Display systems including spacers disposed between frame and display back panel and associated methods

Abstract

A display system includes: a glass substrate; a frame comprising a curved support surface; an adhesive layer including an adhesive and disposed between the curved support surface and the glass substrate; and a display module including a back panel. The adhesive layer holds the glass substrate in the shape of the curved support surface. A gap exists between the peripheral edge of the back panel and the inner edge of the frame. A spacer is disposed in the gap and extends an entire distance between the peripheral edge and the inner edge to maintain the gap and promote the adhesive layer to have a uniform thickness during fabrication of the display system. A spacer for containing the adhesive during manufacture, a method of shaping the adhesive layer, a frame feature for containing a flow of the adhesive, a manner of shaping the adhesive layer, and a method of manufacture are also described.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority under 35 U.S.C. §119 to U.S. Provisional Application No. 63 / 443,079, filed on February 3, 2023, and U.S. Provisional Application No. 63 / 523,699, filed on June 28, 2023, the contents of which are the basis of this application and are incorporated herein by reference in their entirety. Background Art

[0003] The present disclosure relates to glass articles for display systems, including cold-formed glass substrates, whose structures can address various issues that can arise from shape mismatches between various components of the system. In certain embodiments, the present disclosure relates to display systems that include spacers positioned in a gap between a display module and a frame onto which the glass substrate is cold-formed.

[0004] Vehicle interiors may incorporate glass surfaces as part of the vehicle's aesthetic and functional design. Such glass surfaces may be joined to a frame system that attaches the glass surface to the vehicle interior. The frame may be made of a suitable material (e.g., aluminum, magnesium) that is more rigid than the glass, helping the frame maintain a curved shape that deviates from the equilibrium shape of the glass alone. The manufacturing methods for frames formed from such materials may not be completely consistent from part to part, resulting in some shape variation between different frames. This shape variation can present difficulties in manufacturing systems that utilize curved glass.

[0005] Therefore, it is desirable to develop a display system structure and manufacturing method that can mitigate the impact of frame shape differences. Summary of the Invention

[0006] According to an embodiment of the present disclosure, a display system includes: a glass substrate including a first major surface and a second major surface; a frame including a curved support surface, the frame including an inner edge defining an opening; an adhesive layer disposed between the curved support surface and the second major surface and attaching the glass substrate to the frame so that the glass substrate conforms to the curved support surface, wherein the second major surface includes an open area that is not bonded to the frame and overlaps the opening; a display module disposed in the opening and bonded to the open area, wherein the display module includes a display layer and a back panel, wherein a gap is disposed between the peripheral edge and the inner edge of the back panel, wherein the frame is not bolted to the back panel; and a spacer disposed in the gap and extending the entire distance between the peripheral edge and the inner edge.

[0007] According to another embodiment of the present disclosure, a method of forming a display system includes: cold forming a glass substrate against a curved support surface of a frame, wherein an adhesive layer is disposed between the curved support surface and the glass substrate, wherein the frame includes an opening; laminating a display module to the glass substrate within the opening via a layer of optically clear adhesive, wherein the display module includes a back panel, and wherein a peripheral edge of the back panel is separated from an inner edge of the frame by a gap; disposing a spacer in the gap, wherein the spacer bonds the back panel to the frame and maintains a shape of the gap; and curing the adhesive layer so that the glass substrate is held in a curved shape by the frame.

[0008] According to another embodiment of the present disclosure, a display system includes: a glass substrate including a first major surface and a second major surface; a frame including a curved support surface, the frame defining an opening; an adhesive layer disposed between the curved support surface and the second major surface and attaching the glass substrate to the frame so that the glass substrate conforms to the curved support surface, wherein the second major surface includes an open area that is not bonded to the frame and overlaps the opening; a display module disposed in the opening and bonded to the open area, wherein the display module includes a display layer and a back panel, wherein a gap is disposed between a peripheral edge of the back panel and an inner edge of the frame, wherein the frame is not bolted to the back panel; a spacer disposed in the gap and extending the full distance between the peripheral edge and the inner edge; and at least one of: a spacer element disposed between the curved support surface and the second major surface near the periphery of the second major surface, a step or perforation on the curved support surface, and a groove extending from the inner edge of the frame.

[0009] Additional features and advantages will be set forth in the detailed description that follows and, in part, will be apparent to those skilled in the art from that description or will be learned by practicing the embodiments described herein, including the detailed description that follows, the claims, and the accompanying drawings.

[0010] It is to be understood that both the foregoing general description and the following detailed description are merely exemplary and are intended to provide an overview or framework for understanding the nature and character of the claims. The accompanying drawings are included to provide a further understanding, and are incorporated into and constitute a part of this specification. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate several aspects of the invention and, together with the description, serve to explain the principles of the invention. In the drawings:

[0012] Figure 1 is a perspective view of a vehicle interior having a curved glass surface according to an exemplary embodiment;

[0013] Figure 2A and 2B Depicted is a diagram of a method for using a Figure 1 A side view of an embodiment of a curved glass article for a vehicle interior;

[0014] Figure 3 schematically depicts cold forming of a glass substrate onto a frame via vacuum chucks according to an exemplary embodiment;

[0015] Figure 4A schematically depicts a rear view of a display system according to one or more embodiments of the present disclosure;

[0016] Figure 4B Schematically depicts a method of passing through a Figure 4A A cross-sectional view of the display system along line 4B-4B;

[0017] Figure 4C Schematically depicts a process during manufacture according to one or more embodiments of the present disclosure. Figures 4A-4B The display system depicted in , wherein a spacer precursor material is injected into the gap between the back panel and the frame;

[0018] Figure 4D Schematically depicts a process during manufacture according to one or more embodiments of the present disclosure. Figures 4A-4B The display system depicted in , wherein the spacer is attached to the back panel before the display module is laminated to the glass substrate of the display system;

[0019] Figure 5 Schematically depicts a display system according to one or more embodiments of the present disclosure, comprising a spacing element disposed between a glass substrate and its frame;

[0020] Figure 6 schematically depicts a display system according to one or more embodiments of the present disclosure, comprising a step at an inner edge of a curved support surface of a frame and a groove extending from the inner edge;

[0021] Figure 7A Schematically depicts a display system positioned on a vacuum chuck with a removable adhesive shaping element positioned in contact with a minor surface of a glass substrate according to one or more embodiments of the present disclosure;

[0022] Figure 7Bschematically depicts a display system positioned on a vacuum chuck, wherein an adhesive shaping element forms part of a shaping surface of the vacuum chuck and also contacts a secondary surface of a glass substrate, according to one or more embodiments of the present disclosure;

[0023] Figure 8 is a flow chart of a process for manufacturing a display system according to one or more embodiments of the present disclosure;

[0024] Figure 9A Schematically depicts a schematic diagram of a system according to an example embodiment according to one or more embodiments of the present disclosure. Figure 5 a cross-sectional view of a region of the display system depicted in FIG; and

[0025] Figure 9B Schematically depicts a process of manufacturing prior to compressing the adhesive layer 66 according to one or more embodiments of the present disclosure. Figure 9A The part depicted in . DETAILED DESCRIPTION

[0026] Reference will now be made in detail to various embodiments, examples of which are illustrated in the accompanying drawings. The present disclosure generally relates to displays comprising a cold-formed glass substrate bonded to a curved support surface of a frame via an adhesive layer. The curved support surface of the frame defines a bonding area upon which the adhesive layer can be placed. However, during the display manufacturing process, the size and shape of the bonding area may not be precisely known. Consequently, the spacing between the curved support surface and the glass substrate may vary, and / or the amount of adhesive dispensed at various locations within the bonding area may be insufficient. For example, certain areas of the curved support surface may deviate from the desired shape, resulting in the space between the glass substrate and the curved support surface being less deep than other areas. These areas of reduced depth may cause adhesive to be squeezed out of the bonding area (e.g., seeping out from the edge of the frame) and / or result in an uneven thickness of the adhesive layer, resulting in a wavy appearance. Various aspects of the present disclosure are intended to mitigate the effects associated with variations in frame shape. By eliminating or mitigating the negative effects of variations between frames, the present disclosure enables the use of looser manufacturing tolerances in frame construction, thereby reducing costs and simplifying the manufacturing process of curved displays.

[0027] According to various aspects of the present disclosure, a display may include a display module comprising a rigid back panel. The rigid back panel may have a desired shape (e.g., a curvature that substantially matches the curved support surface of the frame). However, the mechanical interaction between the frame and the rigid back panel may cause the back panel to deviate from this desired shape and / or cause the frame to bend unpredictably and deviate from the expected configuration, resulting in uneven spacing between the frame and the glass. According to the present disclosure, to prevent such differences between the frame and the back panel from unpredictably affecting the shape of the glass or adhesive, the back panel is not bolted to the frame as in some existing designs. Instead, a spacer is inserted between the back panel and the frame, the spacer being configured to fix the shape of the gap between the back panel and the frame before any mechanical interaction occurs between the back panel and the frame. For example, the spacer may be a compliant material (e.g., a suitable adhesive or elastomeric material) that can adapt to the geometric mismatch between the frame and the back panel. Due to the use of the spacer, unpredictable bending of the frame and the back panel due to unknown geometric changes is suppressed, and variations in adhesive thickness are also better controlled (by controlling the size of the space between the frame and the glass substrate during the manufacturing process). In another example, the spacer can be made of a rigid material, but its shape must conform to the shape of the gap between the back panel and the frame, thereby maintaining the shape of the gap throughout the manufacturing process. The spacer helps better control the shape of the glass substrate, frame, and overall display module structure during the manufacturing process.

[0028] In addition to the spacers between the back panel and the frame described herein, various other aspects of the frame and the manufacturing process can be customized to control the adhesive thickness and / or prevent the adhesive from overflowing. For example, in an embodiment, before the adhesive layer is deposited, a spacer element is placed around the periphery of the bonding area. The spacer element can determine the thickness of the adhesive layer and prevent the adhesive from overflowing during the manufacturing process. Alternatively or additionally, a feedback mechanism can be added to the adhesive dispensing process so that the amount of adhesive dispensed at the position is changed according to at least one of the size of the frame at a specific position of the bonding area (e.g., the frame width) and / or the curvature of the curved support surface (e.g., for a curved support surface that is curved to deviate from the desired shape, the amount of adhesive dispensed can be more or less than the area where the curved support surface has the desired shape). Additionally or alternatively, during or after dispensing the adhesive, at least the outer surface of the adhesive can be textured to reduce the gloss and visibility of the adhesive. Additionally or alternatively, the curved support surface of the frame may include one or more steps or openings placed inside the peripheral edge of the frame. The steps or openings can form a space between the glass and the curved support surface for the adhesive to flow into, thereby preventing overflow. Additionally or alternatively, an external barrier can be placed around the periphery of the glass substrate and frame to prevent adhesive from escaping during cold forming. The external barrier can be removably positioned around the periphery of the glass to control adhesive thickness and prevent adhesive from escaping. In embodiments, the spacer can be a component of the vacuum chuck used during the manufacturing process and can be a support for the glass substrate on the vacuum chuck. Any of these concepts can be used alone or in combination with any other concepts described herein to help provide a uniform adhesive layer in situations where the frame shape is unpredictable.

