Cold forming 3D products and processes utilizing vacuum chucks

Abstract

The present disclosure relates to a vacuum forming method, apparatus, and resulting display that represent improvements in a variety of key areas. The method greatly improves manufacturing yield, for example, by reduced cure times. The method further facilitates improved control of glass shape to target shape and improved control of bondline thickness, which leads to, for example, improved survivability and long-term reliability.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority to U.S. Provisional Application Serial No. 62 / 840237, filed April 29, 2019, the contents of which are incorporated herein by reference in their entirety. Background Technology

[0003] Vehicle interior trim may include curved surfaces incorporating displays and / or touch panels. Materials used to form such curved surfaces are typically limited to polymers, which do not exhibit the durability and optical properties of glass. Therefore, curved glass substrates are ideal, particularly when used as covers for displays and / or touch panels. Existing methods for forming curved glass substrates, such as thermoforming, have drawbacks including high cost and optical distortion and / or surface scratches during bending or forming. Therefore, there is a need for a vehicle interior trim system that can incorporate curved glass substrates in a cost-effective manner without the problems typically associated with glass thermoforming processes. However, current cold forming methods have various disadvantages, including the adhesive layer being susceptible to both shear and tensile stresses in some cases and / or difficulty in achieving rapid manufacturing volumes. Summary of the Invention

[0004] Among other things, this disclosure provides cold-formed 3D products such as curved glass substrates for vehicle interior surfaces. Furthermore, the methods and apparatus for forming such curved glass substrates offer improved control over the glass shape to achieve the desired shape, improved control over the bond line thickness, significantly reduced processing time, flexibility in various designs, and bond line thickness compatibility with all types of displays, including laminated displays. Attached Figure Description

[0005] The accompanying figures illustrate, rather than limit, the various implementations discussed herein in a illustrative manner.

[0006] Figure 1 It is a perspective view illustrating a vehicle interior having a vehicle interior system according to one or more embodiments.

[0007] Figure 2A This is a top view of a display that includes a curved glass substrate and a frame.

[0008] Figure 2B Is it through Figure 2A A cross-sectional view of the curved portion of the display.

[0009] Figure 2C yes Figure 2B An enlarged view of a portion of the cross-sectional diagram, further showing the adhesive medium and spacers.

[0010] Figure 3 is Figure 2A and Figure 2B a comparison of the glass shape cross-sectional thickness in the center region of a bend of a display to a target curvature.

[0011] Figure 4 is a cross-sectional view of a display taken in one of the wing regions Figure 2A

[0012] Figure 5 shows the relative flatness of a display including a frame and a glass substrate in a wing segment Figure 4

[0013] Figure 6A and Figure 6B shows a vacuum forming apparatus according to one example embodiment.

[0014] Figure 7 illustrates a center forming block of a vacuum apparatus that is removed from the rest of the apparatus and clamped to the display during the curing process.

[0015] Figure 8 illustrates the interaction of the frame cantilever with the bond line feature to create a mechanical hard stop device to set the adhesive bond thickness. The set screw or other mechanical device can be adjusted to meet a specific bond line target and can be adjusted to reduce variation.

[0016] Figure 9 shows the uniformity of the bond line in multiple sections of a display.

[0017] The repeated use of reference numbers in the present description and drawings is intended to represent the same or similar features or elements include in the present disclosure, even if the numbers increase by 100 when crossing a figure or drawing. It will be understood that many other variations and examples fall within the scope and spirit of the disclosed principles. DETAILED DESCRIPTION

[0018] Reference will now be made in detail to some embodiments of the subject disclosure, examples of which are illustrated in part in the accompanying drawings. While the disclosed subject matter will be described in conjunction with the enumerated claims, it will be understood that the exemplary subject matter is not intended to limit the claims to the disclosed subject matter.

[0019] ​​Cold forming (e.g., bending) is an energy-efficient method of producing a curved glass substrate based on elastically deforming the glass at a relatively low temperature (e.g., < 140 °C) using the application of an out-of-plane load to produce a desired shape. During the cold forming process, a flat high-strength glass substrate is deformed in three dimensions (3D) and is mechanically fixed to a target pre-shaped 3D frame, for example, a frame that mounts a display functional module, by an adhesive interlayer.

[0020] The present disclosure provides for improved vacuum forming methods, apparatuses, and resulting displays in various key areas. The methods greatly improve manufacturing throughput, for example, by reduced curing times. The methods further facilitate improved control of glass shape to target shape and improved control of adhesive line thickness, which, for example, leads to improved survivability and long-term reliability.

[0021] Vehicle interior systems can include various different curved surfaces designed to be transparent, such as curved display surfaces, and the present disclosure provides for articles and methods of forming these curved surfaces including glass substrates. Displays for vehicle interior systems are often fitted with a frame that allows the display component to be easily viewed when the display is on, but can contrast the color or pattern of the display with adjacent automotive interior components.

[0022] As used herein, the terms "cold forming," "cold bending," or "cold bend" refer to bending a glass substrate at a cold forming temperature that is below the softening point of the glass. The term "cold bendable" refers to the ability of a glass substrate to be cold bent.

[0023] Figure 1 A vehicle interior 10 including three different vehicle interior systems 100, 200, 300 is shown in accordance with example embodiments. The vehicle interior system 100 includes a center console base 110 having a curved surface 120 that includes a display shown as a curved display 130. The vehicle interior system 200 includes an instrument panel base 210 having a curved surface 220 that includes a display shown as a curved display 230. The instrument panel base 210 typically includes an instrument panel 215 that can also include a curved display. The vehicle interior system 300 includes an instrument panel steering wheel base 310 having a curved surface 320 and a display shown as a curved display 330. In one or more embodiments, the vehicle interior system can include a base that is an armrest, a pillar, a seat back, a floor, a headrest, a door panel, or any portion of a vehicle interior that includes a curved surface.

[0024] The articles and techniques described herein can be used in any or all of the vehicle interior systems 100, 200, and 300. Although Figure 1Automotive interiors are shown, but various embodiments of vehicle interior systems can be incorporated into any type of vehicle, such as trains, motor vehicles (e.g., cars, trucks, buses, and the like), marine vessels (boats, ships, submarines, and the like), and aircraft (e.g., drones, airplanes, jets, helicopters, and the like), including manned vehicles, semi-autonomous vehicles, and fully autonomous vehicles.

