Method and system for separating glass substrates

Abstract

A method for separating glass sheets includes engaging a scribing wheel with a first surface of the glass sheet, the first surface defining a thickness of the glass sheet, moving the scribing wheel along the glass sheet at a scribing speed of at least 35 meters per minute, applying a force to the glass sheet with the scribing wheel and maintaining the force within 1.0 Newtons of a predetermined force, and forming a median crack with the scribing wheel that extends along the length of the first surface and into the glass sheet, the median crack defining a crack depth that extends into the glass sheet, and the depth of the crack that extends into the glass sheet varies by less than 2.0% along the length of the median crack on the first surface.

Description

Priority

[0001] This application claims the benefit of priority under 35 U.S.C. § 119 of U.S. Provisional Patent Application No. 62 / 988,606, filed March 12, 2020, the entire disclosure of which is incorporated herein by reference. [Technical Field]

[0002] The present disclosure relates generally to methods and systems for separating glass substrates, and more particularly to methods and systems for forming a median crack in a glass substrate. [Background technology]

[0003] Flexible, thin glass substrates can be used in a variety of applications, including so-called "electronic paper," color filters, solar cells, displays, organic light-emitting diode (OLED) lighting, and touch sensors. The glass for such substrates can be very thin. These substrates can be processed either individually or as a continuous web of glass (which may be wound on a roll or spool). In either case, the individual glass sheets or individual portions of the glass web can be cut into multiple sheets for further processing or for preparation before assembly into a final product.

[0004] When cutting a glass sheet or a glass web, a score line can be created in the glass sheet or the glass web. For example, a scribing wheel is used to create a crack along the glass sheet or the glass web to create the score line. Then, a tensile force is applied to the glass sheet or the glass web, so that the glass sheet or the glass web can be separated along the crack. However, if there is variation (change) in the crack depth, this can cause the glass sheet or the glass web to not separate properly or to break, which can lead to an increase in defects and an increase in production costs. Summary of the Invention [Problem to be solved by the invention]

[0005] Therefore, it is desirable to maintain a consistent crack depth, and therefore there is a need for an apparatus and method for forming a uniform median crack in a glass sheet to promote the desired separation along the median crack. [Means for solving the problem]

[0006] In a first aspect A1, a method of separating a glass sheet according to the present disclosure includes engaging a scribing wheel with a first surface of a glass sheet having a first surface, a second surface opposite the first surface, and a sheet thickness between the first surface and the second surface; moving the scribing wheel along the first surface of the glass sheet at a scribing speed of at least about 35 meters per minute; applying and maintaining a predetermined force with the scribing wheel on the first surface of the glass sheet that is within about 1.0 Newtons of force as the scribing wheel moves along the first surface of the glass sheet; and forming a median crack with the scribing wheel, the median crack extending along the length of the first surface and extending into the glass sheet, wherein the median crack has a crack depth extending into the glass sheet that is less than the thickness of the glass sheet, and the crack depth along the length of the median crack on the first surface varies by less than about 2.0%.

[0007] In a second aspect A2, the present disclosure provides a method according to aspect A1, wherein the step of applying the force includes maintaining the position of the scribing wheel in a first direction perpendicular to the first surface of the glass sheet with an air cylinder coupled to the scribing wheel.

[0008] In a third aspect A3, the present disclosure provides a method according to aspect A2, further comprising restricting movement of the air cylinder rod with a linear guide rail that engages with the air cylinder rod, the linear guide rail allowing movement of the rod in a first direction and restricting movement of the rod in a direction perpendicular to the first direction.

[0009] In a fourth aspect A4, the present disclosure provides a method according to aspect A2 or A3, wherein the step of applying the force includes maintaining the position of the scribing wheel in the first direction with a first actuator coupled to the scribing wheel via an air cylinder.

[0010] In a fifth aspect A5, the present disclosure provides a method according to any of aspects A1-A4, wherein the variation in crack depth of the median crack along the length of the median crack on the first surface is less than about 1.5%.

[0011] In a sixth aspect A6, the present disclosure provides a method according to any of aspects A1-A5, wherein the variation in crack depth of the median crack along the length of the median crack on the first surface is less than about 1.0%.

[0012] In a seventh aspect A7, the present disclosure provides a method according to any of aspects A1-A6, wherein the scribing speed is at least about 40 meters per minute.

[0013] In an eighth aspect A8, the present disclosure provides a method according to any of aspects A1-A7, wherein the scribing speed is at least about 45 meters per minute.

[0014] In a ninth aspect A9, the present disclosure provides a method according to any of aspects A1-A8, wherein the variation in crack depth along the length of the median crack on the first surface is less than about 5 micrometers.

[0015] In a tenth aspect A10, the present disclosure provides a method according to any of aspects A1-A9, wherein the thickness is less than about 0.5 millimeters.

[0016] In an eleventh aspect A11, the present disclosure provides a method according to any one of aspects A1-A9, wherein the thickness is about 0.30 millimeters.

[0017] In a twelfth aspect A12, the present disclosure provides a method according to any of aspects A1-A11, wherein the step of applying a force to the first surface of the glass sheet with a scribing wheel further comprises maintaining the force within about 0.2 Newtons of the predetermined force.