[0029] Figure 1 An exemplary interior 10 of a vehicle is shown that includes three different embodiments of vehicle interior systems 20, 30, and 40. Vehicle interior system 20 includes a base, shown as a center console base 22, having a curved surface 24 that includes a display 26. Vehicle interior system 30 includes a base, shown as an instrument panel base 32, having a curved surface 34 that includes a display 36. The instrument panel base 32 typically includes an instrument panel 38 that may also include a display. Vehicle interior system 40 includes a base, shown as a steering wheel base 42, having a curved surface 44 and a display 46. In one or more embodiments, the vehicle interior system includes a base, that is, an armrest, pillar, seat back, floor, headrest, door panel, or any part of the vehicle interior that includes a curved surface. In other embodiments, the base is part of a housing for a freestanding display (i.e., a display that is not permanently connected to any part of the vehicle). Although displays 26 and 36 and instrument panel 38 are in Figure 1Although depicted as separate from one another, it should be understood that embodiments are contemplated in which at least two of displays 26 and 36 and instrument panel 38 are combined with one another. For example, in an embodiment, a single glass substrate extends the entire length of instrument panel base 32 between pillars (not depicted) of interior trim 10. As described herein, such a glass substrate can be bent into a desired shape and have one or more displays attached thereto via the methods described herein. In an example, a pillar-to-pillar display can be implemented in which a single display extends substantially the length of the glass substrate.

[0030] The embodiments of the curved glass articles described herein may be used in each of the vehicle interior systems 20, 30, 40, and so forth. In some such embodiments, the glass articles discussed herein may comprise a cover glass sheet that also covers the non-display surfaces of the instrument panel, center console, steering wheel, door panels, and the like. In such embodiments, the glass material may be selected based on its weight, aesthetic appearance, and the like, and may be provided with a coating (e.g., an ink or pigment coating) with a pattern (e.g., a brushed metal look, a wood grain look, a leather look, a colored look, and the like) to visually match the glass component to adjacent non-glass components. In particular embodiments, such ink or pigment coatings may have a degree of transparency to enable a deadfront or color matching function when the display 26, 36, 46 is not activated. Furthermore, although Figure 1 The vehicle interiors described herein depict vehicles in the form of automobiles (e.g., cars, trucks, buses, etc.), but the glass articles disclosed herein may be incorporated into other vehicles, such as trains, marine vessels (boats, ships, submarines, etc.), and aircraft (e.g., drones, airplanes, jets, helicopters, etc.).

[0031] In an embodiment, the curved surfaces 24, 34, 44 can be any of various curved shapes, such as Figure 2A and 2B The V-shape or C-shape shown in FIG. First refer to Figure 2A , shows a side view of an embodiment of a V-shaped glass article 50. Glass article 50 includes a glass substrate 52 having a first major surface 54, a second major surface 56 opposite first major surface 54, and a minor surface 58 joining first major surface 54 to second major surface 56. First major surface 54 and second major surface 56 define a thickness T of glass substrate 52. In an embodiment, thickness T of glass substrate 52 is 0.3 mm to 2 mm, more particularly 0.5 mm to 1.1 mm. In a vehicle, first major surface 54 faces an occupant of the vehicle.

[0032] In an embodiment, first major surface 54 and / or second major surface 56 include one or more surface treatments. Examples of surface treatments that can be applied to one or both of first major surface 54 and second major surface 56 include anti-glare coatings, anti-reflective coatings, coatings that provide contact functionality, decorative (e.g., ink or paint) coatings, and easy-to-clean coatings.

[0033] exist Figure 2A As can be seen in FIG. 5 , the glass substrate 52 has a curved region 60 disposed between a first flat section 62a and a second flat section 62b. In an embodiment, the radius of curvature R of the curved region 60 ranges from 75 mm to a radius of curvature less than that of a substantially flat or planar surface (e.g., R=10 mm). Specifically, the radius of curvature R of the curved region 60 ranges from 150 mm to 3000 mm. Figure 2A As shown, the curved region 60 defines a concave curve relative to the first major surface 54 , but in other embodiments, the curved region 60 is a convex curve relative to the first major surface 54 .

[0034] exist Figure 2A In the glass article 50, the frame 64, and in particular the curved support surface 65 thereof, is bonded to the second major surface 56 of the glass substrate 52 using an adhesive layer 66. The adhesive layer 66 can be initially deposited as a liquid bead on the glass substrate 52 or the frame 64 and then cured. In embodiments, exemplary adhesives for the adhesive layer 66 include epoxies, acrylics, polyurethanes, polyurethane hot melts, silane-modified polymers, and / or silicones. In specific embodiments, the adhesive layer 66 includes one or more toughened epoxy resins, such as EP21TDCHT-LO (available from Epoxy Labs, Inc., Hackensack, New Jersey). Acquired), 3M TM Scotch-Weld TM Epoxy DP460 off-white (available from 3M in St. Paul, Minnesota). In other embodiments, adhesive layer 66 comprises one or more flexible epoxy resins, such as MasterBond EP21TDC-2LO (available from 3M in Hackensack, New Jersey). Acquired), 3M TM Scotch-Weld TM Epoxy Resin 2216B / A Gray (available from 3M, St. Paul, Minnesota) and 3M TM Scotch-Weld TM Epoxy resin DP125.

[0035] In yet other embodiments, the adhesive layer 66 comprises one or more acrylic resins, such as Adhesive 410 / Accelerator 19w / AP 134 primer, Adhesive 852 / Accelerator 25GB (both available from LORD Corporation, Cary, North Carolina), DELO PUR SJ9356 (available from DELO Industrial Adhesives, Windach, Germany), AA4800, HF8000. In yet other embodiments, the liquid adhesive comprises a silane-modified polymer, such as MS 9399 and MS 647-2C (the latter four polymers are available from Henkel AG, Düsseldorf, Germany), or one or more silicones, e.g. 995, 7091 (available from Dow Corning Corporation, Midland, Michigan), etc.

[0036] In other embodiments, the adhesive layer 66 comprises one or more polyurethane hot melt adhesives, such as Loctite HHD 3542 (available from Henkel AG & Co. KGaA, Düsseldorf, Germany). In still other embodiments, the adhesive layer 66 comprises one or more polyurethanes, such as 3M TM Scotch-Weld TM Polyurethane DP640 brown, 3M TM Scotch-Weld TM Polyurethane DP604 (both available from 3M, St. Paul, Minnesota), Betamate TM 73100、Betaseal TM X2500 and Betalink TM K2 (the latter three are available from The Dow Chemical Company, Midland, Michigan).

[0037] In an embodiment, the material of the adhesive layer 66 comprises an elastic modulus of from 0.1 MPa to 50 MPa. Furthermore, in an embodiment, the material of the adhesive layer 66 comprises a viscosity of from 1 kcps to 500 kcps when deposited. In part, the frame 64 facilitates mounting the glass article 50 to a vehicle interior mount (e.g., Figure 16, and / or the steering wheel base 42 shown). In addition, the frame 64 maintains the glass substrate in a curved state via the shape of the curved support surface 65 and the bonding using the adhesive layer 66, so that the curved area 60 is not permanent. That is, if the glass substrate 52 is not bonded to the frame 64 using the adhesive layer 66, the glass substrate 52 will rebound to a flat, non-curved configuration. Therefore, the glass substrate 52 is stressed to produce a curvature and remains in a stressed state for the life of the glass article 50. According to the embodiment, the curved support surface 65 may have different sizes and shapes. In an embodiment, for example, the curved support surface 65 includes a peripheral shape that substantially matches the peripheral shape of the glass substrate 52 (once the glass substrate 52 is bent in the stressed configuration). In such an embodiment, the curved support surface may include a length greater than or equal to 500 mm and less than or equal to 3000 mm, a width less than half of the length, and a minimum radius of curvature greater than or equal to 100 mm and less than or equal to 1500 mm.

[0038] The stress in the glass substrate 52 can cause it to tend to detach from the frame 64, which means that the adhesive layer 66 will also be stressed. The stress caused by thermal cycling can further exacerbate this stress. Specifically, the coefficient of thermal expansion of the glass substrate 52 is different from the coefficient of thermal expansion of the frame 64, because the frame is typically a metal (e.g., aluminum or magnesium), a composite material, or a plastic component. The difference in thermal expansion coefficient means that the glass substrate 52 and the frame expand or contract by different amounts during thermal cycling between extreme temperatures (e.g., as low as -40°C and as high as 80°C), resulting in additional stress in the adhesive layer 66. Although mechanical and thermal stresses can be addressed by expanding the adhesive layer 66 (in terms of thickness and / or surface area), aesthetic considerations limit the size of the adhesive layer 66. Specifically, it is desirable to minimize the area of ​​contact between the adhesive layer 66 and the glass substrate 52 in order to maximize the display area of ​​the glass article 50.

[0039] Figure 2B Another embodiment of a glass article 50, particularly a C-shaped glass article 50, is depicted. Figure 2A V-shaped glass products 50, Figure 2BThe C-shaped glass article 50 has a larger curved region 60 and shorter flat sections 62a, 62b. V- and C-shapes are just two examples of curved glass articles 50 that can be formed according to the present disclosure. In other embodiments, the glass article 50 may include configurations where the curved region 60 has opposing curvatures to form an S-shape, the curved region 60 is followed by a flat section 62a to form a J-shape, the curved regions 60 are separated by flat sections 62a to form a U-shape, and so on. Also contemplated are embodiments where the curved region 60 is cylindrical with a constant minimum radius of curvature. Also contemplated are embodiments where at least a portion of the curved region 60 includes a compound curvature (wherein the major surfaces 54 and 56 are curved along at least two axes of curvature extending in different directions from one another).

[0040] The glass article 50 according to the present disclosure is formed by cold forming techniques. An example process of cold forming involves applying a bending force to the glass substrate 52 while the glass substrate 52 is positioned on a suction cup 68, such as Figure 3 As shown. It can be seen that the suction cup 68 has a curved forming surface 70, and the glass substrate 52 is bent to fit the curved forming surface 70. Advantageously, it is easier to apply surface treatment to the flat glass substrate 52 before the glass substrate 52 is formed into a curvature; and cold forming can bend the treated glass substrate 52 without damaging the surface treatment (in contrast, the high temperature associated with hot forming technology easily damages the surface treatment layer, so hot forming requires a more complicated process to surface treat the curved product). In an embodiment, the cold forming process is performed at a temperature below the glass transition temperature of the glass substrate 52. Specifically, the cold forming process can be performed at room temperature (e.g., about 20°C) or slightly higher temperature, for example, at a temperature of 200°C or lower, 150°C or lower, 100°C or lower, or 50°C or lower.

