 and the second isolator 324 may isolate the portion of the glass ribbon 330 that is to be cut or separated from the upstream portions of the glass ribbon 330. In this manner, the stability and position of the glass ribbon can be maintained to improve quality and/or reduce a likelihood of contamination or defects in the glass.

[00108] The initiator 322 may be positioned on one side of the glass ribbon 330 and the backer 320 may be positioned on the opposite side of the glass ribbon 330. In the example shown, the initiator 322 is positioned on a front side of the glass ribbon 330 and the backer is positioned on a back side of the glass ribbon 330. In other examples, the positions of the initiator 322 and the backer 320 may be reversed. The initiator 322 may be a blade, point, cutter, scoring element or other device that can nick, cut or score the glass ribbon 330 at a desired position. The backer 320 may engage the glass ribbon by exerting a force against the glass ribbon 330. The backer 320 may be curved, rounded, or otherwise shaped to move the glass in a direction substantially perpendicular to the longitudinal direction of the glass ribbon 330. When such force is exerted, the glass ribbon 330 can break or fracture along a score line, mark or flaw that was created by the initiator 322.

[00109] Once a glass sheet has been separated from the glass ribbon 330, a transfer tool 326 can move the glass sheet away from the roll-to-sheet apparatus 300 to a packing station or other process station. The transfer tool 326 may include one or more gripping elements that may retain the glass sheet in a desired position during the transfer. For example, the transfer tool 326 may include one or more vacuum cups that can attach to the glass sheet. The vacuum cups may be positioned in an edge or margin portion of the glass sheet to prevent or minimize contamination of the quality area of the glass sheet. The vacuum cups may be arranged in a row along each edge of the glass sheet, for example. In other examples, the transfer tool 326 may include other gripping or support elements. A support tool 328 may be positioned on an opposite side of the glass sheet than the transfer tool 326 to provide support when the transfer tool 326 engages the glass sheet. Similarly to the transfer tool 326, the support tool 328 may be configured to contact and/or support the glass sheet at margin or edge portions of the glass sheet to minimize contamination to the quality area of the glass sheet.

[00110] The transfer tool 326 may be coupled to a manipulator arm, robot arm, or other articulating member to move the transfer tool 326 and the glass sheet coupled thereto to a predetermined location away from the roll-to-sheet apparatus 300.

[00111] While not show, the roll-to-sheet apparatus 300 may also include a marking tool that can operate to print, deposit, or otherwise apply a marking to the glass sheet. In various examples, a timestamp, part number, identification number, barcode or other identification mark can be applied by the marking tool to the glass sheet.

[00112] Turning now to FIGs. 5 A and 5B, another example roll-to-sheet apparatus 500 is shown. The roll-to-sheet apparatus 500 may be similar to the roll-to-sheet apparatus 300 previously described. As shown, the roll-to-sheet apparatus 500 includes a controller 502, a spool unwinder 504, an interleaf rewinder 506, guide rollers 508, 510, sensors 512, 514, 516, 518, and separation assembly 520. The controller 502 may be electrically coupled to the controller 502, a spool unwinder 504, an interleaf rewinder 506, guide rollers 508, 510, sensors 512, 514, 516, 518, and separation assembly 520 using wired or wireless connections. The controller 502 may operate as a central control unit to control the operation of the spool unwinder 504, the interleaf rewinder 506, guide rollers 508, 510, sensors 512, 514, 516, 518, and separation assembly 520 and/or to obtain operating information regarding the operating conditions of the roll-to-sheet apparatus 500.

[00113] The roll-to-sheet apparatus 500 may operate to unroll a glass ribbon 330 that has been collected on a spool. The glass ribbon 330 may be an ultra-thin glass (UTG), for example. In some examples, the thickness of the glass is in a range of about 30 micrometers to about 100 micrometers. In other examples, the thickness of the glass is less than about 100 micrometers. In still other examples, the thickness of the glass is less than about 60 micrometers. The roll-to-sheet apparatus 500 may also remove and collect an interleaf layer that is positioned between layers of glass ribbon on the spool. The roll-to-sheet apparatus 500 may also move the glass ribbon to a separation assembly 520 where the glass ribbon is cut or separated into individual glass sheets of a predetermined size for further processing. [00114] The spool unwinder 504 may include an unwinder shaft 530 and a unwinder motor 532. The controller 502 can be coupled to the unwinder motor 532 and/or the unwinder shaft 530 to control an unwinding speed of the spool of glass ribbon that is positioned on the unwinder shaft 530. The unwinder motor 532 can be a servo motor or other electrically controllable motor, for example. The interleaf rewinder 506 may be similarly configured with a rewinder shaft 534 and a rewinder motor 536. The controller 502 can be coupled to the rewinder motor 536 and/or the rewinder shaft 534 to control a rewinding speed of the spool that collects the interleaf. The rewinder motor 536 may be a servo motor or other electrically controllable motor, in some examples.

[00115] The roll-to-sheet apparatus 500 may receive positioning information from one or more of the sensors 512, 514 to determine a position of the glass ribbon 330. The sensors 512, 514 may be edge position sensors, for example, that are configured to determine a position of the edges of the glass ribbon. A sensor 512 may be positioned at each of the lateral sides of the glass ribbon 330. A sensor 514 may also be positioned at each lateral side of the glass ribbon 330. The sensors 514 may be positioned at a location downstream of the sensors 512. With inputs from the sensors 512 and the sensors 514 an alignment and position of the glass ribbon 330 can be determined by the controller 502. Based on the determined position and/or alignment, the controller may then make adjustments to other elements of the roll-to-sheet apparatus 500 to move the glass ribbon 330 to a predetermined alignment and or predetermined position. For example, the predetermined alignment and/or predetermined position of the glass ribbon 330 may correspond to a substantially vertical alignment. The predetermined alignment and/or predetermined position of the glass ribbon 330 may also or alternatively correspond to a centered position relative to the separation assembly 520.

[00116] In order to adjust the position of the glass ribbon 330, the controller 502 may send instructions or control signals to the guide rollers 508, 510, to the spool unwinder 504, and/or to the interleaf rewinder 506. In the example shown, the spool unwinder 504 and the interleaf rewinder may be supported by a support structure 538. The support structure 538 may be a frame of support beams, a housing, or other rigid members that can retain the spool unwinder 504 and the interleaf rewinder 506. The support structure 538 may be connected to a cylinder, actuator, robotic positioner, or other adjuster to allow the position of the spool unwinder 504 and/or the interleaf rewinder 506 to be moved to align the glass ribbon 330 to the predetermined alignment/position. In other examples, the spool unwinder 504 and the interleaf rewinder 506 may be decoupled and be attached to independently controlled adjusters.

