Apparatus and method for forming a glass sheet

• US 9,969,643 B2
• Filed: 10/29/2014
• Issued: 05/15/2018
• Est. Priority Date: 11/01/2013
• Status: Active Grant

• Current Assignee: Corning Incorporated
• Original Assignee: Corning Incorporated
• Inventors: Darcangelo, Charles Michael
• Primary Examiner(s): Herring, Lisa L
• Application Number:
  US15/033,259
• Publication Number:
  US 20160272528A1
• Time in Patent Office: 1,294 Days
• Field of Search: None
• CPC Class Codes: C03B 17/02 Forming molten glass coated with coloured layers; Forming molten glass of different compositions or layers; Forming molten glass comprising reinforcements or inserts
• CPC Class Codes: C03B 17/064 by the overflow downdraw fusion process; Isopipes therefor
• CPC Class Codes: C03B 17/065 Forming profiled, patterned or corrugated sheets
• CPC Class Codes: C03B 17/068 Means for providing the drawing force, e.g. traction or draw rollers
• CPC Class Codes: C03B 33/0215 the ribbon being in a substantially vertical plane

Abstract

A method includes forming a continuous ribbon of glass. The continuous ribbon includes a first surface, a second surface opposite the first surface, a first edge region, a second edge region opposite the first edge region, and a central region extending between the first edge region and the second edge region. Each of the first edge region and the second edge region has a greater thickness than the central region of the continuous ribbon. An indented pattern is formed longitudinally along the first edge region of the continuous ribbon by forming a first series of indentations in the first surface of the continuous ribbon and forming a second series of indentations in the second surface of the continuous ribbon. The indented pattern includes intermediate segments interconnected with one another by webs. Each intermediate segment is thicker than adjacent webs.

Claims

1. A method comprising:

forming a continuous ribbon of glass, the continuous ribbon comprising a first surface, a second surface opposite the first surface, a first edge region, a second edge region opposite the first edge region, and a central region extending between the first edge region and the second edge region, each of the first edge region and the second edge region comprising a greater thickness than the central region of the continuous ribbon, the continuous ribbon comprising a laminate structure comprising a core layer disposed between a first cladding layer and a second cladding layer, wherein the core layer is wider than at least one of the first cladding layer or the second cladding layer such that the core layer comprises an uncovered portion that is uncovered by the at least one of the first cladding layer or the second cladding layer;

forming an indented pattern longitudinally in the first edge region of the continuous ribbon by forming a first series of indentations in the first surface of the continuous ribbon and forming a second series of indentations in the second surface of the continuous ribbon, the indented pattern comprising intermediate segments interconnected with one another by webs, wherein each intermediate segment is thicker than adjacent webs, wherein the indented pattern extends across substantially the entire width of the uncovered portion of the core layer; and

separating a sheet from the continuous ribbon, wherein the separating the sheet comprises fracturing the first edge region at a web of the indented pattern formed in the first edge region and fracturing the second edge region at a web of the indented pattern formed in the second edge region.

2. The method of claim 1, wherein the first series of indentations is formed in the first cladding layer and the second series of indentations is formed in the second cladding layer.

3. The method of claim 1, wherein the forming the indented pattern comprises passing the first edge region of the continuous ribbon between a first patterning roller and a second patterning roller each comprising a series of protrusions engaging the continuous ribbon, the first patterning roller and the second patterning roller are synchronized such that, upon rotation of the first patterning roller and the second patterning roller, the protrusions of the first patterning roller and the protrusions of the second patterning roller engage the first surface and the second surface, respectively, of the continuous ribbon at substantially the same transverse and longitudinal positions to align the first series of indentations and the second series of indentations with one another.

4. The method of claim 1, wherein the forming the indented pattern comprises pinching the first edge region of the continuous ribbon between a first patterning member and a second patterning member, the first patterning member and the second patterning member movable toward one another to engage the first surface and the second surface, respectively, of the continuous ribbon at substantially the same transverse and longitudinal positions.

5. The method of claim 1, wherein the fracturing comprises:

forming a stress region extending at least partially across the central region of the continuous ribbon; and

applying a stress to the continuous ribbon to sever the stress region of the continuous ribbon.

6. The method of claim 5, wherein the forming the stress region comprises scoring the central region of the continuous ribbon to form a scored region extending at least partially between the first edge region and the second edge region.

7. The method of claim 5, wherein the applying the stress to the continuous ribbon comprises applying a bending force to the continuous ribbon proximate the stress region.

8. The method of claim 5, wherein the applying the stress to the continuous ribbon comprises cooling the stress region of the continuous ribbon.

9. The method of claim 1, wherein each web of the indented pattern is disposed between one indentation of the first series of indentations and a corresponding indentation of the second series of indentations.

10. The method of claim 1, further comprising forming a second indented pattern longitudinally in the second edge region of the continuous ribbon by forming a third series of indentations in the first surface of the continuous ribbon and forming a fourth series of indentations in the second surface of the continuous ribbon, the second indented pattern comprising intermediate segments interconnected with one another by webs, wherein each intermediate segment is thicker than adjacent webs.

11. The method of claim 10, wherein each web of the indented pattern formed in the first edge region is at substantially the same longitudinal position on the continuous ribbon as a corresponding web of the second indented pattern formed in the second edge region.

12. The method of claim 1, wherein each of the first cladding layer and the second cladding layer has a lower average coefficient of thermal expansion than the core layer such that, upon cooling of the continuous ribbon, a compressive stress forms in each of the first cladding layer and the second cladding layer and a tensile stress forms in the core layer.

13. A method comprising:

forming a continuous ribbon of glass, the continuous ribbon comprising a laminate structure comprising a core layer disposed between a first cladding layer and a second cladding layer, wherein the core layer is wider than at least one of the first cladding layer or the second cladding layer such that the core layer comprises an uncovered portion that is uncovered by the at least one of the first cladding layer or the second cladding layer;

passing a first edge region of the continuous ribbon between a first patterning roller and a second patterning roller, each of the first patterning roller and the second patterning roller comprising a series of protrusions successively engaging the continuous ribbon as the continuous ribbon is passed between the first patterning roller and the second patterning roller, the first patterning roller and the second patterning roller being synchronized such that each protrusion of the first patterning roller engages the first cladding layer of the continuous ribbon at substantially the same longitudinal position on the continuous ribbon as a corresponding protrusion of the second patterning roller engages the second cladding layer of the continuous ribbon to form an indented pattern longitudinally along the first edge region of the continuous ribbon, the indented pattern comprising intermediate segments interconnected with one another by webs, wherein the indented pattern extends across substantially the entire width of the uncovered portion of the core layer; and

separating a sheet from the continuous ribbon, wherein the separating the sheet comprises fracturing the first edge region at a web of the indented pattern formed in the first edge region.

14. The method of claim 13, further comprising passing a second edge region of the continuous ribbon between a third patterning roller and a fourth patterning roller, each of the third patterning roller and the fourth patterning roller comprising a series of protrusions successively engaging the continuous ribbon as the continuous ribbon is passed between the third patterning roller and the fourth patterning roller, the third patterning roller and the fourth patterning roller being synchronized such that each protrusion of the third patterning roller engages the first cladding layer of the continuous ribbon at substantially the same longitudinal position on the continuous ribbon as a corresponding protrusion of the fourth patterning roller engages the second cladding layer of the continuous ribbon to form a second series of thinned regions extending along the length of the second edge region of the continuous ribbon.