WO2019136050A1

WO2019136050A1 - Stacks including a plurality of sheets and an interleaf layer and method of forming said stacks

Info

Publication number: WO2019136050A1
Application number: PCT/US2019/012029
Authority: WO
Inventors: Makoto KAWAHATA
Original assignee: Corning Inc
Current assignee: Corning Inc
Priority date: 2018-01-04
Filing date: 2019-01-02
Publication date: 2019-07-11
Anticipated expiration: 2020-07-04
Also published as: TW201934315A

Abstract

A stack can comprise a plurality of sheets and an interleaf layer (105) freely positioned between a first sheet (103a) of the plurality of sheets and a second sheet (103b) of the plurality of sheets. A first pattern (407) of protrusions can be defined by the first major surface of the interleaf layer. The second major surface of the interleaf layer can freely contact the first major surface of the first sheet and the first pattern of protrusions can freely contact the second major surface of the second sheet. In further embodiments, a method of generating a stack of sheets from a plurality of sheets can be provided.

Description

STACKS INCLUDING A PLURALITY OF SHEETS AND AN INTERLEAF

LAYER AND METHOD OF FORMING SAID STACKS

CROSS-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. 62/613487 filed on January 4, 2018, the content of which is relied upon and incorporated herein by reference in its entirety.

BACKGROUND

[0002] It is known to provide a stack of sheets. An interleaf layer is commonly positioned between adjacent pairs of sheets within the stack to prevent the sheets in the stack from damaging one another.

SUMMARY

[0003] The following presents a simplified summary of the disclosure to provide a basic understanding of some exemplary embodiments described in the detailed description.

[0004] The present disclosure relates generally to a stack of sheets and, more particularly, to a stack of sheets with an interleaf layer positioned between a first sheet of the plurality of sheets and a second sheet of the plurality of sheets.

[0005] In accordance with some embodiments, a stack can comprise a plurality of glass sheets. Each glass sheet can comprise an average thickness defined between a first major surface and a second major surface. The stack can comprise a crimped paper interleaf layer positioned between a first glass sheet of the plurality of glass sheets and a second glass sheet of the plurality of glass sheets. The crimped paper interleaf layer can comprise an average thickness defined between a first major surface of the interleaf layer and a second major surface of the interleaf layer. A first pattern of protrusions defined by the first major surface of the interleaf layer can contact the second major surface of the second sheet. A second pattern of protrusions defined by the second major surface of the interleaf layer can contact the first major surface of the first glass sheet. [0006] In one embodiment, the average thickness of each of the g can be from about 100 microns to about 1 millimeter.

[0007] In another embodiment, an average height of the first pattern of protrusions can be from about 500 microns to about 1 millimeter.

[0008] In another embodiment, the stack can be supported by a base of the carrier.

[0009] In accordance with other embodiments, a stack can comprise a plurality of sheets. Each sheet can comprise an average thickness defined between a first major surface and a second major surface. The stack can further include an interleaf layer freely positioned between a first sheet of the plurality of sheets and a second sheet of the plurality of sheets. The interleaf layer can comprise an average thickness defined between a first major surface of the interleaf layer and a second major surface of the interleaf layer. A first pattern of protrusions can be defined by the first major surface of the interleaf layer. The second major surface of the interleaf layer can freely contact the first major surface of the first sheet and the first pattern of protrusions can freely contact the second major surface of the second sheet.

[0010] In one embodiment, a second pattern of protrusions can be defined by the second major surface of the interleaf layer. The second pattern of protrusions can freely contact the first major surface of the first sheet.

[0011] In another embodiment, the interleaf layer can comprise paper.

[0012] In another embodiment, the interleaf layer can comprise a crimped layer.

[0013] In another embodiment, an average height of the first pattern of protrusions can be from about 500 microns to about 1 millimeter.

[0014] In another embodiment, an average thickness of the interleaf layer can be from about 500 microns to about 1 millimeter.

[0015] In another embodiment, the average thickness of each sheet can be from about 100 microns to about 1 millimeter.

[0016] In another embodiment, each sheet of the plurality of sheets can comprise glass. [0017] In another embodiment, a carrier can comprise the stack of more of the embodiments set forth above, wherein the stack can be supported by a base of the carrier.