[00117] The controller 502 can also operate to control the guide rollers 508, 510. As previously described, the guide rollers 508, 510 may contact a non-quality margin or edge portion of the glass ribbon 330. The guide rollers 508 may be adjustable to apply a predetermined pressure or torque to the glass ribbon 330. In addition, the guide rollers 508 can be adjusted to be angled or skewed relative to a longitudinal direction of the glass ribbon 330. As shown in FIG. 5B, the guide rollers 508 can be adjusted so that an angle A can be adjusted. Angle A corresponds to an angle between the axis of the roller 508 and a direction substantially perpendicular to the longitudinal direction of the glass ribbon 330. As can be appreciated, the adjustment of the angle A can adjust a force or torque that is applied to the glass ribbon 330 in a lateral direction. In some examples, angle A is an oblique angle.

[00118] The controller 502 can operate to manually or automatically control and adjust a position of the glass ribbon, the speed of the ribbon, and/or a tension of the ribbon (in both longitudinal and transverse directions). In a manual mode of operation, position, speed, force and/or other operating information that is obtained by the controller 502 can be display or otherwise provided to an operator via the Input/Output (I/O) Unit 524. The I/O Unit 524 may be various suitable user interface devices such as a display, speaker, smart phone, workstation, laptop, tablet, or the like. The I/O Unit may also include various elements to allow an operator to input information to the controller 502 such as a mouse, keyboard, microphone, touchscreen, or the like. Upon receiving the information regarding the operating conditions of the roll-to-sheet apparatus 500, the operator may adjust the speed, position, force, or other operating parameter via a user interface or by using a suitable command on the I/O Unit 524. The operator may set or adjust operating parameter levels, ranges, targets or the like using the I/O Unit 524. While not shown, the controller 502 may also be coupled to a database, server or other data store from which it may obtain glass production standards, recipes, specifications or other information to set, adjust, or recommend changes and/or settings for the roll-to-sheet apparatus 500.

[00119] In an automatic mode of operation, the controller 502 may automatically adjust one or more operating parameters of the roll-to-sheet apparatus 500. For example, if the information from the sensors 512, 514 indicate that the glass ribbon 330 is misaligned or is not positioned in a predetermined position, the controller 502 may automatically send a signal to the spool unwinder 504, the interleaf rewinder 506, the guide rollers 508, 510 or other adjuster to move a position of the glass ribbon 330. This process can be a closed loop system that operates to automatically control and maintain a position of the glass ribbon 330 in a desired position. This automatic control may also be used to maintain and/or control a tension or force that is applied to the glass ribbon 330.

[00120] The controller 502 may operate to control various operating conditions of the roll-to-sheet apparatus 500. The controller 502 may control, adjust, monitor, and manage aspects of the spool unwinder mechanism such an unwinding speed of the unwinder mechanism, a position of the spool unwinder 504 (e.g., a lateral or other position), and an operation of a clutch that may be incorporated into the spool unwinder 504 that may allow adjustment of a force or tension applied by the guide rollers 508, 510. The controller 502 may also control, adjust, monitor, and manage aspects of the interleaf rewinder 506 such as rewinding speed, a position of the interleaf rewinder 506 (e.g., a lateral or other position), and an operation of a clutch that may be incorporated into the interleaf rewinder 506 that may allow adjustment of the force or tension to the interleaf). [00121] The controller 502 may also control, adjust, monitor, and manage aspects of the guide rollers 508, 510. The speed of the guide rollers may be used to control a movement of the glass ribbon 330, that may be called a mast speed. A cross-directional or lateral tension of the glass ribbon 330 may be controlled by adjustment of the angle of the guide rollers 508, 510 (e.g., by adjustment of angle A). The controller 502 may also control the longitudinal tension of the glass ribbon 330 using a torque applied by the guide rollers 508, 510 as well as be the adjustment of the angle of the rollers. The pressure applied by the guide rollers 508, 510 may also be adjusted. The guide rollers 508, 510 may also be used to adjust a position of the glass ribbon 330. Any or all of these parameters can be set, adjusted and/or otherwise controlled by the controller 502. For example, Proportional-Integral-Derivative (PID) control loops may be used to adjust the operating parameters in an automated manner. [00122] As shown in the previously described examples, the roll-to-sheet apparatus may be arranged so the glass ribbon 330 travels in a substantially vertical direction. The roll- to-sheet apparatuses of the present disclosure do not need to be arranged in a vertical manner with the various elements arranged above or below each other. The roll-to-sheet apparatus may be arranged to allow for easier spool changes and to require a reduced floor space or height in a manufacturing environment. One such alternate arrangement is shown in FIG. 6. The roll-to-sheet apparatus 600 may be arranged to allow the glass ribbon 330 to move in horizontal, angled orientations, or other positions to reduce a required floor space and to reduce the height above the floor at which the spool of glass ribbon 330 and/or the spool of interleaf is mounted.

[00123] In the example shown, the roll-to-sheet apparatus 600 is configured in which the glass ribbon may travel upwardly from a spool unwinder 602 to a first guide roller 608. The glass ribbon 330 may then wrap and be moved downwardly toward a separation assembly 650. At a position following the first guide roller 608, the interleaf 332 may be removed from the glass ribbon 330 via an interleaf roller 610. The interleaf 332 can then travel around one or more additional interleaf rollers before the interleaf 332 is collected by the interleaf rewinder 604. With the interleaf removed, the glass ribbon 330 can move to the separation assembly 650 where the glass ribbon 330 can be cut into individual glass sheets. The glass sheets can be moved away from the roll-to-sheet apparatus 600 using a transfer tool (not shown) as previously described.

[00124] As can be seen, the arrangement of the roll-to-sheet apparatus 600 can allow the spools to be inserted and/or removed from the spool unwinder 602 and/or the interleaf rewinder 604 more easily since their positions are not located at elevated heights above the separation assembly. In this example, the interleaf rewinder 604 may be located at a similar vertical height as the separation assembly 650. In other examples, the interleaf rewinder 604 can be positioned at other desirable locations. The spool unwinder 602 can also be located at other desirable locations.

[00125] Turning now to FIG. 7, another roll-to-sheet apparatus 700 is shown. In this example, the roll-to-sheet apparatus may be configured similarly to the roll-to-sheet apparatuses previously described. This example, however, is configured similarly to the roll- to-sheet apparatus 600 in that the spool unwinder 702 and the interleaf rewinder 704 may be positioned to allow for improved packaging and location to minimize floor space and to allow for a reduced height to improve spool loading and unloading. In this example, the glass ribbon 330 may be managed and controlled to improve stability and control over existing apparatuses and methods.