[0018] In a thirteenth aspect A13, a glass cutting system according to the present disclosure includes a scribing wheel, a regulator, an air cylinder coupled to the scribing wheel and in communication with the regulator, a second actuator coupled to the air cylinder, and a controller communicatively coupled to the regulator and the second actuator. The controller includes a processor and a memory including a computer-readable and executable instruction set. When the processor executes the computer-readable and executable instruction set, the processor performs the following steps: directing the regulator to cause the air cylinder to apply and maintain a force with the scribing wheel on a first surface of a glass sheet that is within about 1.0 Newtons of a predetermined force; and directing the second actuator to move the scribing wheel along the glass sheet at a scribing speed of at least about 35 meters per minute, thereby forming a median crack that extends along the length of the first surface and into the glass sheet. The median crack has a depth extending into the glass sheet that is less than the thickness of the glass sheet, and the variation in crack depth along the length of the median crack on the first surface is less than about 5 micrometers.

[0019] In a fourteenth aspect A14, the present disclosure provides a system according to aspect A13, further comprising a first actuator coupled to the air cylinder.

[0020] In a fifteenth aspect A15, the present disclosure provides a system according to aspect A14, wherein the first actuator is communicatively coupled to a controller, and wherein, when the processor executes a set of computer-readable and executable instructions, the processor further performs the step of instructing the first actuator to move the air cylinder toward the first side of the glass sheet.

[0021] In a sixteenth aspect A16, the present disclosure provides a system according to any one of aspects A13 to A15, further comprising a linear guide rail that engages with the rod of the air cylinder, the linear guide rail allowing movement of the rod in a first direction and restricting movement of the rod in a direction perpendicular to the first direction.

[0022] In a seventeenth aspect A17, the present disclosure provides a system according to any of aspects A13-A16, wherein when the processor executes the set of computer readable and executable instructions, the processor performs the step of directing the second actuator to move the scribing wheel along the glass sheet at a scribing speed of at least about 40 meters per minute.

[0023] In an eighteenth aspect A18, the present disclosure provides a system according to any of aspects A13 to A17, wherein, when the processor executes the set of computer readable and executable instructions, the processor further performs the step of instructing a regulator to cause the air cylinder to apply and maintain a force on the first surface of the glass sheet within about 0.2 Newtons of the predetermined force of the scribing wheel.

[0024] In a nineteenth aspect A19, the present disclosure provides a system according to any of aspects A13-A18, wherein the variation in crack depth of the median crack along the length of the median crack on the first surface is less than about 1.5%.

[0025] In a twentieth aspect A20, the present disclosure provides a system according to any of aspects A13-A19, wherein the step of applying a force to the first surface of the glass sheet with a scribing wheel includes maintaining the force within about 0.2 Newtons of a predetermined force.

[0026] Additional features and advantages of each embodiment are described in the detailed description that follows, and will become apparent to those skilled in the art in part from the description, or may be learned by practice of the embodiments described herein, including the following detailed description, claims, and accompanying drawings.

[0027] It should be understood that both the foregoing general description and the following detailed description describe various embodiments and are intended to provide an overview or framework for understanding the nature and features of the claimed subject matter. In addition, the accompanying drawings are included to provide a further understanding of the various embodiments, and are incorporated into and constitute a part of this specification. The drawings illustrate by way of example various embodiments described herein, and together with the following detailed description, serve to explain the principles and operation of the claimed subject matter. [Brief explanation of the drawings]

[0028] [Figure 1] FIG. 1 is a schematic perspective view of a glass cutting system according to one or more embodiments shown or described herein. [Figure 2] 2 is a schematic control diagram of the glass cutting system shown in FIG. 1 according to one or more embodiments shown or described herein. [Figure 3] FIG. 2 is a schematic diagram illustrating the glass cutting system shown in FIG. 1 and a glass sheet according to one or more embodiments shown or described herein. [Figure 4] 4 is a schematic diagram illustrating the glass pane shown in FIG. 3 with a median crack extending into the glass pane, according to one or more embodiments shown or described herein; [Figure 5A]5 is a schematic perspective view of the glass plate shown in FIG. 4 and a median crack, according to one or more embodiments shown or described herein. [Figure 5B] Schematic diagram showing a glass plate with a non-uniform median crack [Figure 5C] Schematic diagram showing another glass plate with a non-uniform median crack DETAILED DESCRIPTION OF THE INVENTION

[0029] Next, embodiments of an apparatus and method for separating glass sheets will be described in detail. The same reference numerals will be used to indicate identical or similar parts throughout the drawings whenever possible. A glass cutting system according to the embodiments described herein primarily includes a scribing wheel and an air cylinder that maintains the position of the scribing wheel in a first direction perpendicular to the glass sheet. Specifically, the air cylinder can maintain the position of the scribing wheel in the first direction, allowing the scribing wheel to form a median crack in the glass sheet while maintaining a constant or nearly constant force on the glass sheet. Maintaining a constant or nearly constant force on the glass sheet minimizes the amount of variation in the crack depth of the median crack. Minimizing the amount of variation in the crack depth minimizes undesirable and / or unexpected separation of the glass sheet along the median crack, thereby reducing debris and manufacturing costs. These and other embodiments will now be described in more detail with reference to the accompanying drawings.

[0030] As used herein, the term "communicatively coupled" is used to describe the interconnectivity of various components of a glass cutting system, meaning that the components are connected together either by wired, fiber optic, or wireless connections, allowing the exchange of electrical, optical, and / or electromagnetic signals between the components.