[0025] FIG. 2 shows a display 400 for a vehicle interior system, according to one embodiment. Referring to FIG. 2, the display 400 includes a glass substrate 402 and a frame 404. The frame 404 includes a first opening 406A and a second opening 406B, which are configured to receive further display components or modules (not shown). The frame 404 includes a curved central portion 408, a first wing portion 410A, and a second wing portion 410B. Similarly, the glass substrate 402 can include a curved central portion 412, a first wing portion 414A, and a second wing portion 414B. Figure 6A to Figure 8 Methods and apparatus for forming the display 400 are further described. It is recognized that the techniques and apparatus are not limited to the display 400, but can be used for any display including those in FIGS. 1 and 2. Figure 6A to Figure 8 The techniques and apparatus are not limited to the display 400, but can be used for any display including those in FIGS. 1 and 2. Figure 1 As shown in FIGS. 2 and 3, the display 400 includes a glass substrate 402 and a frame 404. As shown only in FIG. 2, the frame 404 includes a first opening 406A and a second opening 406B, which are configured to receive further display components or modules (not shown). The frame 404 includes a curved central portion 408, a first wing portion 410A, and a second wing portion 410B. Similarly, the glass substrate 402 can include a curved central portion 412, a first wing portion 414A, and a second wing portion 414B. Figure 2A As shown in FIGS. 2 and 3, the display 400 includes a glass substrate 402 and a frame 404. As shown only in FIG. 2, the frame 404 includes a first opening 406A and a second opening 406B, which are configured to receive further display components or modules (not shown). The frame 404 includes a curved central portion 408, a first wing portion 410A, and a second wing portion 410B. Similarly, the glass substrate 402 can include a curved central portion 412, a first wing portion 414A, and a second wing portion 414B. Figure 2A As shown in FIG. 2, the first wing portion 410A can be connected to a first side of the central portion 408 and can define the first opening 406A, which is configured to receive one of the display modules therein. Similarly, the second wing portion 410B can be connected to an opposite second side of the central portion 408 and can define the second opening 406B, which is configured to receive a second one of the plurality of display modules therein. Figure 2A As shown in FIG. 2, the first wing portion 410A can be connected to a first side of the central portion 408 and can define the first opening 406A, which is configured to receive one of the display modules therein. Similarly, the second wing portion 410B can be connected to an opposite second side of the central portion 408 and can define the second opening 406B, which is configured to receive a second one of the plurality of display modules therein.

[0026] The glass substrate 402 can be composed of a suitable glass composition for cold-formed glass substrates described herein, including soda-lime glass, aluminosilicate glass, borosilicate glass, boroaluminosilicate glass, alkali-containing aluminosilicate glass, alkali-containing borosilicate glass, and alkali-containing boroaluminosilicate glass.

[0027] The glass substrate 402 can be composed of a suitable glass composition for cold-formed glass substrates described herein, including soda-lime glass, aluminosilicate glass, borosilicate glass, boroaluminosilicate glass, alkali-containing aluminosilicate glass, alkali-containing borosilicate glass, and alkali-containing boroaluminosilicate glass.

[0028] The glass substrate 402 can be strengthened using any suitable method known in the art, including by including compressive stress (CS) extending from the surface to a depth of compression (DOC) into the glass substrate; by utilizing a mismatch in the coefficient of thermal expansion between portions of the article to create a compressive stress region and a central region exhibiting tensile stress; by thermal strengthening by heating the glass to a temperature above the glass transition point and then rapidly quenching; and by chemical strengthening by ion exchange, in which ions, for example at or near the surface of the glass substrate, are replaced or exchanged with larger ions of the same valence or oxidation state.

[0029] As used herein, the term "glass substrate" is used in its broadest sense to include any object made wholly or partly of glass. Glass substrates include laminates of glass and non-glass materials, laminates of glass and crystalline materials, and glass-ceramics (including amorphous and crystalline phases). Glass substrates can be transparent or opaque. Cold-formed glass substrates can include colorants that provide a particular color.

[0030] The glass substrate 402 can be positioned on the frame 404 and can include a curved central portion 412 that interfaces with and generally conforms to the curved central portion 408 of the frame 404. A first wing portion 414A of the glass substrate 402 can interface with and generally conform to the first wing portion 410A of the frame 404. A second wing portion 414B of the glass substrate 402 can interface with and generally conform to the second wing portion 410B of the frame 404. The glass substrate 402 in the wing portions 414A, 414B can cover the first and second openings 406A, 406B. Figure 2B An interface between the glass substrate 402 and the frame 404 is shown. It occurs along a first major surface 416 of the glass substrate 402 and a first major surface 418 of the frame 404.

[0031] The frame 404 has an interior surface that defines the first opening 406A and a second interior edge that defines the second opening 406B. The first interior surface provides mechanical alignment for positioning a first display module of the plurality of display modules within the first opening 406A, while the second interior surface provides mechanical alignment for positioning a second display module of the plurality of display modules within the second opening 406B.

[0032] Figure 2C Further shown is Figure 2BFIG. 4B is a cross-sectional view of the glass substrate 502 attached to the frame 404 at the first major surfaces 416 and 418. According to one embodiment, the adhesive medium 420 can include a structural adhesive. The structural adhesive can include polyurethane (e.g., available from 3M Company, St. Paul, MN as DP604NS), silicone and silane modified polymers (e.g., available from Dow Corning, Midland, MI as TEROSON RB IX, also known as TEROSTAT MS 9399 and TEROSON MS 647), and epoxy (e.g., available from Huntsman Advanced Materials, Conroe, TX as Araldite® 2000-2K). DP604NS from 3M Company, St. Paul, MN; and Betamate 73100 / 002, 73100 / 005, 73100 / 010, Betaseal X2500, and Betalink K2 from Huntsman Advanced Materials, Wilmington, DE), silicone and silane modified polymers (e.g., available from Dow Corning, Midland, MI as TEROSON RB IX, also known as TEROSTAT MS 9399 and TEROSON MS 647), and epoxy (e.g., available from Huntsman Advanced Materials, Conroe, TX as Araldite® 2000-2K). TEROSON RB IX from Dow Corning, Midland, MI, also known as TEROSTAT MS 9399 and TEROSON MS 647, and Araldite® 2000-2K from Huntsman Advanced Materials, Conroe, TX). Scotch-Weld DP125 and DP604 from 3M Company, St. Paul, MN. TM Scotch-Weld DP125 and DP604 from 3M Company, St. Paul, MN.

[0033] Other adhesives include, but are not limited to, adhesives selected from one or more of the following classes: (a) toughened epoxy resins (e.g., Masterbond EP21TDCHT-LO, 3M Scotch Weld Epoxy DP460 Off-white); (b) flexible epoxy resins (e.g., Masterbond EP21TDC-2LO, 3M Scotch Weld Epoxy 2216); (c) acrylic resins and / or toughened acrylic resins (e.g., LORD adhesive 403, 406, or 410 acrylic adhesive with LORD accelerator 19 or 19GB w / LORD AP 134 primer; LORD adhesive 850 or 852 / LORD accelerator 25GB, Loctite HF8000, Loctite AA4800); (d) urethanes (e.g., 3M Scotch Weld Urethane DP640 Brown, SikaForce 7570L03, SikaForce 7550L15, Sikaflex 552, and polyurethane (PUR) hot melt adhesives such as Technomelt PUR 9622-02UVNA, Loctite HHD3542, Loctite HHD 3580, 3M Hotmelt adhesives 3764 and 3748); and (e) polysilicones (Dow Corning 995, Dow Corning 3-0500 polysilicone composite adhesive, Dow Corning 7091, SikaSil-GP). In some cases, structural adhesives that can be provided as a sheet or film can be utilized (e.g., but not limited to, 3M structural adhesive film AF126-2, AF 163-2M, SBT 9263, and 9214, Masterbond FLM36-LO). In addition, pressure sensitive adhesives such as 3M VHB tape can be utilized. In these embodiments, the use of pressure sensitive adhesives allows for the bonding of curved glass substrates to a frame without at least the need for a curing step.

