Glass unpacking systems and methods

Abstract

In an example embodiment, a system for separation of a glass sheet from other glass sheets in a stack of glass sheets is provided. The system includes the stack of glass sheets, and each glass sheet in the stack of glass sheets comprises film on at least one side. The system also includes a suction pad configured to come in contact with a contact surface of the glass sheet in the stack of glass sheets. The suction pad is configured to apply a suction force on the glass sheet to assist in separation of the glass sheet from the other glass sheets within the stack of glass sheets. The suction pad defines a suction coverage area, the suction coverage area defines a first dimension and a second dimension, the second dimension is perpendicular to the first dimension, and the first dimension is greater than the second dimension.

Description

GLASS UNPACKING SYSTEMS AND METHODSCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of priority under 35 U.S.C. § 119 of U.S. Provisional Application Serial No. 63 / 642926 filed on May 6, 2024, the content of which is relied upon and incorporated herein by reference in its entirety.FIELD

[0002] Embodiments relate generally to systems and methods for overcoming forces causing glass sheets to stick together so that glass sheets may be separated.BACKGROUND

[0003] Glass sheets are often bundled together in a stack so that the glass sheets may be transported from one location to another. When the glass sheets are bundled together in a stack, an adhesion force between the surfaces of adjacent glass sheets tends to hold the glass sheets together. Thus, as a user attempts to unpack a glass sheet from other glass sheets within the stack, one or more other glass sheets within the stack tend to remain stuck to the glass sheet. In some cases, the glass sheet may not be separated after multiple attempts (e.g., three attempts). This causes delays in the manufacturing process, leading to increased costs. This may also require glass sheets to be separated using approaches that may be more likely to damage the glass sheets.BRIEF SUMMARY

[0004] In various embodiments, systems and methods are provided that effectively separate glass sheets that are stacked together in a stack of glass sheets. Non-circular shaped suction pads may be used to apply a suction force proximate to a comer of a glass sheet, and these suction pads may be effective in overcoming an adhesion force holding glass sheets together. Constraint devices may also be used to further improve the ability to separate glass sheets. Both the constraint devices and non-circular shaped suction pads may have more localized stress and deformation than where only circular shaped suction pads are used. The use of constraint devices and / or non-circular shaped suction pads may also allow for a smaller bending radius and a larger peeling force to be generated proximate to a corner of a glass sheet, making it easier to separate a single glass sheet from other glass sheets in a stack.

[0005] The use of constraint devices and / or non-circular shaped suction pads may lead to an improved ability to separate glass sheets within a stack, which opens the door to severalother benefits. While glass sheets have typically been laminated with film on both sides in the past to help avoid glass sticking issues, the constraint devices and the non-circular shaped suction pads described herein may allow glass sheets to be used with film on only one side of the glass sheets. Doing so may reduce film usage by 50 percent and may allow for less expenditures on film lamination equipment and maintenance of film lamination equipment. This enables glass sheets to be manufactured with lower costs.

[0006] Additionally, while high-roughness films may be used to help reduce the likelihood of glass sticking, these high-roughness films tend to be more expensive than other low- roughness films. As used herein, high-roughness films have an average surface roughness of greater than about 850 nanometers, and low-roughness films have an average surface roughness of less than about 850 nanometers. Glass sheets may optionally be used with only a low- roughness film positioned on one side of the glass sheet and with no film positioned at the other side of the glass sheet, and the use of constraint devices and / or non-circular shaped suction pads may allow these glass sheets to be effectively separated. Thus, the use of constraint devices and / or non-circular shaped suction pads may allow for even more cost savings by allowing low-roughness films to be used rather than high-roughness films.

[0007] The use of constraint devices and / or non-circular shaped suction pads may also generally increase the efficiency of glass manufacturing and unpacking. The constraint devices and suction pads described herein may allow glass to be separated more quickly, avoiding any delays during manufacturing and unpacking.

[0008] In an example embodiment, a system for separation of a glass sheet from other glass sheets in a stack of glass sheets is provided. The system comprises the stack of glass sheets, and each glass sheet in the stack of glass sheets comprises film on at least one side. The system also comprises a suction pad configured to come in contact with a contact surface of the glass sheet in the stack of glass sheets. The suction pad is configured to apply a suction force on the glass sheet to assist in separation of the glass sheet from the other glass sheets within the stack of glass sheets. The suction pad defines a suction coverage area, the suction coverage area defines a first dimension and a second dimension, the second dimension is perpendicular to the first dimension, and the first dimension is greater than the second dimension.

[0009] In some embodiments, the suction coverage area may be rectangular in shape. Additionally, in some embodiments, the first dimension may be at least about twice the second dimension. In some embodiments, the suction coverage area may have rounded comers. In some embodiments, the suction coverage area for the suction pad may be between about 1,000 square millimeters and about 20,000 square millimeters.

[0010] In some embodiments, the glass sheet may have a first surface and a second surface opposite the first surface, and film may be positioned at only one of the first surface or the second surface. In some embodiments, the glass sheet may have a first surface and a second surface opposite the first surface, and film may be positioned at both the first surface and the second surface. In some embodiments, the film may have a surface roughness between about 650 nanometers and about 850 nanometers. In some embodiments, the film may have a surface roughness between about 850 nanometers and about 1050 nanometers.

[0011] In some embodiments, the system may also comprise a constraint device having a surface that is configured to come in contact with the glass sheet. The surface of the constraint device may remain in contact with the glass sheet as the suction force is applied.

[0012] In some embodiments, the system may also include an actuator, one or more processors, and one or more memory devices comprising computer program code. The computer program code may be configured, when executed by the one or more processors, to cause the one or more processors to position the suction pad at a first location relative to the glass sheet. The glass sheet may comprise a first edge and a second edge that meet at a first corner. The computer program code may also be configured, when executed by the one or more processors, to cause the one or more processors to cause the actuator to urge the suction pad into the contact surface of the glass sheet so that the suction force is applied and to cause the actuator to pull the suction pad in a direction about normal to the contact surface of the glass sheet. Additionally, in some embodiments, the first location may be less than 40 millimeters from the first edge and less than 40 millimeters from the second edge.

[0013] In some embodiments, the system may also include a first actuator associated with the suction pad, a constraint device having a surface configured to come in contact with the contact surface of the glass sheet, a second actuator associated with the constraint device, one or more processors, and one or more memory devices comprising computer program code. The computer program code may be configured, when executed by the one or more processors, to cause the one or more processors to position the suction pad at a first location relative to the glass sheet, and the glass sheet may comprise a first edge and a second edge that meet at a first corner. The computer program code may be configured, when executed by the one or more processors, to cause the one or more processors to position the constraint device at a second location relative to the glass sheet, to cause the first actuator to urge the suction pad into the contact surface of the glass sheet to generate suction, to cause the second actuator to urge the constraint device into the contact surface of the glass sheet so that a constraint force is applied by the constraint device on the glass sheet, and to cause the first actuator to pull the suction padin a direction about normal to the contact surface of the glass sheet so that the suction pad applies a suction force on the glass sheet and so that the glass sheet separates the other glass sheets within the stack of glass sheets. Causing the first actuator to pull the suction pad in a direction about normal to the contact surface of the glass sheet may occur while the constraint device applies the constraint device. Additionally, in some embodiments, the first location may be less than 40 millimeters from the first edge and less than 40 millimeters from the second edge, and the second location may be between about 100 millimeters and about 300 millimeters from the first edge and between about 25 millimeters and about 100 millimeters from the second edge. Furthermore, in some embodiments, the second location may be between about 160 millimeters and about 260 millimeters from the first edge and between about 40 millimeters and about 80 millimeters from the second edge.

[0014] In another example embodiment, a method for separation of a glass sheet from other glass sheets in a stack of glass sheets is provided. The method comprises positioning a suction pad at a first location relative to the glass sheet, and the glass sheet comprises a first edge and a second edge that meet at a first corner. The method also comprises causing a first actuator to urge the suction pad into a contact surface of the glass sheet to generate suction and also comprises causing the first actuator to pull the suction pad in a direction about normal to a contact surface of the glass sheet so that the suction pad applies a suction force on the glass sheet and so that the glass sheet separates from the other glass sheets within the stack of glass sheets. The suction pad defines a suction coverage area, the suction coverage area defines a first dimension and a second dimension, the second dimension is perpendicular to the first dimension, and the first dimension is greater than the second dimension.