[0031] Referring now to FIG. 1, FIG. 1 is a schematic diagram illustrating an exemplary glass cutting system 100. In various embodiments, the glass cutting system 100 primarily comprises a cutting device (illustrated as a scribing wheel 140). As described in more detail herein, the glass cutting system 100 is operatively configured to move the scribing wheel 140 in a first direction (i.e., the illustrated Y-direction) toward or away from the glass sheet. The glass cutting system 100 is also operatively configured to move the scribing wheel 140 in at least a second direction (i.e., the illustrated X-direction) and / or a third direction (i.e., the illustrated Z-direction), where the second and third directions are orthogonal to the first direction. In various embodiments, the scribing wheel 140 comprises a wheel having a geometry appropriately selected to produce controlled mechanical damage in the glass sheet. The scribing wheel 140 can comprise a scribe grinding wheel, such as a sawtooth scribe wheel or a diamond scribe wheel.

[0032] In the embodiment shown in FIG. 1 , the glass cutting system 100 can include an air cylinder 120 coupled to a scribing wheel 140. The air cylinder 120 can primarily include a body 122 and a rod 124 movably engaged with the body 122. Specifically, the rod 124 can be moved by extending it out of the body 122 or retracting it toward the body 122. In some embodiments, the air cylinder 120 is in communication with a regulator 115 that can adjust the pressure of air supplied to the air cylinder 120. By adjusting the pressure of air supplied to the air cylinder 120, the rod 124 can be moved relative to the body 122 and the position of the rod 124 relative to the body 122 (e.g., in a first direction) can be maintained. Because the scribing wheel 140 is coupled to the rod 124, the position of the scribing wheel 140 in the first direction can be maintained by maintaining the position of the rod 124 relative to the body 122 using the regulator 115. As described in more detail herein, air cylinder 120 and regulator 115 can assist in maintaining the position of scribing wheel 140 while allowing scribing wheel 140 to apply force to the glass sheet.

[0033] In some embodiments, the glass cutting system 100 can include one or more sensors that detect the position of the scribing wheel 140. For example, in the embodiment shown in FIG. 1, the glass cutting system 100 includes a displacement sensor 117 that is structurally configured to detect the position of the scribing wheel 140 in a first direction (i.e., the Y-direction as shown). While the glass cutting system 100 includes a displacement sensor 117 in the embodiment shown in FIG. 1, it should be understood that the glass cutting system 100 can include any sensor suitable for detecting the position of the scribing wheel 140 in the first direction. Such suitable sensors include, but are not limited to, Hall effect sensors, eddy current sensors, inductive sensors, laser sensors, piezoelectric transducers, and the like.

[0034] In some embodiments, the glass cutting system 100 can include a linear guide rail 130 that engages with the rod 124 of the air cylinder 120. The linear guide rail 130 primarily permits movement of the rod 124 in a first direction (i.e., the Y direction as shown) while restricting movement of the rod 124 in directions orthogonal to the first direction, such as a second and / or third direction (i.e., the X and / or Z directions as shown). As described in more detail herein, by restricting movement of the rod 124 in directions orthogonal to the first direction, the linear guide rail 130 can help minimize movement of the scribing wheel 140 in other directions, such as the second and third directions (i.e., the X and Z directions as shown), as the scribing wheel 140 moves along the glass sheet.

[0035] In some embodiments, the air cylinder 120 can be coupled to the first actuator 110. The first actuator 110 is operable to move the air cylinder 120 toward or away from the glass sheet. For example, in the embodiment shown in FIG. 1 , the air cylinder 120 can be coupled to the cylinder plate 114, which can be coupled to the actuator plate 112. In the embodiment, the actuator plate 112 can engage with the first guide 116 and be configured to be movable along the first guide 116. The first actuator 110 is coupled to the actuator plate 112 and is primarily configured to be operable to move the actuator plate 112, thereby moving the cylinder plate 114 and the air cylinder 120. The first actuator 110 can then move the air cylinder 120 in a first direction (i.e., the Y direction in the figure) to position the air cylinder 120 and thereby position the scribing wheel 140 on the glass sheet. For example, the first actuator 110 can operate to move the scribing wheel 140 to engage the glass sheet, and the air cylinder 120 can assist in maintaining contact between the scribing wheel 140 and the glass sheet as it moves along the glass sheet. For example, the air cylinder 120 can move the scribing wheel 140 in a first direction (i.e., the Y direction as shown) to follow changes in the first direction of the glass sheet, thereby maintaining contact between the scribing wheel 140 and the glass sheet as it moves along the glass sheet.

[0036] In embodiments, the first actuator 110 can comprise any actuator suitable for moving the air cylinder 120. Such actuators include, but are not limited to, direct current (DC) motors, alternating current (AC) motors, etc. The first actuator 110 can also be a servo motor equipped with a position encoder. Note that, while the glass cutting system 100 includes an actuator plate 112 and a cylinder plate 114 in the embodiment shown in FIG. 1 , this is merely an example. In embodiments, the first actuator 110 can be coupled to the air cylinder 120 in any suitable manner that enables the first actuator 110 to move the air cylinder 120, and thereby move the scribing wheel 140.