[0018] In accordance with other embodiments, a method of generating a stack of sheets from a plurality of sheets can be provided. Each sheet can comprise an average thickness defined between a first major surface and a second major surface. The method can comprise freely positioning an interleaf layer on a first major surface of a first sheet of the plurality of sheets. The interleaf layer can comprise an average thickness defined between a first major surface of the interleaf layer and a second major surface of the interleaf layer. The second major surface of the interleaf layer can freely contact the first major surface of the first sheet. The method can further comprise positioning a second sheet of the plurality of sheets on the interleaf layer. A first pattern of protrusions defined by the first major surface of the interleaf layer can freely contact the second major surface of the second sheet. The method can include exhausting air through a first pattern of channels defined by the first major surface of the interleaf layer while positioning the second sheet of the plurality of sheets on the interleaf layer.

[0019] In one embodiment, freely positioning the interleaf layer on the first major surface of the first sheet can comprise freely contacting a second pattern of protrusions defined by the second major surface of the interleaf layer with the first major surface of the first sheet.

[0020] In another embodiment, the interleaf layer can comprise paper.

[0021] In another embodiment, the interleaf layer can comprise a crimped layer.

[0022] In another embodiment, an average height of the first pattern of protrusions can be from about 500 microns to about 1 millimeter.

[0023] In another embodiment, the average thickness of the interleaf layer can be from about 500 microns to about 1 millimeter.

[0024] In another embodiment, the average thickness of each sheet can be from about 100 microns to about 1 millimeter.

[0025] In another embodiment, wherein each sheet of the plurality of sheets can comprise glass. [0026] In another embodiment, the method can further comprise

the first sheet with a base of a carrier.

[0027] It is to be understood that both the foregoing general description and the following detailed description present embodiments of the present disclosure, and are intended to provide an overview or framework for understanding the nature and character of the embodiments as they are described and claimed. The accompanying drawings are included to provide a further understanding of the embodiments, and are incorporated into and constitute a part of this specification. The drawings illustrate various embodiments of the disclosure, and together with the description serve to explain the principles and operations thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

[0028] These and other features, embodiments and advantages of the present disclosure can be further understood when read with reference to the accompanying drawings:

[0029] FIG. 1 illustrates a stack including a plurality of sheets being supported by a base of a carrier;

[0030] FIG. 2 illustrates an enlarged view of a portion of the stack taken at view 2 of FIG. 1;

[0031] FIG. 3 is a perspective view of an interleaf layer being crimped by a pair of rollers;

[0032] FIG. 4 is a cross-sectional view of the crimped interleaf layer along line 4-4 of FIG. 3; and

[0033] FIG. 5 is a cross-sectional view of another embodiment of an interleaf layer;

[0034] FIG. 6 illustrates a first sheet being supported by the base of the carrier;

[0035] FIG. 7 illustrates freely positioning an interleaf layer on a first major surface of the first sheet;

[0036] FIG. 8 illustrates exhausting a quantity of air through a first pattern of channels defined by a first major surface of the interleaf layer while freely positioning a second sheet on the interleaf layer; and [0037] FIG. 9 is an enlarged view of the quantity of air being

through the first pattern of channels taken at view 9 of FIG. 8.

DETAILED DESCRIPTION

[0038] Apparatus and methods will now be described more fully hereinafter with reference to the accompanying drawings in which exemplary embodiments are shown. Whenever possible, the same reference numerals are used throughout the drawings to refer to the same or like parts. However, this disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein.

[0039] FIG. 1 illustrates a stack 101 including a plurality of sheets 103a-e. Each sheet (e.g., see sheet 103a in FIG. 6) of the plurality of sheets 103a-e can include a first major surface 601 and a second major surface 603. As shown, in some embodiments, the first major surface 601 and the second major surface 603 can comprise planar surfaces that are parallel to one another although curved surfaces may be provided in further embodiments. For instance, the first major surface 601 may be convex and the second major surface 603 may be concave. Furthermore, the area of the first major surface 601 and second major surface 603 may have a wide range of shapes. For instance, the area of the first and second major surfaces 601, 603 can each comprise a rectangular shape although other shaped sheets may be provided in further embodiments. As further shown, an average thickness 605 can be defined between the first major surface 601 and the second major surface 603 of each sheet of the plurality of sheets 103a-e. In some embodiments, the average thickness 605 can be from about 100 microns to about 1 millimeter although other thicknesses may be provided in further embodiments. In some embodiments, each sheet of the plurality of sheets 103a-e can comprise glass although the sheets can comprise glass-ceramic, ceramic, silicon or other materials in further embodiments.