[0015] In some embodiments, the first location may be less than 40 millimeters from the first edge and less than 40 millimeters from the second edge. Additionally, in some embodiments, the method may also include positioning a constraint device having a surface at a second location relative to the glass sheet and causing a second actuator to urge the constraint device into a contact surface of the glass sheet so that the surface of the constraint device contacts the contact surface of the glass sheet and so that a constraint force is applied by the constraint device on the glass sheet. Additionally, causing the first actuator to pull the suction pad in a direction about normal to the contact surface of the glass sheet may occur while the constraint device applies the constraint force, and the second location may be between about 100 millimeters and about 300 millimeters from the first edge and between about 25 millimeters and about 100 millimeters from the second edge. Also, in some embodiments, thesecond location may be between about 160 millimeters and about 260 millimeters from the first edge and between about 40 millimeters and about 80 millimeters from the second edge.

[0016] In another example embodiment, a system for separation of a glass sheet from other glass sheets in a stack of glass sheets is provided. The system comprises the stack of glass sheets, with each glass sheet in the stack of glass sheets comprising film on at least one side. The system also includes a suction pad configured to come in contact with a contact surface of the glass sheet in the stack of glass sheets, and the system also includes a constraint device having a surface configured to come in contact with a contact surface of the glass sheet. The suction pad is configured to apply a suction force at the contact surface of the glass sheet to cause the glass sheet to separate from the other glass sheets within the stack of glass sheets, and the surface of the constraint device remains in contact with the glass sheet as the suction force is applied.

[0017] In some embodiments, the glass sheet may have a first surface and a second surface opposite the first surface, and film may be positioned at only one of the first surface or the second surface. Additionally, in some embodiments, the film may have a surface roughness between about 650 nanometers and about 850 nanometers. Furthermore, in some embodiments, the film may have a surface roughness between about 850 nanometers and about 1050 nanometers. In some embodiments, the glass sheet may comprise a first edge and a second edge that meet at a first corner, and the constraint device may be positioned at a location relative to the first comer of the glass sheet when the constraint device comes in contact with the glass sheet. This location may be between about 100 millimeters and about 300 millimeters from the first edge of the glass sheet and between about 25 millimeters and about 100 millimeters from the second edge of the glass sheet. Also, in some embodiments, the location may be between about 160 millimeters and about 260 millimeters from the first edge of the glass sheet and between about 40 millimeters and about 80 millimeters from the second edge of the glass sheet.BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

[0019] FIG. l is a schematic view illustrating an example glass lamination machine for the formation of glass sheets, with the glass sheets having film on two opposing sides, in accordance with some embodiments discussed herein;

[0020] FIG. 2 is a schematic view illustrating an example crate with two glass sheets positioned in the crate, with both glass sheets having film on two opposing sides, in accordance with some embodiments discussed herein;

[0021] FIG. 3 is a schematic view illustrating an example crate with a stack of glass sheets positioned in the crate, with a machine configured to separate a single glass sheet from the remainder of the stack and then move that glass sheet to another location, in accordance with some embodiments discussed herein;

[0022] FIG. 4 is a schematic view illustrating an example crate with a stack of glass sheets positioned in the crate, with a suction pad configured to separate a single glass sheet from the remainder of the stack, in accordance with some embodiments discussed herein;

[0023] FIG. 5 is a schematic view illustrating an example crate with a stack of glass sheets positioned in the crate, with a suction pad configured to separate a single glass sheet from the remainder of the stack, in accordance with some embodiments discussed herein;

[0024] FIG. 6 is a schematic view illustrating an example crate with a stack of glass sheets positioned in the crate where a suction pad is being used to separate a glass sheet and where glass sheets are sticking together, in accordance with some embodiments discussed herein;

[0025] FIG. 7A is a perspective view illustrating an example test configuration used for an adhesion force test to test the required load force to separate glass, in accordance with some embodiments discussed herein;

[0026] FIG. 7B includes schematic views illustrating various stages of the adhesion force test, in accordance with some embodiments discussed herein;

[0027] FIG. 8 is a line graph illustrating results of an example adhesion force test, in accordance with some embodiments discussed herein;

[0028] FIG. 9 is a perspective view illustrating an example circular suction pad, in accordance with some embodiments discussed herein;

[0029] FIG. 10 is a perspective view illustrating an example suction pad, in accordance with some embodiments discussed herein;

[0030] FIG. 11A illustrates an example stress model for a glass sheet when the circular suction pad of FIG. 9 is used, in accordance with some embodiments discussed herein;

[0031] FIG. 11B illustrates an example deformation model for a glass sheet when the circular suction pad of FIG. 9 is used, in accordance with some embodiments discussed herein;

[0032] FIG. 12A illustrates an example stress model for a glass sheet when the suction pad of FIG. 10 is used, in accordance with some embodiments discussed herein;

[0033] FIG. 12B illustrates an example deformation model for a glass sheet when the suction pad of FIG. 10 is used, in accordance with some embodiments discussed herein;

[0034] FIG. 13 A is a side view illustrating an example suction pad being used to separate a single glass sheet from the remainder of the stack, in accordance with some embodiments discussed herein;

[0035] FIG. 13B is a perspective view illustrating an example model showing the amount of deflection in a glass sheet when a suction pad is used to separate the glass sheet from the remainder of the stack without any constraint device, in accordance with some embodiments discussed herein;

[0036] FIG. 14 is a perspective view illustrating an example model showing the amount of deflection in a glass sheet when a suction pad and constraint device are both used to separate a single glass sheet from the remainder of the stack, with the constraint device making it easier to separate the glass sheet, in accordance with some embodiments discussed herein;

[0037] FIG. 15 is a schematic view illustrating example positions for a suction pad and a constraint device, in accordance with some embodiments discussed herein;

[0038] FIG. 16A-16B are perspective views illustrating a machine having a suction pad and a constraint device, with the machine being used to separate glass sheets from a stack of glass sheets, in accordance with some embodiments discussed herein;

[0039] FIG. 17 is a block diagram illustrating an example components of a machine used to separate glass sheets from a stack of glass sheets, in accordance with some embodiments discussed herein; and

[0040] FIG. 18 is a flow chart illustrating an example method for separating glass sheets from a stack of glass sheets, in accordance with some embodiments discussed herein.DETAILED DESCRIPTION

[0041] Example embodiments now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments are shown. Other than for FIG. 18, like reference numerals generally refer to like elements throughout. For example, reference numerals 214A, 414A, 514A, 614A each are used for a glass sheet. Additionally, any connections or attachments may be direct or indirect connections or attachments unless specifically noted otherwise.

[0042] An example glass lamination machine 100 for the formation of glass sheets is illustrated in FIG. 1, with the glass having film on two opposing sides. A glass body 102 is illustrated in the middle of the glass lamination machine 100, with the glass body 102positioned between rollers 108B, 108D and also between rollers 108C, 108E. Rollers 108B, 108C may rotate in a clockwise manner from the perspective illustrated in FIG. 1 as indicated by arrows Rl, R2, and rollers 108D, 108E may rotate in a counterclockwise manner from the perspective illustrated in FIG. 1 as indicated by arrows R3, R4. As a result, the rollers 108B- 108E tend to cause the glass body 102 to move down.

[0043] A film roll 108 A may have film 104 wound around the film roll 108 A, and the film roll 108A may be rotated counterclockwise as indicated by arrow R5 to remove film 104 from the film roll 108 A. Using one or more guides, the film 104 may be directed to the roller 108B so that the film 104 extends between the roller 108B and the glass body 102. The film 104 may then be laminated onto the glass body 102 at side 103 A as the glass body 102 and the film 104 move down.

[0044] Similarly, the film roll 108F may have film 106 wound around the film roll 108F, and the film roll 108F may be rotated clockwise as indicated by arrow R6 to remove film 106 from the film roll 108F. Using one or more guides, the film 106 may be directed to the roller 108D so that the film 106 extends between the roller 108D and the glass body 102. The film 106 may then be laminated onto the glass body 102 at side 103B as the glass body 102 and the film 106 move down. In some embodiments, the film 104 and the film 106 may have distinct properties to provide different surface attributes (e.g., surface roughness) and to make it easier to unpack the glass.

