Apparatus and methods for separating a ribbon of brittle material

Abstract

Methods of separating a ribbon include moving the ribbon along a travel path in a travel direction. Methods include supporting the ribbon with a first support member and a second support member positioned on a first side of the travel path. The first support member applies a force to the ribbon at a first location, and the second support member applies a force to the ribbon at a second location. A distance separating the first location from the second location is less than about 100 millimeters. As the ribbon moves, a flaw is initiated in the ribbon at an intermediate location between the first location and the second location. Methods include separating the ribbon into a first ribbon portion and a second ribbon portion by propagating the flaw across the ribbon. A ribbon separation apparatus is also provided.

Description

APPARATUS AND METHODS FOR SEPARATING A RIBBON OF BRITTLE MATERIALCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of priority under 35 U.S.C. §119 of U.S. Provisional Application Serial No. 63 / 568569 filed on March 22, 2024, the content of which is relied upon and incorporated herein by reference in its entirety.FIELD

[0002] The present disclosure relates generally to apparatus and methods for separating a ribbon of brittle material and, more particularly, to apparatus and methods for separating a ribbon of brittle material with a three-point bend system.BACKGROUND

[0003] It is known to separate a ribbon of brittle material with a ribbon separating device. Conventional ribbon separating devices are known to separate a ribbon of brittle material (hereinafter “ribbon”), for example, a glass ribbon, into a plurality of ribbon portions. However, during the separation process, areas of the ribbon can experience stress that is outside of a predetermined stress range. Further, characteristics of the ribbon, such as edge quality and performance, may be undesirably altered.SUMMARY

[0004] The following presents a simplified summary of the disclosure to provide a basic understanding of some aspects described in the detailed description.

[0005] There are set forth methods of separating a ribbon with a ribbon separation apparatus. For example, a ribbon can travel along a ribbon travel path in a ribbon travel direction. As the ribbon is moving, the ribbon can be supported by the ribbon separation apparatus. The ribbon separation apparatus can engage the ribbon and form a three-point bend in the ribbon, which can generate a stress profile in the ribbon. The ribbon separation apparatus can initiate a flaw in the ribbon at the three-point bend, which can separate the ribbon into a plurality of ribbon portions.

[0006] In aspects, methods of separating a ribbon comprising moving the ribbon along a travel path in a travel direction. Methods can comprise supporting the ribbon with a first support memberand a second support member positioned on a first side of the travel path. The first support member can apply a first force to the ribbon at a first location of the travel path. The second support member can apply a second force to the ribbon at a second location of the travel path downstream from the first location relative to the travel direction. A distance separating the first location from the second location can be less than about 100 millimeters. As the ribbon moves in the travel direction, methods can comprise initiating a flaw in the ribbon at an intermediate location of the travel path between the first location and the second location. Methods can comprise separating the ribbon into a first ribbon portion and a second ribbon portion by propagating the flaw across the ribbon in a propagation direction transverse to the travel direction.

[0007] In aspects, one or more of the first support member or the second support member may comprise a roller rotating at a rotational speed within about 10% of a travel speed of the ribbon moving along the travel path in the travel direction.

[0008] In aspects, one or more of the first support member or the second support member can comprise an air bearing.

[0009] In aspects, initiating the flaw can comprise contacting the ribbon with a scoring apparatus.

[0010] In aspects, initiating the flaw further can comprise applying a third force to the ribbon from a force applicator at the intermediate location to move the ribbon toward the scoring apparatus.

[0011] In aspects, applying the third force to the ribbon from the force applicator can comprise moving the force applicator between a first position, in which the force applicator is not in contact with the ribbon, and a second position, in which the force applicator contacts the ribbon.

[0012] In aspects, methods of separating a ribbon can comprise moving the ribbon along a travel path in a travel direction. Methods can comprise supporting the ribbon on a first side of the ribbon with a first support member and a second support member. The first support member and the second support member can be spaced apart to form a gap therebetween. As the ribbon moves in the travel direction, initiating a flaw in the ribbon by engaging the first side of the ribbon within the gap with a scoring apparatus, and applying a force to a second side of the ribbon with a force applicator. The scoring apparatus can be aligned with the force applicator such that the flaw can be formed at a location of the ribbon between the scoring apparatus and the force applicator and between the first support member and the second support member. Methods can comprise separating the ribbon into a first ribbon portion and a second ribbon portion by propagating the flaw across the ribbon in a propagation direction transverse to the travel direction.

[0013] In aspects, one or more of the first support member or the second support member may comprise a roller rotating at a rotational speed within about 10% of a travel speed of the ribbon moving along the travel path in the travel direction.

[0014] In aspects, engaging the ribbon can comprise contacting the ribbon with the scoring apparatus and moving the scoring apparatus in the propagation direction. The scoring apparatus can move at an average velocity in the propagation direction within a range from about 500 millimeters / second to about 1500 millimeters / second while the scoring apparatus is in contact with the ribbon.

[0015] In aspects, engaging the ribbon can comprise moving the scoring apparatus between a non-contacting position, in which the scoring apparatus is not in contact with the ribbon, and a contacting position, in which the scoring apparatus contacts the ribbon and moves in the propagation direction.

[0016] In aspects, applying the force to the ribbon from the force applicator can comprise moving the force applicator between a first position, in which the force applicator is not in contact with the ribbon, and a second position, in which the force applicator contacts the ribbon.

[0017] In aspects, the scoring apparatus and the force applicator can be in contact with the ribbon at the same time.

[0018] In aspects, the ribbon can comprise a thickness within a range from about 25 micrometers to about 250 micrometers.

[0019] In aspects, a ribbon separation apparatus can comprise a first support member positioned on a first side of a travel path along which a ribbon travels. The first support member can apply a first force to the ribbon at a first location of the travel path. The ribbon separation apparatus can comprise a second support member spaced apart from the first support member to form a gap between the first support member and the second support member. The second support member can apply a second force to the ribbon at a second location of the travel path. A distance separating the first location from the second location can be less than about 100 millimeters. A force applicator can be positioned on a second side of the travel path and aligned with the gap. The force applicator can move the ribbon toward the gap. A scoring apparatus can be positioned within the gap and aligned with the force applicator. The scoring apparatus can engage the ribbon and initiate a flaw in the ribbon while the ribbon is moved toward the gap.

[0020] In aspects, the force applicator can be attached to a cam assembly configured to rotate to move the force applicator between a first position, in which the force applicator is spaced a distancefrom the ribbon and not in contact with the ribbon, and a second position, in which the force applicator is in contact with the ribbon and the ribbon is moved toward the gap.

[0021] In aspects, one or more of the first support member or the second support member comprises a roller rotating at a rotational speed within about 10% of atravel speed ofthe ribbon moving along the travel path in a travel direction.

[0022] In aspects, one or more of the first support member or the second support member can comprise an air bearing.

[0023] In aspects, the scoring apparatus can engage the ribbon by contacting the ribbon. The scoring apparatus can comprise one or more of a scribe comprising a tip that contacts the ribbon and moves relative to the ribbon in a propagation direction transverse to a travel direction of the ribbon along the travel path, or a wheel comprising a circumferential edge that contacts the ribbon and moves relative to the ribbon in the propagation direction while the wheel rotates.

[0024] In aspects, the scoring apparatus can engage the ribbon without contacting the ribbon. The scoring apparatus can comprise one or more of a laser that directs a laser beam toward the ribbon, the laser beam impinging upon the ribbon to initiate the flaw, or a nozzle that directs a fluid toward the ribbon, the fluid impinging upon the ribbon to initiate the flaw.

[0025] In aspects, the distance separating the first location from the second location can be within a range from about 40 millimeters to about 60 millimeters.