[0041] In an embodiment, the bending force applied to the glass substrate 52 may take the form of vacuum pressure drawn by suction cups 68. In an embodiment, the suction cups 68 include an internal channel with ports on the forming surface 70 of the suction cups 68. When the glass substrate 52 is positioned on the forming surface 70, a vacuum is drawn through the channel, forcing the glass substrate 52 against the suction cups and conforming to the curvature of the forming surface 70. In other embodiments, the forming surface 70 may utilize other techniques to maintain the glass substrate 52 in conformity to the curvature. For example, during the cold forming process, the forming surface 70 may be a self-adhesive material configured to provide sufficient adhesion to maintain the glass substrate 52 in the curved configuration, or the suction cups 68 may operate in conjunction with a press or clamp to maintain the glass substrate 52 in conformity to the forming surface 70 during the cold forming process. In an embodiment, the cold forming of the glass substrate 52 may be performed without the use of vacuum cups 68. For example, while the adhesive layer 66 cures, the glass substrate 52 may be bent onto the frame 64 and secured thereto using a clamp or other suitable securing member.

[0042] exist Figure 3 In the illustrated embodiment, the adhesive layer 66 is applied to the second major surface 56 of the glass substrate 52, and the frame 64 is lowered onto the glass substrate 52. However, in other embodiments, the adhesive layer 66 can be applied to the curved support surface 65 of the frame 64. In either case, the frame 64 compresses the adhesive layer 66 between the curved support surface 65 and the second major surface 56 of the glass substrate 52. Figure 3 As can be seen in FIG, adhesive layer 66 is applied to glass substrate 52 such that the shape formed by adhesive layer 66, i.e., a "bead path," substantially matches the shape of frame 64. In an embodiment, adhesive layer 66 defines a closed bead path, such that adhesive layer 66 is continuous on glass substrate 52. In other embodiments, adhesive layer 66 may have a discontinuous bead path, e.g., with breaks between sections of adhesive layer 66. Figure 3 The material of adhesive layer 66 is depicted in an uncured, bead-applied state.

[0043] In an embodiment, the adhesive layer 66 is applied via a nozzle 71 having a circular port 73, as shown. Figure 3 Advantageously, such nozzles are easy to manufacture because the orientation of the nozzle relative to the glass substrate 52 is not restricted, in contrast to certain nozzles, such as those with triangular ports, which must be aligned in a specific orientation relative to the glass sheet in order to apply a specific shaped bead of glue in the correct location. Figure 3 While the adhesive layer 66 is depicted as being applied to the glass substrate 52 while the glass substrate 52 is in a curved configuration on the suction cup 68, the adhesive layer 66 can actually be applied to the glass substrate 52 while the glass substrate 52 is in a flat configuration, such that the glass substrate 52 with the adhesive layer 66 applied thereto is subsequently bent on the forming surface 70 of the suction cup 68. In an embodiment, the nozzle 71 is connected to a motion system and a controller (not depicted). The controller can include an imaging device for determining the shape of the curved support surface 65 via image analysis techniques. The shape of the curved support surface 65 can be compared to an idealized surface (representing the designed curved shape of the curved support surface 65). The deviation between the actual and idealized shapes can be used to control the rate and / or amount of adhesive dispensed at a specific location on the glass substrate 52 or frame 64. A higher amount of adhesive can be set for areas where the actual shape of the curved support surface 65 is farther from the second major surface 56 than the idealized surface (by reducing the movement speed of the nozzle 71 or increasing the deposition rate); whereas a lower amount of adhesive can be set for areas where the actual shape of the curved support surface 65 is closer to the second major surface 56 than the idealized shape (by increasing the movement speed of the nozzle 71 or reducing the deposition rate). This type of adhesive deposition control can reduce the amount of adhesive overflow.

[0044] Regardless of the specific process steps employed, cold forming of the glass substrate generally involves applying a force to the glass substrate 52 to bend the glass substrate 52 into a shape that substantially conforms to the shape of the frame 64. For example, in an embodiment, the shape of the forming surface 70 of the suction cup 68 substantially corresponds to the shape of the curved support surface 65 of the frame 64, such that applying a vacuum to the glass substrate 52 to conform the glass substrate 52 to the forming surface 70 can cause the second major surface 56 to bend into the shape of the curved support surface 35. Alternatively or additionally, a preform, pressure rollers, or other force-applying device can be used to press the glass substrate 52 directly against the curved support surface 65 to bend the second major surface 56 into conformity thereto.

[0045] Problems can arise when frame 64 deviates from a desired shape. For example, when constructed from a metal such as aluminum or magnesium, frame 64 can be manufactured using a casting process that has some variability. In the depicted example, curved support surface 65 may not precisely match the shape of molding surface 70 of suction cup 68. Consequently, the spacing between curved support surface 65 and second major surface 56 may be uneven, even if the positioning of frame 64 is precisely controlled during manufacturing. Furthermore, the dimensions of frame 64 may vary, causing the dimensions of curved support surface 65 to deviate from the expected values ​​at different locations, resulting in variations in the available bonding area between glass substrate 52 and frame 64 where adhesive layer 66 can be positioned. This inconsistency in the shape of frame 64 can cause problems when applying adhesive layer 66. To illustrate, if adhesive layer 66 is dispensed with a uniform volume throughout the entire bead path, a smaller-than-expected bonding area and / or spacing between curved support surface 65 and second major surface 56 may cause adhesive overflow (e.g., outward from the periphery of frame 64 or inward toward the center of glass substrate 52). The variation in curvature of curved support surface 65 may cause the thickness of adhesive layer 66 to vary because adhesive layer 66 is compressed by curved support surface 65 before curing. Such thickness variation may give adhesive layer 66 a wavy appearance, which is undesirable.

[0046] Such problems associated with frame shape differences may be further exacerbated when the display module is incorporated into a curved glass article to form a display system. Figure 4A and 4B A display system 400 according to an exemplary embodiment of the present disclosure is schematically depicted. Figure 4A A rearward view of the display system 400 (eg, viewed from the side of the second major surface 56) is schematically depicted, and Figure 4B Schematically depicts the passage through Figure 4A4B-4B in a cross-sectional view. As shown in the figure, in the depicted embodiment, the curved support surface 65 of the frame 64 is curved to have a concave shape, and the glass substrate 52 is cold-formed and bonded to the curved support surface 65 via the adhesive layer 66 so that the first major surface 54 also has a concave shape. The glass substrate 52 is cold-formed onto the curved support surface 65 via any suitable technique. For example, in an embodiment, Figure 3 The vacuum chuck 68 and nozzle 71 depicted in FIG. 5 can be used to bend the glass substrate 52 and to dispense the adhesive layer 66 .

[0047] like Figure 4B As shown, the overlapping area between the curved support surface 65 and the second major surface 56 defines a bonding area 80, on which the adhesive layer 66 can be placed to attach the glass substrate 52 to the frame 64. In an embodiment, the frame 64 is configured to have an outer peripheral shape that substantially matches the outer peripheral shape of the glass substrate 52 after the glass substrate is bent. In such embodiments, the outer periphery of the frame 64 is formed from the minor surface 58 (see FIG. Figure 2A ) are inserted, the bonding area 80 extends from the peripheral edge 415 of the frame to the inner edge 416 of the frame 64. That is, the shapes of the peripheral edge 415 and the inner edge 416 determine the extent of the bonding area 80. Furthermore, when the frame 64 is held in a fixed positional relationship with the glass substrate 52, the shape of the curved support surface 65 and the bonding area 80 together determine the volume of space between the curved support surface 65 and the second major surface 56. Therefore, the shape and size of the frame 64 determine the amount of adhesive that can be applied at a specific location between the glass substrate 52 and the frame 64.

[0048] refer to Figure 4A and 4B , an inner edge 416 of frame 64 can define an opening 402. Due to the presence of opening 402, second major surface 506 includes an open area 403 that is not bonded to frame 64 via adhesive layer 66. Display module 404 is positioned within opening 402 and is bonded to second major surface 56 via a layer of optically clear adhesive 405. Display module 404 can be attached to glass substrate 52 via a suitable lamination technique during a cold forming process (e.g., while glass substrate 52 is positioned on suction cup 68 and before adhesive layer 66 is cured or before frame 64 is attached to glass substrate 52).

[0049] The display module 404 may include a display layer 406 and a back panel 408. The display layer 406 may include a touch panel and other display components (e.g., a liquid crystal display panel, an organic light emitting diode display panel). The back panel 408 may generally be more rigid than the display layer 406 and may be pre-bent into a desired shape. For example, in an embodiment where the display module 404 is a liquid crystal display, the back panel 408 may be a backlight unit and include a light source and a light guide layer. In an embodiment where the display module 404 is an organic light emitting diode display, the back panel 408 may be a built-in heat sink. The different components of the display module 404 may be attached to the glass substrate 52 in various ways. For example, in an embodiment, the display module 404 is a pre-assembled unit (e.g., a curved display) and is laminated to the glass substrate in a single processing step. In an embodiment, the display layer 406 and the back panel 408 are sequentially attached to the glass substrate 52 in different steps of the cold forming process. For example, the display layer 406 can be attached to the glass substrate 52 in a first step (when the glass is flat or curved), and the back panel 408 can be attached to the glass substrate 52 in a second step after the display layer 406 is attached.

[0050] In an embodiment, the back panel 408 is more rigid than the glass substrate 52 and is curved to have a shape that matches the desired shape of the open area 403. For example, the back panel 408 can be curved to have a shape that substantially corresponds to the frame 64. However, the variability in the shape of the frame 64 described herein may make it difficult to achieve a perfect fit. As a result, the curvature of the frame 64 may deviate from the curvature of the back panel 408, and / or the opening 402 may not be exactly the expected size. Such differences may cause difficulties in attaching the back panel 408 to the frame 64. In some existing display systems, the back panel 408 and the frame 64 are secured to each other by rigid fasteners (e.g., bolts) that use pressure to secure the frame 64 and the back panel 408 to each other and stabilize the system. Such fastener-based attachment mechanisms may form an ultra-static system and cause the less rigid components of the frame 64 and the back panel 408 to bend. Because the precise shape of the frame 64 may be unknown, the frame 64 or back panel 408 may bend in an unpredictable manner, causing the spacing between the second major surface 56 and the curved support surface 65 to vary, thereby changing the thickness profile of the adhesive layer 66 .

[0051] In view of the aforementioned problems caused by the variability in the shape of the frame 64, the frame 64 is not secured to the back panel 408 by rigid fasteners such as bolts. Instead, a spacer 418 is positioned in a gap 410 extending between the peripheral edge 414 of the back panel 408 and the inner edge 416 of the frame 64. The size and shape of the gap 410 are generally determined by the size and shape of each of the frame 64 and the back panel 408. In an embodiment, the size of the opening 402 is larger than the back panel 408; and the gap 410 surrounds the entire peripheral edge 414. In an alternative embodiment, the gap 410 does not completely surround the back panel 408 (for example, the gap 410 may only extend on one side of the back panel 408). The gap 410 is shown as having a width 412 that extends perpendicular to the inner edge 416 of the frame 64. In an embodiment, width 412 is less than or equal to 2 mm (e.g., greater than or equal to 0.01 mm and less than or equal to 2.0 mm, or greater than or equal to 0.2 mm and less than or equal to 2.0 mm). In an embodiment, back panel 408 is positioned within opening 402 (e.g., centered) such that width 412 is circumferentially uniform (deviating from an average by less than 5% depending on azimuth position). Minimizing the size of gap 410 facilitates maximizing the portion of opening 402 that is filled by display module 404.