[00126] The roll-to-sheet apparatus 700 may include a spool diameter detector 706 and a spool pressure roller 708. The spool diameter detector 706 may be located proximate the spool unwinder 702 and be configured to determine an amount or thickness of material located on the spool during unwinding. The spool diameter detector 706 may include any suitable sensor to determine a distance between the sensor and the surface of the glass ribbon 330 on the spool. As the glass ribbon 330 unwinds from the spool, the spool diameter detector 706 can monitor this removal of material. The spool diameter detector 706 can be coupled to the controller (not shown) to allow the controller to control a speed of the spool unwinder 702. The spool diameter detector 706 may be configured to read a “head-on” measurement from a direction substantially perpendicular to the surface of the glass ribbon 330 on the spool. In other examples, the spool diameter detector may be offset laterally relative to the spool to allow more measurements to be monitored.

[00127] The spool pressure roller 708 may be positioned proximate to the spool and may be configured to apply a force or pressure to the outside surface of the glass ribbon 330 on the spool. The spool pressure roller 708 can be configured as two or more rollers that may be positioned at the edge or margin portions of the glass ribbon 330. The spool pressure roller 708 can be configured not to contact a quality area of the glass ribbon 330 to reduce a likelihood of contamination. The spool pressure roller 708 can be configured to move radially toward and away from the glass ribbon. As shown, the spool pressure roller 708 may be moved to a position at or near 708a when the spool is full of glass ribbon 330. As the glass ribbon 330 is unwound, the spool pressure roller 708 may move toward a position 708b. The spool pressure roller 708 may be configured to apply a predetermined force or pressure or be configured to apply such force or pressure in a predetermined range.

[00128] The spool pressure roller 708 may apply a force or pressure to the glass ribbon 330 to maintain stability during the unwinding process. The glass ribbon 330 may vibrate, bounce, or otherwise move as it is unwound from the spool. Such spool swelling can be mitigated by the application of a force or pressure to the glass ribbon 330 by the spool pressure roller. The controller (not shown) may be coupled to the spool pressure roller 708 to apply the force or pressure in a predetermined level or in a predetermined range. The controller may adjust the pressure or force applied to the glass ribbon 330 in response to information that is received from the spool diameter detector 706. The spool diameter detector 706 may indicate vibrations, bouncing, or other spool swelling that may occur during unwinding. The controller can then control the pressure or force of the spool pressure roller 708 to mitigate such undesirable movement of the glass ribbon 330.

[00129] The roll-to-sheet apparatus 700 may also include a spool exit detector 710. The spool exit detector 710 is positioned downstream of the spool unwinder 702 and is configured to detect issues with the glass ribbon 330 as the glass ribbon 330 leaves the spool. The spool exit detector 710 may include two edge sensors that are positioned at opposite side edges of the glass ribbon 330 as the glass ribbon 330 exits the spool. One or more support rollers 712 may be positioned at or near the spool exit detector 710 to guide the glass ribbon 330 through or past the spool exit detector 710.

[00130] The spool exit detector 710 may be configured to measure a location of the edge of the glass ribbon 330. This information may be obtained by the controller so that the controller can control other elements of the roll-to-sheet apparatus 700 in a manner previously described with respect to roll-to-sheet apparatuses 300, 500. The spool exist detector 710 may also be configured to detect defects or breakage of the glass ribbon 330. If a defect or breakage is detected, the controller can stop operation of the roll-to-sheet apparatus 700 so that appropriate action can be taken.

[00131] The glass ribbon 330 may proceed in a free loop 720 before passing over a free roller 714. The free loop 720 may be configured as a portion of the glass ribbon that is allowed to sag or form a curved or U-shape in the glass ribbon 330. The free loop 720 can assist with managing the tension of the glass ribbon 330. In addition, the use of the free loop 720 can allow geometry variations or other dimensional inconsistencies to be alleviated after the glass ribbon 330 is unwound from the spool. As can be appreciated, the glass ribbon 330 may have a bow, warpage, or other undesirable shape from the glass forming process and/or from being wound on the spool. The free loop 720 can allow the glass ribbon 330 to relax and remove or mitigate the dimensional inconsistencies in the glass ribbon 330.

[00132] The size and shape of the free loop 720 can be managed by the controller via a speed and tension of the spool unwinder 702 and/or the free roller 714. Additional guide rollers 716 may also be positioned at or near the free roller 714 to further control the free loop 720. A free loop sensor 718 may be positioned at or near the free loop 720. The free loop sensor 718 may measure and/or monitor a size and shape of the free loop 720. This information can be obtained by the controller that can, in turn, control the speed and tension of the glass ribbon 330 to maintain a predetermined size and shape of the free loop 720. [00133] The interleaf 332 may be removed from the glass ribbon after the free roller 714. The interleaf rewinder 704 may collect the interleaf 332. The interleaf 332 may pass over one or more interleaf rollers 722 that may be configured as described earlier with respect to the roll-to-sheet apparatus 300.

[00134] The glass ribbon 330 may proceed in the roll-to-sheet apparatus 700 and be guided to a separation assembly (not shown) after passing one or more guide rollers 724 and a first edge position sensor 726 and a second edge position sensor 728. The controller may receive information from the edge position sensors 726, 728 and then adjust the guide rollers 724 or other positional adjustment elements of the roll-to-sheet apparatus 700 to maintain or control the glass ribbon 330 in a predetermined position or predetermined range. The glass ribbon 330 may then proceed to being cut, broken or otherwise separated into individual glass sheets. While not shown, the roll-to-sheet apparatus 700 may include the other elements of the roll-to-sheet apparatuses described herein such as in roll-to-sheet apparatuses 300, 500. [00135] Referring now to FIG. 8, another example roll-to-sheet apparatus 800 is shown. The roll-to-sheet apparatus 800 is similar to the roll-to-sheet apparatus 700 previously described. The components that the roll-to-sheet apparatus 800 has in common with the roll-to-sheet apparatus 700 are not repeated here for the sake of brevity. The roll-to- sheet apparatus 800 includes a stress zone 802. The stress zone 802 includes a second free roller 804 and a second guide roller 806. In addition, the stress zone 802 includes a pressure roller 808. The second free roller 804 and the second guide roller 806 can have similar configurations to the first free roller 714 and the first guide roller 716 previously described. The second free roller 804 and the second guide roller 806 may be positioned upstream of the first free roller 714 and the first guide roller 716. The pressure roller 808 can be positioned to apply a pressure or force to the glass ribbon 330 between the first free roller 714 and the second free roller 804. [00136] Each of the first free roller 714, the second free roller 804, the first guide roller 716 and the second guide roller 806 as well as the pressure roller 808 can be operated to control the speed and tension of the glass ribbon 330. The pressure roller 808 can be moved in a direction toward or away from the surface of the glass ribbon to modify a tension to the glass ribbon 330. The pressure roller 808 can be configured to contact an edge or margin portion of the glass ribbon 330 to reduce a likelihood of contamination to the quality surface of the glass ribbon 330.