[0026] Additional features and advantages of the aspects disclosed herein will be set forth in the detailed description that follows, and in part will be clear to those skilled in the art from that description or recognized by practicing the aspects described herein, including the detailed description which follows, the claims, as well as the appended drawings. It is to be understood that both the foregoing general description and the following detailed description present aspects intended to provide an overview or framework for understanding the nature and character of the aspects disclosed herein. The accompanying drawings are included to provide further understanding and are incorporated into and constitute a part of this specification. The drawings illustrate various aspects of the disclosure, and together with the description explain the principles and operations thereof.BRIEF DESCRIPTION OF THE DRAWINGS

[0027] These and other features, aspects and advantages are better understood when the following detailed description is read with reference to the accompanying drawings, in which:

[0028] FIG. 1 schematically illustrates example aspects of a glass manufacturing apparatus in accordance with aspects of the disclosure;

[0029] FIG. 2 illustrates a perspective view of a ribbon separation apparatus in accordance with aspects of the disclosure;

[0030] FIG. 3 illustrates a side view of a portion of the ribbon separation apparatus in accordance with aspects of the disclosure;

[0031] FIG. 4 illustrates a side view of a portion of the ribbon separation apparatus in accordance with aspects of the disclosure;

[0032] FIG. 5 illustrates a side view of a scoring apparatus of the ribbon separation apparatus in accordance with aspects of the disclosure.

[0033] FIG. 6 illustrates a side view of a force applicator of the ribbon separation apparatus in accordance with aspects of the disclosure;

[0034] FIG. 7 illustrates a side view of the force applicator of the ribbon separation apparatus in accordance with aspects of the disclosure;

[0035] FIG. 8 illustrates a side view of the force applicator of the ribbon separation apparatus in accordance with aspects of the disclosure;

[0036] FIG. 9 illustrates a side view of the force applicator of the ribbon separation apparatus in accordance with aspects of the disclosure.

[0037] FIG. 10 illustrates a top-down view of a portion of the ribbon separation apparatus in accordance with aspects of the disclosure; and

[0038] FIG. 11 illustrates a top-down view of a portion of the ribbon separation apparatus in accordance with aspects of the disclosure.DETAILED DESCRIPTION

[0039] Aspects will now be described more fully hereinafter with reference to the accompanying drawings in which example aspects are shown. Whenever possible, the same reference numerals are used throughout the drawings to refer to the same or like parts. However, this disclosure may be embodied in many different forms and should not be construed as limited to the aspects set forth herein.

[0040] As used herein, the term “about” means that amounts, sizes, formulations, parameters, and other quantities and characteristics are not, and need not be, exact, but may be approximate and / or larger or smaller, as desired, reflecting tolerances, conversion factors, rounding off, measurement error and the like, and other factors known to those of skill in the art.

[0041] Ranges can be expressed herein as from “about” one value, and / or to “about” another value. When such a range is expressed, aspects include from the one value to the other value. Similarly,when values are expressed as approximations by use of the antecedent “about,” it will be understood that the value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

[0042] Directional terms as used herein - for example up, down, right, left, front, back, top, bottom, upper, lower, etc. - are made only with reference to the figures as drawn and are not intended to imply absolute orientation.

[0043] Unless otherwise expressly stated, it is in no way intended that any methods set forth herein be construed as requiring that its steps be performed in a specific order, nor that with any apparatus, specific orientations be required. Accordingly, where a method claim does not actually recite an order to be followed by its steps, or that any apparatus claim does not actually recite an order or orientation to individual components, or it is not otherwise specifically stated in the claims or description that the steps are to be limited to a specific order, or that a specific order or orientation to components of an apparatus is not recited, it is in no way intended that an order or orientation be inferred in any respect. This holds for any possible non-express basis for interpretation, including matters of logic relative to arrangement of steps, operational flow, order of components, or orientation of components; plain meaning derived from grammatical organization or punctuation, and; the number or type of aspects described in the specification.

[0044] As used herein, the singular forms “a,” “an” and “the” include plural references unless the context clearly dictates otherwise. Thus, for example, reference to “a” component includes aspects having two or more such components, unless the context clearly indicates otherwise.

[0045] The word “exemplary,” “example,” or various forms thereof are used herein to mean serving as an example, instance, or illustration. Any aspect or design described herein as “exemplary” or as an “example” should not be construed as preferred or advantageous over other aspects or designs. Furthermore, examples are provided solely for purposes of clarity and understanding and are not meant to limit or restrict the disclosed subject matter or relevant portions of this disclosure in any manner. It can be appreciated that a myriad of additional or alternate examples of varying scope could have been presented but have been omitted for purposes of brevity.

[0046] As used herein, the terms “comprising” and “including”, and variations thereof, shall be construed as synonymous and open-ended, unless otherwise indicated. A list of elements following the transitional phrases comprising or including is a non-exclusive list, such that elements in addition to those specifically recited in the list may also be present.

[0047] The terms “substantial,” “substantially,” and variations thereof as used herein are intended to represent that a described feature is equal or approximately equal to a value or description.For example, a “substantially planar” surface is intended to denote a surface that is planar or approximately planar. Moreover, “substantially” is intended to denote that two values are equal or approximately equal. The term “substantially” may denote values within about 10% of each other, for example, within about 5% of each other, within about 2%, within about 1%, or within about 0.5% of each other.

[0048] Modifications may be made to the instant disclosure without departing from the scope or spirit of the claimed subject matter. Unless specified otherwise, “first,” “second,” or the like are not intended to imply a temporal aspect, a spatial aspect, an ordering, etc. Rather, such terms are merely used as identifiers, names, etc. for features, elements, items, etc. For example, a first end and a second end generally correspond to end A and end B or two different ends.

[0049] The present disclosure relates to a ribbon separation apparatus for separating a ribbon (e.g., of brittle material) into a plurality of ribbon portions. For purposes of this application, “ribbon” may be considered one or more of a glass ribbon in a viscous state, a glass ribbon in an elastic state (e.g., at room temperature) and / or a glass ribbon in a viscoelastic state between the viscous state and the elastic state. The ribbon may comprise a glass ribbon of an indeterminate length or one or more separated glass articles (e.g., separated ribbons, separated sheets, separated portions, etc.) that comprise multiple, e.g., four, discrete edges. Methods and apparatus for separating a ribbon (e.g., of brittle material) will now be described by way of example aspects. As schematically illustrated in FIG. 1, an exemplary glass manufacturing apparatus 100 can comprise a glass melting and delivery apparatus 102 and a forming device 101 designed to produce a glass ribbon 103 from a quantity of molten material 121. The glass ribbon 103 can comprise a central portion 152 positioned between opposite edge portions (e.g., edge beads) formed along a first edge 153 and a second edge 155 of the glass ribbon 103, wherein a thickness of the edge portions can be greater than a thickness of the central portion. Additionally, a separated ribbon (e.g., separated ribbon portions 1001, 1003) can be separated from the ribbon 103 along a separation path 151 by a ribbon separation apparatus 149 (e.g., described herein relative to FIGS. 2-11).

[0050] In aspects, the glass melting and delivery apparatus 102 can comprise a melting vessel 105 oriented to receive batch material 107 from a storage bin 109. The batch material 107 can be introduced by a batch delivery device 111 powered by a motor 113. An optional controller 115 can be operated to activate the motor 113 to introduce a desired amount of batch material 107 into the melting vessel 105, as indicated by arrow 117. The melting vessel 105 can heat the batch material 107 to provide molten material 121. A melt probe 119 can be employed to measure a level of molten material121 within a standpipe 123 and communicate the measured information to the controller 115 by way of a communication line 125.

[0051] Additionally, in aspects, the glass melting and delivery apparatus 102 can comprise a first conditioning station comprising a fining vessel 127 located downstream from the melting vessel 105 and coupled to the melting vessel 105 by way of a first connecting conduit 129. For example, molten material 121 can be gravity fed from the melting vessel 105 to the fining vessel 127 by way of an interior pathway of the first connecting conduit 129. Additionally, bubbles can be removed from the molten material 121 within the fining vessel 127 by various techniques.