[0045] The use of film 104, 106 may be beneficial to prevent surface contamination at the glass body 102. However, attaching film 104 and film 106 the glass body 102 at opposing sides may result in a high cost. Thus, in some embodiments herein, either film 104 or film 106 may be removed so that film is provided on only one side of the glass body 102. This reduces the amount of film consumption by 50 percent, thereby lowering the cost of manufacturing glass. Use of film on only one side also mitigates the risk of surface defects caused by film and enables sustainable growth. Glass with film on only one side may also reduce the amount of film lamination equipment that is required. For example, in FIG. 1, the use of a film on only one side of glass would allow film roll 108 A, guides, and other film lamination equipment on the left side of the glass body 102 to be removed — rollers 108B, 108C may still be required in some embodiments to control the motion and positioning of the glass body 102. Actuators may be used to control the positioning of components within the glass lamination machine 100.

[0046] The glass body 102 may be provided in the form of glass sheets that have already been cut. Alternatively, the glass body 102 may be provided in another form. For example,actuators 110A, HOB may be used to control the positioning of rollers 108B, 108C, and actuators 1 IOC, HOD may be used to control the positioning of rollers 108D, 108E.

[0047] In some embodiments, glass sheets may be utilized with film positioned on both sides of the glass sheets, and FIG. 2 illustrates an example system 201 where glass sheets 214A, 214B are provided with film positioned on both sides. The glass sheets 214A, 214B are initially positioned in a crate 212 before the glass sheets 214A, 214B are separated from each other. The crate 212 may have a first portion 212A and a second portion 212B. The first portion 212A may be tilted at an angle 01 relative to a vertical plane. The second portion 212B generally extends in a plane that is perpendicular to the plane that the first portion 212A extends in.

[0048] The glass sheet 214A comprises a glass body 216 with film positioned on two opposing sides of the glass body 216. The glass sheet 214A has a first surface 215A at a first side of the glass sheet 214A. The glass sheet 214A has a second surface 215B at a second side of the glass sheet 214A, and the second surface 215B is opposite the first surface 215A. The glass sheet 214A has film positioned at both the first surface 215 A and the second surface 215B, but other glass sheets may only have film positioned at only one of the surfaces. Each of these glass sheets 214A-214B are generally identical in FIG. 2, but these glass sheets may differ in other embodiments.

[0049] The film positioned at the first surface 215A of the glass sheet 214A is a low- roughness film 218, and the film positioned at the second surface 215B of the glass sheet 214A is a high-roughness film 220. The low-roughness film 218 and other low-roughness films discussed herein have an average surface roughness of less than about 850 nanometers. In some embodiments, the low-roughness film 218 may have a surface roughness of between about 650 nanometers and about 850 nanometers. The high-roughness film 220 and other high-roughness films discussed herein have an average surface roughness of greater than about 850 nanometers. In some embodiments, the high-roughness film 220 may have an average surface roughness between about 850 nanometers and about 1050 nanometers. Compared to the low- roughness film 218, the high-roughness film 220 may have larger beads 221 (e.g., protrusions or bumps) on its surface. Most of these beads 221 may have a diameter ranging from about 200 nanometers to about 400 nanometers, and most of the beads 221 may have a thickness ranging from about 100 nanometers to about 200 nanometers, but these beads 221 may not be perfectly circular or spherical in shape. In some embodiments, the high roughness film 200 may also have a greater number of beads 221 on its surface relative to the low-roughness film 218. The size of the beads 221 and other beads illustrated in the figures are exaggerated for the purposes of explanation.

[0050] Ihlshin MS film is an example of a high-roughness film, and Visqueen film is an example of a low-roughness film. High-roughness films like Ihlshin MS film may make it easier to separate glass sheets, but these high-roughness films are often more expensive than low-roughness films.

[0051] FIG. 3 illustrates a system 301 including a machine 324 and a stack 322 of glass sheets, with the machine 324 being used to separate a glass sheet 314 from other glass sheets within the stack 322. The machine 324 is also configured to move the glass sheet 314 to another location after separating the glass sheet 314.

[0052] The stack 322 is initially positioned in a crate 312, which may have a first portion 312A and a second portion 312B. The first portion 312A may be tilted at an angle relative to a vertical plane similar to the first portion 212A of FIG. 2, and the second portion 312B generally extends in a plane that is perpendicular to the plane that the first portion 212A extends in.

[0053] During the unpacking process, the machine 324 causes the glass sheet 314 to move in at least two ways. First, the machine 324 causes the suction pad 328 to move along the line indicated by arrows Al. The machine 324 causes the suction pad 328 to first move towards the glass sheet 314 to generate suction. The machine 324 then causes the suction pad 328 to move in a direction away from the glass sheet 314. This causes separation between the glass sheet 314 and other glass sheets in the stack 322 of glass sheets. This separation first occurs proximate to the area 330 near the corner of the glass sheet 314 where the suction force is applied by the suction pad 328, but other portions of the glass sheet 314 may also separate once separation starts at the area 330. The use of a suction pad 328 to apply suction force may be beneficial to reduce the likelihood of damages to glass sheets relative to other approaches for separating glass sheets.

[0054] In some embodiments, the suction force may need to be applied multiple times for the glass sheet 314 to be separated. After initially applying the suction force using the suction pad 328, the suction force may not be sufficiently large to overcome the adhesion force between the glass sheet 314 and an adjacent glass sheet within the stack 322. Where this occurs, the suction pad 328 may be pushed back towards the glass sheet 314 to cause the glass sheet 314 to return to its initial position and then the suction pad 328 may again be moved in a direction away from the glass sheet 314 in attempt to again apply a suction force to cause separation. In some embodiments, the suction pad 328 may be removed from the glass sheet 314, and the suction pad 328 may then be pressed against the glass sheet 314 to generate a larger amount of suction between the suction pad 328 and the glass sheet 314 before making a second attempt to cause separation.

[0055] Once the glass sheet 314 is fully separated, the machine 324 may cause the glass sheet 314 to move along the line indicated by arrows A2 so that the glass sheet 314 is moved away from the stack 322 and the crate 312 so that the glass sheet 314 may be used. As the suction pad 328 is used to apply a suction force, the constraint devices 326 may be positioned at other locations and may have a surface that is urged against the contact surface of the glass sheet 314 to partially restrain movement of the glass sheet 314 at locations proximate to the constraint devices 326. The constraint devices 326 may cause increased stress to be present at the area 330 and may make separation of the glass sheet 314 easier. The constraint devices 326 and other constraint devices described herein may be provided in the form of a pad, a cup, a peg, a pole, or a bar, but constraint devices may be provided in other forms.

[0056] Where glass sheets are utilized with film positioned on both sides, the glass sheets may be relatively easy to separate from each other through the application of a suction force. However, having film positioned on both sides of glass sheets may increase costs and reduce profits as noted herein. FIG. 4 is a schematic view illustrating a stack of glass sheets, with a suction pad configured to separate a single glass sheet from the remainder of the stack.

[0057] A stack of glass sheets is initially positioned in a crate 412, which may have a first portion 412A and a second portion 412B. The first portion 412A may be tilted at an angle relative to a vertical plane similar to the first portion 212A of FIG. 2, and the second portion 412B generally extends in a plane that is perpendicular to the plane that the first portion 412A extends in.

[0058] The stack of glass sheets may include glass sheet 414A, 414B, 414C. The glass sheet 414A comprises a glass body 416 with film positioned on two opposing sides of the glass body 416. The glass sheet 414A has a first surface 415A at a first side of the glass sheet 414A. The glass sheet 414A has a second surface 415B at a second side of the glass sheet 414A, and the second surface 415B is opposite the first surface 415A. The glass sheet 414A has a high- roughness film 420 positioned at the first surface 415 A and has a low-roughness film 418 positioned at the second surface 415B. The high-roughness film 420 may have beads 421 similar to the beads 221 of FIG. 2. Each of these glass sheets 414A-414C are generally identical in FIG. 4, but other glass sheets may have film positioned at only one of the surfaces or may use different types of film.