[00137] As can be seen, the interleaf 332 is positioned on a surface of the glass ribbon 330 until it is removed by the interleaf rewinder 704. The positioning of the interleaf 332 on a lower surface of the glass ribbon 330 can be advantageous to prevent damage or contamination of the glass as it is supported on this lower surface for portions of the roll-to- sheet apparatus 800 and/or on the spool. It can be difficult, however, to detect cracks, defects, or breakage of the glass ribbon 330 when the interleaf 332 is positioned on the glass ribbon 330. The stress zone 802 may assist in detecting a crack, defect, or breakage of the glass ribbon. When the pressure roller 808 applies a force or pressure to the glass ribbon, such a breakage may occur in the stress zone 802. Using one or more sensors, this breakage can be detected. When such a breakage is detected, action can be taken without unnecessary downtime or other issues arising from such breakage.

[00138] Turning now to FIG. 9, an example separation assembly 900 is shown. The separation assembly 900, in this example is shown with a glass ribbon 330. The separation assembly 900 includes various elements positioned on either side of the glass ribbon 330. In this example, the separation assembly 900 includes a backer 920, an upper isolator 904, a lower isolator 906 and an initiator 902. The initiator 902 is positioned between the upper isolator 904 and the lower isolator 906. The initiator 902 may include a cutter 916 positioned at a distal end of the initiator that is configured to contact the glass and cut or nick the glass to initiate a breakage of the glass as a predetermined location. The cutter 916 may be a cutting wheel or other nicking device.

[00139] During operation, the separation assembly 900 operates to cut or break the glass ribbon 330 into a glass sheet of a predetermined size. When the glass ribbon 330 is moved into a desired position and a predetermined length of the glass ribbon 330 is located below the separation assembly 900, the controller can cause the movement of the glass ribbon 330 to stop moving. The upper isolator 904 and the lower isolator 906 can clamp the glass ribbon 330 to isolate the glass ribbon from vibration or movement during the separation or singulation process. The upper isolator 904 may include a first bar 912 positioned on a first side of the glass ribbon 330 and a second bar 918 positioned on a second side the glass ribbon 330 opposite to the first bar 912. The first bar 912 and the second bar 918 can clamp the glass ribbon 330. Similarly, but at a position located further downstream on the glass ribbon 330, the lower isolator 906 can clamp the glass ribbon 330 by moving a first bar 912 and a second bar 914 against the glass ribbon 330 on opposing sides.

[00140] After isolation, the backer 920 may move toward the glass ribbon 330 and apply a pressure or force to the glass ribbon 330 at a position opposite to the initiator 902. The backer 920 may induce a stress into the glass ribbon 330 at the location where the initiator 902 will initiate a flaw, nick or cut. The initiator 902 may move toward the glass ribbon 330 and initiate the flaw, nick or cut. Once the flaw, nick or cut has been made the stress in the glass ribbon 330 will cause the glass ribbon 330 to break across the lateral width at the location of the flaw, nick or cut. Once a glass sheet has been separated from the glass ribbon 330, the backer 920, the lower isolator 906 may move away from the glass ribbon 330 and the transfer tool can move the glass sheet to a packing or other processing station.

[00141] FIGs. 10-12 show various example configuration of isolators and backers that may be used in various example separation assemblies. For example, FIG. 10 shows an example configuration 1000. In this configuration, the upper isolator 1002, the backer 1004, and the lower isolator 1006 may operate similarly to the elements of the separation assembly 900 previously described. FIG. 11 shows a configuration 1100 that is similar to the configuration 1000. The configuration 1100 has different sizing and spacing than the configuration 1000.

[00142] FIG. 12 shows another example configuration 1200. In this configuration, the separation assembly includes an upper isolator 1202, a lower isolator 1204, and a backer 1206. the upper isolator 1202 may include a single bar rather than a pair of opposing bars located on opposite sides of the glass ribbon 330. In this example, the backer 1206 may be configured to not only apply a bend, pressure, or stress to the glass ribbon 330 but may also be positioned opposite to the upper isolator 1202 and the lower isolator 1204 to clamp the glass ribbon 330 and isolate the glass ribbon 330 during the separation process. In still other examples, other configurations of isolators and backers can also be used.

[00143] Referring now to FIGs. 13 and 14, another example separation assembly 1300 is shown. The separation assembly 1300 is similar to the separation assembly 350 of roll-to- sheet apparatus 300 previously described. The elements of the separation assembly 1300 may have similar structures and operation as previously described and may be coupled to a controller as described with respect to roll-to-sheet apparatus 500. [00144] The separation assembly 1300 may operate to separate glass sheets from the glass ribbon 330. The separation assembly 1300 may include a first sensor 1302, a second sensor 1306, and a third sensor 1316. In other examples, additional sensors may also be used. The first sensor 1302, the second sensor 1306, and the third sensor 1316 may be positioned at different longitudinal locations along the glass ribbon 330 and may be configured to determine an edge position of the glass ribbon 330. The first sensor 1302 is positioned upstream of guide rollers 1304. The second sensor 1306 and the third sensor 1316 are positioned downstream of the first sensor and on opposite longitudinal sides of the separation assembly 1300. In the example shown, the first sensor 1306 is positioned upstream of the upper isolator 1308 and the third sensor 1316 is located downstream of the lower isolator 1314. The third sensor 1316 may be located on a movable tool or arm to allow the third sensor 1316 to be moved away from the glass ribbon 330 when a glass sheet is moved away from the separation assembly 1300. These different longitudinal positions can be used to determine an accurate alignment and position of the glass ribbon 330 in the separation assembly 1300.

[00145] As shown in FIG. 15, the separation assembly 1300 can be used to perform a method of separating a glass sheet 1502 from the glass ribbon 330. FIG. 15 shows example steps that may be performed by the separation assembly 1300. Each step is denoted by a time t and successive steps, for this example method, are denoted by successive letters A through G. At time t=A, the glass ribbon 330 may be moved into the separation assembly 1300 until a predetermined length of the glass ribbon is positioned below the initiator 1312. The sensors 1302, 1306, 1316 can determine a position of the glass ribbon 330 and shift or move the glass ribbon 330 as the glass ribbon 330 moves into the separation assembly 350. When the controller determines that the glass ribbon 330 is in a predetermined position in the separation assembly 1300, the method may proceed to the step at time t=B.