[0040] The stack 101 can further include at least one interleaf freely positioned between a pair of adjacent sheets 103a-e. For instance, referring to FIGS. 1 and 2, the stack 101 can include an interleaf 105 positioned between a first sheet 103a of the plurality of sheets 103a-e and a second sheet 103b of the plurality of sheets 103a-e. FIG. 4 illustrates an exemplary embodiment of the interleaf 105 including a first major surface 401, a second major surface 403 and ;

thickness 405 defined between the first major surface 401 and the second major surface 403. In some embodiments, the average thickness 405 can be from about 500 microns to about 1 millimeter although other thicknesses may be provided in further embodiments. In the embodiment shown in FIG. 4, the average thickness 405 can be substantially constant across the entire area of the interleaf although the thickness may fluctuate over the area of the interleaf in further embodiments.

[0041] The interleaf layer 105 can comprise a wide range of materials. For instance, the interleaf maybe a paper layer or a plastic layer (e.g., plastic sheet or paper sheet). In some embodiments, a coated paper layer may be used to increase the friction between the glass sheet and the interleaf layer to inhibit relative slipping between the sheet and the interleaf layer.

[0042] In some embodiments, the interleaf layer may comprise a material with reduced fiber shedding such that sheets in the stack have little or no fiber transfer of material from the interleaf layer to the sheet. Preventing little or no fiber transfer can avoid extensive subsequent cleaning procedures that may otherwise be necessary to remove the fibers from the sheets. In some embodiments, clean room paper may be used as the interleaf layer to provide minimal, if any, shedding of paper fibers when contacting the sheets. In further embodiments, the interleaf layer can comprise glassine paper that may be a super-calendared paper manufactured principally from chemically-bleached wood pulps that have been beaten to secure a high degree of stock hydration. Glassine paper may be generally grease resistant. Furthermore, glassine paper can be dense, which results in a paper having a high resistance to the passage of air and relatively impervious to the passage of water vapor when compared to other paper products. Glassine paper can also be smooth and transparent or translucent and can have a low inorganic content. Due to the lack of fillers, binders, resins and other additives, any organic contaminants can be minimized and stain formation on the sheets 103a-e due to contact with the glassine interleaf layer can be prevented. Inorganic contaminants present in the glassine paper are generally locked within the paper by processing, which prevents subsequent scratching of the glass surface. Glassine paper can be manufactured so that it may be translucent, white or colored, and may also be made opaque by the addition of fillers. [0043] In some embodiments, the interleaf layer 105 may incli pattern of protrusions 407 defined by the first major surface 401 of the interleaf layer 105 and a second pattern of protrusions 409 defined by the second major surface 403 of the interleaf layer 105. In some embodiments, a single pattern of protrusions may be provided. For instance, as shown in the embodiment of FIG. 5, the interleaf layer 501 can include a first major surface 503 including a first pattern of protrusions 505. In some embodiments, the interleaf layer 501 may include a second major surface 507 that may not include a pattern of protrusions. Rather, as shown, the second major surface 507 may comprise a substantially flat surface although other surface configurations may be provided in further embodiments.

[0044] The first pattern of protrusions 407, 505 and the second pattern of protrusions 409 can include an average height 411 of, for example, from about 500 microns to about 1 millimeter. For purposes of this application, the height 411 of each protrusion in the pattern of protrusions is considered the maximum distance between the top of the protrusion and the major surface surrounding the protrusion. Consequently, the average height 411 of the pattern of protrusions is the average height of each protrusion of the pattern of protrusions.

[0045] As shown in FIG. 4, the first pattern of protrusions 407 and the second pattern of protrusions 409 can be identical mirror images of each other although other configurations of different protrusions may be provided in further embodiments. The first pattern of protrusions 407, 505 and/or the second pattern of protrusions 409 can comprise a wide range of patterns, shapes and sizes depending on the particular application. In some embodiments, the protrusions can comprise raised bumps that are each surrounded by a channel 413 such that a network of channels is defined by the first pattern of protrusions 409. In further embodiments, the protrusions can comprise a cross shape, or a linear shape or other shape that can define at least one channel between adjacent protrusions.