[0059] The system 401 also includes a suction pad 432. The suction pad 432 may initially be urged towards the glass sheet 414A (e.g., in a direction opposite the direction indicated by arrow A3) so that suction is formed between the suction pad 432 and the second surface 415B of the glass sheet. Once suction is formed, the suction pad 432 may be urged in the directionindicated by arrow A3. This may generate a suction force on the glass sheet 414A to cause the glass sheet 414A to separate from glass sheet 414B and any other glass sheets within a stack.

[0060] In some embodiments, glass sheets may be created that have high-roughness film on only one side. Doing so may allow for cost savings over other glass sheets having film on opposing sides. Using film on only one side allows 50 percent less film to be used and allows for less capital to be spent to obtain and maintain film lamination equipment. The use of high- roughness film may help to reduce the likelihood of glass sticking relative to where low- roughness film is used. FIG. 5 provides a schematic view a stack of glass sheets, with each glass sheet having a high-roughness film on one side and having no film on the opposing side.

[0061] In the system 501 of FIG. 5, the stack of glass sheets is positioned in a crate 512. The crate 512 may have a first portion 512A and a second portion 512B. The first portion 512A may be tilted at an angle relative to a vertical plane similar to the first portion 212A of FIG. 2, and the second portion 512B generally extends in a plane that is perpendicular to the plane that the first portion 512A extends in.

[0062] The stack includes a first glass sheet 514A, a second glass sheet 514B, and a third glass sheet 514C. For the sake of simplicity, the stack of glass sheets includes just three glass sheets in the system 501, but a different number of glass sheets may be included in a stack in other embodiments.

[0063] The glass sheets 514A-514C each comprise film on just one side, with the film being a high-roughness film 520. The use of the high-roughness film 520 may help to reduce the likelihood of glass sticking relative to where a low-roughness film 618 (see FIG. 6) is used, but the high-roughness film 520 may have a higher cost relative to a low-roughness film 618. The high-roughness film 520 may have beads 521 similar to beads 221 of FIG. 2. The glass sheet 514A comprises a glass body 516 with film positioned on only one side of the glass body 516. The glass sheet 514A has a first surface 515A at a first side of the glass sheet 514A. The glass sheet 514A has a second surface 515B at a second side of the glass sheet 514A, and the second surface 515B is opposite the first surface 515A. The glass sheet 514A has film positioned at the second surface 515B, but the glass sheet 514A does not have film positioned at the first surface 515A. In other embodiments, the glass sheet 514A may only have film positioned at the first surface 515A without any film positioned at the second surface 515B. Each of these glass sheets 514A-514C are generally identical in FIG. 5, but these glass sheets may differ in other embodiments.

[0064] The system 501 also includes a suction pad 532. The suction pad 532 may initially be urged towards the glass sheet 514A (e.g., in a direction opposite the direction indicated byarrow A4) so that suction is formed between the suction pad 532 and the second surface 515B of the glass sheet. Once suction is formed, the suction pad 532 may be urged in the direction indicated by arrow A4. This may generate a suction force on the glass sheet 514A to cause the glass sheet 514A to separate from glass sheet 514B and any other glass sheets within a stack.

[0065] Where the suction pad 532 is used, the suction force generated by the suction pad 532 may not be sufficient to separate a glass sheet from a remainder of a stack, especially where a high amount of adhesion force is generated from other sheets. In some cases, the suction pad 532 may not be able to separate the glass sheet after multiple attempts (e.g., three attempts). This may cause delays in the manufacturing process, leading to lower revenues and profits. This may also require other approaches to be used in order to separate glass sheets that may be more likely to damage the glass sheets.

[0066] In some embodiments glass sheets may be created that have low-roughness film on only one side. Doing so may allow for cost savings over other glass sheets having film on opposing sides. Using film on only one side allows 50 percent less film to be used and allows for less capital to be spent to obtain and maintain film lamination equipment. Using glass sheets with a low-roughness film on one side and no film on the other side may also allow for cost savings over other glass sheets having high-roughness film on one side and no film on the other side.

[0067] FIG. 6 provides a schematic view illustrating a stack of glass sheets, with each glass sheet having a low-roughness film 618 on second surface 615B and having no film on a first surface 615 A that is opposite the second surface 615B. While utilizing low-roughness film 618 on only one side of the glass sheets 614A, 614B, 614C helps reduce costs, it may lead to a potential glass sticking issue as illustrated in FIG. 6 if left unaddressed. While glass sheets having low-roughness film on one side and no film on the other side may have an increased likelihood of glass sticking relative to glass sheets having high-roughness film on one side and no film on the other side, the use of a non-circular suction pad (e.g., a suction pad 1046 of FIG. 10) and / or the use of a constraint device (e.g., constraint device 1480 of FIG. 14) may help to address any glass sticking issues.

[0068] The crate 612 may have a first portion 612A and a second portion 612B. The first portion 612A may be tilted at an angle relative to a vertical plane similar to the first portion 212A of FIG. 2, and the second portion 612B generally extends in a plane that is perpendicular to the plane that the first portion 612A extends in.

[0069] The stack of glass sheets is positioned in the crate 612, with the stack including a first glass sheet 614A, a second glass sheet 614B, and a third glass sheet 614C. For the sake ofsimplicity, the stack of glass sheets includes just three glass sheets in the system 601, but a different number of glass sheets may be included in a stack in other embodiments.

[0070] The glass sheet 614A comprises a glass body 616 with film positioned on only one side of the glass body 616. The glass sheet 614A has a first surface 615A at a first side of the glass sheet 614A. The glass sheet 614A has a second surface 615B at a second side of the glass sheet 614A, and the second surface 615B is opposite the first surface 615A. The glass sheet 614A has low-roughness film 618 positioned at the second surface 615B, but the glass sheet 614A does not have any film positioned at the first surface 615 A. In other embodiments, the glass sheet 614A may only have low-roughness film 618 positioned at the first surface 615 A without any film positioned at the second surface 615B. Each of these glass sheets 614A-614C are generally identical in FIG. 6, but these glass sheets may differ in other embodiments.

[0071] The system 601 also includes a suction pad 632. The suction pad 632 may initially be urged towards the glass sheet 614A (e.g., in a direction opposite the direction indicated by arrow A5) so that suction is formed between the suction pad 632 and the second surface 615B of the glass sheet. Once suction is formed, the suction pad 632 may be urged in the direction indicated by arrow A5. This may generate a suction force on the glass sheet 614A to cause the glass sheet 614A to separate from glass sheet 614B and any other glass sheets within a stack.

[0072] Where glass sheets are used with only a low-roughness film 618 on one side of the glass sheets, these glass sheets may tend to stick together as a suction force is applied with a suction pad 632 that is circular in shape at the contact surface. The lower roughness of the low- roughness film causes a large amount of surface contact to be present between adjacent glass sheets, creating a substantial adhesion force. For example, in FIG. 6, a large amount of surface contact is present between the first surface 615A of the glass sheet 614A and the surface 617 of the glass sheet 614B. Thus, as the circular suction pad 632 applies a suction force on glass sheet 614A, this suction force may not be sufficient to overcome the strong adhesion force holding the adjacent glass sheets together, and one or more additional glass sheets within a stack may remain attached to the glass sheet 614A as illustrated.

[0073] The amount of adhesion force between adjacent glass sheets may differ based on the surface properties for the glass sheets. Adhesion force tests were performed to evaluate the amount of load force required to overcome the adhesion force acting on a glass sheet where glass sheets having different surface properties were used. An example test configuration 734 used for the adhesion force test is illustrated in FIG. 7A.

[0074] A glass sheet 742 was provided. The glass sheet 742 was initially allowed to rest on another glass sheet, with this other glass sheet being allowed to rest on the base surface 741.A suction cup 740 was attached to a surface of the glass sheet 742 so that the suction cup 740 applied a suction force on the surface. The suction cup 740 was also attached to a string 738. To conduct the adhesion test, the string 738 was pulled up as indicated by the arrow A6, and the displacement of the glass sheet 742 from its initial position was measured using the measurement tool 736, which may be a yard stick, a meter stick, a ruler, etc.

[0075] The forces acting on glass sheets during the adhesion force tests may potentially be more easily understood in reference to the schematic views of FIG. 7B. At the initial stage 735A, a second glass sheet 743A was allowed to rest on a base surface 741 A, and a first glass sheet 742A was allowed to rest on the second glass sheet 743A. A suction cup 740A was attached to a contact surface of the first glass sheet 742A so that suction was applied between the suction cup 740A and the contact surface. A string 738 A was also attached to the suction cup 740A.