[0037] In some embodiments, the glass cutting system 100 further comprises one or more linear actuators operable to move the air cylinder 120, and thus the scribing wheel 140, in a second and a third direction (i.e., the X and Z directions). In the embodiment shown in FIG. 1 , the glass cutting system 100 comprises a second actuator 111 coupled to the air cylinder 120 and / or the first actuator 110. The second actuator 111 is configured to be operable to move the air cylinder 120, and thus the scribing wheel 140, in at least the second direction (i.e., the X direction as shown). In some embodiments, the glass cutting system 100 further comprises a third actuator 113 operable to move the air cylinder 120, and thus the scribing wheel 140, in a third direction (i.e., the Z direction as shown). The second actuator 111 and the third actuator 113 can comprise any actuators suitable for moving the air cylinder 120, and thus the scribing wheel 140. For example, without limitation, the second actuator 111 and the third actuator 113 can both be linear actuators equipped with DC motors or AC motors, or servo motors equipped with position encoders. In the embodiment shown in FIG. 1 , the second actuator 111 and the third actuator 113 are connected to the air cylinder 120 via the actuator plate 112 and the cylinder plate 114, but this is merely an example. In the embodiment, the second actuator 111 and the third actuator 113 can be connected to the air cylinder 120 in any manner suitable for moving the air cylinder 120 and the scribing wheel 140.

[0038] Reference is now made to Figure 2, which is a schematic control diagram of glass cutting system 100. In an embodiment, glass cutting system 100 includes a controller 160, which includes a processor 162, a data storage component 164, and / or a memory component 166. Memory component 166 may be configured as volatile and / or non-volatile memory, and, if so, may include random access memory (including types of RAM such as SRAM, DRAM, etc.), flash memory, secure digital (SD) memory, registers, compact discs (CDs), digital versatile discs (DVDs), and other types of non-transitory computer-readable media. Note that these non-transitory computer-readable media may be internal to controller 160 and / or external to controller 160, depending on the particular embodiment.

[0039] The memory component 166 may store operational logic, analysis logic, and communication logic in the form of one or more computer-readable and executable instruction sets. Each of the analysis logic and communication logic may include multiple distinct logic elements, each of which may be embodied as, for example, a computer program, firmware, and / or hardware. The controller 160 also includes a local interface. The local interface may be implemented as a communications interface, such as a bus, that facilitates communication between the components of the controller 160.

[0040] Processor 162 may comprise any processing component operable to receive and execute instructions (such as from data storage component 164 and / or memory component 166). Note that while FIG. 2 depicts each component as being internal to controller 160, this is merely an example. In some embodiments, one or more of these components may be external to controller 160. Furthermore, while controller 160 is depicted as a single device, this is also merely an example. Controller 160 may comprise any suitable number of devices.

[0041] In an embodiment, the controller 160 is communicatively coupled to one or more components of the glass cutting system 100. For example, in the embodiment shown in Figure 2, the controller 160 is communicatively coupled to the first actuator 110, the second actuator 111, the third actuator 113, and the regulator 115. As described in more detail herein, in an embodiment, the controller 160 can provide movement instructions to the first actuator 110, the second actuator 111, the third actuator 113, and the air cylinder 120 (via the regulator 115), which can enable the glass cutting system 100 to form a crack in the glass sheet.

[0042] For example, refer to Figure 3, which is a schematic side view illustrating a glass cutting system 100 and a glass sheet 200. In the embodiment illustrated in Figure 3, the glass sheet 200 defines a first edge 206 and a second edge 208 opposite the first edge 206. In the embodiment illustrated in Figure 3, the glass sheet 200 is a discrete sheet defining the first edge 206 and the second edge 208, although this is merely an example and the glass sheet 200 can also be a continuous web.

[0043] In embodiments, the glass sheet 200 defines a first surface 202 and a second surface 204 opposite the first surface 202, and a thickness S determined as the distance between the first surface 202 and the second surface 204. As shown and described herein, the first direction (i.e., the Y direction) is perpendicular to the first surface 202 of the glass sheet 200. In some embodiments, the thickness S is less than 0.5 millimeters. In some embodiments, the thickness S is greater than or equal to 0.25 millimeters and less than or equal to 0.5 millimeters (including all ranges between these endpoints). In some embodiments, the thickness S is about 0.25 millimeters. In some embodiments, the thickness S is about 0.30 millimeters. In some embodiments, the thickness S is about 0.4 millimeters. In some embodiments, the thickness S is about 0.5 millimeters.

[0044] When separating a portion from the glass sheet 200, the scribing wheel 140 of the glass cutting system 100 engages the first surface 202 of the glass sheet 200. For example, with reference to FIGS. 1-3 , in some embodiments, the controller 160 directs the regulator 115 to actuate the air cylinder 120 to move the scribing wheel 140 toward the first surface 202 to engage (e.g., contact) the first surface 202 of the glass sheet 200.

[0045] In some embodiments, the controller 160 may additionally or alternatively direct the first actuator 110 to move the air cylinder 120 toward the first side 202 of the glass sheet 200. For example, in some embodiments, the controller 160 may direct the first actuator 110 to move the air cylinder 120 toward the first side 202 of the glass sheet 200, thereby allowing the scribing wheel 140 to engage the first side 202 of the glass sheet 200.

[0046] Then, with the scribing wheel 140 engaged with the first surface 202 of the glass sheet 200, the scribing wheel 140 moves at a scribing speed along the first surface 202 of the glass sheet 200. For example, in an embodiment, the controller 160 instructs the second actuator 111 and / or the third actuator 113 to move the air cylinder 120, thereby moving the scribing wheel 140 along the first surface 202 of the glass sheet 200.