[0034] As Figure 2CAs shown, the adhesive medium may include rigid, semi-rigid, or compliant spacers 422, which have a different material and / or a different thickness T than the structural adhesive or other adhesive medium 420. In other embodiments, the spacers 422 may have the same material as the structural adhesive or other adhesive medium 420, but may have a different thickness T as shown. The spacers 422, for example, may be used in critical stress regions to prevent the glass from compressing before the structural adhesive is fully cured. The spacers 422 may, for example, be features that are separate from the structural adhesive. The spacers 422 may be any or a combination of VHB tape, foam tape, pre-cured adhesive dots, rigid polymers, compliant polymers, or fully or partially cured structural adhesives (fully or partially cured before the residue of the adhesive medium 420). The spacers 422 may be applied to the glass and / or the frame. In the areas of the display utilizing the spacers 422, the frame 404 may have mechanical features 424 such as grooves, ridges, etc., to, for example, improve the alignment or performance of the spacers 422. The spacer 422 can be sacrificial or permanent. A sacrificial spacer 422 can be subsequently replaced by structural adhesive.

[0035] according to Figure 2C Implementation methods (and as in) Figure 3 and / or Figure 9 As shown in the diagram, the adhesive medium 420 may have a thickness between the glass and the frame, said thickness varying between the lesser of + / - 200 μm or 10% of the desired thickness. This is a direct result of the method and apparatus used for molding the display 400, which will be referred to... Figure 6A to Figure 8 The methods and apparatus will be discussed further, as will be discussed later. Exemplary thicknesses of the adhesive medium 420 may be 3 mm, 2 mm, 1 mm, 0.5 mm, 0.25 mm, 0.01 mm, or less, and can be applied in various ways. In one embodiment, the adhesive is applied using a trowel and mixing nozzle or a premixed syringe or automatic adhesive dispenser, and spread evenly using any of the following (e.g., rollers, brushes, scrapers, or pull strips).

[0036] The adhesive medium 420 may also have any suitable length and / or width. For example, one of the width and / or length may be about 25 mm or less. The length and / or width may be in the range of about 1 mm to about 15 mm, about 5 mm to about 20 mm, about 10 mm to about 15 mm, about 1 mm to about 10 mm, about 5 mm to about 10 mm, about 5 mm to about 15 mm, about 10 mm to about 20 mm, or about 1 mm to about 5 mm.

[0037] The adhesive medium 420 can have any suitable thickness, measured from the surface of the adhesive medium 420 that contacts the glass substrate 402 to the frame 404. Among other things, the thickness of the adhesive medium 420 can be tailored to ensure lamination between the frame 404 and the cold-formed glass substrate 402. For example, the adhesive medium can have a thickness of about 5 mm or less. The adhesive medium 420 can have a thickness in a range from about 200 μιη to about 500 μιη, from about 225 μιη to about 500 μιη, from about 250 μιη to about 500 μιη, from about 275 μιη to about 500 μιη, from about 300 μιη to about 500 μιη, from about 325 μιη to about 500 μιη, from about 350 μιη to about 500 μιη, from about 375 μιη to about 500 μιη, from about 400 μιη to about 500 μιη, from about 200 μιη to about 475 μιη, from about 200 μιη to about 450 μιη, from about 200 μιη to about 425 μιη, from about 200 μιη to about 400 μιη, from about 200 μιη to about 375 μιη, from about 200 μιη to about 350 μιη, from about 200 μιη to about 325 μιη, from about 200 μιη to about 300 μιη, or from about 200 μιη to about 275 μιη.

[0038] The thickness of the glass substrate 402 can be tailored to allow the glass substrate to be more flexible to achieve a desired radius of curvature. Also, a thinner glass substrate 402 can deform more easily, which can potentially compensate for shape mismatches and gaps that can result from the shape of the display 400 when bent. At least a portion of the glass substrate 402 and the frame 404 can have substantially similar radii of curvature to provide a substantially uniform distance between the first major surface 416 and the first major surface 418, which can be filled by the adhesive medium 420 and / or the spacer 422.

[0039] Now returning to Figure 2BThe radius of curvature of the central portion 408 of the frame 404 and / or the radius of curvature of the central portion 412 of the glass substrate 402 can be, for example, about 20 mm or more, 40 mm or more, 50 mm or more, 60 mm or more, 100 mm or more, 250 mm or more, or 500 mm or more. For example, the first radius of curvature can range from about 20 mm to about 2000 mm, from about 30 mm to about 2000 mm, from about 40 mm to about 1500 mm, from about 50 mm to about 1500 mm, from about 60 mm to about 1500 mm, from about 70 mm to about 2000 mm, from about 80 mm to about 1500 mm, from about 90 mm to about 2000 mm, from about 100 mm to about 2000 mm, from about 120 mm to about 2000 mm, from about 140 mm to about 2000 mm, from about 150 mm to about 2000 mm, from about 160 mm to about 2000 mm, from about 180 mm to about 2000mm, from about 200mm to about 2000mm, from about 220mm to about 2000mm, from about 240mm to about 2000mm, from about 250mm to about 2000mm, from about 260mm to about 2000mm, from about 270mm to about 2000mm, from about 280mm to about 2000mm, from about 290mm to about 2000mm, from about 300mm to about 2000mm, from about 350mm to about 2000mm, from about 400mm to about 2000mm, from about 450mm to about 2000mm, from about 500mm to about 2000mm, from about 550mm to about 2000mm m to approximately 2000 mm, from approximately 600 mm to approximately 2000 mm, from approximately 650 mm to approximately 2000 mm, from approximately 700 mm to approximately 2000 mm, from approximately 750 mm to approximately 2000 mm, from approximately 800 mm to approximately 2000 mm, from approximately 900 mm to approximately 2000 mm, from approximately 950 mm to approximately 2000 mm, from approximately 1000 mm to approximately 2000 mm, from approximately 1250 mm to approximately 2000 mm, from approximately 20 mm to approximately 1400 mm, from approximately 20 mm to approximately 1300 mm, from approximately 20 mm to approximately 1200 mm, from approximately 20 mm to approximately 1100 mm, from approximately 20 mm to about 1000 mm, from about 20 mm to about 950 mm, from about 20 mm to about 900 mm, from about 20 mm to about 850 mm, from about 20 mm to about 800 mm, from about 20 mm to about 750 mm, from about 20 mm to about 700 mm, from about 20 mm to about 650 mm, from about 20 mm to about 600 mm, from about 20 mm to about 550 mm, from about 20 mm to about 500 mm, from about 20 mm to about 450 mm, from about 20 mm to about 400 mm, from about 20 mm to about 350 mm, from about 20 mm to about 300 mm, from about 20 mm to about 250 mm.From approximately 20mm to approximately 200mm, from approximately 20mm to approximately 150mm, from approximately 20mm to approximately 100mm, from approximately 20mm to approximately 50mm, from approximately 60mm to approximately 1400mm, from approximately 60mm to approximately 1300mm, from approximately 60mm to approximately 1200mm, from approximately 60mm to approximately 1100mm, from approximately 60mm to approximately 1000mm, from approximately 60mm to approximately 950mm, from approximately 60mm to approximately 900mm, from approximately 60mm to approximately 850mm, from The range is from about 60 mm to about 800 mm, from about 60 mm to about 750 mm, from about 60 mm to about 700 mm, from about 60 mm to about 650 mm, from about 60 mm to about 600 mm, from about 60 mm to about 550 mm, from about 60 mm to about 500 mm, from about 60 mm to about 450 mm, from about 60 mm to about 400 mm, from about 60 mm to about 350 mm, from about 60 mm to about 300 mm, or from about 60 mm to about 250 mm. In one or more embodiments, a glass substrate with a thickness of less than about 0.4 mm may exhibit a radius of curvature of less than about 100 mm or less than about 60 mm. According to one embodiment, the central portion of the bend in the frame and the central portion of the bend in the glass substrate each have a radius of curvature of 20 mm but less than 500 mm.