[00146] At time t=B, the backer 1310 may begin to apply a pressure or force to the glass ribbon 330. As can be seen, the backer 1310 may begin to move the glass ribbon 330 when the backer contacts the glass ribbon 330. As such action occurs, the sensors 1306, 1316 can obtain position information regarding a position of the edges of the glass ribbon 330. The method can then proceed to the step at time t=C.

[00147] At time t=C, the upper isolator 1308 and the lower isolator 1314 can move toward the glass ribbon 330. Such action can clamp the glass ribbon 330 in the current position and prevent movement during the separation process. As such action occurs, the sensors 1306, 1316 can continue to obtain position information regarding the position of the edges of the glass ribbon 330. Such information can be sent to or obtained by the controller. Since the edge positions of the glass ribbon 330 are fixed when the glass ribbon 330 is clamped by the upper isolator 1308 and the lower isolator 1314, the controller can cause the initiator to be moved and positioned in a desired initiation position. The controller may cause the initiator to be moved to the desired initiation position during the step at time t=C.

[00148] The initiation position can correspond to a position of the initiator relative to the edge of the glass ribbon where a flaw, nick, cut or other mark will be made by the initiator to begin a break of the glass at a desired position. As can be appreciated, the glass ribbon 330 may have bends, bows, warpage or other shapes that may cause the edges of the glass ribbon 330 to move when the backer 1310 contacts the glass ribbon 330 or when the upper isolator 1308 and/or the lower isolator 1314 contact the glass ribbon 330. The amount of movement of the edges of the glass ribbon 330 determines an amount that the initiator 1312 may need to be adjusted (to the initiation position) before the initiator 1312 can contact the glass ribbon. When the initiator 1312 is positioned at the initiation position, the method can proceed to the step at time t=D.

[00149] At time t=D, the initiator 1312 can be moved toward the glass ribbon 330. The initiator 1312 can nick, cut, or otherwise create a flaw in the glass at a predetermined position. The initiator 1312 can be moved laterally to create a nick or cut of a predetermined lateral length. The initiator 1312 can initially contact the glass ribbon 330 at a position laterally inward of the edge of the glass ribbon 330 and then be moved laterally outward toward the edge to cause the nick, cut or flaw to extend through the edge of the glass ribbon. As such action by the initiator 1312 occurs, the glass ribbon 330 will break in a lateral direction across the lateral width of the glass ribbon 330. The stress applied by the backer 1310 causes the fracture to propagate from the nick or cut across the lateral width of the glass ribbon 330. The method may then proceed to time t=E.

[00150] At time t=E, the glass sheet 1502 has been separated from the glass ribbon 330. The initiator 1312 may move away from the glass ribbon 330. In addition, the lower isolator 1314 may unclamp and move away from the glass sheet 1502 to its original position. As shown, the backer 1310 and the upper isolator 1308 may remain in their positions relative to the glass ribbon 330. By maintaining their positions, the glass ribbon 330 is maintained in position so that the separated edges of the glass sheet 1502 and the glass ribbon 330 do not contact either other when the glass sheet 1502 is removed from the separation assembly 1300. Contact between the glass ribbon 330 and the glass sheet 1502 is undesirable because contact can cause particles, chips or other contamination to be generated. The likelihood of contact between the glass ribbon 330 and the glass sheet 1502 is minimized when the position of the glass ribbon 330 is maintained by the upper isolator 1308 and the backer 1310 after the glass sheet is separated.

[00151] At time t=F, the glass sheet 1502 can be removed from the separation assembly 1300. While not shown, the glass sheet 1502 can be supported by a transportation tool (such as transportation tool 326) previously described. Once the glass sheet 1502 has been moved a sufficient distance away from the glass ribbon 330, the method may proceed to the step at time T=G.

[00152] At time t=G, the glass sheet 1502 can be further moved. The upper isolator 1308 and the backer 1310 can move away from the glass ribbon 330. The upper isolator 1308 and the backer 1310 can allow movement of the glass ribbon 330 at this step since the glass sheet 1502 is a sufficient distance away from the glass ribbon 330 such the glass sheet 1502 will not contact the glass ribbon 330 when the glass ribbon 330 may flex or move when the upper isolator 1308 and/or the backer 1310 are retracted. The glass sheet 1502 can be moved to a packing station or other processing station.

[00153] The steps shown in FIG. 15 and described above can be repeated to produce glass sheets 1502. After the step shown at t=G, the method may continue and return to the step shown at time t=A. The glass ribbon 330 may be moved into the separation assembly 1300 to allow the separation assembly 1300 to separate another glass sheet 1502 from the glass ribbon 330.

[00154] The roll-to-sheet apparatuses and the separation assemblies of the present disclosure can be used to improve cycle times. As discussed above, the controller and related methods can be used to control a position and alignment of the glass ribbon 330. The position and alignment of the glass ribbon 330 is an important factor that may determine the time required to perform the steps shown and described above. For example, if the initiator 1312 must be moved and/or aligned in response to movement of the glass ribbon 330 during the initial steps of the separation process, the time required to perform each separation is increased. If the glass ribbon 330 does not move during the initial steps, the time associated with moving the initiator 1312 is reduced. This can improve cycle and reduce costs associated with producing the glass sheets 1502.

[00155] For example, Table 1 below shows two circumstances in which the separation method may be performed. In case 1, the edge of the glass ribbon 330 deviates from an initial position by more than about 1 mm. Such a deviation is deemed to be significant because the initiator 1312 must be moved to realign the initiator 1312 before it may contact the glass ribbon 330. In case 2, the edge of the glass ribbon does not deviate significantly and the deviation is determined to be negligible (i.e., the deviation is less than about 0.5 mm). In case 2, the initiator does not require realignment before it may contact the glass ribbon 330.