[0047] In some embodiments, the second actuator 111 and / or the third actuator 113 moves the scribing wheel 140 along the first side 202 of the glass sheet 200 at a scribing speed of at least about 35 meters per minute. In some embodiments, the second actuator 111 and / or the third actuator 113 moves the scribing wheel 140 at a speed of at least about 35 meters per minute and at most about 60 meters per minute, inclusive, including all ranges between the endpoints. In some embodiments, the second actuator 111 and / or the third actuator 113 moves the scribing wheel 140 along the first side 202 of the glass sheet 200 at a scribing speed of at least about 40 meters per minute. In some embodiments, the second actuator 111 and / or the third actuator 113 moves the scribing wheel 140 along the first side 202 of the glass sheet 200 at a scribing speed of at least about 40 meters per minute and at most about 60 meters per minute, inclusive, including all ranges between the endpoints. In some embodiments, the second actuator 111 and / or the third actuator 113 move the scribing wheel 140 along the first side 202 of the glass sheet 200 at a scribing speed of at least about 45 meters per minute. In some embodiments, the second actuator 111 and / or the third actuator 113 move the scribing wheel 140 along the first side 202 of the glass sheet 200 at a scribing speed of at least about 45 meters per minute and at most about 60 meters per minute, including all ranges between these endpoints.

[0048] The scribing wheel 140 applies a force to the first side 202 of the glass sheet 200 as it moves along the first side 202 of the glass sheet 200. For example, in embodiments, the controller 160 directs the air cylinder 120 and / or the first actuator 110 (via the regulator 115) to maintain the position of the scribing wheel 140, thereby allowing the scribing wheel 140 to apply a force to the first side 202 of the glass sheet 200. In embodiments, the scribing wheel 140 moves along the first side 202 of the glass sheet 200 while maintaining the force it applies to the first side 202 of the glass sheet 200 within 1.0 Newtons of the predetermined force. In some embodiments, the scribing wheel 140 moves along the first side 202 of the glass sheet 200 while maintaining the force it applies to the first side 202 of the glass sheet 200 within about 0.75 Newtons of the predetermined force. In some embodiments, the scribing wheel 140 moves along the first side 202 of the glass sheet 200 while maintaining the force it applies to the first side 202 of the glass sheet 200 within about 0.5 Newtons of the predetermined force. In some embodiments, the scribing wheel 140 moves along the first side 202 of the glass sheet 200 while maintaining the force it applies to the first side 202 of the glass sheet 200 within about 0.2 Newtons of the predetermined force.

[0049] In embodiments, the predetermined force is a force associated with a predetermined cutting pressure. Without being bound by theory, the pressure that the scribing wheel 140 applies to the first side 202 of the glass sheet 200 depends on the force applied to the first side 202 and the geometry of the scribing wheel 140. In some embodiments, the predetermined force is a force associated with a predetermined cutting pressure of about 0.09 megapascals. In some embodiments, the predetermined force is a force associated with a predetermined cutting pressure of about 0.12 megapascals. In some embodiments, the predetermined force is a force associated with a predetermined cutting pressure of about 0.09 megapascals or more and about 0.12 megapascals or less (including all ranges between the endpoints). In some embodiments, the predetermined force is a force associated with a predetermined cutting pressure of about 0.05 megapascals or more and about 0.15 megapascals or less (including all ranges between the endpoints). In some embodiments, the predetermined force is a force associated with a predetermined cutting pressure of about 0.05 megapascals or more and about 0.20 megapascals or less (including all ranges between the endpoints). In some embodiments, the predetermined force is a force associated with a predetermined cutting pressure of about 0.05 megapascals or more and about 0.25 megapascals or less, inclusive of all ranges between the endpoints. In some embodiments, the predetermined force is a force associated with a predetermined cutting pressure of about 0.05 megapascals or more and about 0.30 megapascals or less, inclusive of all ranges between the endpoints.

[0050] As the scribing wheel 140 moves along the first surface 202 of the glass sheet 200 at a scribing speed while applying a force, the scribing wheel 140 forms a median crack that extends into the first surface 202. For example, referring to FIG. 4 , FIG. 4 is a side view illustrating the formation of a median crack 210 in the glass sheet 200. The scribing wheel 140 forms the median crack 210 that extends along the length Le of the first surface 202 and into the glass sheet 200. It should be understood that, although the embodiment illustrated in FIG. 4 shows the length Le as extending between the first edge 206 and the second edge 208, with the length Le terminating at the first edge 206 and the second edge 208, this is merely an example. For example, in some embodiments, the median crack 210 can terminate midway between the first edge 206 and / or the second edge 208. Furthermore, although the embodiment shown in FIG. 4 depicts the glass sheet 200 as having a first edge 206 and a second edge 208, it should also be understood that the glass sheet 200 may be a continuous glass web and the median crack 210 may extend a length Le along the continuous glass web.

[0051] The median crack 210 defines a crack depth Cd extending into the glass sheet 200. The crack depth Cd is less than the sheet thickness St. In some embodiments, the crack depth Cd is ≦about 0.75 St. In some embodiments, the crack depth Cd is ≦about 0.5 St. In some embodiments, the crack depth Cd is ≦about 0.4 St. In some embodiments, the crack depth Cd is ≦about 0.3 St. In some embodiments, the target crack depth Td is ≦about 0.25 St. In some embodiments, the crack depth Cd is ≦about 0.2 St.