[0040] like Figure 3 As shown, the radius of curvature of the curved central portion 412 of the glass substrate 402 can be within 100 μm of the radius of curvature of the curved central portion 408 of the frame 404. This is a direct result of the method and apparatus used to mold the display 400, which will be referred to... Figure 6A to Figure 8 The methods and apparatus will be discussed further, as will be discussed later. In short, for glass-molded parts, the two key parameters are the glass shape and the bond thickness. Since the glass and frame thicknesses are relatively consistent, the overall part thickness is usually a substitute for the bond line. Figure 3 This represents a cross-section of the curved area of ​​display 400. The (blue) solid line is the cross-section, and the thickness of this line represents the variation in the adhesive medium 420. The (red) dashed line is the target shape. Figure 6A to Figure 8 Parts manufactured on a vacuum chuck are tightly conformed to the target within a 100μm range. This should be contrasted with conventional methods / equipment where parts deviate from the target shape by more than 1mm.

[0041] The frame 404 can have any suitable thickness. For example, the metal substrate thickness can range from about 0.5 mm to about 20 mm (e.g., from about 2 mm to about 20 mm, from about 3 mm to about 20 mm, from about 4 mm to about 20 mm, from about 5 mm to about 20 mm, from about 6 mm to about 20 mm, from about 7 mm to about 20 mm, from about 8 mm to about 20 mm, from about 9 mm to about 20 mm, from about 10 mm to about 20 mm, from about 12 mm to about 20 mm, from about 14 mm to about 20 mm, from about 1 mm to about 18 mm, from about 1 mm to about 16 mm, from about 1 mm to about 15 mm, from about 1 mm to about 14 mm, from about 1 mm to about 12 mm, from about 1 mm to about 10 mm, from about 1 mm to about 8 mm, from about 1 mm to about 6 mm, from about 1 mm to about 5 mm, from about 1 mm to about 4 mm, from about 1 mm to about 3 mm, from about 1 mm to about 2 mm), and all ranges and sub-ranges therebetween.

[0042] Figure 4 is in the first wing region 410A, 414A Figure 2A The glass substrate 402 has a thickness (t) that is substantially constant and defined as the distance between the first major surface 416 and the second major surface 416A, as shown in Figure 4 The glass substrate includes a width (W) defined as a first maximum dimension of one of the first or second major surfaces 416, 416A, and 418 orthogonal to the thickness (t) and a length (L) defined as a second maximum dimension of one of the first or second surfaces 416, 416A, 418 orthogonal to both the thickness and the width, as shown in Figure 4 The glass substrate includes a width (W) defined as a first maximum dimension of one of the first or second major surfaces 416, 416A, and 418 orthogonal to the thickness (t) and a length (L) defined as a second maximum dimension of one of the first or second surfaces 416, 416A, 418 orthogonal to both the thickness and the width, as shown in Figure 4 The dimensions discussed herein can be average dimensions. The bonding medium is not specifically shown in Figure 4

[0043] ​The glass substrate 402 can have any suitable thickness. For example, it can have a thickness (t) of about 1.5 mm or less. For example, the thickness can be in a range from about 0.01 mm to about 1.5 mm, 0.02 mm to about 1.5 mm, 0.03 mm to about 1.5 mm, 0.04 mm to about 1.5 mm, 0.05 mm to about 1.5 mm, 0.06 mm to about 1.5 mm, 0.07 mm to about 1.5 mm, 0.08 mm to about 1.5 mm, 0.09 mm to about 1.5 mm, 0.1 mm to about 1.5 mm, from about 0.15 mm to about 1.5 mm, from about 0.2 mm to about 1.5 mm, from about 0.25 mm to about 1.5 mm, from about 0.3 mm to about 1.5 mm, from about 0.35 mm to about 1.5 mm, from about 0.4 mm to about 1.5 mm, from about 0.45 mm to about 1.5 mm, from about 0.5 mm to about 1.5 mm, from about 0.55 mm to about 1.5 mm, from about 0.6 mm to about 1.5 mm, from about 0.65 mm to about 1.5 mm, from about 0.7 mm to about 1.5 mm, from about 0.01 mm to about 1.4 mm, from about 0.01 mm to about 1.3 mm, from about 0.01 mm to about 1.2 mm, from about 0.01 mm to about 1.1 mm, from about 0.01 mm to about 1.05 mm, from about 0.01 mm to about 1 mm, from about 0.01 mm to about 0.95 mm, from about 0.01 mm to about 0.9 mm, from about 0.01 mm to about 0.85 mm, from about 0.01 mm to about 0.8 mm, from about 0.01 mm to about 0.75 mm, from about 0.01 mm to about 0.7 mm, from about 0.01 mm to about 0.65 mm, from about 0.01 mm to about 0.6 mm, from about 0.01 mm to about 0.55 mm, from about 0.01 mm to about 0.5 mm, from about 0.01 mm to about 0.4 mm, from about 0.01 mm to about 0.3 mm, from about 0.01 mm to about 0.2 mm, from about 0.01 mm to about 0.1 mm, from about 0.04 mm to about 0.07 mm, from about 0.1 mm to about 1.4 mm, from about 0.1 mm to about 1.3 mm, from about 0.1 mm to about 1.2 mm, from about 0.1 mm to about 1.1 mm, from about 0.1 mm to about 1.05 mm, from about 0.1 mm to about 1 mm, from about 0.1 mm to about 0.95 mm, from about 0.1 mm to about 0.9 mm, from about 0.1 mm to about 0.85 mm, from about 0.1 mm to about 0.8 mm, from about 0.1 mm to about 0.75 mm, from about 0.1 mm to about 0.7 mm, from about 0.1 mm to about 0.65 mm, from about 0.1 mm to about 0.6 mm, from about 0.1 mm to about 0.55 mm, from about 0.1 mm to about 0.5 mm, from about 0.1 mm to about 0.4 mm, or from about 0.3 mm to about 0.7 mm.