[0052] The spacers 418 are configured to maintain the relative positioning of the frame 64 and the back panel 408 throughout the manufacturing process, preventing deformation of the frame 64 and / or the back panel 408. For illustration, Figure 4C An example of a display system 400 being manufactured is depicted. As shown, a glass substrate 52 is positioned on a molding surface 70 of a suction cup 68. The suction cup 68 may be applying negative pressure to the glass substrate 52, causing the glass substrate 52 to bend. In addition, a frame 64 has been aligned with the glass substrate 52, with an adhesive layer 66 positioned between the frame 64 and the glass substrate 52. Based on the desired thickness of the adhesive layer 66 after curing, the frame 64 is positioned a distance away from the glass substrate 52 (the frame 64 can be held in this position by a suitable holding device, which is not depicted in the figure). When the adhesive layer 66 has not yet been fully cured, the display module 404 is laminated to the glass substrate 52 via the layer of optically clear adhesive 405 to form a gap 410 between the frame 64 and the back panel 408. In an embodiment, the periphery of the frame 64 is aligned with the secondary surface 58 (see Figure 2A ) to maximize the size of the opening 402 and the display area. In an embodiment, the periphery of the frame 64 is positioned inside the minor surface 58. Such a structure can help hide variations in the adhesive layer 66.

[0053] The exact geometry and size of the gap 410 will vary depending on the geometry of the frame 64. That is, the construction of the frame 64 may vary, for the reasons described herein, resulting in the exact geometry of the gap 410 being different in different portions. Figure 4B ) are designed to accommodate differences in the various parts by precisely filling the gap 410. Various methods of providing such spacers 418 are contemplated and are within the scope of the present disclosure. Figure 4C An example of a spacer precursor material 422 being dispensed into the gap 410 via a dispensing system 420 (e.g., a dispensing gun, a print head, a nozzle) is depicted. The spacer precursor material 422 is preferably a liquid material so that the material can precisely form to the shape of the gap 410. After the spacer precursor material 422 is applied, the spacer precursor material 422 cures and solidifies into the spacers 218, which advantageously extend the entire distance between the peripheral edge 414 and the inner edge 416.

[0054] A variety of materials can be used as the spacer precursor material 422. For example, in embodiments, the spacer 218 is relatively rigid. For example, in embodiments, the Young's modulus of the spacer 218 (after the spacer precursor material 422 is cured) is greater than the Young's modulus of the adhesive layer 66. In such embodiments, the Young's modulus of the spacer precursor material 422 when cured is greater than or equal to 100 MPa, greater than or equal to 300 MPa, greater than or equal to 500 MPa, or greater than or equal to 800 MPa, such that the size of the gap 410 remains constant throughout the manufacturing process and application of force to the frame 64 or back panel 408 does not cause the size of the gap 410 to change (once the spacer precursor material 422 is cured to a sufficient degree). Suitable rigid materials include acrylic or epoxy adhesives.

[0055] It will be appreciated that the curing of the spacer precursor material 422 will depend on the type of material used to form the spacer precursor material 422. In certain embodiments, the spacer precursor material 422 is a room temperature or thermal curing material, and the curing step involves applying temperature / heat to cure the spacer precursor material 422. In other embodiments, depending on the spacer precursor material 422, the curing mechanism may include radiation curing, pH changes, the use of catalysts, activators, or moisture. It is believed that a 1K moisture cure or 2K adhesive will be particularly beneficial because it can be cured without the need for heat, thereby minimizing the detrimental effects of heat on the components of the display module 404.

[0056] In an embodiment, it may be beneficial if the spacer precursor material 422 has a relatively high viscosity (e.g., greater than or equal to 1 kcps, greater than or equal to 100 kcps, greater than or equal to 300 kcps) when initially deposited. This high viscosity helps the spacer precursor material 422 retain its shape before being fully cured, thereby controlling the shape of the spacer 218.

[0057] In an embodiment, the spacer precursor material 422 may include a reaction injection molding material. As used herein, a "reaction injection molding material" includes a thermosetting polymer that solidifies in a mold during the injection molding process (in this case, the gap 410 serves as a mold). In an embodiment, the reaction injection molding material includes polyurethane, polyurea, polyisocyanurate, polyester, polyphenol, polyepoxide, and nylon 6. In an embodiment, the spacer precursor material 422 may include a reinforcing agent, such as glass fiber or mica. A two-component system of such materials can react and solidify in the case of rapid solidification to form the spacer 418. In an embodiment, the spacer precursor material 422 may include a hot melt adhesive, including suitable thermoplastic polymers, resins, plasticizers, and other additives. The advantage of such hot melt adhesives may be that they solidify relatively quickly after dispensing and can maintain the shape of the gap 410 during the remaining time that the adhesive layer 66 solidifies.

[0058] In embodiments, the spacers 218 can be constructed of a relatively compliant material that can be compressed to the size of the gap 410 rather than a rigid material. In such embodiments, the spacers 218 can be formed of a material having a Young's modulus less than 100 MPa (e.g., less than or equal to 80 MPa, less than or equal to 50 MPa, less than or equal to 30 MPa, less than or equal to 10 MPa). In such embodiments, the spacers 218 can be initially formed on one of the back panel 408 and the frame 64 before the back panel 408 is attached to the glass substrate 52, rather than being injected directly into the gap 410 as described above with respect to the rigid embodiments. To illustrate, Figure 4D An example is depicted where the back panel 408 has not yet been attached to the glass substrate 52. Figure 4D The display layer 406 is depicted disposed on the glass substrate 52 without the back panel 408, but it is understood that it is also contemplated that the spacer 218 may be similarly attached to the entire display module 404 prior to lamination to the glass substrate 52 via the layer of optically clear adhesive 405 (see FIG. Figure 4B ) embodiment. A force can be applied to the glass substrate 52 via the suction cup 68 to keep the glass in a curved state before the adhesive layer 66 is cured, as described in relation to Figure 4C described.

[0059] like Figure 4DAs shown, the spacers 218 are attached to the peripheral edge 414 of the back panel 408 before the back panel 408 is lowered onto the glass substrate 52. In alternative embodiments, the spacers 218 can be attached to the inner edge 416 of the frame 64 rather than the peripheral edge 414. In such embodiments, various materials are contemplated for the spacers 218. For example, the spacers 218 can be a pressure sensitive tape (e.g., 3M TM VHB TM , such as #8412BLACK, #5909, #4611, #4930, #5952, (e.g., #7805, #61057, or DAITAC STA400 or TRYCK). In some embodiments, the spacers 218 can be deposited as a liquid precursor material and cured on the back panel 408 before the back panel 408 is lowered onto the glass substrate 52. In such embodiments, a suitable mold can be used to cure the liquid precursor material in the desired shape. Any suitable material that is compliant and compressible to conform to the shape of the gap 410 can be used, including the materials described above with respect to the adhesive layer 66 and the spacer precursor material 422.

[0060] In an embodiment, when first formed or deposited on the back panel 408, the spacer 218 includes a thickness 424 measured in a direction perpendicular to the peripheral edge 414. The thickness 424 can be selected to be greater than the width 412 of the gap 410 (the width 412 is the same as the dimension of the back panel 408 when it is placed on the glass substrate 52, because the back panel 408 is aligned with its final position on the glass substrate 52). Therefore, lowering the back panel 408 onto the glass substrate 52 (e.g., in the depicted embodiment, in contact with the display layer 406) compresses the spacer 218 so that the spacer 218 takes the precise shape of the gap 410, as shown. Figure 4B As shown. After such compression, the spacers 218 can exert an outward force to maintain the size of the gap 410 and prevent the frame 64 and / or back panel 408 from deforming due to relative movement during the manufacturing process. In such embodiments, using a pressure-sensitive adhesive for the spacers 218 can be beneficial because the spacers 218 can be bonded to both the peripheral edge 414 and the inner edge 416 and will not creep during use of the display system 400.

[0061] refer to Figures 4A-4D, the spacer 218 can have a variety of geometries. In embodiments, the spacer 218 only partially fills the gap 410. Such embodiments can include an air gap between the spacer 218 and the glass substrate 52, which can help hide the spacer 218 when the display system 400 is viewed from the first major surface 54. In embodiments, the spacer 218 is a continuous body that surrounds the entire back panel 408. In embodiments, the spacer 218 includes one or more discrete segments of material that are positioned in the gap 410 and extend the full distance between the peripheral edge 414 and the inner edge 416. Any amount of material sufficient to maintain the size and shape of the gap 410 when the back panel 408 is first positioned on the glass substrate 52 can be used.

[0062] In an embodiment, after the spacers 218 are formed in the gaps 410 (and the precursor material for the spacers 218 is cured), the back panel 408 can maintain the glass substrate 52 in the desired curved shape, even if the adhesive layer 66 is not fully cured. This is particularly likely to occur in embodiments where the material for the spacers 218 is cured before the adhesive layer 66. Therefore, the force applied to the glass substrate 52 to initially bend the glass substrate 52 can be removed before the adhesive layer 66 is fully cured. This is due to the relative positioning between the spacers 218 and the display module 404. This early removal can free up equipment used in the manufacturing process and increase process throughput. For example, in the depicted embodiment, the display system 400 can be removed from the suction cup 68 and placed in a temporary storage area while waiting for the adhesive layer 66 to cure. This allows the suction cup 68 to be used to manufacture another system while the adhesive layer 66 cures.

[0063] In addition to the spacers described herein, various other features may be incorporated into the display system 400 and its manufacture to mitigate issues with frame shape variations. Several such features will now be described. It should be understood that these features may be used in addition to the spacers 218 to achieve better control of the adhesive during manufacturing, or may be used independently. Figures 4A-4D Display system 400 is described as an example system that may incorporate the features described below, but it should be understood that other display systems (having different components, forms, and / or shapes) may also incorporate these features.

[0064] In an embodiment, a material may be incorporated between the glass substrate 52 and the frame 64 to control the adhesive bond. Figure 5An embodiment is depicted in which spacer elements 500 are incorporated between glass substrate 52 and frame 64. Spacer elements 500 are disposed at the periphery of curved support surface 65 and are used to perform at least one of the following functions: (a) masking adhesive layer 66 to eliminate a wavy appearance caused by variations in the shape of frame 64; (b) acting as a barrier to prevent material from escaping from adhesive layer 66 when compressed during the manufacturing process; and (c) controlling the thickness of adhesive layer 66.

[0065] A variety of materials can be used to construct the spacer element 500. In one embodiment, the spacer element 500 can be formed from a pressure-sensitive adhesive tape, which functions as described in U.S. Patent Application No. 17 / 295,742, entitled "Bonding a Cover Glass Sheet to a Frame," which is incorporated herein by reference in its entirety. In such embodiments, the spacer element 500 can help maintain the curved shape of the glass substrate 52 while the adhesive layer 66 cures, thereby allowing the use of cold forming processes other than vacuum chucks. For example, the glass substrate 52 can be pressed against the frame 64 using rollers, preforms, molds, clamping structures, or other suitable structures, and the spacer element 500 can bond the glass substrate 52 to the frame 64 and maintain the curved shape of the glass substrate 52 while the adhesive layer 66 cures.