[0052] In embodiments, the crack depth Cd of the median crack 210 varies by a variation V along the length Le of the median crack 210 (e.g., in the illustrated Y direction). This variation V can be expressed as a percentage of the crack depth Cd. For example, in some embodiments where the sheet thickness St (FIG. 3) is 0.3 millimeters or greater, the crack depth Cd along the length Le of the median crack 210 on the first surface 202 of the glass sheet 200 varies by less than 2.0%. For example, in embodiments where the sheet thickness St (FIG. 3) is 0.3 millimeters or greater, the crack depth Cd of the median crack 210 along the length Le of the median crack 210 on the first surface 202 of the glass sheet 200 varies by less than 1.5%. For example, in embodiments where the sheet thickness St (FIG. 3) is 0.3 millimeters or greater, the crack depth Cd of the median crack 210 along the length Le of the median crack 210 on the first surface 202 of the glass sheet 200 varies by less than 1.0%.

[0053] Another way to state this feature is that in embodiments, the change in crack depth V along the length Le of the median crack 210 on the first side 202 of the glass sheet 200 is less than about 5 micrometers. In some embodiments, the change in crack depth V along the length Le of the median crack 210 on the first side 202 of the glass sheet 200 is less than about 4 micrometers. In some embodiments, the change in crack depth V along the length Le of the median crack 210 on the first side 202 of the glass sheet 200 is less than about 3 micrometers. In some embodiments, the change in crack depth V along the length Le of the median crack 210 on the first side 202 of the glass sheet 200 is less than about 2 micrometers. In some embodiments, the change in crack depth V along the length Le of the median crack 210 on the first side 202 of the glass sheet 200 is greater than or equal to about 2 micrometers and less than or equal to about 5 micrometers, inclusive of all ranges between the endpoints. By minimizing the amount of change in the crack depth Cd, undesirable separation of the glass sheet 200 along the median crack 210 can be minimized.

[0054] For example, referring to Figures 5A, 5B, and 5C, Figure 5A is a perspective view of a glass sheet 200 having a median crack 210, Figure 5B is a perspective view of a glass sheet 200' having a median crack 210', and Figure 5C is a perspective view of a glass sheet 200'' having a median crack 210''. In the example shown in Figure 5A, the median crack 210 defines a crack depth Cd that extends generally uniformly within the first surface 202 of the glass sheet 200. Because the crack depth Cd is generally uniform, separation of the glass sheet 200 along the median crack 210 is also generally uniform, minimizing undesirable breakage.

[0055] Meanwhile, referring to FIG. 5B, FIG. 5B is a perspective view illustrating a glass sheet 200' having a non-uniform median crack 210'. In FIG. 5B, the median crack 210' in the glass sheet 200' defines a recess 230' extending from the median crack 210' (i.e., in the Y direction as shown). The recess 230' may be formed, for example, by a change in force (e.g., an undesired increase in force) applied to the glass sheet 200' by a cutting device, such as a scribing wheel. The recess 230' disrupts the uniformity of the median crack 210' and may result in non-uniform or undesired separation of the glass sheet 200' along the median crack 210'.

[0056] Similarly, referring to FIG. 5C, FIG. 5C is a perspective view illustrating another glass sheet 200″ having a non-uniform median crack 210″. In FIG. 5C, the median crack 210″ in the glass sheet 200″ defines a gap 232″ extending from the median crack 210″ (i.e., in the Y direction as shown). The gap 232″ may be formed, for example, by a change in force (e.g., an undesired decrease in force) applied to the glass sheet 200′ by a cutting device, such as a scribing wheel. Similar to the recess 230′ (FIG. 5B), the gap 232″ disrupts the uniformity of the median crack 210″ and can result in non-uniform or undesirable separation of the glass sheet 200″ along the median crack 210″.

[0057] 1-4, minimizing the amount of variation in crack depth Cd can minimize uneven separation of glass sheet 200. As outlined above, by keeping the force applied by scribing wheel 140 to glass sheet 200 constant (e.g., by air cylinder 120), the amount of variation in crack depth Cd can be minimized.

[0058] Furthermore, by maintaining a constant force applied by the scribing wheel 140, the scribing speed can be increased while maintaining the amount of change in crack depth Cd within an acceptable range. Specifically, as the scribing speed increases, the effect of variations in the force applied by the scribing wheel 140 on the crack depth Cd is amplified, resulting in a larger amount of change in crack depth Cd. Therefore, by maintaining a constant force applied to the glass sheet 200 by the scribing wheel 140 (for example, using the air cylinder 120), the scribing speed of the scribing wheel 140 can be increased while minimizing the amount of change in crack depth Cd. Furthermore, increasing the scribing speed allows the glass sheet 200 to be separated at a higher speed, improving manufacturing throughput.

[0059] It should be understood, therefore, that glass cutting systems according to embodiments described herein primarily comprise a scribing wheel and an air cylinder that maintains the position of the scribing wheel in a first direction perpendicular to the glass sheet. Specifically, the air cylinder can maintain the position of the scribing wheel in the first direction, which allows the scribing wheel to create a median crack in the glass sheet while maintaining a constant or nearly constant force on the glass sheet. Maintaining a constant or nearly constant force on the glass sheet can minimize variation in crack depth of the median crack. Minimizing variation in crack depth can minimize undesirable and / or unexpected separation of the glass sheet along the median crack, thereby reducing debris and lowering production costs.

[0060] It should be noted that when this specification describes a component of the present disclosure as being "structurally configured" in a particular way to achieve a particular property or to cause the component of the present disclosure to function in a particular manner, such a description is a description of the structure and not of the intended use. More specifically, when this specification describes how a component is "structurally configured," such a description refers to the physical state in which the component exists and should therefore be considered a description that clearly indicates the structural characteristics of the component.