[0052] In aspects, the glass melting and delivery apparatus 102 can further comprise a second conditioning station comprising a mixing chamber 131 that can be located downstream from the fining vessel 127. The mixing chamber 131 can be employed to provide a homogenous composition of molten material 121, thereby reducing or eliminating inhomogeneity that may otherwise exist within the molten material 121 exiting the fining vessel 127. As shown, the fining vessel 127 can be coupled to the mixing chamber 131 by way of a second connecting conduit 135. For example, molten material 121 can be gravity fed from the fining vessel 127 to the mixing chamber 131 by way of an interior pathway of the second connecting conduit 135.

[0053] Additionally, in aspects, the glass melting and delivery apparatus 102 can comprise a third conditioning station comprising a delivery chamber 133 that can be located downstream from the mixing chamber 131. The delivery chamber 133 can condition the molten material 121 to be fed into an inlet conduit. For example, the delivery chamber 133 can function as an accumulator and / or flow controller to adjust and provide a consistent flow of molten material 121 to the inlet conduit. As shown, the mixing chamber 131 can be coupled to the delivery chamber 133 by way of a third connecting conduit 137. For example, molten material 121 can be gravity fed from the mixing chamber 131 to the delivery chamber 133 by way of an interior pathway of the third connecting conduit 137. As further illustrated, a delivery pipe 139 can be positioned to deliver molten material 121 to a forming device 101. The forming device 101 is illustrated schematically in FIG. 1 (e.g., vessel 143) because the forming device 101 can comprise several different structures. In a possible aspect, the forming device 101 can comprise structure(s) for fusion drawing molten material 121 off a bottom edge (e.g., a root) of a forming wedge to produce the ribbon 103. In such an example, the forming device 101 can comprise a trough extending along a trough axis between an inlet end and an opposing end. The inlet end is the end of the trough in proximity to the delivery pipe 139 from which the molten material 121 is received. The molten material 121 can be drawn off a bottom edge (e.g., root) of the forming device 101 along a draw path extending in a ribbon travel direction 154 of the glass manufacturing apparatus100. Additional structures, for example, edge directors can direct the molten material 121 off the forming device 101 and define, in part, a width 108 of the ribbon 103. However, in other aspects, other forming apparatuses may be used, such as, for example, a slot draw apparatus wherein the molten material 121 is pulled (e.g., drawn) from a slot in the bottom of a molten material-containing vessel (e.g., vessel 143).

[0054] In aspects, the width 108 of the ribbon 103, which extends between the first edge 153 of the ribbon 103 and the second edge 155 of the ribbon 103, can be selected based on the forming method (e.g., fusion drawing, slot drawing, etc.). In aspects, the width 108 can be greater than or equal to about 20 millimeters (mm), for example, greater than or equal to about 50 mm, for example, greater than or equal to about 100 mm, for example, greater than or equal to about 500 mm, for example, greater than or equal to about 1000 mm, for example, greater than or equal to about 2000 mm, for example, greater than or equal to about 3000 mm, for example, greater than or equal to about 4000 mm, although other widths less than or greater than the widths mentioned above can be provided in aspects. For example, the width 108 can be within a range from about 20 mm to about 4000 mm, for example, within a range from about 50 mm to about 4000 mm, for example, within a range from about 100 mm to about 4000 mm, for example, within a range from about 500 mm to about 4000 mm, for example, within a range from about 1000 mm to about 4000 mm, for example, within a range from about 2000 mm to about 4000 mm, for example, within a range from about 3000 mm to about 4000 mm, for example, within a range from about 20 mm to about 3000 mm, for example, within a range from about 50 mm to about 3000 mm, for example, within a range from about 100 mm to about 3000 mm, for example, within a range from about 500 mm to about 3000 mm, for example, within a range from about 1000 mm to about 3000 mm, for example, within a range from about 2000 mm to about 3000 mm, for example, within a range from about 2000 mm to about 2500 mm, and all ranges and subranges therebetween. In aspects, the ribbon 103 comprises one or more states of material based on a vertical location of the ribbon 103, i.e., distance from vessel 143 of the forming device 101. For example, at a first location, the ribbon 103 can comprise the viscous molten material 121, and at a second location, the ribbon 103 can comprise an amorphous solid in a glassy state (e.g., a glass ribbon).

[0055] The ribbon 103 can comprise a first major surface and a second major surface facing opposite directions and defining a thickness (e.g., average thickness) of the ribbon 103 therebetween. In aspects, the thickness of the ribbon 103 can be less than or equal to about 2 millimeters (mm), less than or equal to about 1 millimeter, less than or equal to about 0.5 millimeters, for example, less than or equal to about 300 micrometers (pm), less than or equal to about 200 micrometers, or less than or equal to about 100 micrometers, although other thicknesses may be provided in further aspects. Forexample, the thickness of the ribbon 103 can be within a range from about 20 micrometers to about 200 micrometers, within a range from about 25 micrometers to about 250 micrometers, within a range from about 50 micrometers to about 750 micrometers, within a range from about 100 micrometers to about 700 micrometers, within a range from about 200 micrometers to about 600 micrometers, within a range from about 300 micrometers to about 500 micrometers, within a range from about 50 micrometers to about 500 micrometers, within a range from about 50 micrometers to about 700 micrometers, within a range from about 50 micrometers to about 600 micrometers, within a range from about 50 micrometers to about 500 micrometers, within a range from about 50 micrometers to about 400 micrometers, within a range from about 50 micrometers to about 300 micrometers, within a range from about 40 micrometers to about 200 micrometers, within a range from about 50 micrometers to about 100 micrometers, within a range from about 25 micrometers to about 125 micrometers, comprising all ranges and subranges of thicknesses therebetween. In addition, the ribbon 103 can comprise a variety of compositions, for example, one or more of soda-lime glass, borosilicate glass, alumino-borosilicate glass, alkali-containing glass, alkali-free glass, aluminosilicate, borosilicate, boroaluminosilicate, silicate, glass-ceramic, or other materials comprising glass. In aspects, the ribbon 103 can comprise one or more of lithium fluoride (LiF), magnesium fluoride (MgF2), calcium fluoride (CaF2), barium fluoride (BaF2), sapphire (AI2O3), zinc selenide (ZnSe), germanium (Ge) or other materials.

[0056] The ribbon separation apparatus 149 (see FIG. 1) can separate the ribbon 103 along the separation path 151 to provide a plurality of separated ribbon portions 1001, 1003 (i.e., a plurality of sheets of glass). In aspects, a longer portion of the ribbon 103 may be coiled onto a storage roll. The separated ribbon can then be processed into a desired application, e.g., a display application. For example, the separated ribbon can be used in a wide range of display and non-display applications comprising, but not limited to, liquid crystal displays (LCDs), electrophoretic displays (EPD), organic light emitting diode displays (OLEDs), plasma display panels (PDPs), microLED displays, miniLED displays, organic light emitting diode lighting, light emitting diode lighting, augmented reality (AR), virtual reality (VR), touch sensors, photovoltaics, foldable phones, or other applications.

[0057] FIG. 2 is a perspective illustration of example aspects of the ribbon separation apparatus 149. For purposes of illustration, the ribbon separation apparatus 149 is illustrated without the ribbon 103 to not obscure structural features of the ribbon separation apparatus 149. However, in operation, and as illustrated relative to at least some of FIGS. 3-11, the ribbon separation apparatus 149 receives and supports the ribbon 103, such that the ribbon 103 can be separated into separate and discrete ribbon portions by the ribbon separation apparatus 149. The ribbon separation apparatus 149can comprise a first support member 301 and a second support member 303 that can support the ribbon 103. By supporting the ribbon 103, the first support member 301 and the second support member 303 can guide the ribbon 103 and allow the ribbon 103 to move relative to the first support member 301 and the second support member 303. The first support member 301 and the second support member 303 are spaced apart along an x-axis (e.g., reference axes illustrated in FIG. 2), such that the ribbon 103 can travel along the x-axis. In aspects, the first support member 301 and the second support member 303 can be positioned below the ribbon 103 relative to a z-axis, wherein the z-axis is parallel to a direction of gravitational force. However, other possible orientations are envisioned, for example, with the z-axis at an angle (e.g., not parallel to) the direction of gravitational force.

