Apparatus and method for preventing peeling of adhesive on convexly curved glass articles

Abstract

A glass article includes a frame having a curved frame surface and a rear frame surface. The curved frame surface defines at least one convex bend. The glass article also includes a glass substrate having a first major surface, a second major surface, a first end, and a second end. A first adhesive attaches the second major surface of the glass substrate to the curved frame surface such that the glass substrate elastically deforms and the first major surface defines a convex curvature. A first anchor has a first portion attached to the second major surface of the glass substrate and a second portion abutting the rear frame surface. The frame and the first anchor are configured such that the first anchor is laterally movable and such that the first anchor is restricted from moving in a direction perpendicular to the second major surface.

Description

Cross Reference to Related Applications

[0001] This application claims priority to U.S. Provisional Application Serial No. 63 / 462,024, filed April 26, 2023, the contents of which are relied upon and incorporated herein by reference in its entirety. TECHNICAL FIELD

[0002] The present disclosure relates to glass articles for vehicle interior components, and more particularly, to glass articles having one or more anchors configured to control movement of a glass substrate relative to a frame. BACKGROUND

[0003] Vehicle interiors include curved surfaces, and displays can be incorporated into such curved surfaces. Materials used to form such curved surfaces are typically limited to polymers that do not exhibit the durability and optical performance of glass. As such, curved glass substrates are desirable, particularly when used as a cover for a display. Existing methods of forming such curved glass substrates, such as thermoforming, have drawbacks including high cost, optical distortion, and surface marking. Accordingly, Applicant has identified a need for vehicle interior components that can incorporate curved glass substrates in a cost-effective manner and without the problems typically associated with glass thermoforming processes. SUMMARY

[0004] According to an aspect, embodiments of the present disclosure relate to a glass article. The glass article includes a frame having a curved frame surface and a back frame surface. The curved frame surface defines at least one convex curvature, and the back frame surface is opposite the curved frame surface. The glass article also includes a glass substrate having a first major surface, a second major surface opposite the first major surface, a first end, and a second end. A first adhesive attaches the second major surface of the glass substrate to the curved frame surface such that the glass substrate is elastically deformed and the first major surface defines a convex curvature between the first end and the second end. A first anchor has a first portion attached to the second major surface of the glass substrate and a second portion proximate the back frame surface. The frame and the first anchor are configured such that the first anchor is able to move laterally in a direction of the first end or the second end and such that the first anchor is restricted from moving in a direction perpendicular to the second major surface.

[0005] According to another aspect, embodiments of the disclosure relate to a method. In the method, a glass substrate is elastically bent over a forming surface at a temperature less than 200 °C. The glass substrate includes a first major surface, a second major surface opposite the first major surface, a first end, and a second end. The second major surface of the glass substrate is adhered to a frame using a first adhesive. A first portion of a first anchor is attached to the second major surface of the glass substrate. A second portion of the first anchor abuts the frame such that the first anchor prevents the second major surface from moving away from the frame. After abutting, the first anchor is configured to move relative to the frame in at least one degree of freedom in response to a thermal dimensional change in at least one of the frame and the glass substrate.

[0006] According to yet another aspect, embodiments of the disclosure relate to a glass article. The glass article includes a frame having a convexly curved surface. The glass article also includes a cold-formed glass substrate adhered to the convexly curved surface. At least one anchor is attached to the cold-formed glass substrate. The at least one anchor engages the frame in a manner that limits the cold-formed glass substrate from moving in a direction away from the convexly curved surface.

[0007] Additional features and advantages will be set forth in the detailed description that follows, and in part will be readily apparent to those skilled in the art who practice the embodiments described herein, including the detailed description that follows, the claims, as well as the appended drawings.