[0061] It should be noted that, as used herein, terms such as "preferably," "commonly," and "typically" are not intended to limit the scope of the claims, nor are they intended to imply that any particular feature is critical or essential to the structure or function of the claims. Rather, these terms are merely intended to highlight particular aspects of certain embodiments of the present disclosure, or to highlight alternative or additional features that may or may not be utilized in a particular embodiment of the present disclosure.

[0062] When the terms "substantially" and "about" are used herein to describe and define the present disclosure, they represent the inherent degree of uncertainty that may arise in any quantitative comparison, value, measurement, etc. The terms "substantially" and "about" are also used herein to represent the degree to which a quantitative expression can vary from the stated reference value without changing the fundamental functionality of the subject matter.

[0063] In the following claims, one or more claims use the transitional term "wherein." This transitional term is incorporated into a claim as an open-ended transitional phrase to introduce a statement reciting structural features for purposes of defining the disclosure, and is to be interpreted similarly to the more general open-ended preamble term "comprising."

[0064] While the subject matter of the present disclosure has been described in detail above with reference to specific embodiments thereof, it should be noted that various details disclosed herein should not be construed as implying that they relate to essential components of the various embodiments described herein. This is true even if a particular element is shown in all of the drawings accompanying this specification. Furthermore, the scope of the present disclosure is defined by the appended claims, including, but not limited to, embodiments, and it will be apparent that variations and modifications can be made without departing from the scope of such disclosure. More particularly, although certain aspects of the present disclosure have been identified herein as preferred or particularly advantageous, it is contemplated that the present disclosure is not necessarily limited to these aspects.

[0065] Preferred embodiments of the present invention will be described below in detail.

[0066] Embodiment 1 Engaging a scribing wheel to a first surface of a glass sheet having a first surface, a second surface opposite the first surface, and a thickness between the first surface and the second surface; moving the scribing wheel along the first surface of the glass sheet at a scribing speed of at least about 35 meters per minute; applying and maintaining a predetermined force within about 1.0 Newtons of force with the scribing wheel on the first surface of the glass sheet as the scribing wheel moves along the first surface of the glass sheet; creating a median crack with the scribing wheel, the median crack extending along the length of the first surface and into the glass sheet; A method for separating glass sheets, comprising: a crack depth extending into the glass sheet of the median crack is less than the thickness of the sheet, and a variation in the crack depth along the length of the median crack on the first surface is less than about 2.0%.

[0067] Embodiment 2 2. The method of claim 1, wherein the applying force step comprises maintaining the position of the scribing wheel in a first direction perpendicular to the glass sheet with an air cylinder coupled to the scribing wheel.

[0068] Embodiment 3 The method further includes limiting the movement of the rod of the air cylinder with a linear guide rail that engages with the rod of the air cylinder; 3. The method of claim 2, wherein the linear guide rail allows movement of the rod in the first direction and restricts movement of the rod in a direction perpendicular to the first direction.

[0069] Embodiment 4 3. The method of claim 2, wherein the applying step includes maintaining the position of the scribing wheel in the first direction with a first actuator coupled to the scribing wheel via the air cylinder.

[0070] Embodiment 5 2. The method of claim 1, wherein the crack depth of the median crack along the length of the median crack on the first surface varies by less than about 1.5%.

[0071] Embodiment 6 2. The method of claim 1, wherein the crack depth of the median crack along the length of the median crack on the first surface varies by less than about 1.0%.

[0072] Embodiment 7 2. The method of claim 1, wherein the scribing speed is at least about 40 meters per minute.

[0073] Embodiment 8 2. The method of claim 1, wherein the scribing speed is at least about 45 meters per minute.

[0074] Embodiment 9 2. The method of claim 1, wherein the crack depth varies by less than about 5 micrometers along the length of the median crack on the first surface.

[0075] Embodiment 10 2. The method of claim 1, wherein the plate thickness is less than about 0.5 millimeters.

[0076] Embodiment 11 2. The method of claim 1, wherein the plate thickness is about 0.30 millimeters.

[0077] Embodiment 12 10. The method of claim 1, wherein applying the force to the first surface of the glass sheet with the scribing wheel further comprises maintaining the force within about 0.2 Newtons of the predetermined force.

[0078] Embodiment 13 A scribing wheel and A regulator and an air cylinder connected to the scribing wheel and communicating with the regulator; a second actuator coupled to the air cylinder; a controller communicatively coupled to the regulator and the second actuator, the controller comprising a processor and a memory containing a set of instructions readable and executable by a computer; 1. A glass cutting system comprising: When the processor executes the set of computer-readable and executable instructions, the processor: directing the regulator to cause the air cylinder to apply and maintain a force on the first surface of the glass sheet within about 1.0 Newtons of a predetermined force with the scribing wheel; directing the second actuator to move the scribing wheel along the glass sheet at a scribing speed of at least about 35 meters per minute, thereby forming a median crack extending along the length of the first surface and extending into the glass sheet; Run a crack depth extending into the glass sheet of the median crack is less than a thickness of the glass sheet, and a variation in the crack depth along the length of the median crack on the first surface is less than about 5 micrometers.

[0079] Embodiment 14 14. The glass cutting system of embodiment 13, further comprising a first actuator coupled to the air cylinder.

[0080] Embodiment 15 the first actuator is communicatively coupled to the controller; 15. The glass cutting system of claim 14, wherein when the processor executes the set of computer-readable and executable instructions, the processor further performs the step of instructing the first actuator to move the air cylinder toward the first side of the glass sheet.