[0076] Once these components were positioned and / or attached appropriately, the string 738 A was urged up to generate a tension force Fl in the string 738 A as indicated at the second stage 735B. At this second stage 735B, the tension force Fl caused the first glass sheet 742A to elevate and separate from the base surface 741 A. However, the tension force Fl was unable to overcome the adhesion force caused by the high surface contact area at the interface 745 between the first glass sheet 742A and the second glass sheet 743 A. As a result, the second glass sheet 743 A also moved up with the first glass sheet 742A due to this adhesion force.

[0077] At the third stage 735C, a tension force F2 was applied at the string 738 A, and this tension force F2 was greater than the tension force Fl. The tension force F2 was sufficient to overcome the adhesion force caused by the high surface contact area at the interface 745 between the first glass sheet 742A and the second glass sheet 743 A. As a result, the first glass sheet 742A was able to separate from the second glass sheet 743A was able to separate, and the string 738 A continued pulling the first glass sheet 742 A upwardly with a lower amount of force only had to overcome gravitational force of one sheet.

[0078] The results of the adhesion force tests are illustrated in the line graph 844 of FIG. 8. The line graph 844 includes a plotline 844A, a plotline 844B, and a plotline 844C. In each of these plotlines, different materials were provided at the interface between the two glass sheets. By changing the surface roughnesses of materials used at the interface, the surface contact area between the two sheets may be changed, causing the amount of force required to overcome the adhesion force to be altered.

[0079] Plotline 844A illustrates results where a low-roughness film was in contact with bare glass at the interface. The low-roughness film used in the testing was Visqueen film, butother low-roughness films may be used in other embodiments. For the plotline 844 A, the amount of force required to overcome the adhesion force was the greatest, with about 26 gramsforce of force required to overcome the adhesion force so that the two glass sheets were separated from each other.

[0080] Plotline 844B illustrates results where a low-roughness film was in contact with another low-roughness film at the interface. Again, the low-roughness film used in the testing was Visqueen film, but other low-roughness films may be used in other embodiments. For the plotline 844B, the amount of force required to overcome the adhesion force was less than in plotline 844A but greater than in plotline 844C, with about 18 grams-force of force required to overcome the adhesion force so that the two glass sheets were separated from each other.

[0081] Plotline 844C illustrates results where a low-roughness film was in contact with a high-roughness film at the interface. The low-roughness film used in the testing was Visqueen film and the high-roughness film used in the testing was Ihlshin MS film, but other low- roughness films and high-roughness films may be used in other embodiments. For the plotline 844C, the amount of force required to overcome the adhesion force was the least of the three plotlines, with about 11 grams-force of force required to overcome the adhesion force so that the two glass sheets were separated from each other. The use of the high-roughness film at the interface tended to reduce the amount of surface contact area between the two sheets, lowering the adhesion force between two sheets. The force required to overcome the adhesion force may also be low for plotline 844C because of beads present in the high-roughness film. For each of plotlines 844 A, 844B, 844C, the single glass sheet could be lifted with around 10 grams-force once the glass sheet had been separated from the second glass sheet.

[0082] A circular suction pad may be used in some embodiments, and FIG. 9 illustrates one example circular suction pad 946. The circular suction pad 946 comprises a top surface 948, a bottom portion 954 having a contact perimeter 952, and a tapered face 950 extending between the top surface 948 and the contact perimeter 952. The contact perimeter 952 generally defines a circular shape in a plane parallel to the X-Z plane. When in a resting state (i.e., when the circular suction pad 946 is not actively being used to apply suction), the contact perimeter 952 may define a diameter DI. This diameter DI was about 55 millimeters where the circular suction pad was used in testing herein. However, the diameter DI may possess a wide variety of values. For example, the diameter DI may range from 20 millimeters to about 250 millimeters, from about 30 millimeters to about 200 millimeters, from about 40 millimeters to about 100 millimeters, or from about 50 millimeters to about 75 millimeters. When the circular suction pad 946 is urged against another contact surface so that suction is applied, the diameterand / or shape of the circular suction pad 946 may be altered. For example, the diameter may increase when suction is applied, and the shape of the contact perimeter 952 may change to a non-circular shape.

[0083] Where the circular suction pad 946 is used, the suction force generated by the circular suction pad 946 may not be sufficient to separate a glass sheet from a remainder of a stack, especially where a high amount of adhesion force is generated from other sheets. The circular suction pad 946 generates less localized stress than suction pad 1046 of FIG. 10 with stresses being distributed over a wider area. The circular suction pad 946 also generates a lesser amount of deformation and a larger bending radius at areas proximate to a corner of a glass sheet relative to the suction pad 1046, thereby making separation more difficult when the circular suction pad 946 is used. In some cases, the circular suction pad 946 may not be able to separate a glass sheet after multiple attempts (e.g., three attempts). This may cause delays in the manufacturing process, leading to lower revenues and profits. This may also require other approaches to be used in order to separate glass sheets that may be more likely to damage the glass sheets.

[0084] Other non-circular suction pads may be used in other embodiments, and FIG. 10 illustrates one example suction pad 1046 that is not circular in shape. The suction pad 1046 comprises a top surface 1048 and a bottom portion 1054 having a contact perimeter 1052. The suction pad 1046 extends from a first end 1056A to a second end 1056B. The contact perimeter 1052 and the suction coverage area of the suction pad 1046 are generally rectangular in shape with curved edges at the ends 1056A, 1056B. The suction pad 1046 extends a distance D2 along a direction parallel to the Z-axis from the extreme tip of the contact perimeter 1052 at the first end 1056A to the extreme tip of the contact perimeter 1052 at the second end 1056B. The suction pad 1046 also extends a distance D3 along a direction parallel to the X-axis from one side of the contact perimeter 1052 to the other.

[0085] The distance D2 is greater than the distance D3. The distance D2 may be at least about twice the distance D3 in some embodiments. In some embodiments, the distance D2 may range from about 0 millimeters to about 100 millimeters, from about 30 millimeters to about 90 millimeters, or from about 40 millimeters to about 80 millimeters. In some embodiments, the distance D3 may range from about 0 millimeters to about 50 millimeters, about 15 millimeters to about 45 millimeters, or about 20 millimeters to about 40 millimeters. In some embodiments, the suction coverage area for the suction pad 1046 may be between about 500 square millimeters and about 25,000 square millimeters, about 1,000 square millimeters and about 20,000 square millimeters, between about 1,250 square millimeters and about 15,000square millimeters, or between about 1,500 square millimeters and about 10,000 square millimeters. In some embodiments, the use of the suction pad 1046 having a generally rectangular shape may allow for the center of the suction force to be applied closer to an edge.

[0086] When the suction pad 1046 is used, the suction force generated by the suction pad 1046 is more likely to separate a glass sheet from a remainder of a stack relative to when a circular suction pad 946 is used. The suction pad 1046 generates a larger localized stress, a higher amount of deformation, and a smaller bending radius at areas proximate to a corner of a glass sheet relative to the circular suction pad 946, thereby allowing separation to occur more easily. The suction pad 1046 may generally be able to separate the glass sheet after just a few attempts (e.g., typically no more than three attempts). This may avoid delays in the manufacturing process, leading to greater revenues and profits. This may also avoid the need to resort to other approaches in order to separate glass sheets that may be more likely to damage the glass sheets.

[0087] The portion of the suction pad 1046 that is configured to come in contact with the contact surface of the glass sheet may define a contact perimeter 1052 within a plane. The contact perimeter 1052 generally extends within the X-Z plane in the suction pad 1046 of FIG. 10, and a suction coverage area is an area in the X-Z plane that falls within the contact perimeter 1052 when the suction pad 1046 is in a resting state.