[0046] The pattern of protrusions can be formed with a wide range of techniques. For instance, FIG. 1 demonstrates an embodiment of producing an interleaf layer including the first pattern of protrusions 407 and the second pattern of protrusions 409 with a pair of rollers. Indeed, a first roller 301 may include an outer rigid cylindrical surface with a pattern 303 corresponding to the desired protrusion pattern. The second roller 305 may comprise an outer compliant surface _j that can be impressed with the pattern 303 of the first roller 301 at a nip 309 between the two rollers. In operation, the rollers can each rotate in the respective directions 311a, 311b such that an interleaf layer 313 may be crimped with the first pattern of protrusions 407 and the second pattern of protrusions 409 shown in FIG. 4. In one embodiment, the interleaf layer 313 comprises a paper layer that may be processed into the illustrated crimped paper interleaf layer 105 including the first and second pattern of protrusions 407, 409.

[0047] In further embodiments, a single side of the interleaf layer may be embossed with a first pattern of protrusions. For instance, a stamp (not shown) may be pressed into the first major surface 503 shown in FIG. 5 to emboss the first pattern of protrusions 505 into the first major surface 503 of the interleaf layer 501. As shown, the second major surface 507 of the interleaf layer 501 may remain substantially flat. In further embodiments, although not shown in FIG. 5, the second major surface 507 may be embossed with a second pattern of protrusions that may be identical or different than the first pattern of protrusions 505.

[0048] A method of generating the stack 101 of sheets from a plurality of sheets 103a-e will be discussed with reference to the illustrative embodiment shown in FIGS. 6-9. As shown in FIG. 6, optionally, a protective layer 607 may be provided for supporting the first sheet 103a on a base 609 of a carrier 611. As shown in FIG. 6, the carrier 611 can comprise a container with an interior containment area. Although not shown, the carrier 611 may simply comprise the base 609 without an interior containment area. For instance, the carrier 611 can comprise a pallet configured to support the weight of the stack 101. The carrier can be effective to transport the stack 101 and/or store the stack 101.

[0049] As shown in FIG. 7, the method can further include freely positioning the interleaf layer 105 on the first major surface 601 of the first sheet 103a of the plurality of sheets 103a-e. Once positioned, the second major surface 403 of the interleaf layer 105 freely contacts the first major surface 601 of the first sheet 103a. For purposes of this application, freely positioning an interleaf layer is intended to mean that the interleaf layer is positioned while being free from being adhered to a sheet. For example, freely positioning the interleaf layer 105 on the first major surface 601 of the first sheet 103a is intended to mean that the interleaf h positioned while being free from being adhered to a sheet (e.g., first or second sheet 103a, 103b). In another example, freely positioning the interleaf layer 105 between a first sheet (e.g., first sheet 103a) of the plurality of sheets and a second sheet (e.g., second sheet 103b) of the plurality of sheets is intended to mean that the interleaf layer is positioned while being free from being adhered to the first sheet (e.g., first sheet 103a) and while being free from being adhered to the second sheet (e.g., second sheet 103b) Furthermore, for purposes of this application, an interleaf layer freely contacting a major surface of the sheet is intended to mean that the interleaf layer contacts the major surface of the sheet while being free of being adhered to the major surface of the sheet. For example, the second major surface 403 of the interleaf layer 105 freely contacting the first major surface 601 of the first sheet 103a is intended to mean that the second major surface 403 of the interleaf layer 105 contacts the first major surface 601 of the first sheet 103a while being free of being adhered to the first major surface 601 of the first sheet 103a. In another example, the second pattern of protrusions 409 defined by the second major surface 403 of the interleaf layer 105 freely contacting the first major surface 601 of the first sheet 103a is intended to mean that the second pattern of protrusions 409 of the interleaf layer 105 contacts the first major surface 601 of the first sheet 103a while being free of being adhered to the first major surface 601 of the first sheet 103a. Furthermore, the first pattern of protrusions 407 defined by the first major surface 401 of the interleaf layer 105 freely contacting the second major surface 603 of the second sheet 103b is intended to mean that the first pattern of protrusions 407 of the interleaf layer 105 contacts the second major surface 603 of the second sheet 103b while being free of being adhered to the second major surface 603 of the second sheet 103b. In some embodiments, the interleaf layer freely contacts the major surface of the sheet with a sufficient frictional force to inhibit inadvertent shifting of the sheet relative to the interleaf layer. However, in such embodiments, the interleaf layer is not adhered to the sheet. In some embodiments, preventing adherence of the interleaf layer with the sheet by freely contacting the interleaf layer with the sheet can simplify removal of a sheet from the stack without further processing to remove an adhered interleaf layer. Furthermore, freely contacting the interleaf layer with the sheet avoids application of adhesive or other materials that may remain on the sheet after removing the adhere layer from the sheet. As such, for example, freely positioning the interleaf layer 105 on the first major surface 601 of the first sheet 103a can simplify subsequent removal of the first sheet 103a from the stack 101 and avoids further processing to remove residual material that may otherwise exist when removing an adhered interleaf layer form the first sheet 103a.