[0058] In aspects, one or more of the first support member 301 or the second support member 303 can comprise rollers, with the rollers extending parallel to one another along the y-axis. As explained below, the support members 301, 303 can comprise structures that are not rollers, for example, air bearings. In aspects, the first support member 301 can comprise a roller (e.g., or multiple rollers spaced apart along the y-axis) and / or the second support member 303 can comprise a roller (e.g., or multiple rollers spaced apart along the y-axis). When the first support member 301 and / or the second support member 303 comprise rollers, the rollers can rotate at a rotational speed that is within about 10% of a travel speed of the ribbon 103, within about 5% of the travel speed, or substantially equal to the travel speed. In this way the rotational speed can be slightly greater than (e.g., less than about 10% greater than, or less than about 5% greater than) the travel speed, or slightly less than (e.g., less than about 10% less than, or less than about 5% less than) the travel speed. Accordingly, the first support member 301 or the second support member 303 may not impede or inhibit movement of the ribbon 103 while the ribbon 103 is supported and separated by the ribbon separation apparatus 149.

[0059] In aspects, the support members, when rollers, may be actively driven (e.g., caused to rotate at a predetermined rotational speed), or may passively rotate without being driven (e.g., such that the rollers rotate in response to the ribbon 103 contacting the rollers and moving relative to the rollers). In aspects, the rollers may move at the same rotational speed as one another, or at different rotational speeds. For example, in aspects, the second support member 303 (e.g., comprising a roller) may be downstream from the first support member 301 (e.g., comprising a roller) relative to the travel direction of the ribbon 103 along the x-axis. In such an example, the second support member 303 may be rotated at a different rotational speed than the first support member 301, for example, with the second support member 303 at a rotational speed that is faster than the rotational speed of the first support member 301 and faster than the travel speed of the ribbon 103. In this way, the rotational speedof the second support member 303 can be selected to increase the speed of the portion of the ribbon 103 in contact with the second support member 303 after the ribbon 103 has been separated.

[0060] The ribbon separation apparatus 149 can comprise a force applicator 307 spaced apart from the first support member 301 and the second support member 303 along the z-axis. In this way, the ribbon 103 can pass between the force applicator 307 and the support members 301, 303, with the force applicator 307 on one side of the ribbon 103 and the support members 301, 303 on an opposite side of the ribbon 103. The force applicator 307 can selectively apply a force to the ribbon 103 to move or bias the ribbon 103 toward the support members 301, 303. In aspects, the ribbon separation apparatus 149 can comprise a control apparatus 309 that is attached to the force applicator 307 and can control movement of the force applicator 307. For example, the control apparatus 309 can comprise a cam assembly 311 attached to the force applicator 307. The cam assembly 311 is illustrated and described fully relative to FIGS. 6-9, however, in general, the cam assembly 311 can comprise, for example, a shaft 313 that is rotatable and may be driven by one or more of gears, motors, chains, belts, etc. In aspects, the shaft 313 can extend along the y-axis. The cam assembly 311 can comprise a movement member 315 attached to the shaft 313. Rotation of the shaft 313 can cause the movement member 315 to rotate. The cam assembly 311 can comprise a linking member 317 attached to the movement member 315, with the linking member 317 configured to move as the movement member 315 rotates. The cam assembly 311 can comprise a translating member 319 attached to the linking member 317, with the translating member 319 configured to move as the linking member 317 moves. The translating member 319 can be attached to the force applicator 307, such that movement of the translating member 319 can cause the force applicator 307 to move along the z-axis in a direction toward and away from the ribbon 103.

[0061] FIG. 3 illustrates a side view of a portion of the ribbon separation apparatus 149 as viewed along lines 3-3 of FIG. 2. For the purposes of illustration, FIG. 3 illustrates less than all of the ribbon separation apparatus 149 to not obscure from view the position of the ribbon 103 relative to the support members 301, 303 and the force applicator 307. In operation, however, the ribbon separation apparatus 149 can comprise additional features and structures, such as those illustrated in FIG. 2. As illustrated in FIG. 3, the ribbon 103 can move along a travel path 401 in a travel direction 403, wherein the travel direction 403 is along the x-axis. The travel path 401, and, therefore, the ribbon 103, can extend between the support members 301, 303 and the force applicator 307, such that the first support member 301 and the second support member 303 are positioned on a first side 405 of the travel path 401 (e.g., along which the ribbon 103 travels) and the force applicator 307 is positioned on an opposing second side 407 of the travel path 401. In aspects, the first side 405 is below the second side 407 (e.g.,relative to the direction of gravitational force along the z-axis). In aspects, at a location upstream from the first support member 301 (e.g., relative to the travel direction 403), the ribbon 103 can be supported by an air bearing, and, at a location downstream from the second support member 303 (e.g., relative to the travel direction 403), the ribbon 103 can be supported by an air bearing. As used herein, an air bearing can comprise at least one wall surrounding a pressurized chamber, with a plurality of orifices extending through the at least one wall, wherein a pressurized gas (e.g. , air) travels from the pressurized chamber and through the plurality of orifices. The gas can impinge upon the ribbon 103 to apply force to the ribbon 103.

[0062] The second support member 303 may be spaced apart from the first support member 301 to form a gap 411 (e.g., space, opening, separation) between the first support member 301 and the second support member 303. In aspects, a center (e.g., midpoint of diameter) of the first support member 301 is spaced a distance 413 apart from a center (e.g., midpoint of diameter) of the second support member 303, wherein the distance 413 may be less than about 100 millimeters, or within a range from about 40 millimeters to about 60 millimeters. The force applicator 307 can be aligned with the gap 411, such that the force applicator 307 can selectively contact the ribbon 103 and move the ribbon 103 toward the gap 411. By being aligned with the gap 411, a longitudinal axis 415 can extend along, and parallel to, the z-axis, with the longitudinal axis 415 intersecting a central axis 416 (e.g., center or midpoint of diameter) of the force applicator 307 and passing through the gap 411. In aspects, when the force applicator 307 comprises a roller, the force applicator 307 extends along the central axis 416 about which the force applicator 307 rotates. The first support member 301 can apply a force to the ribbon 103 at a first location 421 of the travel path 401, and the second support member 303 can apply a force to the ribbon 103 at a second location 423 of the travel path 401. The first location 421 can represent the location along the travel path 401 at which the first support member 301 contacts the ribbon 103 (e.g., when the first support member 301 comprises a roller). Similarly, the second location 423 can represent the location along the travel path 401 at which the second support member 303 contacts the ribbon 103 (e.g., when the second support member 303 comprises a roller). Accordingly, the distance 413 separates the first location 421 and the second location 423.

[0063] Referring to FIGS. 3-4, the ribbon separation apparatus 149 can comprise a scoring apparatus 427 positioned within the gap 411 and aligned with the force applicator 307. By being positioned within the gap 411, the scoring apparatus 427 can be positioned between the first support member 301 and the second support member 303 on the first side 405 of the travel path 401. As illustrated in FIG. 3, the scoring apparatus 427 may initially be spaced a distance apart from the ribbon 103, such that the scoring apparatus 427 may not be in contact with the ribbon 103. As illustrated inFIG. 4, the scoring apparatus 427 can be moved into contact with the ribbon 103, such that the scoring apparatus 427 can engage the ribbon 103 and initiate a flaw in the ribbon 103. The flaw can comprise, for example, a scratch, a nick, a crack, or other deformity formed in the ribbon 103. In aspects, the scoring apparatus 427 can comprise a scribe with a tip (e.g., a diamond-tipped scribe, or a carbide tip, or a score wheel, or a flaw generation device with mechanical contact or laser, etc.) that is attached to an automated nicker, such that the scoring apparatus 427 can selectively engage and contact the ribbon 103. In aspects, when the force applicator 307 comprises a roller, the longitudinal axis 415 can pass through the central axis 416 and through the scoring apparatus 427, such that the force applicator 307 and the scoring apparatus 427 are aligned, with the scoring apparatus 427 configured to move along the y-axis in a direction parallel to the central axis 416 while the scoring apparatus 427 is in contact with the ribbon 103.