[0066] In an embodiment, the spacer element 500 is positioned adjacent to the adhesive layer 66 and can be used to apply a force on the glass substrate 52 when the frame 64 is positioned on the glass substrate 52 during the cold forming process (e.g., the spacer element 500 can bend the glass substrate 52 into conformity with the forming surface 70 of the suction cup 68, as shown in FIG. Figure 4C and 4D ). The use of spacer elements 500 allows for uniform force application despite irregularities in the frame and allows for control of the thickness of adhesive layer 66. For example, in embodiments, spacer elements 500 can be a rigid material (e.g., metal, ceramic, composite material, polymer) bonded to at least one of glass substrate 52 or frame 64. In embodiments, spacer elements 500 are projections from curved support surface 65 of frame 64 (e.g., spacer elements 500 can be integrally formed with frame 64 during the casting process). In embodiments, the spacers are compliant materials, such as rubber or a gasket material.

[0067] As an alternative to or in addition to spacing elements 500 , frame 64 may be modified to accommodate overflow of adhesive toward the interior of display system 400 (inside inner edge 416 ). Figure 6An example is shown in which the curved support surface 65 includes a step 600 extending outward from the inner edge 416. The step 600 provides a flow space for excess adhesive to flow, thereby preventing it from overflowing into the gap 410. In an embodiment, the frame 64 may include a recess or through-hole instead of the step 600, which is offset relative to the inner edge 416 to provide space for excess adhesive to flow. The function of the step 600, hole, or recess can be the same as the opening described in U.S. patent application Ser. No. 17 / 263,378, entitled "Cold-Formed Curved Glass Articles and Methods of Making Same," which is incorporated herein by reference in its entirety. In particular, the step 600, hole, or recess can improve the bond between the glass substrate 52 and the frame 64 and increase impact resistance.

[0068] In addition to or in lieu of the step 600, the display system 400 may further include a groove 602 disposed on the inner side of the inner edge 416. The groove 602 can collect adhesive that overflows inward and prevent the adhesive from interacting with other components of the display system 400. In an embodiment, the groove 602 is integrally formed with the frame 64. In an embodiment, the groove is a component separate from the frame 64 (e.g., formed of a material different from the main body of the frame 64). In an embodiment, the groove 602 extends above the curved support surface 65 to completely prevent the adhesive from overflowing inward. In an embodiment, the groove 602 is an extension of the inner edge 416 (e.g., a protrusion, a bump, a cantilevered portion) to prevent excess adhesive from dripping onto other components in the form of droplets.

[0069] In an embodiment, the adhesive can be controlled by modifying the manufacturing process. An adhesive shaping element can be added to the assembly for cold forming of glass substrates. For example, Figure 7A An example of a shaping element 700 positioned on the molding surface 70 of the suction cup 68 is depicted. In one embodiment, the shaping element 700 contacts the secondary surface 58 of the glass substrate 52 and extends beyond the second major surface 56, allowing the shaping element 700 to act as a barrier for the adhesive layer 66, preventing it from overflowing. In one embodiment, the shaping element 700 extends from the molding surface 70 to the curved support surface 65 (for example, in such an embodiment, the secondary surface 58 may be offset relative to the periphery of the frame to provide space for the shaping element 700 to contact the curved support surface 65). In such an embodiment, the shaping element 700 serves both as a barrier to prevent adhesive overflow and as a spacer to control the thickness of the adhesive layer 66. The shaping element 700 can be removed from the suction cup 68 (and between the frame 64 and the molding surface 70), ensuring that the adhesive layer 66 has a uniform appearance after curing, and the shaping element 700 does not increase the bulk of the display system 400.

[0070] In an embodiment, the shaping element 700 is integrated or attached to the suction cup 68. For example, Figure 7B An embodiment is depicted in which a shaping element 702 forms at least a portion of the forming surface 70 of the vacuum chuck 68. As shown, the shaping element 702 includes a support portion 704 and a side portion 706. The support portion 704 can be positioned on the body of the chuck 68 and form the forming surface 70 that contacts the glass substrate 52. The side portion 706 can extend from the support portion 704 and define a cavity in which the glass substrate 52 is positioned during cold forming. The shape of the side portion 706 can correspond to the outer shape of the glass substrate 52, so that the side portion 706 facilitates alignment of the glass substrate 52. The side portion 706 can contact the secondary surface 58 of the glass substrate 52 and extend beyond the second major surface 56 to form a barrier for the adhesive layer 66. Integrating the shaping element 702 into the chuck 68 can provide consistent alignment of the various components of the assembly and reduce process variability.

[0071] By utilizing the Figures 4A-4C The described spacer 218, in combination with at least one of the spacer element 500, the step 600, the groove 602, and the shaping elements 700 and 702, is believed to prevent adhesive overflow during manufacturing and maintain a uniform thickness of the adhesive layer 66 despite variations in the shape of the frame 64. As described herein, the spacer 218 prevents deformation of the frame 64 and the back panel 408 during manufacturing and provides a more uniform spacing between the frame 64 and the glass substrate 52. The spacer element 500 and / or the shaping elements 700 and 702 can further assist in shaping the adhesive layer 66 by preventing adhesive overflow and controlling the thickness of the adhesive layer 66. The step 600 and / or the groove 602 can be used in combination with the spacer 218 (and optionally also in combination with the spacer element 500 and / or the shaping elements 700 and 702) to prevent adhesive from overflowing into the interior of the frame 64. Thus, by combining any number of the features described herein, varying adhesive dosages can be controlled.

[0072] Now refer to Figure 8 , shows a process 800 of manufacturing a display system according to an example embodiment. Figures 2A-7B In any of the embodiments described, process 800 may be used to manufacture display system 400 described herein. Figures 2A-7B It should be understood that process 800 can be used to manufacture display systems having shapes and configurations different from display system 400 described herein.

[0073] At block 802, the glass substrate 52 is cold formed against the curved support surface 65 of the frame 64, with the adhesive layer 66 disposed between the glass substrate 52 and the curved support surface 65. As described herein, the glass substrate 52 can be cold formed using a variety of different processes. Typically, cold forming involves applying a bending force to the glass substrate 52 to bend the glass substrate 52 into a curved shape (the glass substrate 52 may initially be a flat sheet of glass cut to a suitable size and shape). In an embodiment, the bending force is applied via a vacuum suction cup, such as the suction cup 68 described herein. In an embodiment, a spacer element 500 may be disposed between the glass substrate 52 and the frame 64. For example, the spacer element 500 may be disposed on and attached to one of the second major surface 56 and the curved support surface 65 before the glass substrate 52 is pressed against the frame 64. The spacer element 500 determines the spacing between the glass substrate 52 and the frame 64 and allows the bending force to be applied via the frame 64 rather than via the suction cups 68 (although embodiments are contemplated in which the spacer element 500 is used in combination with the suction cups 68 to provide a uniform thickness of the adhesive layer 66 after curing). In embodiments that include the spacer element 500 (or other spacer element that controls the distance between the frame 64 and the glass substrate 52), the bending force can be applied via a vacuum bag (e.g., the glass substrate 52 and the frame 64 can be inserted into a vacuum bag with the adhesive applied to one of the glass substrate 52 and the frame). Alternatively, the bending force can be applied by contacting the glass substrate 52 with a roller, preform, or mold to conform the glass substrate 52 to the curved support surface 65. Alternatively, the bending force can be applied by clamping the glass substrate 52 to the frame 64 using a plurality of clamps. Rollers, preforms, molds, and clamps can also be used in combination with the suction cups 68.

[0074] Prior to cold forming, adhesive of adhesive layer 66 can be dispensed onto curved support surface 65 or second major surface 56. For example, nozzle 71 can be moved along a bead path having a shape corresponding to frame 64 to dispense adhesive in a desired pattern. As described herein, the rate of adhesive deposition along the bead path can be controlled based on the shape of frame 64. Areas where frame 64 is smaller than intended and / or has bumps on curved support surface 65 can be provided with a reduced amount of adhesive than areas where frame 64 is larger than intended and / or has grooves on curved support surface 65.

[0075] At block 804, the adhesive layer 66 is shaped and / or its appearance is changed. In embodiments, when the adhesive layer 66 is compressed between the frame 64 and the glass substrate 52, excess adhesive material may overflow outwardly or inwardly from the frame 64 (particularly in embodiments that do not include spacer elements 500, where the adhesive is not shaped using one of the shaping elements 700 and 702, the steps 600, or the grooves 602). This excess adhesive can be removed (e.g., scraped) from the frame 64 prior to curing and prior to interacting with any other additional components. In embodiments, the excess adhesive can be cut away after curing to control the appearance of the adhesive layer 66. In embodiments, the adhesive layer 66 can be formed by incorporating the present disclosure regarding Figure 5-6 In an embodiment, the adhesive layer 66 can be shaped by an external shaping element, such as the one described herein with respect to the spacer element 500, the step 600 and / or the groove 602. Figures 7A-7B Shaping elements 700 and 702 are depicted.

[0076] In embodiments, the appearance of adhesive layer 66 can be modified to be less shiny and noticeable, thereby making the ripples in display system 400 less noticeable. In embodiments, after adhesive layer 66 is cured, adhesive layer 66 can be textured to provide a matte effect. Adhesive layer 66 can be textured via any suitable method. In embodiments, adhesive layer 66 can be textured by treating the adhesive while it is uncured, such as by spraying air over adhesive layer 66, spraying water over adhesive layer 66, using a texture roller or sponge over adhesive layer 66, or using other suitable techniques. Such treatment can cause adhesive layer 66 to scatter incident light (e.g., a reflective haze greater than or equal to 20%), reducing its glossiness and making it less noticeable.

[0077] At block 806, the display module 404 is laminated to the glass substrate 52 within the opening 402 defined by the frame 64 such that the gap 410 is positioned between the frame 64 and the back panel 408 of the display module 404. Any suitable method may be used to apply a layer of optically clear adhesive 405 and press the display module 404 against the second major surface 56. At block 808, the spacer 218 is positioned in the gap 410 via any of the methods described herein.

[0078] The following provides a discussion of properties of embodiments of the glass substrate 52. Accordingly, in the following paragraphs, various geometric, mechanical, and strengthening properties of the glass substrate 52, as well as the composition of the glass substrate 52, are provided.

[0079] In various embodiments, the average thickness T of the glass substrate 52 between the first major surface 54 and the second major surface 56 is in the range of 0.3 mm to 2 mm. In various embodiments, the width of the glass substrate 52 is in the range of 5 cm to 250 cm. Furthermore, in various embodiments, the length of the glass substrate 52 is in the range of 5 cm to 1500 cm. The length is the largest dimension of the glass substrate 52 perpendicular to the thickness T. The width is the largest dimension of the glass substrate 52 perpendicular to the thickness T and the length. In various embodiments, one or more radii of curvature of the glass substrate 52 (e.g., Figures 2A-2B The R) shown is 75mm to 10,000mm.