[0044] The glass substrate 402 can also have a width (W) and / or length (not specifically shown) in a range from about 5 cm to about 250 cm, from about 30 cm to about 90 cm, from about 10 cm to about 250 cm, from about 15 cm to about 250 cm, from about 20 cm to about 250 cm, from about 25 cm to about 250 cm, from about 30 cm to about 250 cm, from about 35 cm to about 250 cm, from about 40 cm to about 250 cm, from about 45 cm to about 250 cm, from about 50 cm to about 250 cm, from about 55 cm to about 250 cm, from about 60 cm to about 250 cm, from about 65 cm to about 250 cm, from about 70 cm to about 250 cm, from about 75 cm to about 250 cm, from about 80 cm to about 250 cm, from about 85 cm to about 250 cm, from about 90 cm to about 250 cm, from about 95 cm to about 250 cm, from about 100 cm to about 250 cm, from about 110 cm to about 250 cm, from about 120 cm to about 250 cm, from about 130 cm to about 250 cm, from about 140 cm to about 250 cm, from about 150 cm to about 250 cm, from about 5 cm to about 240 cm, from about 5 cm to about 230 cm, from about 5 cm to about 220 cm, from about 5 cm to about 210 cm, from about 5 cm to about 200 cm, from about 5 cm to about 190 cm, from about 5 cm to about 180 cm, from about 5 cm to about 170 cm, from about 5 cm to about 160 cm, from about 5 cm to about 150 cm, from about 5 cm to about 140 cm, from about 5 cm to about 130 cm, from about 5 cm to about 120 cm, from about 5 cm to about 110 cm, from about 5 cm to about 110 cm, from about 5 cm to about 100 cm, from about 5 cm to about 90 cm, from about 5 cm to about 80 cm, or from about 5 cm to about 75 cm.

[0045] Figure 5 An exemplary flatness of the glass substrate 402 and the frame 404 in the first wing regions 410A, 414A is illustrated. This flatness along the interface of the first major surfaces 416, 418 is particularly important for improving the viewability of the display and reducing mechanical stresses that can lead to premature failure. This improved flatness of the first major surface 416 relative to the first major surface 418 is a direct result of the method and apparatus for shaping the display 400, which will be discussed with reference to Figure 6A to Figure 8 The method and apparatus are further discussed as follows, as will be further discussed subsequently.

[0046] As shown in Figure 5 The flatness of the display 400 in the display region, such as along the first wing portions 410A, 414A and particularly at the first opening 406A, is illustrated.Figure 5 Images collected by deflectometry are shown, where local curvature is in diopters, where non-zero diopter values indicate curvature. Increasing diopters indicate greater local curvature. As shown in Figure 5 clamping for at least 2 hours resulted in the flattest display area, improving optical performance. Thus, as shown in Figure 5 As shown in

[0047] Figure 6A and Figure 6B A forming apparatus 500 is shown, which includes a vacuum forming apparatus (also referred to as a vacuum chuck) for cold forming a glass substrate 402 as previously described. Other components of the display 400 are shown in Figure 6B including the frame 404. Figure 6A A forming apparatus 500 is shown, which includes a vacuum forming apparatus (also referred to as a vacuum chuck) for cold forming a glass substrate 402 as previously described. Other components of the display 400 are shown in

[0048] As best shown in Figure 6B The forming apparatus 500 can optionally include a body 502, a plurality of formers 504A, 504B, and 504C (also referred to as inlays, regions, or pads), a thin coating 506, a first frame securing device 508, and a second frame securing device assembly 510. The second frame securing device assembly 510 can include a handle 512 and a stem 514.

[0049] The body 502 can have formed therein or will house a plurality of independent plenums 516A, 516B, and 516C that are in communication with the plurality of formers 504A, 504B, and 504C, respectively. Alternatively, the body 502 can have a single plenum in communication with the plurality of formers 504A, 504B, and 504C. The plenums can be used to apply independently controlled pressure differentials to the plurality of formers 504A, 504B, and 504C. The pressure differentials applied to the center or wings can be different relative to each other. For example, the pressure differential on the wings can not need to be specially designed, while a greater pressure differential can be needed in the center that is specially designed. The body 502 can be configured to receive the plurality of formers 504A, 504B, and 504C, which can be configured to be removable from the body 502.

[0050] Multiple molded parts 504A, 504B, and 504C may each have main surfaces 505A, 505B, and 505C designed to contact corresponding main surfaces of the glass substrate 402. The multiple molded parts 504A, 504B, and 504C may include a removable center member 504A, which enables seemingly less clamping between the molding and clamping steps (the part does not necessarily need to be removed from the fixture), such as... Figure 7 As further illustrated herein, the removable center member 504A may include a main surface 505A having a center of curvature. The wings 504B and 504C may each have main surfaces 505B and 505C, which may be substantially flat, for shaping the wing regions of the display 400 as previously discussed. The geometry of the device 500 may also be altered so that its curvature can be changed by removing only the center member 504A instead of having to remove multiple components. The multiple shaped members 504A, 504B, and 504C may include features such as holes or channels 518. Figure 6A The surface features (best shown in the image) are configured to provide an improved pressure differential (pull force) to the display 400, and particularly along the main surface of the glass substrate 402. Channels 518 may exist, for example, only on the surfaces of the plurality of molded parts 504A, 504B, and 504C, and may not penetrate the air chamber. (See reference...) Figure 8 As discussed further, the frame fasteners 508, 510, and particularly the second frame fastener assembly 510 and body 502, may have mechanical stops that provide adjustable adhesive line control features. The levers 514 and clamps of the second frame fastener assembly 510 can be configured to apply uniform downward pressure to the display 400 via the frame 404 without applying excessive pressure. The frame fastener 510, with its handle 512 attached to it, increases rigidity and provides ease of operation.

[0051] As discussed previously, the advantages provided by the molding equipment 500 include molding a glass substrate 402 to a target shape within a 100 μm range (as opposed to >1 mm), improved control over the bonding line (e.g., + / -200 μm, as opposed to >1 mm), reduced processing time (e.g., 15 min vs. 2+ hours), the ability to accommodate various designs and bonding line thicknesses (e.g., removing only the center piece 504A and replacing it with a different center piece with different geometries), and greater compatibility with a variety of display types, including laminated displays.

[0052] Figure 6B and Figure 7 The central component 504A is shown to be removable. Figure 7The display 400 is also illustrated as it can remain clamped to the center piece 504A (refer to Figure 6B ) after removal from the rest of the forming apparatus 500. As shown in Figure 7 , the center piece 504A can also be configured to remain connected to a low pressure source P (such as a vacuum) when so removed. This can enable a seemingly less clamping between the forming step and the clamping step (the part does not have to be removed from the fixture).