[0088] FIG. 11A illustrates an example stress model 1158A for a glass sheet 1160 when the circular suction pad 946 of FIG. 9 was used. The glass sheet 1160 that was modeled included a first edge 1164A, a second edge 1164B, and a corner 1162 where the two edges 1164A, 1164B meet. The glass sheet 1160 also included a point 1170 located at some point on the glass sheet 1160. The point 1170 may be a corner opposite the corner 1162 in some embodiments, but the point 1170 may be located at another position on the glass sheet 1160 in other embodiments. The stress model 1158A was obtained for a situation where suction force was applied as indicated by arrow A7 using the circular suction pad 946 until the comer 1162 of the glass sheet 1160 deflected about 10 millimeters relative to the point 1170 of the glass sheet 1160. The stress model 1158A was obtained for a situation where a circular suction pad 946 applied suction force proximate to the corner 1162. This resulted in the highest stresses around area 1166. The area 1166 was located at a position that is separated from the first edge 1164A and the second edge 1164B in about the same amounts. The stresses at area 1166 are between about 375.00 MPa and about 416.67 MPa.

[0089] FIG. 11B illustrates an example deformation model 1158B for a glass sheet 1160 when the circular suction pad 946 of FIG. 9 is used. The deformation model 1158B wasobtained by modelling a situation where suction force was applied using the circular suction pad 946 until the comer 1162 of the glass sheet 1160 deflected about 10 millimeters relative to the point 1170 of the glass sheet 1160. The glass sheet 1160 had the highest amount of deformation at area 1168, which included locations where the glass sheet 1160 had deformation of more than about 9.17 millimeters and less than about 10.00 millimeters.

[0090] Relative to the glass sheet 1260 of FIG. 12B, the glass sheet 1160 of FIG. 1 IB had less localized deformation at areas proximate to the comer 1162, making the glass sheet 1160 more difficult to separate when the circular suction pad 946 was used.

[0091] FIG. 12A illustrates an example stress model 1258 A for a glass sheet 1260 when the suction pad 1046 of FIG. 10 was used. The glass sheet 1260 that was modelled included a first edge 1264 A, a second edge 1264B, and a corner 1262 where the two edges 1264 A, 1264B meet. The glass sheet 1260 also included a point 1270 located at some point on the glass sheet 1260. The point 1270 may be a comer opposite the comer 1262 in some embodiments, but the point 1270 may be located at another position on the glass sheet 1260 in other embodiments. The stress model 1258 A was obtained by applying suction force as indicated by arrow A8 using the suction pad 1046 of FIG. 10 until the corner 1262 of the glass sheet 1260 deflected about 10 millimeters relative to the point 1270 of the glass sheet 1260. This results in the highest stresses around area 1266. As a result of the non-circular shape of the suction pad 1046, the area 1266 is closer to the edge 1264B than it is to the edge 1264A. The stresses at area 1266 are above 458.33 MPa and reach a maximum of about 500.00 MPa, so the stresses are substantially higher than the maximum stresses accomplished by the circular suction pad.

[0092] FIG. 12B illustrates an example deformation model 1258B for glass sheet 1260 when the suction pad 1046 of FIG. 10 was used. The deformation model 1258B was obtained by modeling a situation where a suction force was applied using the suction pad 1046 until the corner 1262 of the glass sheet 1260 deflected about 10 millimeters relative to the point 1270 of the glass sheet 1260. The glass sheet 1260 had the highest amount of deformation at area 1268, which included locations having deformation levels of more than about 9.17 millimeters and less than about 10.00 millimeters. Compared to the area 1168 in the glass sheet 1160 of FIG. 1 IB, the area 1268 in the glass sheet 1260 was significantly smaller. Thus, more localized deformation was accomplished when the suction pad 1046 was used than when the circular suction pad 946 was used.

[0093] Another feature that may be used to accomplish even more localized deformation is a constraint device. A constraint device may tend to prevent deflection at locations proximate to the constraint device, allowing for more localized deformation within a glass sheet betweenthe constraint device and a comer where a suction pad is applied. FIG. 13 A is a side view illustrating an example system 1382 A showing a setup that was used to model deformation results both with and without a constraint device. FIG. 13 A illustrates a suction pad 1346 applying suction force in a direction parallel to the Y-axis as indicated by arrow A9, with the suction pad 1346 being used to separate a single glass sheet 1374 from the remainder of the stack. The stack of glass sheets included the glass sheet 1374 as well as glass sheets 1376, 1378. Glass sheet 1378 was allowed to rest on plate 1370, glass sheet 1376 was allowed to rest on glass sheet 1378, and glass sheet 1374 was allowed to rest on glass sheet 1376.

[0094] FIG. 13B is a perspective view illustrating an example model 1382B showing the amount of glass separation occurring in glass sheets 1374, 1376, 1378 when the glass sheet 1374 was deflected by a certain distance. The glass sheet 1374 that was modeled included an edge 1374A and an edge 1374B, with the two edges 1374A, 1374B meeting at the corner 1362. The suction pad 1346 was used to apply a suction force as indicated by the arrow Al 0 at a location proximate to the comer 1362. As illustrated in the model 1382B of FIG. 13B, the glass sheets 1376, 1378 move away from the plate 1370 and remain in close proximity to glass sheet 1374. Thus, the glass sheets 1376, 1378 are not fully separated from the glass sheet 1374. This may require the suction pad 1346 to apply a greater amount of force, to pull the glass sheet 1374 further, to reapply the suction pad 1346 in attempt to accomplish a greater amount of suction, or to reset the position of the suction pad 1346 and then make another attempt to pull the glass sheet 1374.

[0095] FIG. 14 is a perspective view illustrating an example model 1482 showing the amount of glass separation occurring in glass sheets 1474, 1476, 1478 when the glass sheet 1474 was deflected by a certain distance and when a suction pad 1446 and constraint device 1480 are both used to separate the glass sheet 1474 from the remainder of the stack. As illustrated by the results, the constraint device 1480 may increase the ease of separating glass sheets within the stack.

[0096] The glass sheet 1474 includes an edge 1474A and an edge 1474B, with the two edges 1474A, 1474B meeting at the corner 1462. The suction pad 1446 was used to apply a suction force as indicated by the arrow Al l at a location proximate to the corner 1462. Where a constraint device 1480 and a suction pad 1446 are both used, a glass sheet may be separated more easily than when no constraint device 1480 is used, and the glass sheet may be separated after just a few attempts (e.g., typically no more than three attempts). The constraint device 1480 shortens the bending radius when suction force is applied, causing more localized stress at areas proximate to the corner 1462 when suction force is applied. As illustrated in the model1482 of FIG. 14, the glass sheets 1476, 1478 separate from the glass sheet 1474 by a significant distance at the comer 1462, and a significantly higher amount of separation is accomplished where a constraint device 1480 is used, with the glass sheets 1476, 1478 remaining closer to the plate 1470.

[0097] The model 1482 illustrated in FIG. 14 illustrates resulting deflection when a constraint device 1480 (e.g., a constraint cup) is used. The constraint device 1480 may have a surface that is configured to come in contact with the glass sheet 1474 at a contact surface of the glass sheet 1474. The suction pad 1446 may be positioned at a location that is closer to the corner 1462 of the glass sheet 1474 than the constraint device 1480. Actuators may be used to position and / or move the suction pad 1446 and the constraint device 1480. The suction pad 1446 may initially be urged into a contact surface of the glass sheet 1474 to generate suction, and the constraint device 1480 may also be urged into the contact surface of the glass sheet 1474 to generate a constraint force on the contact surface. As the suction pad is moved in the direction indicated by arrow Al 1 (which may be about normal to the contact surface of the glass sheet when no suction force is applied), a suction force is applied to the glass sheet 1474. At the same time, a surface of the constraint device 1480 may remain in contact with the glass sheet 1474, and the constraint device 1480 may partially restrain movement of the glass sheet 1474 at portions of the glass sheet 1474 proximate to the constraint device 1480. Relative to other embodiments where the constraint device 1480 is not used, the constraint device 1480 may cause more of the stress to be focused at areas closer to the corner 1462, allowing the glass sheet 1474 to be more easily separated from the adjacent glass sheet 1476 and from the rest of a stack.

[0098] Testing was performed to validate that the use of the suction pad and constraint device would be successful in separating glass sheets. Where this approach was taken with glass sheets having low-roughness film on one side and no film on the opposing side, a stack of twenty-five sheets was successfully separated. All glass sheets were successfully separated in no more than two attempts to apply suction force. During this testing, a machine was operated continuously without requiring any pauses in use of the machine, and the machine and other machines in the manufacturing process were able to run at the same production speed used when glass sheets having film on both sides was used. This shows that the cost for forming glass sheets may be drastically reduced without creating any substantial issues in the manufacturing process.