[0064] In operation, and with reference to FIGS. 3-4, methods of separating the ribbon 103 into discrete ribbon portions can comprise moving ribbon 103 along the travel path 401 in the travel direction 403. As the ribbon 103 is moving, methods can comprise supporting the ribbon 103 with the first support member 301 and the second support member 303 positioned on the first side 405 of the travel path 401, with the first support member 301 applying a force to the ribbon 103 at the first location 421 and the second support member 303 applying a force to the ribbon 103 at the second location 423 downstream from the first location 421 relative to the travel direction 403. As the ribbon 103 moves in the travel direction 403, methods can comprise initiating a flaw (e.g., illustrated in FIG. 10) in the ribbon 103 at an intermediate location 501 of the travel path 401 between the first location 421 and the second location 423. Initiating the flaw can comprise contacting the ribbon 103 with the scoring apparatus 427. For example, as the ribbon 103 moves in the travel direction 403, initiating the flaw can comprise engaging the first side 405 of the ribbon 103 within the gap 411 with the scoring apparatus 427 while applying a force to the second side 407 of the ribbon 103 with the force applicator 307. The scoring apparatus 427 is aligned with the force applicator 307 such that the flaw is formed at the location of the ribbon 103 between the scoring apparatus 427 and the force applicator 307, and between the first support member 301 and the second support member 303. As illustrated in FIG. 4, the force applicator 307 can exert the force upon the ribbon 103 to cause the ribbon 103 to deflect and move into the gap 411 and toward the scoring apparatus 427, thus increasing stress within the ribbon 103.

[0065] Referring to FIG. 4, the first support member 301, the second support member 303, and the force applicator 307 can form a three-point bend in the ribbon 103. That is, the first support member 301 and the second support member 303 can each function as supporting rollers by applyinga force to the ribbon 103 at the first side 405. The force applicator 307 can function as a loading roller by applying a force (or load) to the ribbon 103 at the second side 407 at the intermediate location 501 between the first support member 301 and the second support member 303. The force applicator 307 can selectively move between engagement with the ribbon 103 to form the three-point bend (e.g., as illustrated in FIG. 4) and out of engagement with the ribbon 103 (e.g., as illustrated in FIG. 3) to not form the three-point bend. As used herein, the term ‘engage’ (e.g., engaging, engagement, etc.) can comprise contact between the force applicator 307 and the ribbon 103, for example, when the force applicator 307 comprises a roller, such that the force applicator 307 applies a force to the ribbon 103 by contacting the ribbon 103. Alternatively, the term ‘engage’ can comprise the force applicator 307 applying a force to the ribbon 103 without contacting the ribbon 103, for example, when the force applicator 307 comprises an air bearing, fluid-emitting nozzle, etc. that apply the force while not contacting the ribbon 103. When the force applicator 307 engages the ribbon 103 (e.g., to form the three-point bend), the force applicator 307 can create a stress profile across the ribbon 103, for example, a region of localized increased stress across the ribbon 103 in a direction that is orthogonal to the travel direction 403. This stress profile can be used to propagate a flaw created by the scoring apparatus 427. That is, while the ribbon 103 is bent (e.g., three-point bend) and the stress profile is generated, the scoring apparatus 427 can engage the first side 405 of the ribbon 103 to initiate the flaw, whereupon the flaw may be propagated across the ribbon 103 to separate the ribbon 103 into separate ribbon portions.

[0066] When the first support member 301, the second support member 303, and / or the force applicator 307 comprise rollers, the rollers can comprise a diameter that is, for example, within a range from about 5 millimeters to about 30 millimeters, or about 20 millimeters. In aspects, the distance 413 between the first support member 301 and the second support member 303 may be within a range from about 30 millimeters to about 50 millimeters, or about 42 millimeters. In aspects, a distance separating the central axis 416 of the force applicator 307 from a central axis of the first support member 301 and / or a central axis of the second support member 303 along the x-axis may be within a range from about 15 millimeters to about 25 millimeters, or about 21 millimeters. In this way, in aspects, the force applicator 307 can be at a midpoint between the first support member 301 and the second support member 303 (e.g., with a first distance separating the force applicator 307 from the first support member 301 substantially equal to a second distance separating the force applicator 307 from the second support member 303). In aspects, when the support members 301, 303 and / or the force applicator 307 comprise rollers, the rollers may comprise a non-tapered shape along a length of the rollers. In the alternative, the rollers may comprise a tapered shape to adjust a stress profile of a three-point bend, with opposing ends of the rollers comprising a tapered shape with a decreasing diameter relative to a center of the roller. Tapering the ends of the rollers can reduce deflection at edges of the ribbon 103 and to provide a more uniform stress across the ribbon 103, which can reduce the likelihood of defects being formed due to a greater-than-de sired stress. In aspects, when the support members 301, 303 and / or the force applicator 307 comprise tapered rollers (e.g., rollers with tapered ends), the rollers can comprise a central, non-tapered section with a central diameter of about 10 millimeters with ends that are tapered to a minimum diameter of about 7.5 millimeters to about 9.5 millimeters, or about 8 millimeters or about 9 millimeters. In this example, the length of the central, non-tapered section may be within a range from about 250 millimeters to about 450 millimeters, or about 300 millimeters or about 400 millimeters, for example.

[0067] FIG. 5 illustrates positions of the scoring apparatus 427 relative to the ribbon 103 as viewed along lines 5-5 of FIG. 3 (e.g., along the x-axis). In aspects, the scoring apparatus 427 can move between a plurality of positions, for example, a first position 601, a second position 603, a third position, 605, and a fourth position 607 as part of the flaw-initiation process. Three of the positions (e.g., the first position 601, the third position 605, and the fourth position 607) are illustrated with dashed lines since the scoring apparatus 427 can occupy only one position at one time. As such, FIG. 5 illustrates the scoring apparatus 427 in the second position 603 while the other positions 601, 605, 607 are illustrated with dashed lines to represent where the scoring apparatus 427 may be located when not in the second position 603.

[0068] Initially, the scoring apparatus 427 may be in the first position 601, in which the scoring apparatus 427 is spaced a distance apart from the ribbon 103. That is, while the ribbon 103 is moving in the travel direction (e.g., along the x-axis) and when the scoring apparatus 427 is not initiating the flaw, a distance along the z-axis may separate the scoring apparatus 427 from the ribbon 103. In aspects, in the first position 601, the scoring apparatus 427 may he within a footprint of the ribbon 103 such that an axis 609 extending along, and parallel to, the z-axis can intersect the ribbon 103 and the scoring apparatus 427 in the first position 601. In aspects, the axis 609 is located a separating distance 611 from an edge 613 of the ribbon 103.