[0053] Now returning only to Figure 6B , the thin coating 506 can include a polymer coating configured to provide a good seal, protection of the glass 402 but only slight compliance to achieve a good shape, such as a Teflon tape. According to one example, the coating 506 can be a polymer film with adhesive backing having minimal compliance. This choice can protect the glass from damage by the metal chuck while sealing the vacuum sufficiently and having minimal compliance. Using an adhesive film is easy to apply and replace.

[0054] According to one advanced example, for example, a cold forming process using the forming apparatus 500 can entail: aligning a piece of flat glass to the forming apparatus, applying a vacuum or other low pressure differential to hold the glass to the desired shape, applying an adhesive medium such as a structural adhesive to the frame or glass surface in a specific pattern, aligning a three-dimensional shaped frame to the glass on the forming apparatus and pressing it to the glass, applying force to compress the adhesive to a uniform thickness (bondline thickness) and holding the frame to the glass by means of, for example, clamping.

[0055] According to one embodiment, a method of forming a display 400 is disclosed for mounting one or more display modules in a vehicle interior system. The method can include positioning a glass substrate 402 on a forming apparatus 500. The forming apparatus 500 can have a plurality of formers 504A, 504B, 504C each having a major surface 505A, 505B, 505C configured to interface with the glass substrate 402. The major surface 505A of at least one of the plurality of formers (here 504A) has a radius of curvature. The method can include applying an air pressure differential with the forming apparatus 500 to deform the glass substrate 402 along a major surface of the glass substrate 402 and to form a shape corresponding to a shape of each major surface 505A, 505B, 505C of the plurality of formers 504A, 504B, 504C of the forming apparatus 500. A portion of the major surface of the glass substrate 402 is deformed to have a radius of curvature corresponding to the radius of curvature of the major surface 505A of at least one of the plurality of formers 504A. The method can include applying a structural adhesive (or other bonding medium as discussed herein) to one or more of the frame 404 and the glass substrate 402 and positioning the frame 404 on the glass substrate 402 with the structural adhesive positioned between the frame 404 and the glass substrate 402. The method can include applying a desired force to the frame 404 to compress the adhesive to a desired thickness. The method can include removing the glass substrate 402 from one or more of the plurality of formers of the forming apparatus (here 504B and 504C) while maintaining the glass substrate 402 clamped to at least one of the plurality of formers (here 504A, as shown in Figure 7 FIG. 6B). The method can include maintaining the application of the desired force to compress the adhesive to the desired thickness for a desired duration while the glass substrate is clamped to at least one of the plurality of formers as shown in Figure 7 FIG. 6B). The method can include maintaining the application of the desired force to compress the adhesive to the desired thickness for a desired duration while the glass substrate is clamped to at least one of the plurality of formers as shown in

[0056] Conventional processes require the glass and frame to be clamped on a vacuum chuck throughout adhesive cure. Releasing the clamp before the adhesive has cured / achieved sufficient strength causes the glass to change shape and even delaminate from the frame in high stress areas. Moving the parts (glass & frame) while the adhesive is curing is also undesirable.

[0057] One aspect of the invention is that it allows the display 400 to be removed from the vacuum chuck before the adhesive has fully cured, because as Figure 7 As illustrated in the implementation, clamping and / or pressure differential P are sustainably maintained (via rod 514). Figure 7 As shown, the clamping capacity is a combination of rods / threaded rods (used before) across the curved portion of the glass substrate 402 where the stress is highest (e.g., the curve transitions into a substantially flat region, referred to herein as the flat-tip region). Figure 6A and Figure 6B (Two of the rods 514 shown). Center member 504A and including... Figure 7 Other components of the lever 514 include mechanical stop devices (similar to the following references) Figure 8 (Those discussed further) prevent the rod clamps from becoming too tight. With this configuration, the display 400 can be formed on a vacuum chuck and removed before all the adhesive has cured. An additional center piece 504A may be required for each additional display part in the process, but this provides the benefits of faster production runs and replaceable design curvatures.

[0058] like Figure 8 As shown, the main body 502 and the second frame fixing assembly 510 can form a mechanical stop 540. The mechanical stop 540 may include a position-adjustable feature 542 of the main body 502 (such as a screw, set screw, etc.) and a portion 544 of the second frame fixing assembly 510 that clamps the frame 404 downwards. Therefore, the mechanical stop 540 results in a desired thickness of the adhesive line (adhesive medium) varying between + / - 200 μm. More specifically, the second frame fixing assembly 510 may include cantilever or wing 546 (portion 544) that interacts with a corresponding set screw 548 (position-adjustable feature 542) to establish the mechanical stop 540 to set the adhesive bonding thickness. The set screw 544 can be adjusted to meet specific adhesive line targets and can be adjusted to reduce variations in the adhesive line. Multiple set screws may be provided on each side of the molding apparatus 500.

[0059] Figure 9 The diagram shows that the adhesive medium can have a thickness between the glass and the frame, said thickness varying between + / - 200 μm or 10% of the desired thickness. This includes, as referenced... Figure 7 and Figure 8 The mechanical stop device discussed is a direct result of the molding equipment 500 for molding display 400.

[0060] Other methods or product features contemplated herein include localized heating / curing of specific regions of the adhesive using conductive or radiation based methods. Specific regions include those where compressive and tensile stresses are maximized such as flat tips and center regions. Localized heating can be used to "pin" specific regions. Examples of applications include using pre-heated curved center inlays, cylindrical heaters, infrared radiation. For example, specific regions contemplated include those where the glass substrate applies compressive stress to the adhesive medium or tensile stress to the adhesive medium.

[0061] Aspect (1) of the present disclosure is directed to an apparatus for disposing a plurality of display modules within a vehicle interior system, comprising: a frame having a curved center portion, a first wing portion connected to a first side of the center portion and defining a first opening configured to receive one of the plurality of display modules therein, and a second wing portion connected to an opposite second side of the center portion and defining a second opening configured to receive a second one of the plurality of display modules therein; a glass substrate positioned on the frame and comprising a curved center portion interfacing with the curved center portion of the frame, a first wing portion interfacing with the first wing portion of the frame and covering the first opening, and a second wing portion interfacing with the second wing portion of the frame and covering the second opening; and an adhesive medium attaching the glass to the frame, wherein the adhesive medium has a thickness between the glass and the frame that varies between + / - 200 pm or 10% of the desired thickness, whichever is less.

[0062] Aspect (2) of the present disclosure is directed to the apparatus of aspect (1), wherein one or more of the first wing portion of the glass, the first wing portion of the frame, the second wing portion of the glass, and the second wing portion of the frame each has at least one surface that is substantially flat and has a curvature of one of + / - 0.250 units of diopter, + / - 0.150 diopter, and + / - 0.100 diopter with a variation of + / - 0.250 units.

[0063] Aspect (3) of the present disclosure is directed to the apparatus of aspect (1) or aspect (2), wherein the curved center portion of the glass substrate has a radius of curvature that is within 100 pm of a radius of curvature of the curved center portion of the frame.