Table 1

[00156] As can be seen in Table 1 above, in case 2, the cycle time required to separate the glass sheet 1502 is about 2 seconds faster than the cycle time in case 1. This time savings is a result of a reduced time to measure the deviation of the edges of the glass ribbon 330 and move the initiator 1312 into the initiation position. The roll-to-sheet apparatuses of the present disclosure have improved capability to control a position and alignment of the glass ribbon 330. With this control of the alignment and position of the glass ribbon, there is an increased likelihood that the movement of the glass ribbon 330 during separation will be negligible (i.e., case 2 above) and the cycle time of the separation process can be reduced. [00157] The separation assembly 1300 may also be configured to determine whether a successful separation the glass sheet 1502 has occurred. As shown in FIG. 14, the separation assembly may include a separation sensor 1402. In the example shown, the separation sensor 1402 may be positioned at or near an edge of the glass ribbon 330 that is laterally opposite to the initiator 1312. In some examples, the separation sensor 1402 may be positioned in the backer 1310. The separation sensor 1402, in some examples, can be configured to emit a light source, laser, or other beam at the location of where separation or singulation of the glass sheet 1502 is intended to occur. When the beam strikes the location of separation, the light that is reflected and/or refracted can be measured. If separation occurs, the beam is likely to be reflected and/or refracted in a manner that is different from the light that is reflected and/or refracted when separation has not occurred. FIGs. 16 and 17 illustrate such circumstances. In the example shown, the light that is reflected and/or refracted in a circumstance in which separation has occurred (FIG. 16) has varying angles of reflection and/or refraction 1604 and the beam 1602 is dispersed into lower intensity elements. In another example where separation has not been successfully achieved (FIG. 17), the beam 1602 is not dispersed and the light is reflected and refracted in more consistent manner that produces a higher intensity light 1702. In this manner, successful and unsuccessful separations may be detected by the separation sensor 1402. In other examples, the separation sensor 1402 may include other photoelectric sensors, ultrasonic sensors, or the like to determine whether separation has been successful. The separation sensor 1402 may be coupled to the controller in order to obtain information regarding the separation of the glass sheet 1502. In response, the controller may adjust or control the elements of the separation assembly 1300 based on whether the separation was successful or unsuccessful.

[00158] In some examples of the present disclosure, the backer 1310 of the separation assembly 1300 may include a groove 1804 that is located along a center of the backer 1310. As shown in FIG. 18, the groove 1804 may be positioned to extend laterally along the backer 1310b. The groove 1804 may be positioned at the rounded end 1802 of the backer 1310b. The groove 1804 may be positioned in a location to correspond to a location at which the initiator 1312 may contact the glass ribbon 330 on the opposite side. The groove 1804 is configured to prevent or reduce the damage that may otherwise occur to a cutting wheel of the initiator 1312 when the cutting wheel moves across an edge of the glass ribbon 330. [00159] As further shown in FIG. 18, a cutting wheel may be positioned at a first position as indicated by the position of the cutting wheel 1806a when the initiator is moved against the glass ribbon 330 during the separation process. The cutting wheel 1806 can be moved from the position 1806a to the final position 1806b. At the final position 1806b, the cutting wheel has moved past an edge of the glass ribbon 330. There is a possibility that the cutting wheel can contact the surface of the backer 1310a and damage the cutting wheel. If the backer 1310 includes the groove 1804, the cutting wheel can reside in the groove 1804 when the cutting wheel moves past the edge of the glass ribbon 330 when it moves to the final position 1806b.

[00160] FIGs. 19 and 20 illustrate two methods of separating a glass sheet 1902 from the glass ribbon 330. The separation assembly 1300 may be used, for example, to perform the separation. In other examples, similar steps may be used with other separation assemblies. A first method of separating the glass sheet 1902 is shown in FIG. 19. In this method, a first configuration 1920 shows a glass ribbon 330 positioned in a separation assembly. The upper isolator 1308 and the lower isolator 1314 may be engaged to the glass ribbon 330. In addition, a transportation tool 1904 and a support 1906 may be engaged on opposite sides of the glass ribbon 330 that extends below the lower isolator 1314. The initiator 1312 may engage the glass in this configuration to nick, cut or otherwise initiate the break of the glass ribbon 330.

[00161] As shown in configuration 1922, the backer 1310 has moved toward the glass ribbon 330 an applied a pressure or force at the initiation position to cause the glass ribbon 330 to break at the initiation position. At this stage of the process, the support 1906 may move away from the glass sheet 1902. In addition, the initiator 1312 may also move away from the glass ribbon 330.

[00162] In the configuration 1924, the lower isolator 1314 has moved away from the glass ribbon 330 and the glass sheet 1902 to allow the transportation tool 1904 to begin to move the glass sheet 1902. As further shown, the backer 1310 remains in its previous location applying a pressure or force to the glass ribbon 330. The backer 1310 remains in this position so that the glass sheet 1902 will not contact the glass ribbon 330 when the glass sheet 1902 is moved away from the separation assembly 1300.

[00163] FIG. 20 shows an alternate method of separating the glass sheet 1902 from the glass ribbon 330. In the example shown in FIG. 20, the steps and configuration of the separation assembly 1300 are similar to that previously described with reference to FIG. 19. In this example, however, the backer 1310 engages and applies a pressure or force to the glass ribbon 330 before the initiator contacts the glass ribbon 330 to initiate the break. As shown in configuration 2002, the backer 1310 has moved toward the glass ribbon 330 and applied a pressure or force to the glass ribbon 330 to induce a stress in the glass ribbon. In configuration 2004, the initiator 1312 then nick, cuts or otherwise creates a flaw in the glass ribbon 330 causing the glass sheet 1902 to separate from the glass ribbon. In a manner similarly to that previously described, the backer 1310 remains engaged to the glass ribbon 330 when the glass sheet 1902 is moved away from the separation assembly 1300 to reduce a likelihood of contact between the glass ribbon 330 and the glass sheet 1902.

[00164] Referring now to FIG. 21, a layout 2100 of a roll-to-sheet assembly facility is shown. In this example, the layout 2100 shows an example position of different apparatuses and stations for a production facility. In this example, the layout 2100 includes a roll-to-sheet apparatus 2102 that is position adjacent to a packing station 2130. A robot 2104 may be positioned between the roll-to-sheet apparatus 2102 and the packing station 2130. The robot 2104 may include a transportation tool 2106 that can remove the glass sheets from the roll-to- sheet apparatus 2102 and move the glass sheets to the packing station 2130. The robot 2104 may also be configured to move glass sheets that have defects or are otherwise unacceptable for end use to a recycling station 2112.

[00165] The packing station may include one or more zones for the processing and packing of glass sheets. The packing station 2130 may collect the glass sheets in containers suitable for transportation to a customer, end user, or for further processing. The packing station 2130 may include a tray dispenser 2108, a tray buffer 2116, a packing zone 2110, an interleaf container 2114, and a tray conveyor 2118.

[00166] The tray dispenser 2108 may include multiple trays that can be provided to the tray buffer 2116 and/or to the packing zone 2110. The tray dispenser 2108 may move the trays into a predetermined location so that they can each be provided and used for the packing of the glass sheets. The tray buffer 2116 may be positioned between the tray dispenser 2108 and the packing zone 2110 to provide trays without interruption in the event of a malfunction or other issue with the tray dispenser 2108. The packing zone 2110 accepts a tray from the tray buffer 2116 and positions the tray in a predetermined position. The robot 2104 can then accurately and repeatably position the glass sheets from the roll-to-sheet apparatus 2102 into the tray. When the tray is full, the tray can be moved by the tray conveyor 2118 toward the packaged goods exit 2120. The tray conveyor 2118 may include multiple stations 2118a, 2118b, 2118c, 2118d as the trays filled with glass sheets proceed toward the packaged goods exit 2120.