[0069] To initiate the flaw in the ribbon 103, the scoring apparatus 427 can move in a first movement direction 615 from the first position 601 to the second position 603. While moving in the first movement direction 615, the scoring apparatus 427 can simultaneously move along the z-axis and the y-axis. For example, while moving in the first movement direction 615 along the z-axis, the distance between the scoring apparatus 427 and the ribbon 103 can decrease until the scoring apparatus 427 reaches the second position 603, whereupon the scoring apparatus 427 can engage the ribbon 103.In this way, the distance separating the scoring apparatus 427 from the ribbon 103 is greater when the scoring apparatus 427 is in the first position 601 than when the scoring apparatus 427 is in the second position 603. In aspects, when the scoring apparatus 427 comprises a device that contacts the ribbon 103 to initiate the flaw (e.g., a scribe 617 comprising a tip 619, a wheel, etc.), then the distance separating the scoring apparatus 427 and the ribbon 103 may be zero when the scoring apparatus 427 is in the second position 603, due to the scoring apparatus 427 contacting the ribbon 103. However, in aspects, the scoring apparatus 427 can initiate the flaw without contacting the ribbon 103, such as, for example, when the scoring apparatus 427 comprises a laser that directs a laser beam toward the ribbon or when the scoring apparatus 427 comprises a nozzle that directs a fluid toward the ribbon. In these examples, the scoring apparatus 427 may still be spaced a distance apart from the ribbon 103 when the scoring apparatus 427 is in the second position 603, however, in aspects, the distance may be less than when the scoring apparatus 427 is in the first position 601.

[0070] In aspects, while moving in the first movement direction 615 along the y-axis, the separating distance 611 can decrease, due to the scoring apparatus 427 moving closer to the edge 613 of the ribbon 103. In this way, the separating distance 611 separating the scoring apparatus 427 from the edge 613 is greater when the scoring apparatus 427 is in the first position 601 than when the scoring apparatus 427 is in the second position 603.In aspects, the separating distance 611 (e.g., between the scoring apparatus 427 and the edge 613) once the scoring apparatus 427 engages or contacts the ribbon 103 in the second position 603 may be within a range from about 2 millimeters to about 14 millimeters, or about 10 millimeters. In this way, the distance that the scoring apparatus 427 is in contact with the ribbon 103 while the scoring apparatus 427 moves along the y-axis may be between about 2 millimeters to about 14 millimeters, or about 10 millimeters. While in the second position 603, the scoring apparatus 427 can engage the ribbon 103 by either contacting the ribbon 103 or not contacting the ribbon 103. For example, when contacting the ribbon 103, the scoring apparatus 427 can comprise the scribe 617 comprising the tip 619 that contacts the ribbon 103. While in contact with the ribbon 103, the scoring apparatus 427 can move relative to the ribbon 103 in a second movement direction 623 (e.g., a propagation direction) transverse to the travel direction 403 of the ribbon 103 along the travel path 401 (e.g., into and out of the page in FIG. 5). The second movement direction can be along the y-axis toward the edge 613. In this way, the tip 619 can remain in contact with the ribbon 103 while the scoring apparatus 427 moves in the second movement direction 623 toward the edge 613. The contact between the tip 619 and the ribbon 103 can create the flaw in the first side 405 of the ribbon 103. Alternatively, contact between the scoring apparatus 427 and the ribbon 103 can occur when the scoring apparatus 427 comprises a wheelcomprising a circumferential edge that contacts the ribbon 103 and moves relative to the ribbon 103 in the second movement direction 623 (e.g., a propagation direction) while the wheel rotates.

[0071] Accordingly, methods can comprise engaging the ribbon by moving the scoring apparatus 427 between the first position 601, in which the scoring apparatus 427 is not in contact with the ribbon 103, and the second position 603, in which the scoring apparatus 427 contacts the ribbon 103 and moves in the propagation direction or second movement direction 623. In this way, engaging the ribbon 103 can comprise contacting the ribbon 103 with the scoring apparatus 427 and moving the scoring apparatus 427 in the second movement direction 623, with the scoring apparatus 427 moving at an average velocity in the second movement direction 623 (e.g., propagation direction) within a range from about 500 millimeters / second to about 1500 millimeters / second, or about 1090 millimeters / second, while the scoring apparatus 427 is in contact with the ribbon 103. However, this range (e.g., from about 500 millimeters / second to about 1500 millimeters / second) is not intended to be limiting, and other ranges are envisioned, for example, if the ribbon 103 is thicker and moves slower. Alternatively, the scoring apparatus 427 can engage the ribbon 103 without contacting the ribbon 103 while in the second position 603. For example, the scoring apparatus 427 can comprise a laser that directs a laser beam toward the ribbon 103, with the laser beam impinging upon the ribbon 103 to initiate the flaw. In this example, the laser beam can be moved relative to the ribbon 103 in the second movement direction 623 (e.g., propagation direction). In other aspects, the scoring apparatus 427 can comprise a nozzle that directs a fluid toward the ribbon, with the fluid impinging upon the ribbon 103 to initiate the flaw. In this example, the fluid can be moved relative to the ribbon 103 in the second movement direction 623 (e.g., propagation direction). The flaw can be created at an edge bead or edge portion of the ribbon 103 due to the edge bead comprising the area of greatest stress because of an increased thickness of the edge bead as compared to a center of the ribbon 103.

[0072] The scoring apparatus 427 can continue moving in the second movement direction 623 from the second position 603 to the third position 605. In aspects, when the scoring apparatus 427 is in the third position 605, the scoring apparatus 427 may no longer be in engagement with or in contact with the ribbon 103. For example, in the third position 605, the scoring apparatus 427 may lie outside of a footprint of the ribbon 103, such that an axis 629 (e.g., parallel to axis 609) extending along, and parallel to, the z-axis intersects the scoring apparatus 427 while not intersecting the ribbon 103. To return from the third position 605 to the first position 601, the scoring apparatus 427 can first move in a third movement direction 631 (e.g., parallel to the z-axis and along the axis 629) from the third position 605 to the fourth position 607. The scoring apparatus 427 can then move in a fourth movement direction 633 (e.g., parallel to the y-axis) from the fourth position 607 to the first position 601. Uponreaching the first position 601, the scoring apparatus 427 can then selectively repeat the process of engaging the ribbon 103 and initiating the flaw.

[0073] The movement of the scoring apparatus 427 between the illustrated positions 601, 603, 605, 607 illustrated in FIG. 5 can yield several benefits. For example, initially, the scoring apparatus 427 is in the first position 601, which is a distance apart from the ribbon 103. In this way, the scoring apparatus 427 is limited from inadvertently contacting the ribbon 103. While moving from the first position 601 to the second position 603 in the first movement direction 615, the scoring apparatus 427 can move along the y-axis for a period of time. This movement along the y-axis can allow the scoring apparatus 427 time to move from a static position to a desired velocity upon reaching the second position 603. In aspects, the scoring apparatus 427 may not stop upon reaching the second position 603, but, rather, may continue moving upon reaching the second position 603 in the second movement direction 623. Accordingly, the scoring apparatus 427 may be at the desired velocity upon reaching the second position 603, with the scoring apparatus 427 continuing to move, while engaging the ribbon 103, at the average velocity in a range from about 500 millimeters / second to about 1500 millimeters / second. Further, due to the scoring apparatus 427 continuing to move in the second movement direction 623 toward the third position 605 even after the scoring apparatus 427 no longer engages the ribbon 103 (e.g., when the scoring apparatus 427 is outside of the footprint of the ribbon 103), the scoring apparatus 427 can be slowed to a velocity that is at or near zero upon reaching the third position 605. In this way, the movement of the scoring apparatus 427 between the illustrated positions 601, 603, 605, 607 affords time for the scoring apparatus 427 to increase and decrease speed.

[0074] The scoring apparatus 427 is not limited to moving between the positions 601, 603, 605, 607 illustrated in FIG. 5. Rather, in aspects, the scoring apparatus 427 can move between none, some, or all of those positions 601, 603, 605, 607. For example, in aspects, when the scoring apparatus 427 comprises a laser or nozzle, such that the scoring apparatus 427 does not contact the ribbon 103, the scoring apparatus 427 may remain in a single position, for example, the second position 603, with the scoring apparatus 427 being rotatable to direct the laser beam or fluid toward the ribbon 103. In this way, the scoring apparatus 427 can engage the ribbon 103 while remaining in a single position and not contacting the ribbon 103.