[0099] FIG. 15 is a schematic view illustrating an example system 1582 where a suction pad 1546 and a constraint device 1580 are positioned relative to a glass sheet 1574. The glasssheet 1574 includes an edge 1574A and an edge 1574B, with the two edges 1574A, 1574B extending perpendicularly and with the two edges 1574A, 1574B meeting at a comer 1562. The suction pad 1546 defines a first edge 1546 A and a second edge 1546B. The first edge 1546A may include the closest points on the suction pad 1546 to the edge 1574A of the glass sheet 1574, and the second edge 1546B may be the closest point on the suction pad 1546 to the edge 1574B of the glass sheet 1574.

[0100] A distance D4 extends parallel to the Z-axis from the edge 1574A of the glass sheet 1574 to the first edge 1546A of the suction pad 1546. In some embodiments, the distance D4 may be less than about 50 millimeters, less than about 40 millimeters, less than about 30 millimeters, or less than about 20 millimeters.

[0101] A distance D5 extends from the edge 1574B of the glass sheet 1574 to the second edge 1546B of the suction pad 1546. In some embodiments, the distance D5 may be less than about 50 millimeters, less than about 40 millimeters, less than about 30 millimeters, or less than about 20 millimeters. The distance D5 may be greater than the distance D4 in some embodiments, and the distance D5 may even be greater than or equal to about three times more than the distance D4 in some embodiments.

[0102] A distance D6 extends parallel to the X-axis from the edge 1574A of the glass sheet 1574 to the center of the constraint device 1580. In some embodiments, the distance D6 may be between about 50 millimeters and about 500 millimeters from the edge 1574A, between about 75 millimeters and about 400 millimeters from the edge 1574A, between about 100 millimeters and about 300 millimeters from the edge 1574A, or between about 160 millimeters and about 260 millimeters from the edge 1574A.

[0103] A distance D7 extends parallel to the Z-axis from the edge 1574B of the glass sheet 1574 to the center of the constraint device 1580. In some embodiments, the distance D7 may be between about 15 millimeters and about 120 millimeters from the edge 1574B, between about 25 millimeters and about 100 millimeters from the edge 1574B, or between about 40 millimeters and about 80 millimeters from the edge 1574B.

[0104] FIG. 16A-16B are perspective views illustrating a machine 1686 having a suction pad 1646 and a constraint device 1680, with the machine 1686 being used to separate glass sheets from a stack 1684 of glass sheets. The actuator 1646A is associated with the suction pad 1646. The actuator 1646A may cause the suction pad 1646 to move in a direction parallel to the Y-axis, with this movement being towards the stack 1684 (e.g., along arrow A12) or away from the stack 1684 (e.g., along arrow A13 of FIG. 16B). Arrows A12, A13 may both be about perpendicular to a contact surface of the glass sheet 1674. However, in some embodiments, theactuator 1646A may also allow the suction pad 1646 to be moved to a new location within the X-Z plane. Using the actuator 1646A to move the suction pad 1646 towards the stack 1684 may allow suction to be generated at a glass sheet 1674 within the stack 1684, and using the actuator 1646 A to move the suction pad 1646 away from the stack 1684 may generate a suction force on the glass sheet 1674 to separate the glass sheet 1674 from the remainder of the stack 1684.

[0105] The actuator 1680A is associated with the constraint device 1680. The actuator 1680 A may cause the constraint device 1680 to move in a direction parallel to the Y-axis, with this movement being towards the stack 1684 or away from the stack 1684. This movement may be in a direction that is about perpendicular to the contact surface of the glass sheet 1674. However, in some embodiments, the actuator 1680A may also allow the constraint device 1680 to be moved to a new location within the X-Z plane. Using the actuator 1680A to move the constraint device 1680 towards the stack 1684 may allow the constraint device 1680 to come in contact with the contact surface of a glass sheet 1674 at the end of the stack 1684. As the suction pad 1646 pulls the glass sheet 1674 along the direction A13, a surface of the constraint device 1680 may remain in contact with glass sheet 1674 and the constraint device 1680 may continue applying a force on the glass sheet 1674 to partially restrain movement of the glass sheet 1674 at portions of the glass sheet 1674 proximate to the constraint device 1680. Once the glass sheet 1674 is separated, the actuator 1680A may stop applying force at the constraint device 1680.

[0106] FIG. 17 is a block diagram illustrating an example components of a machine 1794 used to separate glass sheets from a stack of glass sheets. The machine 1794 may include one or more processors 1788, one or more memory devices 1790, and one or more actuators 1792. The actuator(s) 1792 may be used to assist with positioning a constraint device and / or a suction pad, with generating a force on the suction pad to generate suction on a glass sheet, generating a force on the suction pad so that a suction force is applied to pull on the glass sheet, generating a force on the constraint device so that the constraint device partially constrains movement of the glass sheet, and for other purposes.

[0107] The processor(s) 1788 may be any means configured to execute various programmed operations or instructions stored in a memory device (e.g., memory device(s) 1790) such as a device or circuitry operating in accordance with software or otherwise embodied in hardware or a combination of hardware and software (e.g. a processor operating under software control or the processor embodied as an application specific integrated circuit (ASIC) or field programmable gate array (FPGA) specifically configured to perform theoperations described herein, or a combination thereof) thereby configuring the device or circuitry to perform the corresponding functions of the processor(s) 1788 as described herein.

[0108] The memory device(s) 1790 may include one or more non-transitory storage or memory devices such as, for example, volatile and / or non-volatile memory that may be either fixed or removable. The memory device(s) 1790 may be configured to store instructions, computer program code, and / or data in a non-transitory computer readable medium for use, such as by the processor(s) 1788, for enabling the components of the machine 1794 to carry out various functions and methods in accordance with example embodiments of the present invention. For example, the memory device(s) 1790 may be configured to buffer input data for processing by the processor(s) 1788. Additionally or alternatively, the memory device(s) 1790 may be configured to store instructions for execution by the processor(s) 1788. The memory device(s) 1790 may include computer program code that is configured to, when executed, cause processor(s) 1788 to perform various methods described herein. The memory device(s) 1790 may serve as non-transitory computer readable mediums having stored thereon software instructions that, when executed by one or more processors, cause methods described herein to be performed.

[0109] The techniques described above and below may be implemented, for example, in hardware, one or more computer programs tangibly stored on one or more computer-readable media, firmware, or any combination thereof. The techniques described herein may be implemented in one or more computer programs executing on (or executable by) a programmable computer or electronic or computing device having any combination of any number of the following: a processor, a storage medium readable and / or writable by the processor (including, for example, volatile and non-volatile memory and / or storage elements and non-transitory mediums), an input device, an output device, a display, and the like. Program code may be applied to input entered using the input device to perform the functions described herein and to generate output using the output device.

[0110] While various components are illustrated in the block diagram of FIG. 17, this block diagram is merely exemplary. In some embodiments, additional components may be added to the machine 1794 or certain components may be removed from the machine 1794.

[0111] Methods for the separating glass sheets from a stack of glass sheets are also contemplated, and FIG. 18 provides a flow chart illustrating one example method 1800 for separating glass sheets. At operation 1802, a suction pad is positioned at a first location relative to a glass sheet. The glass sheet comprises a first edge and a second edge that meet at a first corner. The first location may be positioned similar to how the suction pad 1546 is positionedas described in reference to FIG. 15. The suction pad may define a suction coverage area. The portion of the suction pad that is configured to come in contact with the contact surface of the glass sheet may define a perimeter within a plane. This perimeter may define a first dimension and a second dimension, with the first dimension being perpendicular to the second dimension. The first dimension may be greater than the second dimension. In some embodiments, the first dimension may define a maximum width of the perimeter and the second dimension may define the minimum width of the perimeter.

[0112] At operation 1804, a constraint device is positioned at a second location relative to the glass sheet. This second location may be positioned similar to how the constraint device 1580 is positioned as described in reference to FIG. 15.

[0113] At operation 1806, a first actuator urges a suction pad into a contact surface of the glass sheet to generate suction. At operation 1808, a second actuator urges the constraint device into the contact surface of the glass sheet so that a constraint force is applied by the constraint device on the glass sheet.