[0064] Aspect (4) of the present disclosure is directed to the apparatus of any one of aspects (1) to (3), wherein one or more of the curved center portion of the frame and the curved center portion of the glass substrate each has a radius of curvature of 20 mm but less than 500 mm.

[0065] Aspect (5) of the present disclosure pertains to the apparatus of any one of aspects (1) through (4), wherein the frame has an interior surface defining the first opening and a second interior edge defining the second opening, and wherein the first interior surface provides a mechanical alignment for positioning a first one of the plurality of display modules within the first opening and the second interior surface provides a mechanical alignment for positioning a second one of the plurality of display modules within the second opening.

[0066] Aspect (6) of the present disclosure pertains to the apparatus of any one of aspects (1) through (5), wherein the adhesive medium comprises a structural adhesive.

[0067] Aspect (7) of the present disclosure pertains to the apparatus of any one of aspects (1) through (6), further comprising a spacer positioned between the frame and the glass substrate and positioned adjacent to the adhesive medium.

[0068] Aspect (8) of the present disclosure pertains to the apparatus of aspect (7), wherein the spacer comprises one or more of VHB tape, foam tape, rigid polymer, compliant polymer, or a structural adhesive that is fully or partially cured.

[0069] Aspect (9) of the present disclosure pertains to the apparatus of aspect (1) or aspect (8), wherein the frame can have one or more features configured to improve alignment or performance of the spacer.

[0070] Aspect (10) of the present disclosure pertains to an apparatus for disposing a plurality of display modules within a vehicle interior, comprising: a frame having a curved center portion and configured to dispose at least one of the plurality of display modules therein; a glass substrate attached to and positioned on the frame and comprising a curved center portion that interfaces with the curved center portion of the frame, wherein a radius of curvature of the curved center portion of the glass substrate is within 100 pm of a radius of curvature of the curved center portion of the frame.

[0071] Aspect (11) of the present disclosure pertains to the apparatus of aspect (10), wherein the frame further comprises: a first wing portion connected to a first side of the center portion and defining a first opening configured to receive one of the plurality of display modules therein; and a second wing portion connected to an opposite second side of the center portion and defining a second opening configured to receive another of the plurality of display modules therein.

[0072] Aspect (12) of the present disclosure pertains to the apparatus of Aspect (11), wherein the glass substrate further comprises: a first wing portion interfacing with a first wing portion of the frame and covering the first opening; and a second wing portion interfacing with a second wing portion of the frame and covering the second opening.

[0073] Aspect (13) of the present disclosure pertains to the apparatus of Aspect (12), wherein one or more of the first wing portion of the glass, the first wing portion of the frame, the second wing portion of the glass, and the second wing portion of the frame each has at least one surface that is substantially planar and has a curvature of refractive power with a variation of + / - 0.250 units.

[0074] Aspect (14) of the present disclosure pertains to the apparatus of any one of Aspects (10) to (13), wherein the glass is attached to the frame by an adhesive medium, and wherein the adhesive medium has a thickness between the glass and the frame that varies between + / - 200 pm of a desired thickness.

[0075] Aspect (15) of the present disclosure pertains to a method for positioning one or more display modules in a molded display in a vehicle interior system, the method comprising: positioning a glass substrate on a molding apparatus, wherein the molding apparatus has a plurality of moldings, each of the moldings having a major surface configured to interface with the glass substrate, wherein the major surface of at least one of the plurality of moldings has a radius of curvature; applying an air pressure differential with the molding apparatus to deform the glass substrate along its major surface and to form a shape corresponding to the shape of the respective major surfaces of the molding apparatus, wherein a portion of the major surface of the glass substrate is deformed to have a radius of curvature corresponding to the radius of curvature of the major surface of at least one of the plurality of moldings; applying a structural adhesive to one or more of a frame and the glass substrate; positioning the frame on the glass substrate with the structural adhesive positioned between the frame and the glass substrate; applying a desired force to the frame to compress the adhesive to a desired thickness; removing the glass substrate from one or more of the plurality of moldings of the molding apparatus while maintaining the glass substrate clamped to at least one of the plurality of moldings; and maintaining the application of the desired force to compress the adhesive to the desired thickness for a desired duration while the glass substrate is clamped to at least one of the plurality of moldings and while the glass substrate is removed from one or more of the plurality of moldings of the molding apparatus.

[0076] Aspect (16) of the present disclosure pertains to the method of aspect (15), wherein the plurality of formers includes a center former, the center former including at least one of the plurality of formers having a major surface with a radius of curvature.

[0077] Aspect (17) of the present disclosure pertains to the method of aspect (16), wherein the plurality of formers further includes a first wing and a second wing, a major surface of the first wing being substantially flat, a major surface of the second wing being substantially flat.

[0078] Aspect (18) of the present disclosure pertains to the method of any one of aspects (15) through (17), wherein the application of the desired force to the frame to compress the adhesive to the desired thickness is controlled by a mechanical stop.

[0079] Aspect (19) of the present disclosure pertains to the method of aspect (18), wherein the mechanical stop includes a position adjustable feature of the forming apparatus and a portion of a fixture that clamps the frame downward.

[0080] Aspect (20) of the present disclosure pertains to the method of any one of aspects (18) through (19), wherein the variation in the desired thickness between + / - 200 pm is a result of the mechanical stop.

[0081] Aspect (21) of the present disclosure pertains to the method of any one of aspects (15) through (20), wherein the radius of curvature of the glass substrate is within 100 pm of a radius of curvature of a major surface of at least one of the plurality of formers.

[0082] Aspect (22) of the present disclosure pertains to the method of any one of aspects (15) through (20), wherein the application of the air pressure differential with the forming apparatus includes applying different amounts of the air pressure differential to one or more of the plurality of formers.

[0083] Aspect (23) of the present disclosure pertains to the method of any one of aspects (15) through (22), wherein a major surface of the forming apparatus defines a plurality of channels that are in communication with the glass substrate to allow the application of the air pressure differential.

[0084] Aspect (24) of the present disclosure pertains to the method of any one of aspects (15) through (23), further comprising accelerating the cure of the structural adhesive in a selected region.

[0085] Aspect (25) of the present disclosure pertains to the method of any one of aspects (15) through (24), further comprising maintaining the application of the air pressure differential while the glass substrate is clamped to at least one of the plurality of forming members and while the glass substrate is removed from one or more of the plurality of forming members of the forming apparatus.

[0086] Values stated in a range format should be interpreted in the context of the application as an abnormally flexible recitation so that the limits of ranges given - by endpoints, by single numerical values, as "between X and Y" or as "from about X to about Y" are to be interpreted as "at least as low as X and as high as Y." For example, a range of "about 0.1% to about 5%" or "about 0.1% to 5%" should be interpreted to include not only individual values between the recited ranges, but also the individual values themselves, e.g., 1%, 2%, 3%, and 4%, and sub-ranges within the indicated range, e.g., 0.1% to 0.5%, 1.1% to 2.2%, 3.3% to 4.4%. The statement "about X to Y" has the same meaning as "about X to about Y" unless otherwise indicated. Likewise, the statement "about X, Y, or about Z" has the same meaning as "about X, about Y, or about Z" unless otherwise indicated.