[0075] FIGS. 6-9 illustrate a side view of the operation of the cam assembly 311 that moves the force applicator 307 between a first position (e.g., illustrated in FIG. 6) and a second position (e.g., illustrated in FIG. 8). For example, referring to FIG. 6, the shaft 313 (e.g., illustrated with dashed lines) can be attached to the movement member 315. In aspects, the shaft 313 and the movement member 315 can comprise circular cross-sectional shapes, although other shapes (e.g., square, oval,etc.) are envisioned. The atachment of the shaft 313 to the movement member 315 allows for the shaft 313 to transmit rotation to the movement member 315. For example, the shaft 313 can rotate in a rotation direction 701, which can cause the movement member 315 to likewise rotate in the rotation direction 701.

[0076] The linking member 317 can be attached to the movement member 315, for example, at a first attachment location 703. In aspects, the first attachment location 703 can be located toward an outer periphery or toward an outer radial side of the movement member 315. The linking member 317 can be pivotably attached to the movement member 315, such that the linking member 317 can pivot relative to the movement member 315 at the first attachment location 703. The linking member 317 can be attached to the movement member 315 in several ways, for example, with mechanical fasteners such as screws, bolts, or other structures that permit the linking member 317 to pivot and move relative to the movement member 315. In aspects, the linking member 317 can comprise an elongated, rectangularly shaped structure that extends between a first end (e.g., which is attached to the movement member 315) and an opposing second end (e.g., which can be attached to the translating member 319). In aspects, the linking member 317 can be pivotably attached to the translating member 319, for example, at a second attachment location 705. The linking member 317 can pivot relative to the translating member 319 at the second attachment location 705. The linking member 317 can be atached to the translating member 319 in several ways, for example, with mechanical fasteners such as screws, bolts, or other structures that permit the linking member 317 and the translating member 319 to pivot and rotate relative to one another.

[0077] In aspects, the translating member 319 can comprise an elongated, rectangularly shaped structure that extends between a first end (e.g., which is attached to the linking member 317) and an opposing second end (e.g., which can be attached to the force applicator 307). Movement of the translating member 319 can cause the force applicator 307 to move between the first position (e.g., illustrated in FIG. 6) and the second position (e.g., illustrated in FIG. 8). For example, in the first position, the force applicator 307 may be spaced a distance apart from the ribbon 103, such that the force applicator 307 is not in contact with the ribbon 103 and does not exert a force upon the ribbon 103. In aspects, during a time period when the ribbon 103 is not being separated, the force applicator 307 may remain in the first position. When the ribbon 103 is to be separated, the force applicator 307 can move from the first position to the second position.

[0078] Referring to FIGS. 6-7, to begin the process of separating the ribbon 103, the cam assembly 311 can rotate and cause the force applicator 307 to move from the first position to an intermediate position (e.g., illustrated in FIG. 7). For example, with reference to FIG. 7, the shaft 313can rotate in the rotation direction 701, which can cause the movement member 315 to rotate in the rotation direction 701. Rotation of the movement member 315 can cause the linking member 317 to pivot relative to the movement member 315 and move downwardly (e.g., in the z-direction) and toward the ribbon 103. This downward movement of the linking member 317 can cause the translating member 319 and the force applicator 307 to move downwardly (e.g., in the z-direction) and toward the ribbon 103.

[0079] Referring to FIGS. 7-8, the shaft 313 can continue to rotate at least until the force applicator 307 has moved downwardly from the intermediate position of FIG. 7 to the second position of FIG. 8. For example, in the second position, the force applicator 307 can contact the ribbon 103 and apply a force to the ribbon in the z-direction. In aspects, and as illustrated in FIG. 8, the force applied to the ribbon 103 by the force applicator 307 can cause the ribbon 103 to move toward the gap 411. As the force applicator 307 contacts the second side 407 of the ribbon 103, the scoring apparatus 427 can engage and contact the first side 405 of the ribbon 103, in a similar manner as described relative to FIGS. 3-5. In this way, the force applicator 307 is attached to the cam assembly 311, and the cam assembly 311 can rotate to move the force applicator 307 between the first position, in which the force applicator 307 is spaced a distance from the ribbon 103 and not in contact with the ribbon 103, and the second position, in which the force applicator 307 is in contact with the ribbon 103 and the ribbon 103 is moved toward the gap 411. Methods can therefore comprise applying a force to the ribbon 103 from the force applicator 307 by moving the force applicator 307 between the first position and the second position. In aspects, initiating the flaw can comprise applying the force to the ribbon 103 from the force applicator 307 at the intermediate location to move the ribbon 103 toward the scoring apparatus 427 as the scoring apparatus 427 engages the ribbon 103 to form the flaw. In aspects, the total time at which the force applicator 307 and the scoring apparatus 427 are simultaneously engaging the ribbon 103, for example, in contact with the ribbon 103, is within a range from about 50 milliseconds to about 150 milliseconds, or about 100 milliseconds. In aspects, the force applicator 307 may be in the fully-extended, second position for less than about 0.3 seconds, for example, within a range from about 0.2 seconds to about 0.3 seconds.

[0080] As illustrated in FIG. 9, following the engagement of the ribbon 103 with the force applicator 307 and the scoring apparatus 427, the ribbon 103 can be separated into a first ribbon portion 1001 and a second ribbon portion 1003. The shaft 313 can continue to rotate to return the force applicator 307 from the second position to the first position. For example, FIG. 9 illustrates the force applicator 307 in an intermediate position between the first position and the second position. As the shaft 313 rotates in the rotation direction 701, the movement member 315 can also rotate in the rotationdirection 701, which can cause the linking member 317, the translating member 319, and the force applicator 307 to move upwardly (e.g., in the z-direction) away from the ribbon 103. The shaft 313 can continue to rotate at least until the force applicator 307 has returned to the first position (e.g., illustrated in FIG. 6). In aspects, the cam assembly 311 can function to move the force applicator 307 between the first position and the second position while minimizing machine vibration, which provides for accuracy and quality during the separation process.

[0081] FIG. 10 illustrates a top-down view of the ribbon separation apparatus 149 as viewed along lines 10-10 of FIG. 4 when the force applicator 307 is in the second position (e.g., also illustrated in FIG. 8) and the scoring apparatus 427 is in the second position (e.g., second position 603 also illustrated in FIG. 5 and FIG. 8). As illustrated, with the force applicator 307 and the scoring apparatus 427 engaging the ribbon 103, the scoring apparatus 427 can initiate a flaw 1101 in the ribbon 103. The flaw 1101 can be formed in the first side 405 of the ribbon 103. Referring to FIGS. 10-11, methods can comprise separating the ribbon 103 into the first ribbon portion 1001 and the second ribbon portion 1003 by propagating the flaw 1101 across the ribbon 103 in a propagation direction 1201 transverse to the travel direction 403. For example, as illustrated in FIG. 10, the scoring apparatus 427 can move in the second movement direction 623 from the second position 603 to the third position 605. Movement of the scoring apparatus 427 relative to the ribbon 103 can initiate and form the flaw 1101. In aspects, the central axis 416 along which the force applicator 307 extends is substantially parallel to the second movement direction 623 along which the scoring apparatus 427 moves while engaging the ribbon 103. In this way, the stress profile in the ribbon 103 is created parallel to the central axis 416 and the second movement direction 623, such that upon the formation of the flaw 1101, the flaw 1101 is propagated in the propagation direction 1201 (e.g., illustrated in FIG. 11) that is substantially parallel to the central axis 416 and the second movement direction 623.

[0082] FIG. 11 illustrates the result of the propagation of the flaw 1101, wherein the force applicator 307 is omitted from view to not obscure the illustration of a gap 1200 between the ribbon portions 1001, 1003. As illustrated in FIG. 11, the flaw 1101 can propagate across the ribbon 103 along a separation path 151 in the propagation direction 1201, which can cause the ribbon 103 to separate into the first ribbon portion 1001 and the second ribbon portion 1003. Due to the alignment of the force applicator 307 and the scoring apparatus 427 (e.g., the central axis 416, the second movement direction 623, the separation path 151, and the propagation direction 1201 being parallel to one another), the ribbon portions 1001, 1003 can be separated along the separation path 151 that is substantially orthogonal to the travel direction 403 of the ribbon 103.