[0081] Embodiment 16 a linear guide rail that engages with the rod of the air cylinder; 14. The glass cutting system of claim 13, wherein the linear guide rail allows movement of the rod in a first direction perpendicular to the glass sheet and restricts movement of the rod in a direction perpendicular to the first direction.

[0082] Embodiment 17 14. The glass cutting system of claim 13, wherein, when the processor executes the set of computer-readable and executable instructions, the processor performs the step of directing the second actuator to move the scribing wheel along the glass sheet at a scribing speed of at least about 40 meters per minute.

[0083] Embodiment 18 14. The glass cutting system of claim 13, wherein when the processor executes the set of computer readable and executable instructions, the processor further performs the step of directing the regulator to cause the air cylinder to apply and maintain a force on the first side of the glass sheet within about 0.2 Newtons of a predetermined force at the scribing wheel.

[0084] Embodiment 19 14. The glass cutting system of claim 13, wherein the crack depth of the median crack along the length of the median crack on the first surface varies by less than about 1.5%.

[0085] Embodiment 20 14. The glass cutting system of claim 13, wherein applying a force to the first side of the glass sheet with the scribing wheel includes maintaining the force within about 0.2 Newtons of the predetermined force. [Explanation of symbols]

[0086] 100 Glass Cutting System 110 first actuator 111 Second Actuator 112 Actuator Plate 113 Third Actuator 114 Cylinder Plate 115 Regulator 116 First Guide 117 Displacement Sensor 120 Air Cylinder 122 Main Unit 124 rods 130 Linear guide rail 140 Scribing Wheel 160 Controller 162 processors 164 Data Storage Components 166 Memory Components 200 glass plates 202 First Side 204 Second Side 206 First Edge 208 The Second Edge 210 Median crack 230 recess 232 Gap

Claims

1. engaging a scribing wheel with a first surface of a glass sheet having a first surface, a second surface opposite the first surface, and a thickness between the first surface and the second surface; moving the scribing wheel along the first surface of the glass sheet at a scribing speed of at least about 35 meters per minute; applying and maintaining a predetermined force of within about 1.0 Newtons with the scribing wheel on the first surface of the glass sheet as the scribing wheel moves along the first surface of the glass sheet, wherein an air cylinder coupled to the scribing wheel maintains the position of the scribing wheel in a first direction perpendicular to the glass sheet; limiting movement of the rod of the air cylinder with a linear guide rail that engages with the rod of the air cylinder, the linear guide rail allowing movement of the rod in the first direction and limiting movement of the rod in a direction perpendicular to the first direction; creating a median crack with the scribing wheel, the median crack extending along the length of the first surface and into the glass sheet; A method for separating glass sheets, comprising: a crack depth extending into the glass sheet of the median crack is less than the thickness of the sheet, and a variation in the crack depth along the length of the median crack on the first surface is less than about 2.0%.

2. 2. The method of claim 1, wherein the step of applying a force includes maintaining the position of the scribing wheel in the first direction with a first actuator coupled to the scribing wheel via the air cylinder.

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

4. The method of claim 1 , wherein the scribing speed is at least about 40 meters per minute.

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

6. 10. The method of claim 1, wherein applying the force to the first surface of the glass sheet with the scribing wheel further comprises maintaining the force within about 0.2 Newtons of the predetermined force.

7. A scribing wheel and A regulator and an air cylinder connected to the scribing wheel and communicating with the regulator; a second actuator coupled to the air cylinder; a controller communicatively coupled to the regulator and the second actuator, the controller comprising a processor and a memory including a set of computer readable and executable instructions; 1. A glass cutting system comprising: When the processor executes the set of computer-readable and executable instructions, the processor: maintaining the position of the scribing wheel in a first direction perpendicular to the glass sheet with the air cylinder so as to direct the regulator to cause the air cylinder to apply and maintain a force on a first surface of the glass sheet within about 1.0 Newtons of a predetermined force with the scribing wheel; directing the second actuator to move the scribing wheel along the glass sheet at a scribing speed of at least about 35 meters per minute, thereby forming a median crack extending along the length of the first surface and extending into the glass sheet; Run a crack depth of the median crack extending into the glass sheet is less than a thickness of the glass sheet, and a variation in the crack depth along the length of the median crack on the first surface is less than about 5 micrometers; a linear guide rail that engages with a rod of the air cylinder, the linear guide rail allowing movement of the rod in a first direction perpendicular to the glass sheet and restricting movement of the rod in a direction perpendicular to the first direction.

8. further comprising a first actuator coupled to the air cylinder; the first actuator is communicatively coupled to the controller; 8. The glass cutting system of claim 7, wherein when the processor executes the computer readable and executable instructions, the processor further performs the step of directing the first actuator to move the air cylinder toward the first side of the glass sheet.

9. 8. The glass cutting system of claim 7, wherein when the processor executes the computer readable and executable instructions, the processor performs the step of directing the second actuator to move the scribing wheel along the glass sheet at a scribing speed of at least about 40 meters per minute.

10. 8. The glass cutting system of claim 7, wherein when the processor executes the computer readable and executable instructions, the processor further performs the step of directing the regulator to cause the air cylinder to apply and maintain a force on the first side of the glass sheet within about 0.2 Newtons of a predetermined force at the scribing wheel.

11. 8. The glass cutting system of claim 7, wherein the crack depth of the median crack along the length of the median crack on the first surface varies by less than about 1.5%.

12. 8. The glass cutting system of claim 7, wherein applying a force to the first surface of the glass sheet with the scribing wheel includes maintaining the force within about 0.2 Newtons of the predetermined force.

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