[0114] At operation 1810, the first actuator pulls the suction pad in a direction normal to the contact surface of the glass sheet. Consequently, a suction force is applied on the glass sheet, causing the glass sheet to separate from another glass sheet within a stack of glass sheets. As the suction force is applied by the suction pad at the first location, the constraint device may continue applying the constraint force at the second location. Thus, the constraint device may partially restrict movement of the glass sheet at locations proximate to the second location, but the suction force may pull on the glass sheet at the first location, causing deflection within the glass sheet at locations proximate to the first corner. This deflection may assist in separating the glass sheet from other glass sheets in the stack.

[0115] The method 1800 is merely exemplary, and the method 1800 may be modified in various ways. For example, additional operations may be added in some embodiments. Alternatively, some of the operations of method 1800 may be omitted. For example, the method 1800 may be performed without any constraint device in some embodiments. Furthermore, the order of operations may be altered in other embodiments, and certain operations may be performed simultaneously in some embodiments.CONCLUSION

[0116] Many modifications and other embodiments set forth herein will come to mind to one skilled in the art to which these embodiments pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to beunderstood that the embodiments are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the invention. Moreover, although the foregoing descriptions and the associated drawings describe example embodiments in the context of certain example combinations of elements and / or functions, it should be appreciated that different combinations of elements and / or functions may be provided by alternative embodiments without departing from the scope of the invention. In this regard, for example, different combinations of elements and / or functions than those explicitly described above are also contemplated within the scope of the invention. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

THAT WHICH IS CLAIMED:

1. A system for separation of a glass sheet from other glass sheets in a stack of glass sheets, the system comprising: the stack of glass sheets, wherein each glass sheet in the stack of glass sheets comprises film on at least one side; and a suction pad configured to come in contact with a contact surface of the glass sheet in the stack of glass sheets, wherein the suction pad is configured to apply a suction force on the glass sheet to assist in separation of the glass sheet from the other glass sheets within the stack of glass sheets, wherein the suction pad defines a suction coverage area, wherein the suction coverage area defines a first dimension and a second dimension, wherein the second dimension is perpendicular to the first dimension, wherein the first dimension is greater than the second dimension.

2. The system of claim 1, wherein the suction coverage area is rectangular in shape.

3. The system of claim 2, wherein the first dimension is at least about twice the second dimension.

4. The system of claim 2, wherein the suction coverage area has rounded comers.

5. The system of any of claims 1-4, wherein the suction coverage area for the suction pad is between about 1,000 square millimeters and about 20,000 square millimeters.

6. The system of any of claims 1-5, wherein the glass sheet has a first surface and a second surface opposite the first surface, wherein film is positioned at only one of the first surface or the second surface.

7. The system of any of claims 1-5, wherein the glass sheet has a first surface and a second surface opposite the first surface, wherein film is positioned at both the first surface and the second surface.

8. The system of any of claims 1-7, wherein the film has a surface roughness between about 650 nanometers and about 850 nanometers.

9. The system of any of claims 1-7, wherein the film has a surface roughness between about 850 nanometers and about 1050 nanometers.

10. The system of any of claims 1-9, further comprising: a constraint device having a surface configured to come in contact with the glass sheet, wherein the surface of the constraint device remains in contact with the glass sheet as the suction force is applied.

11. The system of claim 1, further comprising: an actuator; one or more processors; and one or more memory devices comprising computer program code configured, when executed by the one or more processors, to cause the one or more processors to: position the suction pad at a first location relative to the glass sheet, wherein the glass sheet comprises a first edge and a second edge that meet at a first corner; cause the actuator to urge the suction pad into the contact surface of the glass sheet so that the suction force is applied; and cause the actuator to pull the suction pad in a direction about normal to the contact surface of the glass sheet.

12. The system of claim 11, wherein the first location is less than 40 millimeters from the first edge and less than 40 millimeters from the second edge.

13. The system of claim 1, further comprising: a first actuator associated with the suction pad; a constraint device having a surface configured to come in contact with the contact surface of the glass sheet; a second actuator associated with the constraint device; one or more processors; andone or more memory devices comprising computer program code configured, when executed by the one or more processors, to cause the one or more processors to: position the suction pad at a first location relative to the glass sheet, wherein the glass sheet comprises a first edge and a second edge that meet at a first corner; position the constraint device at a second location relative to the glass sheet; cause the first actuator to urge the suction pad into the contact surface of the glass sheet to generate suction; cause the second actuator to urge the constraint device into the contact surface of the glass sheet so that a constraint force is applied by the constraint device on the glass sheet; and cause the first actuator to pull the suction pad in a direction about normal to the contact surface of the glass sheet so that the suction pad applies a suction force on the glass sheet and so that the glass sheet separates the other glass sheets within the stack of glass sheets, wherein causing the first actuator to pull the suction pad in a direction about normal to the contact surface of the glass sheet occurs while the constraint device applies the constraint device.

14. The system of claim 13, wherein the first location is less than 40 millimeters from the first edge and less than 40 millimeters from the second edge, and wherein the second location is between about 100 millimeters and about 300 millimeters from the first edge and between about 25 millimeters and about 100 millimeters from the second edge.

15. The system of claim 13, wherein the second location is between about 160 millimeters and about 260 millimeters from the first edge and between about 40 millimeters and about 80 millimeters from the second edge.

16. A method for separation of a glass sheet from other glass sheets in a stack of glass sheets, the method comprising: positioning a suction pad at a first location relative to the glass sheet, wherein the glass sheet comprises a first edge and a second edge that meet at a first corner; causing a first actuator to urge the suction pad into a contact surface of the glass sheet to generate suction; andcausing the first actuator to pull the suction pad in a direction about normal to a contact surface of the glass sheet so that the suction pad applies a suction force on the glass sheet and so that the glass sheet separates from the other glass sheets within the stack of glass sheets, wherein the suction pad defines a suction coverage area, wherein the suction coverage area defines a first dimension and a second dimension, wherein the second dimension is perpendicular to the first dimension, and wherein the first dimension is greater than the second dimension.

17. The method of claim 16, wherein the first location is less than 40 millimeters from the first edge and less than 40 millimeters from the second edge.

18. The method of claim 16, further comprising: positioning a constraint device having a surface at a second location relative to the glass sheet; and cause a second actuator to urge the constraint device into a contact surface of the glass sheet so that the surface of the constraint device contacts the contact surface of the glass sheet and so that a constraint force is applied by the constraint device on the glass sheet, wherein causing the first actuator to pull the suction pad in a direction about normal to the contact surface of the glass sheet occurs while the constraint device applies the constraint force, and wherein the second location is between about 100 millimeters and about 300 millimeters from the first edge and between about 25 millimeters and about 100 millimeters from the second edge.

19. The method of claim 18, wherein the second location is between about 160 millimeters and about 260 millimeters from the first edge and between about 40 millimeters and about 80 millimeters from the second edge.

20. A system for separation of a glass sheet from other glass sheets in a stack of glass sheets, the system comprising: the stack of glass sheets, wherein each glass sheet in the stack of glass sheets comprises film on at least one side; a suction pad configured to come in contact with a contact surface of the glass sheet in the stack of glass sheets; anda constraint device having a surface configured to come in contact with a contact surface of the glass sheet, wherein the suction pad is configured to apply a suction force at the contact surface of the glass sheet to cause the glass sheet to separate from the other glass sheets within the stack of glass sheets, wherein the surface of the constraint device remains in contact with the glass sheet as the suction force is applied.

21. The system of claim 20, wherein the glass sheet has a first surface and a second surface opposite the first surface, wherein film is positioned at only one of the first surface or the second surface.

22. The system of claim 21, wherein the film has a surface roughness between about 650 nanometers and about 850 nanometers.

23. The system of claim 21, wherein the film has a surface roughness between about 850 nanometers and about 1050 nanometers.

24. The system of any of claims 21-23, wherein the glass sheet comprises a first edge and a second edge that meet at a first comer, wherein the constraint device is positioned at a location relative to the first corner of the glass sheet when the constraint device comes in contact with the glass sheet, wherein the location is between about 100 millimeters and about 300 millimeters from the first edge of the glass sheet and between about 25 millimeters and about 100 millimeters from the second edge of the glass sheet.

25. The system of claim 24, wherein the location is between about 160 millimeters and about 260 millimeters from the first edge of the glass sheet and between about 40 millimeters and about 80 millimeters from the second edge of the glass sheet.

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