[0087] In this document, the terms "a," "an," or the "the" are used to include one or more than one, independent of other instances or referents, unless otherwise clearly indicated contextually. The term "or" is used to mean, and is used interchangeably with, the disjunctive "or," unless otherwise indicated. In addition, it is to be understood that the phraseology or terminology employed herein, and the like, are for the purpose of description and not of limitation. Any use of section headings is intended to aid reading the document and is not to be interpreted as limiting; information that is relevant to a section heading can occur within or outside of that particular section. Furthermore, all publications, patents and patent documents cited in this document are incorporated by reference herein in their entirety, as if each were individually incorporated by reference. In the event of inconsistent usages between this document and documents so incorporated by reference, the use in the incorporated reference is intended to prevail. If a period appears in the citation of a patent document, the period has been inserted only for the sake of readability and should be disregarded in interpreting the citation.

[0088] The term "about" as used herein can allow for a degree of variability in a value or range, for example within 5%, or alternatively within 1%, of a stated limit of a stated value or range.

[0089] The term "substantially" as used herein refers to a majority, or a significantly great number, of a quantity or number that is at least about 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98%, 99%, 99.5%, 99.9%, 99.99%, or at least about 99.999% or more.

[0090] The present disclosure provides the following embodiments, the numbering of which is not to be interpreted as specifying a level of importance.

Claims

1. An apparatus for positioning a plurality of display modules within a vehicle interior system, comprising: a frame having a curved central portion, a first wing portion integrally connected to a first side of the central portion and defining a first opening configured to receive one of the plurality of display modules therein, and a second wing portion integrally connected to an opposite second side of the central portion and defining a second opening configured to receive a second one of the plurality of display modules therein; a glass substrate positioned on the frame and including a curved central portion interfacing with the curved central portion of the frame, a first wing portion interfacing with the first wing portion of the frame and covering the first opening, and a second wing portion interfacing with the second wing portion of the frame and covering the second opening; and an adhesive medium attaching the glass substrate to the frame, wherein the adhesive medium is simultaneously compressed between the glass substrate and each of the curved central portion, the first wing portion, and the second wing portion, such that the entire adhesive medium has a thickness between the glass substrate and the frame that varies between the lesser of + / - 200 pm and + / - 10% of a desired thickness, wherein the glass substrate comprises one of a soda lime glass, an alumino-silicate glass, a borosilicate glass, a boro-alumino-silicate glass, an alkali-containing alumino-silicate glass, an alkali-containing borosilicate glass, and an alkali-containing boro-alumino-silicate glass.

2. The apparatus of claim 1, wherein one or more of the first wing portion of the glass substrate, the first wing portion of the frame, the second wing portion of the glass substrate, and the second wing portion of the frame each has at least one surface that is substantially planar and has a curvature of one of a dioptric power that varies + / - 0.250 units, + / - 0.150 diopters, and + / - 0.100 diopters.

3. The apparatus of claim 1, wherein a radius of curvature of the curved central portion of the glass substrate is within 100 pm of a radius of curvature of the curved central portion of the frame.

4. The apparatus of claim 1, wherein one or more of the curved central portion of the frame and the curved central portion of the glass substrate each has a radius of curvature of at least 20 mm but less than 2000 mm.

5. The apparatus of any one of claims 1 to 4, wherein the frame has a first interior surface defining the first opening and a second interior surface defining the second opening, and wherein the first interior surface provides a mechanical alignment for positioning a first one of the plurality of display modules within the first opening and the second interior surface provides a mechanical alignment for positioning the second one of the plurality of display modules within the second opening.

6. The apparatus of any of claims 1 to 4, wherein the bonding medium comprises a structural adhesive.

7. The apparatus of any of claims 1 to 4, further comprising a spacer positioned between the frame and the glass substrate and positioned adjacent to the bonding medium.

8. The apparatus of claim 7, wherein the spacer comprises one or more of VHB tape, foam tape, rigid polymer, compliant polymer.

9. The apparatus of claim 7, wherein the spacer comprises a structural adhesive that is fully or partially cured.

10. The apparatus of claim 7, wherein the frame has one or more features configured to improve alignment or performance of the spacer.

11. An apparatus for positioning a plurality of display modules within a vehicle interior, comprising: a frame having a curved central portion and configured to position at least one display module of the plurality of display modules therein; a glass substrate attached to and positioned on the frame and comprising a curved central portion that interfaces with the curved central portion of the frame, wherein a radius of curvature of the curved central portion of the glass substrate is within 100 µm of a radius of curvature of the curved central portion of the frame; a bonding medium attaching the glass substrate to the frame, wherein the bonding medium has a thickness between the glass substrate and the frame that varies between the lesser of + / - 200 µm and + / - 10% of a desired thickness; and wherein the glass substrate comprises one of a soda lime glass, an alumino-silicate glass, a borosilicate glass, a boro-alumino-silicate glass, an alkali-containing alumino-silicate glass, an alkali-containing borosilicate glass, and an alkali-containing boro-alumino-silicate glass, wherein the apparatus is formed by a method comprising: positioning the glass substrate on a forming apparatus, wherein the forming apparatus has a plurality of formers, each of the formers having a major surface configured to interface with the glass substrate, wherein the major surface of at least one of the plurality of formers has a radius of curvature; applying an air pressure differential with the forming apparatus to deform the glass substrate along its major surface and to form a shape corresponding to a shape of each major surface of the forming apparatus, wherein a portion of the major surface of the glass substrate is deformed to have a radius of curvature corresponding to the radius of curvature of the major surface of at least one of the plurality of formers; applying the bonding medium to one or more of the frame and the glass substrate; positioning the frame on the glass substrate with the bonding medium positioned between the frame and the glass substrate; applying a desired force to the frame to compress the bonding medium to a desired thickness; removing the glass substrate from one or more of the plurality of formers of the forming apparatus while maintaining the glass substrate clamped to at least one of the plurality of formers; and and In the case where the glass substrate is clamped to at least one of the plurality of formers and in the case where the glass substrate is removed from one or more of the plurality of formers of the forming apparatus, the application of the desired force to compress the bonding medium to the desired thickness is maintained for a desired duration.

12. The apparatus of claim 11, wherein the frame further comprises: a first wing connected to a first side of the center portion and defining a first opening configured to receive one of the plurality of display modules therein; and a second wing connected to an opposite second side of the center portion and defining a second opening configured to receive another of the plurality of display modules therein.

13. The apparatus of claim 12, wherein the glass substrate further comprises: a first wing interfacing with the first wing of the frame and covering the first opening; and a second wing interfacing with the second wing of the frame and covering the second opening.

14. The apparatus of claim 13, wherein one or more of the first wing of the glass substrate, the first wing of the frame, the second wing of the glass substrate, and the second wing of the frame each has at least one surface that is substantially flat and has a curvature of a diopter with a variation of + / - 0.250 units.

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