[0080] In one or more embodiments, the glass substrate 52 can be strengthened to include a compressive stress extending from the surface to a depth of compression (DOC). The compressive stress region is balanced by a central region exhibiting tensile stress. At the DOC, the stress transitions from positive (compressive) stress to negative (tensile) stress. In various embodiments, the glass substrate 52 can be mechanically strengthened by exploiting the mismatch in thermal expansion coefficients between various portions of the article to form a compressive stress region and a central region exhibiting tensile stress. In some embodiments, the glass sheet can be thermally strengthened by heating the glass to a temperature above the glass transition point and then rapidly quenching it.

[0081] In yet other embodiments, the glass substrate 52 is chemically strengthened by an ion exchange process. In an ion exchange process, ions at or near the surface of the glass sheet are replaced or exchanged with larger ions of the same valence or oxidation state. In those embodiments in which the glass sheet comprises an alkali-aluminosilicate glass, the ions in the surface layer of the article and the larger ions are monovalent alkali metal cations, such as Li + 、Na + , K + , Rb + and Cs + Alternatively, the monovalent cations in the surface layer may be replaced by monovalent cations other than alkali metal cations, such as Ag + Etc. In such embodiments, the monovalent ions (or cations) exchanged into the glass sheet generate stress.

[0082] The ion exchange process is typically performed by immersing the glass sheet in a molten salt bath (or two or more molten salt baths) containing larger ions to be exchanged with smaller ions in the glass sheet. It should be noted that aqueous salt baths may also be utilized. Furthermore, the composition of the bath may include more than one type of larger ion (e.g., Na+ and K+) or a single larger ion. Those skilled in the art will appreciate that the parameters of the ion exchange process, including but not limited to bath composition and temperature, immersion time, number of immersions of the glass sheet in the salt bath, use of multiple salt baths, and additional steps such as annealing and washing, are generally determined by the composition of the glass sheet (including the structure of the article and any crystalline phases present) and the desired DOC and compressive stress (CS) of the glass sheet resulting from strengthening. Exemplary molten bath compositions may include nitrates, sulfates, and chlorides of larger alkali metal ions. Typical nitrates include KNO3, NaNO3, LiNO3, NaSO4, and combinations thereof. The temperature of the molten salt bath is typically in the range of about 380° C. to about 450° C., and the immersion time is in the range of about 15 minutes to about 100 hours, depending on the thickness of the glass sheet, the bath temperature, and the diffusivity of the glass (or monovalent ions). However, temperatures and immersion times different from those described above may also be used.

[0083] In one or more embodiments, the glass piece may be immersed in a molten salt bath comprising 100% NaNO3, 100% KNO3, or a combination of NaNO3 and KNO3 at a temperature of about 370°C to about 480°C. In some embodiments, the glass piece may be immersed in a molten mixed salt bath comprising about 5% to about 90% KNO3 and about 10% to about 95% NaNO3. In one or more embodiments, the glass piece may be immersed in a second bath after being immersed in the first bath. The first and second baths may have different compositions and / or temperatures from each other. The immersion times in the first and second baths may be different. For example, the immersion in the first bath may be longer than the immersion in the second bath.

[0084] In one or more embodiments, the glass piece can be immersed in a molten mixed salt bath containing NaNO3 and KNO3 (e.g., 49% / 51%, 50% / 50%, 51% / 49%) at a temperature of less than about 420°C (e.g., about 400°C or about 380°C) for less than about 5 hours, or even about 4 hours or less.

[0085] Ion exchange conditions can be tailored to provide a "spike" or increase the slope of the stress profile at or near the surface of the resulting glass sheet. The spike can result in a greater surface CS value. Due to the unique properties of the glass compositions used in the glass sheets described herein, this spike can be achieved using a single bath or multiple baths, where the baths have a single composition or a mixed composition.

[0086] In one or more embodiments, when more than one univalent ion is exchanged into the glass sheet, different univalent ions can be exchanged to different depths within the glass sheet (and generate stresses of varying magnitude at different depths within the glass sheet). The resulting relative depths of the stress-generating ions can be determined and result in stress profiles with varying characteristics.

[0087] CS can be measured using means known in the art, such as by using a commercially available surface stress meter (FSM), such as the FSM-6000 manufactured by Orihara Industrial Co., Ltd. (Japan). Surface stress measurements rely on accurate measurement of the stress-optical coefficient (SOC), which is related to the birefringence of the glass. SOC is measured by methods known in the art, such as the fiber method and the four-point bend method, as well as the bulk cylinder method, both of which are described in ASTM Standard C770-98 (2013), entitled "Standard Test Method for Measurement of Glass Stress-Optical Coefficient," the contents of which are incorporated herein by reference in their entirety.

[0088] Depending on the strengthening method and conditions, DOC can be measured by FSM or by a scattered light polariscope (SCALP) (e.g., a SCALP-04 scattered light polariscope available from GlasStress Ltd. in Tallinn, Estonia). When the glass sheet is chemically strengthened by an ion exchange process, either FSM or SCALP can be used depending on which ions are exchanged into the glass sheet. When the stress in the glass sheet is generated by exchanging potassium ions into the glass sheet, DOC is measured using FSM. When the stress is generated by exchanging sodium ions into the glass sheet, DOC is measured using SCALP. When the stress in the glass sheet is generated by exchanging both potassium and sodium ions into the glass, DOC is measured using SCALP, because it is believed that the depth of exchange of sodium indicates DOC, and the depth of exchange of potassium ions indicates a change in the magnitude of compressive stress (rather than a change from compressive stress to tensile stress); the depth of exchange of potassium ions in such glass sheets is measured by FSM. CT is the maximum tensile stress and is measured by SCALP.

[0089] Suitable glass compositions for the glass substrate 52 include soda-lime glass, aluminosilicate glass, borosilicate glass, boroaluminosilicate glass, alkali-containing aluminosilicate glass, alkali-containing borosilicate glass, and alkali-containing boroaluminosilicate glass.

[0090] In one or more embodiments, the glass composition may include SiO2 in an amount ranging from about 66 mol% to about 80 mol%, Al2O3 in an amount ranging from about 4 mol% to about 15 mol%, B2O3 in an amount ranging from about 0 mol% to about 5 mol%, P2O5 in an amount ranging from about 0 mol% to about 2 mol%, RO in an amount ranging from about 8 mol% to about 20 mol%, RO in an amount ranging from about 0 mol% to about 2 mol%, ZrO2 in an amount ranging from about 0 mol% to about 0.2 mol%, and SnO2 in an amount ranging from about 0 mol% to about 0.2 mol%. In the above composition, RO refers to the total amount of alkali metal oxides, such as Li2O, Na2O, KO, Rb2O, and Cs2O. Specifically, Na2O may be present in an amount ranging from about 8 mol% to about 20 mol%, and KO may be present in an amount ranging from about 0 mol% to about 4 mol%. In addition, in the above composition, RO refers to the total amount of alkaline earth metal oxides, such as CaO, MgO, BaO, ZnO, and SrO. Specifically, CaO may be present in an amount ranging from about 0 mol% to about 1 mol%, and MgO may be present in an amount ranging from about 0 mol% to about 7 mol%.

[0091] In an embodiment, the glass composition may include other oxides of metals such as Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Ce, W, and Mo. Specifically, Fe in the form of Fe2O3 may be present in an amount ranging from about 0 mol% to about 1 mol%, and TiO2 may be present in an amount ranging from about 0 mol% to about 5 mol%.

[0092] Exemplary glass compositions include SiO in an amount ranging from about 65 mol% to about 75 mol%, AlO in an amount ranging from about 8 mol% to about 14 mol%, NaO in an amount ranging from about 12 mol% to about 17 mol%, KO in an amount ranging from about 0 mol% to about 0.2 mol%, and MgO in an amount ranging from about 1.5 mol% to about 6 mol%. Optionally, SnO may be included in amounts otherwise disclosed herein.

[0093] ***

[0094] The embodiments of the present disclosure may be further understood based on the following information.

[0095] As this article about Figure 5As described, embodiments of the present disclosure may include a spacer element 500 disposed on one of the frame 64 or the glass substrate 52, which may be configured to act as a barrier to prevent the adhesive layer 66 from overflowing when compressed to bond the frame 64 to the glass substrate 52. Other aspects of example embodiments of such spacer elements 500 are described herein with reference to FIG. Figures 9A-9B Describe it. Figure 9A Schematically depicts a Figure 5 900 of display system 400. In this embodiment, spacer element 500 includes an auxiliary bead of glue 902 positioned proximate the peripheral edge of frame 64 and / or minor surface 58 of glass substrate 52. Auxiliary bead of glue 902 contacts adhesive layer 66 and serves to prevent the material of adhesive layer 66 from flowing outward when the material of adhesive layer 66 is compressed during any of the manufacturing processes described herein. Figure 9A Auxiliary glue bead 902 and adhesive layer 66 are depicted in a fully cured state. As shown, when fully cured, adhesive layer 66 includes a thickness 904 corresponding to the separation distance between second major surface 56 and frame 64, such that adhesive layer 66 bonds glass substrate 52 to frame 64 and maintains the separation distance therebetween.

[0096] In an embodiment, the auxiliary glue bead 902 is formed of the same material as the adhesive layer 66 and is dispensed and cured by a similar process. Figure 3 The nozzle 71 depicted in FIG. 7 is used to dispense both the auxiliary glue bead 902 and the adhesive layer 66 . Figure 9B Schematically depicts portion 900 before adhesive layer 66 is compressed during manufacturing according to an example embodiment. Figure 9B As shown, the nozzle 71 can be used to dispense an auxiliary glue bead 902 along a first glue bead path at the periphery of one of the glass substrate 52 and the frame 64. In an embodiment, the nozzle 71 can also be used to dispense a main glue bead 908 along a second glue bead path inside the first glue bead path after the auxiliary glue bead 902 is at least partially cured. Figure 9A 6. In an embodiment, an active step is taken to cure the auxiliary bead 902 (e.g., heating, exposure to radiation, time delay, exposure to a curing assembly) prior to dispensing the primary bead 908. In an embodiment, the auxiliary bead 902 is at least partially cured after its dispensing is completed (e.g., the initially dispensed portion may be partially cured before the auxiliary bead 902 is positioned along the entire first bead path), and dispensing of the primary bead 908 may begin immediately after dispensing of the auxiliary bead 902 is completed. Using the same material for the primary bead 908 and the auxiliary bead 902 facilitates the use of the same dispensing equipment for each bead and can simplify the manufacturing process.