[0050] As shown in FIG. 8, the method can further include freely positioning a second sheet 103b of the plurality of sheets 103a-e on the interleaf layer 105. As shown in FIG. 9, while freely positioning, the method can include exhausting a quantity of air 901 through a first pattern of channels 413 defined by the first major surface 401 of the interleaf layer 105. Indeed, a first stream of air 903a may be exhausted in addition to a second stream 903b flowing through the pattern of channels 413. The pattern of channels 413 defined by the first pattern of protrusions 407 can help minimize formation of an air cushion between the interleaf layer 105 and the second sheet 103b that may otherwise cause the second sheet 103b to float on the air cushion and undesirably shift laterally during placement. Although not shown, in some embodiments, the interleaf layer 105 may optionally include apertures extending between the first major surface 401 and the second major surface 403 to facilitate exhausting of air to further prevent development of the above-referenced air cushion during positioning of the second sheet 103b on the interleaf layer 105.

[0051] As shown in FIG. 2, once positioned, the first pattern of protrusions 407 defined by the first major surface 401 of the interleaf layer 105 freely contacts the second major surface 603 of the second sheet 103b. Since the pattern of channels 413 defined by the first pattern of protrusions 407 allow exhausting of the quantity of air to prevent development of an air cushion, the second sheet 103b can be more accurately placed relative to the first sheet 103a. Indeed, as shown in FIG. 2, an overhang 201 of an outer edge of one of the first sheet 103a and the second sheet 103b laterally extending beyond an outer edge of the other of the first sheet 103a and second sheet 103b can be kept below a predetermined amount, such as below about 0.5 millimeters. Consequently, as shown in FIG. 1, placing an interleaf layer 105 between the plurality of sheets 103a-e as they are stacked in the stack 101 can provide desirable alignment of the outer edges such that adjacent edges have an ov of below, for example, about 0.5 millimeters.

[0052] As shown in FIG. 7, freely positioning the interleaf layer 105 can optionally include freely contacting the second pattern of protrusions 409 defined by the second major surface 403 of the interleaf layer 105 with the first major surface 601 of the first sheet. Providing the second pattern of protrusions 409 can further facilitate exhausting the quantity of air in applications where the air can freely pass through the thickness 405 of the interleaf layer. For instance, the material of the interleaf layer 105 may be air permeable and/or include apertures to permit air to pass through the interleaf layer 105.

[0053] As shown in FIG. 2, once positioned, the second major surface 403 of the interleaf layer 105 can feely contact the first major surface 601 of the first sheet 103a. In some embodiments, as further shown in FIG. 2, the second pattern of protrusions 409 defined by the second major surface 403 of the interleaf layer 105 freely contacts the first major surface 601 of the first sheet 103a and the first pattern of protrusions 407 freely contacts the second major surface 603 of the second sheet 103b. As shown in FIG. 1, the stack 101 can be supported by the base 609 of the carrier 611

[0054] It will be appreciated that the various disclosed embodiments may involve particular features, elements or steps that are described in connection with that particular embodiment. It will also be appreciated that a particular feature, element or step, although described in relation to one particular embodiment, may be interchanged or combined with alternate embodiments in various non-illustrated combinations or permutations.

[0055] It is also to be understood that, as used herein the terms“the,”“a,” or “an,” mean“at least one,” and should not be limited to“only one” unless explicitly indicated to the contrary. Likewise, a“plurality” is intended to denote“more than one.”

[0056] Ranges can be expressed herein as from“about” one particular value, and/or to“about” another particular value. When such a range is expressed, examples include from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent“ab< be understood that the particular value forms another embodiment. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

[0057] The terms“substantial,”“substantially,” and variations thereof as used herein are intended to note that a described feature is equal or approximately equal to a value or description.

[0058] Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is no way intended that any particular order be inferred.

[0059] While various features, elements or steps of particular embodiments may be disclosed using the transitional phrase“comprising,” it is to be understood that alternative embodiments, including those that may be described using the transitional phrases“consisting” or“consisting essentially of,” are implied. Thus, for example, implied alternative embodiments to an apparatus that comprises A+B+C include embodiments where an apparatus consists of A+B+C and embodiments where an apparatus consists essentially of A+B+C.