[00167] The interleaf container 2114 may include layers of interleaf that can be positioned between glass sheets when the glass sheets are loaded into the trays in the packing zone 2110. The interleaf can be similar to the interleaf layer previously described. The interleaf layer is configured to prevent damage to the glass sheets. The interleaf layer maintains a separation between the adjacent glass sheets in the trays.

[00168] The tray dispenser 2108 can be configured in various manners to provide trays to the tray buffer 2116 and/or to the packing zone 2110. One example tray dispenser is illustrated in FIG. 22. As shown, the trays 2202 may include a bottom, side walls and a flanged rim. The trays 2202 can be configured to nest one inside the other. A tray elevator 2204 may be configured to support the stacked trays 2202 at a desired interval and to move the trays to a desired location so that a top tray in the stack of trays is positioned in a predetermined location and is ready to be moved to the tray buffer 2116 and/or to the packing zone 2110. The tray elevator 2204 may be configured as a helically shaped member with a diameter sized to support the flanges of each tray 2202. When the tray elevator 2204 rotates, the helical shape pushes the trays upwards until the top tray is resting on top of the uppermost ring of the helical member. Once this tray is removed, the helical member can rotate again moving the stack of trays upwards until the next tray is positioned on top of the uppermost wing of the helical member. In other examples, the tray elevator can be configured in other manners to position the top tray of the stack of trays in the predetermined location.

[00169] When the tray 2202 is moved into the packing zone 2110, the tray 2202 is located in a predetermined packing location. One or more locators 2302 (FIG. 23) may be positioned in the packing zone 2110 to guide the tray 2202 into the predetermined packing location. The locators 2302 may be configured as pushers, rollers, sloped ramps or other shapes to move the tray 2202 into the predetermined packing location. When the tray is positioned in the predetermined packing location, the robot 2104 can move the transportation tool 2106 that is holding the glass sheet 1902 into the tray 2202 and deposit the glass sheet 1902.

[00170] As shown in FIG. 24, the glass sheets 1902 can be deposited into the tray 2202 with interleaf layers 2402 positioned between adjacent glass sheets 1902. The glass sheets 1902 and the interleaf layers 2402 can continue to be deposited into the tray 2202 until the tray 2202 is full. The tray 2202 can then be moved away from the packing zone 2110 as previously described.

[00171] The process previously described with respect to the layout 2100 can be performed automatically via a controller, processing device, computer or other automation. The packing of the glass sheets 1902 may be performed, controlled, and synchronized with the separation of the glass sheets 1902 from the glass ribbon 330 by the separation assembly 1300. In this manner, glass sheets 1902 can be produced and packaged for end use or further processing.

[00172] The methods and apparatuses for separating glass sheets from a glass ribbon may include variations from the methods and apparatuses described above. In some instances, it has been determined that variation in glass characteristics may cause incomplete or insufficient glass separation. For example, in instances when a glass ribbon may have varying thickness along its width, or when a common glass separation assembly is used for multiple different thickness of glass, incomplete or insufficient glass separation may occur. It may be desirable, in such instances, to utilize variations of the methods and apparatuses described above. Such variations may allow multiple different glass ribbon thicknesses to be separated and/or glass ribbons with varying thicknesses along their widths to be separated into glass sheets using a common glass separation assembly.

[00173] Referring now to FIG. 25, an example separation assembly 2500 is shown. The separation assembly 2500 may include a backer 2502, a first isolator 2504, and a second isolator 2506. The separation assembly 2500 may include other elements as previously described and may operate to separate glass sheets from a glass ribbon. In order to adapt the separation assembly 2500 to robustly separate glass sheets from a glass ribbon, various aspects of the separation assembly 2500 were investigated. Some of the aspects that were investigated include a backer height (BH), an overhang (OH), a backer width (BW), a backer curvature (BC), an isolator curvature (IC), and an isolator width (IW).

[00174] Investigations were performed to understand the effects of these aspects and others on the separation process. It is desirable to have a process that can perform glass separations for various thickness of glass ribbons and for variations in the glass ribbon along its width. The wider the range of variations that can be supported using a common separation assembly results in improved efficiencies and reduced levels of incomplete or unacceptable glass separation. The various aspects of the separation assembly 2500 were varied and tested to separate glass sheets from 75 pm and 100 pm glass ribbons. The backer height (BH), overhang (OH), backer width (BW), backer curvature (BC), isolator curvature (IC), and isolator width (IW) were investigated to determine their effects and the stress imparted on the glass ribbon during the separation process.

[00175] It was determined that the bending stress imparted during the separation process is a significant factor that causes a satisfactory break or separation of the glass sheet or can lead to insufficient breaks or unacceptable glass sheet separation. For example, in glass ribbons in the range of about 75 pm to about 100 pm, high quality /or acceptable glass separations occurred in circumstances in which a 20 MPa or greater bending stress was applied to the glass ribbon in the separation process. In such acceptable glass separations, the glass break propagated after being initiated from end-to-end across the width of the glass ribbon. It was also observed that acceptable or high quality glass separations occurred when the bending stress in the glass ribbon at the edges (i.e., at the beads of the glass ribbon) were maintained in a range of about 60 MPa to about 100 MPa. Bending stresses above this range often resulted in branched cracks and/or singulation failure.

[00176] FIG. 26 is a graph showing multiple test results that were performed. The graph 2600 illustrates the imparted bending stress as a function of the backer height (BH). As shown, the workable range for the separation assembly is a backer height (BH) of about 1 mm to about 1.25 mm. The graph 2600 also illustrates that at the same backer height BH, a much higher bending stress is imparted at the glass ribbon bead (i.e., at the edge) than at the center region of the glass ribbon. Further, it was observed that the backer height (BH) and the overhang (OH) had the most influence on the bending stress imparted on the glass ribbon. [00177] In one embodiment, a variation of the separation processes discussed above was developed to improve the robustness of the separation process and to achieve high quality, satisfactory glass separations for varying glass ribbons. The variation to the glass separation process includes a two-step bending stress process of imparting a first level of bending stress to the glass ribbon before initiation of a crack (e.g., nicking) and then imparting a second level of bending stress to the glass ribbon after the crack is initiated. The second level of bending stress causes the crack to propagate across the width of the glass ribbon to separate the glass sheet from the glass ribbon. The second level of bending stress may be greater than the first level of bending stress. In one example, the first and second level of bending stress are caused by moving the backer 2502 to different backer heights (BH) during the separation process.