[0097] During the dispensing of the primary glue bead 908 and the auxiliary glue bead 902, the nozzle 71 can be controlled so that each glue bead has a desired volume. Figure 9B , when uncured, the primary bead of glue has a thickness 910 measured in a direction perpendicular to the dispensing surface (in this example, the second major surface 56) and a width 912 measured in a direction parallel to the surface; and the auxiliary bead of glue 902 has a thickness 914 and a width 916. In an embodiment, the auxiliary bead of glue 902 includes a smaller volume than the primary bead of glue 908, such that the width 916 is less than the width 912, and the thickness 914 is less than the thickness 910. As described herein, during assembly of the display system 400, it is preferable to compress the primary bead of glue 908 so that the adhesive material contacts a relatively large area of ​​the glass substrate 52 and the frame 64 before curing to promote the formation of a reliable bond. To promote such compression, the thickness 910 of the primary bead of glue 908 can be greater than the thickness 904 of the adhesive layer 66 after manufacture (see Figure 9A ).

[0098] In an embodiment, the thickness 914 of the auxiliary glue bead 902 is less than or equal to the thickness 904 (see Figure 9A ) to achieve compression of the main bead 908. In order for the auxiliary bead 902 to effectively act as a baffle to prevent the uncured adhesive of the main bead 908 from flowing outward after the main bead 908 is compressed, the auxiliary bead 902 is partially cured when the main bead 908 is dispensed, and therefore has a certain degree of rigidity. Because it has been cured, the auxiliary bead 902 can prevent the main bead 908 from being compressed to a certain extent. Therefore, in order for the main bead 908 to obtain the desired thickness 904 after compression, the height of the auxiliary bead 902 is less than or equal to the thickness 904. In an embodiment, the thickness 914 is greater than or equal to 50% of the thickness 910 and less than or equal to 80% of the thickness 910 to allow the main bead 908 to be compressed a sufficient amount while still providing a baffle that is high enough to effectively prevent the material of the main bead 908 from overflowing after compression. When the thickness 914 is equal to the thickness 904, the auxiliary bead 902 can determine the thickness 904 by limiting the amount that the main bead 908 can be compressed. Such a configuration advantageously provides a uniform thickness for adhesive layer 66 regardless of the irregular shape of frame 64 .

[0099] Various configurations of the primary bead 908 and the auxiliary bead 902 are contemplated and are within the scope of the present disclosure. In an embodiment, the primary bead 908 and the auxiliary bead 902 include uniform cross-sectional dimensions around the periphery of the frame 64. For example, the primary bead 908 and the auxiliary bead 902 may each include a plurality of line segments that follow corresponding segments of the periphery of the glass substrate 52 and the frame 64. The beads may use any suitable cross-sectional dimensions. For example, in an embodiment, the width 912 is greater than the thickness 910, and the width 916 is greater than the thickness 914. A relatively large width can improve the reliability of the bond by increasing the bonding area. In an embodiment, the width 912 is greater than the width 916. The auxiliary bead 902 will not be bonded to both the frame 64 and the glass substrate 52 at the same time, so its width 916 is not particularly limited. However, making the width 916 as small as possible while still achieving the desired thickness 914 can effectively save adhesive material and also maximize the available bonding area of ​​the adhesive layer 66. In an embodiment, after the manufacturing process is completed (see Figure 9A ) thereafter, the thickness 910 of the primary bead 908 is at least 110% of the thickness 904 of the adhesive layer 66 (e.g., greater than or equal to 120% of the thickness 904 and less than or equal to 130% of the thickness 904) to achieve a sufficient amount of compression.

[0100] Reference again Figure 9A , because the auxiliary bead 902 is at least partially cured when the primary bead 908 is compressed, the auxiliary bead 902 may include an unbonded surface 918 that is not directly bonded to either the glass substrate 52 or the frame 64. In the depicted example, the unbonded surface 918 does not contact the frame 614 (such that an air gap exists between the auxiliary bead 902 and the frame 64). It has been found that if the thickness 906 of the auxiliary bead 902 after the manufacturing process is at least 50% of the thickness 904 of the adhesive layer 66, such an air gap does not prevent the auxiliary bead 902 from effectively acting as a baffle, thereby preventing the primary bead 908 from overflowing after compression. It has been found that the auxiliary bead 902 presses the adhesive of the primary bead 908 inward, preventing overflow, even in the presence of an air gap. In an embodiment, the thickness 906 can be equal to the thickness 904, indicating contact between the unbonded surface 918 and the frame 64 or the glass substrate 52. Such an embodiment without an air gap may represent the use of an auxiliary bead 902 to set the desired thickness 904 by limiting the compression of the primary bead 908 .

[0101] The embodiments of the present disclosure may be further understood according to the following aspects.

[0102] Aspect (1) of the present disclosure relates to a display system comprising: a glass substrate comprising a first major surface and a second major surface; a frame comprising a curved support surface, the frame comprising an inner edge defining an opening; an adhesive layer disposed between the curved support surface and the second major surface and attaching the glass substrate to the frame so that the glass substrate conforms to the curved support surface, wherein the second major surface comprises an open area that is not adhered to the frame and overlaps the opening; a display module disposed in the opening and adhered to the open area, wherein the display module comprises a display layer and a back panel, wherein a gap is disposed between the peripheral edge and the inner edge of the back panel, wherein the frame is not bolted to the back panel; and a spacer disposed in the gap and extending the entire distance between the peripheral edge and the inner edge.

[0103] Aspect (2) of the present disclosure relates to the display system according to aspect (1), wherein the gap surrounds the entire peripheral edge of the back panel.

[0104] Aspect (3) of the present disclosure relates to a display system according to any one of aspects (1) to (2), wherein the back panel includes a backlight unit or a heat sink, the backlight unit or the heat sink is curved and includes a surface whose minimum curvature radius is within 10% of the minimum curvature radius of the curved support surface.

[0105] Aspect (4) of the present disclosure relates to the display system according to any one of aspects (1) to (3), wherein the spacer partially fills the gap.

[0106] Aspect (5) of the present disclosure relates to a display system according to any one of aspects (1) to (4), wherein the spacer comprises at least one of: polyurethane, polyurea, polyisocyanurate, polyester, polyphenol, polyepoxide, nylon 6, 1K component adhesive or sealant and 2K component adhesive or sealant.

[0107] Aspect (6) of the present disclosure relates to the display system according to any one of aspects (1) to (5), wherein the spacer comprises a Young's modulus greater than 100 MPa.

[0108] Aspect (7) of the present disclosure relates to the display system according to any one of aspects (1) to (5), wherein the spacer comprises a Young's modulus less than or equal to 50 MPa and is compressed inside the gap.

[0109] Aspect (8) of the present disclosure relates to a display system according to any one of aspects (1) to (7), wherein the curved support surface includes: a length greater than or equal to 500 mm and less than or equal to 3000 mm; a width less than half of the length; and a minimum radius of curvature greater than or equal to 100 mm and less than or equal to 1500 mm.

[0110] Aspect (9) of the present disclosure relates to a display system according to any one of aspects (1) to (8), further comprising at least one of: a spacer element disposed between the curved support surface and the second major surface near the periphery of the second major surface; a step or perforation on the curved support surface; and a groove extending from the inner edge of the frame.

[0111] Aspect (10) of the present disclosure relates to the display system according to any one of aspects (1) to (9), wherein the outer surface of the adhesive layer is textured.

[0112] Aspect (11) of the present disclosure relates to a method of forming a display system, the method comprising: cold forming a glass substrate against a curved support surface of a frame, wherein a layer of adhesive is disposed between the curved support surface and the glass substrate, wherein the frame includes an opening; laminating a display module to the glass substrate within the opening via a layer of optically clear adhesive, wherein the display module includes a back panel, and wherein a peripheral edge of the back panel is separated from an inner edge of the frame by a gap; disposing a spacer in the gap, wherein the spacer joins the back panel to the frame and maintains the shape of the gap; and curing the adhesive layer so that the glass substrate is held in a curved shape by the frame.

[0113] Aspect (12) of the present disclosure relates to the method according to aspect (11), wherein the cold forming comprises: applying negative pressure to the glass substrate via a vacuum suction cup so that the glass substrate adheres to the vacuum suction cup; and pressing the curved support surface against the glass substrate after the negative pressure is applied to the glass substrate.

[0114] Aspect (13) of the present disclosure relates to the method according to aspect (12), wherein: the back panel is bent before being laminated to the glass substrate, and the spacer bonds the back panel to the frame before the adhesive layer is cured.

[0115] Aspect (14) of the present disclosure relates to the method according to aspect (13), further comprising: removing the glass substrate, frame and display module from the vacuum suction cup before the adhesive layer is cured, wherein the back panel holds the glass substrate in the curved shape before the adhesive is fully cured.

[0116] Aspect (15) of the present disclosure relates to the method according to any one of aspects (11) to (14), wherein disposing the spacer includes injecting a spacer precursor material into the gap and curing the spacer precursor material.

[0117] Aspect (16) of the present disclosure relates to the method according to any one of aspects (11) to (14), wherein positioning the spacer includes attaching the spacer to the peripheral edge or the inner edge before laminating the display module to the glass substrate.

[0118] Aspect (17) of the present disclosure relates to a method according to any one of aspects (11) to (16), wherein the cold forming comprises dispensing the adhesive of the adhesive layer along a bead path onto the curved support surface of the frame and one of the glass substrates, wherein the bead path comprises a shape corresponding to the shape of the curved support surface of the frame.

[0119] Aspect (18) of the present disclosure relates to the method according to aspect (17), wherein dispensing the adhesive includes controlling a dispensing rate of the adhesive according to a shape of the curved support surface.

[0120] Aspect (19) of the present disclosure relates to a method according to any one of aspects (17) to (18), further comprising: attaching a spacer element to one of the frame and the glass substrate before dispensing the adhesive, the spacer element being configured to prevent the adhesive from flowing outward from the frame when the adhesive is compressed between the glass substrate and the frame.

[0121] Aspect (20) of the present disclosure relates to a method according to any one of aspects (17) to (18), further comprising: shaping the adhesive via an adhesive shaping element when the adhesive is compressed between the glass substrate and the frame, the adhesive shaping element being positioned on the outside of the glass substrate.

[0122] Aspect (21) of the present disclosure relates to a display system comprising: a glass substrate comprising a first major surface and a second major surface; a frame comprising a curved support surface, the frame defining an opening; an adhesive layer disposed between the curved support surface and the second major surface and attaching the glass substrate to the frame so that the glass substrate conforms to the curved support surface, wherein the second major surface comprises an open area that is not bonded to the frame and overlaps the opening; a display module disposed in the opening and bonded to the open area, wherein the display module comprises a display layer and a back panel, wherein a gap is disposed between a peripheral edge of the back panel and an inner edge of the frame, wherein the frame is not bolted to the back panel; a spacer disposed in the gap and extending the full distance between the peripheral edge and the inner edge; and at least one of: a spacer element disposed between the curved support surface and the second major surface near the periphery of the second major surface, a step or perforation on the curved support surface, and a groove extending from the inner edge of the frame.

[0123] Aspect (22) of the present disclosure relates to a display system according to aspect (21), wherein the back panel includes a backlight unit or a heat sink, the backlight unit or the heat sink is curved and includes a surface whose minimum curvature radius is within 10% of the minimum curvature radius of the curved support surface.

[0124] Aspect (23) of the present disclosure relates to the display system according to any one of aspects (21) to (22), wherein the spacer partially fills the gap.