[0060] It will be apparent to those skilled in the art that various modifications and variations can be made to the present disclosure without departing from the spirit and scope of the appended claims. Thus, it is intended that the present disclosure cover the modifications and variations of the embodiments herein provided they come within the scope of the appended claims and their equivalents.

Claims

What is claimed is:

1. A stack comprising:

a plurality of glass sheets, each glass sheet comprising an average thickness defined between a first major surface and a second major surface; and

a crimped paper interleaf layer positioned between a first glass sheet of the plurality of glass sheets and a second glass sheet of the plurality of glass sheets, the crimped paper interleaf layer comprising an average thickness defined between a first major surface of the interleaf layer and a second major surface of the interleaf layer, wherein a first pattern of protrusions defined by the first major surface of the interleaf layer contacts the second major surface of the second sheet and a second pattern of protrusions defined by the second major surface of the interleaf layer contacts the first major surface of the first glass sheet.

2. The stack of claim 1, wherein the average thickness of each of the glass sheets is from about 100 microns to about 1 millimeter.

3. The stack of any one of claims 1 and 2, wherein an average height of the first pattern of protrusions is from about 500 microns to about 1 millimeter.

4. A carrier comprising the stack according to any one of claims 1-3, wherein the stack is supported by a base of the carrier.

5. A stack comprising:

a plurality of sheets, each sheet comprising an average thickness defined between a first major surface and a second major surface; and

an interleaf layer freely positioned between a first sheet of the plurality of sheets and a second sheet of the plurality of sheets, the interleaf layer comprising an average thickness defined between a first major surface of the interleaf layer and a second major surface of the interleaf layer, and a first pattern of protrusions defined by the first major surface of the interleaf layer, wherein the second major surface of the interleaf layer freely contacts the first major surface of the first sheet a pattern of protrusions freely contacts the second major surface of the second sheet.

6. The stack of claim 5, wherein a second pattern of protrusions defined by the second major surface of the interleaf layer freely contacts the first major surface of the first sheet.

7. The stack of any one of claims 5 and 6, wherein the interleaf layer comprises paper.

8. The stack of any one of claims 5-7, wherein the interleaf layer comprises a crimped layer.

9. The stack of any one of claims 5-8, wherein an average height of the first pattern of protrusions is from about 500 microns to about 1 millimeter.

10. The stack of any one of claims 5-9, wherein an average thickness of the interleaf layer is from about 500 microns to about 1 millimeter.

11. The stack of any one of claims 5-10, wherein the average thickness of each sheet is from about 100 microns to about 1 millimeter.

12. The stack according to any one of claims 5-11, wherein each sheet of the plurality of sheets comprises glass.

13 A carrier comprising the stack according to any one of claims 5-12, wherein the stack is supported by a base of the carrier.

14. A method of generating a stack of sheets from a plurality of sheets, each sheet comprising an average thickness defined between a first major surface and a second major surface, the method comprising: freely positioning an interleaf layer on a first major surface of a fn the plurality of sheets, the interleaf layer comprising an average thickness defined between a first major surface of the interleaf layer and a second major surface of the interleaf layer, wherein the second major surface of the interleaf layer freely contacts the first major surface of the first sheet;

positioning a second sheet of the plurality of sheets on the interleaf layer, wherein a first pattern of protrusions defined by the first major surface of the interleaf layer freely contacts the second major surface of the second sheet; and

exhausting air through a first pattern of channels defined by the first major surface of the interleaf layer while positioning the second sheet of the plurality of sheets on the interleaf layer.

15. The method of claim 14, wherein freely positioning the interleaf layer on the first major surface of the first sheet comprises freely contacting a second pattern of protrusions defined by the second major surface of the interleaf layer with the first major surface of the first sheet.

16. The method of any one of claims 14 and 15, wherein the interleaf layer comprises paper.

17. The method of any one of claims 14-16, wherein the interleaf layer comprises a crimped layer.

18. The method of any one of claims 14-17, wherein an average height of the first pattern of protrusions is from about 500 microns to about 1 millimeter.

19. The method of any one of claims 14-18, wherein the average thickness of the interleaf layer is from about 500 microns to about 1 millimeter.

20. The method of any one of claims 14-19, wherein the average thickness of each sheet is from about 100 microns to about 1 millimeter.

21. The method of any one of claims 14-20, wherein each sheet of the sheets comprises glass.

22. The method of any one of claims 14-21, further comprising supporting the first sheet with a base of a carrier.