[00178] The separation assembly that is used to perform the two-step bending stress process may be similar to the separation assemblies described above, such as separation assembly 1300. In the separation assemblies that perform the two-step bending stress process the backer (such as backer 2502, 1310) may be coupled to one or more servo motors that may be controlled to variably move the backer to a first predetermined backer height (BH1) and to a second predetermined backer height (BH2) at different times during the separation process. [00179] Referring now to FIG. 27, an example of the two-step bending stress separation process is illustrated. In each step of the illustrated examples, a relative time is shown and labelled as times A to E. As can be appreciated, each illustrated step shows the relative positions of some elements of the separation assembly. For the sake of simplicity, not all elements of the separation assembly are shown in FIG. 27.

[00180] At time A, a glass ribbon 2708 may move into position relative to the glass separation assembly. In this example, the glass ribbon 2708 may move downward until it reaches a desired position relative to the backer 2702, the first isolator 2704, and the second isolator 2706.

[00181] At time B, the backer 2702 may move toward a first side of the glass ribbon 2708 and the first isolator 2704 and the second isolator 2706 may move toward a second side of the glass ribbon 2708. The backer 2702, the first isolator 2704, and the second isolator 2706 may be positioned so as to be at the first predetermined backer height (BH1) to impart a first level of bending stress to the glass ribbon 2708.

[00182] At time C, the initiator 2710 may move toward the glass ribbon 2708 and initiate a crack or defect at a center portion of the glass ribbon 2708. The initiator 2710 may be configured as previously described as a cutting wheel or other suitable crack initiator. [00183] At time D, the backer 2702, the first isolator 2704 and/or the second isolator 2706 may move a second time toward the glass ribbon 2708 to impact the second level of bending stress to the glass ribbon 2708. In some examples, the backer 2702 moves. In other examples, the first isolator 2704 or the second isolator 2706 moves. In still other examples, both the first isolator 2704 and the second isolator 2706 moves. In yet another example, all of the backer 2702, the first isolator 2704, and the second isolator 2706 moves. The backer 2702, the first isolator 2704 and/or the second isolator 2706 may move to be positioned at the second backer height (BH2). At the second backer height, the second level of bending stress may be greater than the first level of bending stress imparted on the glass ribbon.

[00184] At time E, the initiated crack that was created at time C may propagate across the width of the glass ribbon 2708 to separate a glass sheet from the glass ribbon. The separation process may proceed to withdraw the glass sheet and/or package the glass sheets as described previously with reference to FIGs. 19-24.

[00185] The first backer height (BH1) and the second backer height (BH2) can be various suitable heights as may be needed to cause a suitable bending stress to be imparted on the glass ribbon during the separation process. Testing was performed for various thickness of glass ribbon. Test results for a 100 pm thickness glass ribbon is shown in FIG. 28. The graph 2800 shows the test results that were observed as “OK” or acceptable glass separation. In other circumstance the glass separation exhibit various failures or defects that were unacceptable. Such failures or defects include instances of “crack stop” that exhibited a failure of the crack to propagate completely across the width of the glass ribbon. Other instances showed a “start defect” or an “end defect” that exhibited unacceptable glass cracking or separation at the start of the crack or at the end of the crack. Still other instances showed “crack open w/o post bending” that exhibited a full propagation of the crack before the second level of bending stress was imparted on the glass ribbon (e.g., a full glass separation occurred prior to time D or E as shown in the process of FIG. 27). As can be observed from the graph 2800, a predetermined range for the first backer height (BH1) and the second backer height (BH2) may be determined. [00186] In some embodiments and with reference to FIG. 25, the first isolator 2504 and the second isolator 2506 may be positioned at different distances from the glass ribbon during the separation process. The first isolator 2504 and/or the second isolator 2506 may be coupled to a servomotor or other adjustable actuator to allow the isolator to be variably controlled and moved relative to the glass ribbon. In such embodiments, when the backer 2502 is moved toward the glass ribbon to impart a bending stress the backer height (BH) may be different at an upstream position (i.e., at the first isolator 2504) than at a downstream position (i.e., at the second isolator 2506). It has been observed that a backer height (BH) at the downstream location that is greater than a backer height (BH) at the upstream location provides satisfactory glass separation. In some examples, the backer height (BH) at the downstream location may be at least 2 times greater than the backer height (BH) at the upstream location.

[00187] In addition, it was observed that the separation process was more robust and able to provide satisfactory separations in instances in which the overhang (OH) was the greatest. The allowable size of the overhang (OH), however, is limited by the size of the glass sheet. As previously discussed above, it is desirable not to contact the quality area of the glass sheet to maintain high quality standards for the glass sheet. The overhang (OH) therefore cannot be increased such that one or more of the isolators contact the glass at the quality area of the glass sheet. In glass ribbons having a thickness of about 75 pm to about 100 pm, the limit of the overhang (OH) in the example separation assembly was about 40 mm. With this limitation, a suitable overhang (OH) to robustly perform high quality glass separations for a glass ribbon of about 75 pm in thickness was found to be in a range of about 28 mm to about 40 mm. For glass ribbons having a thickness of about 100 pm, a suitable overhang (OH) to robustly perform high quality glass separations was found to be in a range of about 32 mm to about 40 mm. In one example assembly, an overhang (OH) of about 38 mm was used to accommodate varying thicknesses of glass ribbons. In other assemblies and with other sizes of glass ribbons, the overhang (OH) may have other dimensions.

[00188] The methods and system described herein may be at least partially embodied in the form of computer-implemented processes and apparatus for practicing those processes. The disclosed methods may also be at least partially embodied in the form of tangible, nontransient machine readable storage media encoded with computer program code. The media may include, for example, RAMs, ROMs, CD-ROMs, DVD-ROMs, BD-ROMs, hard disk drives, flash memories, or any other non-transient machine-readable storage medium, or any combination of these mediums, wherein, when the computer program code is loaded into and executed by a computer, the computer becomes an apparatus for practicing the method. The methods may also be at least partially embodied in the form of a computer into which computer program code is loaded and/or executed, such that, the computer becomes an apparatus for practicing the methods. When implemented on a general-purpose processor, the computer program code segments configure the processor to create specific logic circuits. The methods may alternatively be at least partially embodied in a digital signal processor formed of application specific integrated circuits for performing the methods.

[00189] Although the subject matter has been described in terms of exemplary embodiments, it is not limited thereto. Rather, the appended claims should be construed broadly, to include other variants and embodiments, which may be made by those skilled in the art.