[0125] Aspect (24) of the present disclosure relates to a display system according to any one of aspects (21) to (23), wherein the spacer comprises at least one of: polyurethane, polyurea, polyisocyanurate, polyester, polyphenol, polyepoxide, nylon 6, a 1K component adhesive or sealant and a 2K component spacer or sealant.

[0126] Aspect (25) of the present disclosure relates to a display system according to any one of aspects (21) to (24), wherein the spacer comprises a Young's modulus greater than 100 MPa.

[0127] Aspect (26) of the present disclosure relates to a display system according to any one of aspects (21) to (24), wherein the spacer comprises a Young's modulus less than or equal to 50 MPa and is compressed inside the gap.

[0128] Aspect (27) of the present disclosure relates to a display system according to any one of aspects (21) to (26), wherein the curved support surface includes: a length greater than or equal to 500 mm and less than or equal to 3000 mm; a width less than half of the length; and a radius of curvature greater than or equal to 100 mm and less than or equal to 1500 mm.

[0129] Aspect (28) of the present disclosure relates to a display system according to any one of aspects (21) to (27), wherein the outer surface of the adhesive layer is textured.

[0130] Aspect (29) of the present disclosure relates to a display system according to aspect (9), wherein the display system includes the spacer element, and the spacer element includes an auxiliary glue bead, the auxiliary glue bead including an unbonded surface that is not directly bonded to the curved support surface or the second main surface.

[0131] Aspect (30) of the present disclosure relates to a method according to any one of aspects (17) to (18), wherein: the adhesive of the adhesive layer is arranged in the form of a main glue bead along a first glue bead path, and the main glue bead includes a first thickness measured in a direction perpendicular to the surface on which the main glue bead is arranged and a first width measured in a direction parallel to the surface, and the method further includes: before dispensing the adhesive of the adhesive layer, dispensing an auxiliary glue bead along a second glue bead path surrounding the first glue bead path, the auxiliary glue bead includes a second thickness that is less than the first thickness of the main glue bead when dispensing the main glue bead, and the auxiliary glue bead is at least partially cured when the adhesive of the adhesive layer is dispensed.

[0132] Aspect (31) of the present disclosure relates to the method according to aspect (30), wherein the second thickness is less than or equal to the thickness of the adhesive layer after curing the adhesive.

[0133] Aspect (32) of the present disclosure relates to a display system according to any one of aspects (21) to (28), wherein the display system includes the spacer element, and the spacer element includes an auxiliary glue bead, the auxiliary glue bead including an unbonded surface that is not directly bonded to the curved support surface or the second main surface.

[0134] Unless otherwise expressly stated, it is not intended that any method described herein be construed as requiring that its steps be performed in a specific order. Therefore, if a method claim does not actually recite the order in which its steps are to be followed, or if the claims or description do not otherwise specifically state that the steps are to be limited to a specific order, no specific order is intended to be inferred. In addition, as used herein, the article "a" is intended to include one or more than one component or element and is not intended to be understood as meaning only one.

[0135] It will be apparent to those skilled in the art that various modifications and variations can be made without departing from the scope of the disclosed embodiments. Since modifications, combinations, sub-combinations, and variations of the disclosed embodiments that incorporate the spirit and substance of the embodiments may occur to those skilled in the art, the disclosed embodiments should be construed to include all contents within the scope of the appended claims and their equivalents.

Claims

1. A display system comprising: a glass substrate comprising a first major surface and a second major surface; a frame comprising a curved support surface, the frame including an inner edge defining an opening; an adhesive layer disposed between the curved support surface and the second major surface and attaching the glass substrate to the frame such that the glass substrate conforms to the curved support surface, wherein the second major surface includes an open area that is not bonded to the frame and overlaps the opening; a display module disposed in the opening and bonded to the open area, wherein the display module includes a display layer and a back panel, wherein a gap is disposed between a peripheral edge and the inner edge of the back panel, wherein the frame is not bolted to the back panel; as well as A spacer is disposed in the gap and extends the full distance between the peripheral edge and the inner edge.

2. The display system of claim 1, wherein the gap surrounds the entire peripheral edge of the back panel.

3. A display system according to any one of claims 1 to 2, wherein the back panel includes a backlight unit or a heat sink, the backlight unit or the heat sink is curved and includes a surface whose minimum curvature radius is within 10% of the minimum curvature radius of the curved support surface.

4. The display system according to any one of claims 1 to 3, wherein the spacer partially fills the gap.

5. The display system of any one of claims 1 to 4, wherein the spacer comprises at least one of the following: polyurethane, polyurea, polyisocyanurate, polyester, polyphenol, polyepoxide, nylon 6, a 1K component adhesive or sealant, and a 2K component adhesive or sealant.

6. The display system of any one of claims 1 to 5, wherein the spacer comprises a Young's modulus greater than 100 MPa.

7. The display system of any one of claims 1 to 5, wherein the spacer comprises a Young's modulus less than or equal to 50 MPa and compresses inside the gap.

8. The display system according to any one of claims 1 to 7, wherein the curved support surface comprises: Length greater than or equal to 500 mm and less than or equal to 3000 mm; a width less than half the length; as well as The minimum radius of curvature is greater than or equal to 100 mm and less than or equal to 1500 mm.

9. The display system according to any one of claims 1 to 8, further comprising at least one of the following: a spacer element disposed between the curved support surface and the second major surface near the periphery of the second major surface, steps or perforations on the curved support surface, and A groove extends from the inner edge of the frame.

10. The display system according to claim 9, wherein: The display system includes the spacing element, and The spacer element includes an auxiliary glue bead including a non-bonded surface that is not directly bonded to the curved support surface or the second major surface.

11. The display system according to any one of claims 1 to 9, wherein an outer surface of the adhesive layer is textured.

12. A method of forming a display system, the method comprising: cold forming a glass substrate against a curved support surface of a frame with an adhesive layer disposed between the curved support surface and the glass substrate, wherein the frame includes an opening; laminating a display module to the glass substrate within the opening via a layer of optically clear adhesive, wherein the display module includes a back panel, and wherein a peripheral edge of the back panel is separated from an inner edge of the frame by a gap; placing a spacer in the gap, wherein the spacer joins the back panel to the frame and maintains the shape of the gap; as well as The adhesive layer is cured so that the glass substrate is held in a curved shape by the frame.

13. The method of claim 12, wherein the cold forming comprises: applying negative pressure to the glass substrate via a vacuum suction cup to make the glass substrate adhere to the vacuum suction cup; as well as The curved support surface is pressed against the glass substrate after the negative pressure is applied to the glass substrate.

14. The method according to claim 13, wherein: The back panel is curved before being laminated to the glass substrate, and The spacers bond the back panel to the frame before the adhesive layer cures.

15. The method according to claim 14, further comprising: The glass substrate, frame, and display module are removed from the vacuum chuck before the adhesive layer is cured, wherein the back panel holds the glass substrate in the curved shape before the adhesive is fully cured.

16. The method of any one of claims 12 to 15, wherein disposing the spacers comprises injecting a spacer precursor material into the gap and curing the spacer precursor material.

17. The method of any one of claims 12 to 15, wherein positioning the spacer comprises attaching the spacer to the peripheral edge or the inner edge before laminating the display module to the glass substrate.

18. The method of any one of claims 12 to 17, wherein the cold forming comprises dispensing the adhesive of the adhesive layer onto one of the curved support surface of the frame and the glass substrate along a bead path, wherein the bead path comprises a shape corresponding to the shape of the curved support surface of the frame.

19. The method of claim 18, wherein dispensing the adhesive comprises controlling a dispensing rate of the adhesive based on a shape of the curved support surface.

20. The method according to any one of claims 18 to 19, further comprising: A spacer element is attached to one of the frame and the glass substrate prior to dispensing the adhesive, the spacer element being configured to prevent the adhesive from flowing outward from the frame when the adhesive is compressed between the glass substrate and the frame.

21. The method according to any one of claims 18 to 19, further comprising: When the adhesive is compressed between the glass substrate and the frame, the adhesive is shaped by an adhesive shaping member, which is positioned outside the glass substrate.

22. The method according to any one of claims 18 to 19, wherein: the adhesive of the adhesive layer being deposited along a first bead path in the form of a primary bead, the primary bead comprising a first thickness measured perpendicular to a surface on which the primary bead is deposited and a first width measured parallel to the surface, The method further comprises: before dispensing the adhesive of the adhesive layer, dispensing an auxiliary glue bead along a second glue bead path surrounding the first glue bead path, The auxiliary bead comprises a second thickness that is less than the first thickness of the primary bead when the primary bead is dispensed, and The auxiliary glue bead is at least partially cured when the adhesive of the adhesive layer is dispensed.

23. The method of claim 22, wherein the second thickness is less than or equal to a thickness of the adhesive layer after curing the adhesive.

24. A display system comprising: a glass substrate comprising a first major surface and a second major surface; a frame including a curved support surface, said frame defining an opening; an adhesive layer disposed between the curved support surface and the second major surface and attaching the glass substrate to the frame such that the glass substrate conforms to the curved support surface, wherein the second major surface includes an open area that is not adhered to the frame and overlaps the opening; a display module disposed in the opening and bonded to the open area, wherein the display module includes a display layer and a back panel that is more rigid than the display layer, wherein a gap is disposed between a peripheral edge of the back panel and an inner edge of the frame, wherein the frame is not bolted to the back panel, wherein a width of the gap is less than or equal to 2 mm; a spacer disposed in the gap and extending the full distance between the peripheral edge and the inner edge; as well as At least one of the following: a spacer element disposed between the curved support surface and the second major surface near the periphery of the second major surface, steps or perforations on the curved support surface, and A groove extends from the inner edge of the frame.

25. The display system of claim 24, wherein the back panel comprises a backlight unit or a heat sink, the backlight unit or heat sink being curved and comprising a surface having a minimum radius of curvature within 10% of a minimum radius of curvature of the curved support surface.

26. The display system of any one of claims 24 to 25, wherein the spacer partially fills the gap.

27. The display system of any one of claims 24 to 26, wherein the spacer comprises at least one of: polyurethane, polyurea, polyisocyanurate, polyester, polyphenol, polyepoxide, nylon 6, a 1K component adhesive or sealant, and a 2K component adhesive or sealant.

28. The display system of any one of claims 24 to 27, wherein the spacer comprises a Young's modulus greater than 100 MPa.

29. The display system of any one of claims 24 to 27, wherein the spacer comprises a Young's modulus less than or equal to 50 MPa and compresses inside the gap.

30. The display system of any one of claims 24 to 29, wherein the curved support surface comprises: Length greater than or equal to 500 mm and less than or equal to 3000 mm; a width less than half the length; as well as A radius of curvature greater than or equal to 100 mm and less than or equal to 1500 mm.

31. The display system according to any one of claims 24 to 30, wherein an outer surface of the adhesive layer is textured.

32. A display system according to any one of claims 24 to 31, wherein: The display system comprises the spacing element, The spacer element includes an auxiliary glue bead including a non-bonded surface that is not directly bonded to the curved support surface or the second major surface.

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