[0083] The ribbon separation apparatus 149 provides several benefits related to the separation of the ribbon 103 into the ribbon portions 1001, 1003. For example, the ribbon separation apparatus 149 can create the three-point bend in the ribbon 103 as the ribbon 103 moves in the travel direction 403, with the three-point bend creating a stress profile across the ribbon 103. As the three-point bend is formed to generate the stress profile, the scoring apparatus 427 can initiate the flaw 1101, which may then be propagated across the ribbon 103 to separate the ribbon 103 into the ribbon portions 1001, 1003. In this way, since the separation may occur as the ribbon 103 moves, an offline sheeting process may not be needed, which can reduce sheet separation cycle time by up to 70% (e.g., 3.5 seconds per sheet versus 12 seconds per sheet). Further, when the support members 301, 303 and the force applicator 307 comprise rollers, the support members 301, 303 and the force applicator 307 may be rotated at a speed that substantially matches or is within about 10% of a travel speed of the ribbon 103 moving along the travel path in the travel direction 403. In this way, the support members 301, 303 and the force applicator 307 can function to not impede conveyance of the ribbon 103 while the three- point bend is formed. In aspects, to further improve conveyance of the ribbon 103, the second support member 303 may be rotated at a faster speed than the first support member 301, such that after separation of the ribbon 103 into ribbon portions 1001, 1003, ends of the ribbon portions 1001, 1003 may not inadvertently contact one another and to pull the recently separated ribbon portion away from the ribbon 103. Further, the separation of the ribbon portions 1001, 1003 can occur with minimized particulate generation while producing ribbon portions having high quality edges.

[0084] It should be understood that while various aspects have been described in detail relative to certain illustrative and specific examples thereof, the present disclosure should not be considered limited to such, as numerous modifications and combinations of the disclosed features are possible without departing from the scope of the following claims.

Claims

CLAIMSWhat is claimed:

1. A method of separating a ribbon comprising: moving the ribbon along a travel path in a travel direction; supporting the ribbon with a first support member and a second support member positioned on a first side of the travel path, the first support member applying a first force to the ribbon at a first location of the travel path, and the second support member applying a second force to the ribbon at a second location of the travel path downstream from the first location relative to the travel direction, wherein a distance separating the first location from the second location is less than about 100 millimeters; as the ribbon moves in the travel direction, initiating a flaw in the ribbon at an intermediate location of the travel path between the first location and the second location; and separating the ribbon into a first ribbon portion and a second ribbon portion by propagating the flaw across the ribbon in a propagation direction transverse to the travel direction.

2. The method of claim 1, wherein one or more of the first support member or the second support member comprises a roller rotating at a rotational speed within about 10% of a travel speed of the ribbon moving along the travel path in the travel direction.

3. The method of claim 1 , wherein one or more of the first support member or the second support member comprises an air bearing supporting the ribbon.

4. The method of any one of claims 1-3, wherein the initiating the flaw comprises contacting the ribbon with a scoring apparatus.

5. The method of claim 4, wherein the initiating the flaw further comprises applying a third force to the ribbon from a force applicator at the intermediate location to move the ribbon toward the scoring apparatus.

6. The method of claim 5, wherein the applying the third force to the ribbon from the force applicator comprises moving the force applicator between a first position, in which the forceapplicator is not in contact with the ribbon, and a second position, in which the force applicator contacts the ribbon.

7. A method of separating a ribbon comprising: moving the ribbon along a travel path in a travel direction; supporting the ribbon on a first side of the ribbon with a first support member and a second support member, the first support member and the second support member spaced apart to form a gap therebetween; as the ribbon moves in the travel direction, initiating a flaw in the ribbon by: engaging the first side of the ribbon within the gap with a scoring apparatus; and applying a force to a second side of the ribbon with a force applicator, the scoring apparatus aligned with the force applicator such that the flaw is formed at a location of the ribbon between the scoring apparatus and the force applicator and between the first support member and the second support member; separating the ribbon into a first ribbon portion and a second ribbon portion by propagating the flaw across the ribbon in a propagation direction transverse to the travel direction.

8. The method of claim 7, wherein or more of the first support member or the second support member comprises a roller rotating at a rotational speed within about 10% of a travel speed of the ribbon moving along the travel path in the travel direction.

9. The method of any one of claims 7-8, wherein the engaging the ribbon comprises contacting the ribbon with the scoring apparatus and moving the scoring apparatus in the propagation direction, the scoring apparatus moving at an average velocity in the propagation direction within a range from about 500 millimeters / second to about 1500 millimeters / second while the scoring apparatus is in contact with the ribbon.

10. The method of claim 9, wherein the engaging the ribbon comprises moving the scoring apparatus between a non-contacting position, in which the scoring apparatus is not in contact with the ribbon, and a contacting position, in which the scoring apparatus contacts the ribbon and moves in the propagation direction.

11. The method of claim 10, wherein the applying the force to the ribbon from the force applicator comprises moving the force applicator between a first position, in which the force applicator is not in contact with the ribbon, and a second position, in which the force applicator contacts the ribbon.

12. The method of claim 11, wherein the scoring apparatus and the force applicator are in contact with the ribbon at the same time.

13. The method of claim 7, wherein the ribbon comprises a thickness within a range from about 25 micrometers to about 250 micrometers.

14. A ribbon separation apparatus comprising: a first support member positioned on a first side of a travel path along which a ribbon travels, the first support member configured to apply a first force to the ribbon at a first location of the travel path; a second support member spaced apart from the first support member to form a gap between the first support member and the second support member, the second support member configured to apply a second force to the ribbon at a second location of the travel path, wherein a distance separating the first location from the second location is less than about 100 millimeters; a force applicator positioned on a second side of the travel path and aligned with the gap, the force applicator configured to move the ribbon toward the gap; and a scoring apparatus positioned within the gap and aligned with the force applicator, the scoring apparatus configured to engage the ribbon and initiate a flaw in the ribbon while the ribbon is moved toward the gap.

15. The ribbon separation apparatus of claim 14, wherein the force applicator is attached to a cam assembly configured to rotate to move the force applicator between a first position, in which the force applicator is not in contact with the ribbon, and a second position, in which the force applicator is in contact with the ribbon and the ribbon is moved toward the gap.

16. The ribbon separation apparatus of claim 14, wherein one or more of the first support member or the second support member comprises a roller rotating at a rotational speed within about 10% of a travel speed of the ribbon moving along the travel path in a travel direction.

17. The ribbon separation apparatus of claim 14, wherein one or more of the first support member or the second support member comprises an air bearing.

18. The ribbon separation apparatus of any one of claims 14-17, wherein the scoring apparatus engages the ribbon by contacting the ribbon, and the scoring apparatus comprises one or more of: a scribe comprising a tip that contacts the ribbon and moves relative to the ribbon in a propagation direction transverse to a travel direction of the ribbon along the travel path; or a wheel comprising a circumferential edge that contacts the ribbon and moves relative to the ribbon in the propagation direction while the wheel rotates.

19. The ribbon separation apparatus of any one of claims 14-17, wherein the scoring apparatus engages the ribbon without contacting the ribbon, and the scoring apparatus comprises one or more of: a laser that directs a laser beam toward the ribbon, the laser beam impinging upon the ribbon to initiate the flaw; or a nozzle that directs a fluid toward the ribbon, the fluid impinging upon the ribbon to initiate the flaw.

20. The ribbon separation apparatus of any one of claims 14-17, wherein the distance separating the first location from the second location is within a range from about 40 millimeters to about 60 millimeters.

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