[0008] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only, and are intended to provide a further explanation of the nature and advantages of the claims. The accompanying drawings are incorporated in and constitute a part of this specification, and serve to illustrate various aspects of the present application. The drawings are not intended to be to scale. BRIEF DESCRIPTION OF DRAWINGS

[0009] The accompanying drawings incorporated in and forming a part of the specification, illustrate several aspects of the present application, and together with the description serve to explain the principles of the application. In the drawings:

[0010] Figure 1 is a vehicle interior having a convexly curved glass article according to an example embodiment;

[0011] Figure 2 is a side view of a convexly curved glass article according to an example embodiment;

[0012] Figure 3 is a cross-sectional view of a convexly curved glass article of Figure 2 Figure 2

[0013] Figure 4 ​​FIG. 1 depicts a glass substrate that can be used to form a convexly curved glass article according to example embodiments; Figure 3 FIG. 2 depicts a detailed view of a portion of a convexly curved glass article according to example embodiments;

[0014] Figure 5 FIG. 3 depicts a schematic depiction of a location of an anchor for attaching a glass substrate to a frame according to example embodiments;

[0015] Figure 6 FIG. 4 depicts a schematic depiction of a slot in a frame that houses a plurality of anchors according to example embodiments;

[0016] Figure 7 FIG. 5 depicts a flowchart of a method for forming a convexly curved glass article according to example embodiments; and

[0017] Figure 8 FIG. 6 depicts a glass substrate that can be used to form a convexly curved glass article according to example embodiments. DETAILED DESCRIPTION

[0018] Reference will now be made in detail to various embodiments of glass articles for vehicle interior systems in which a glass substrate is cold formed to be convexly curved and secured to a frame using a plurality of anchors. Glass articles for vehicle interiors are subjected to a wide range of temperatures, and the glass substrate and frame can thermally expand and contract at different rates, resulting in stress in an adhesive layer that bonds the glass substrate and the frame. A cold formed and convexly curved glass substrate has placed high tensile stress on the adhesive layer, as the adhesive must hold the glass substrate from elastically returning to an initial (e.g., planar) configuration. In certain situations, the combination of the heat-induced stress and the tensile stress associated with cold forming can overcome the strength of the adhesive layer, causing the glass substrate to peel away from the frame.

[0019] According to the present disclosure, the glass substrate is restrained in a direction perpendicular to a major surface of the glass substrate by one or more anchors to prevent the glass substrate from peeling away from the frame. Additionally, the anchors engage the frame in a manner that still provides for relative lateral movement of the glass substrate and the frame to account for different thermal expansion and contraction of the glass substrate and the frame. That is, the anchors are attached to the glass substrate in a manner that allows the anchors to move relative to the frame in at least one degree of freedom in response to heat-induced dimensional changes of the glass substrate and the frame. Allowing movement between the anchors and the frame advantageously reduces stress on the glass substrate and promotes durability of the connection between the glass substrate and the frame. These and other aspects and advantages of the glass article will be described with respect to the embodiments provided below and depicted in the figures. These embodiments are presented by way of illustration and not by way of limitation.

[0020] Typically, various different curved surfaces, such as display surfaces or decorative surfaces, can be included in the interior or exterior of a vehicle. Covering such vehicle surfaces with a glass material provides a number of advantages over typical curved plastic panels commonly found in the interior of a vehicle. For example, glass is generally considered to provide enhanced functionality and user experience in many cover material applications, such as display applications and touch screen applications, compared to plastic cover materials.

[0021] Figure 1 An exemplary vehicle 10 is shown including two different embodiments of vehicle interior components 20, 30. In the depicted embodiments, vehicle interior component 20 includes a display 22 mounted on an instrument panel 24 of vehicle 10. Display 22 includes a convexly curved surface 26. Additionally, in the depicted embodiments, vehicle interior component 30 is a display 32 mounted in a center console 34 of vehicle 10. Display 32 includes a convexly curved surface 36. In one or more embodiments, a vehicle includes a convexly curved surface mounted in an armrest, a pillar, a seatback, a floor, a headrest, a door panel, or any portion of a vehicle interior that includes or can include a curved surface. While exemplary embodiments relate to vehicle interior components, the present disclosure is not so limited, and embodiments of the present disclosure can also relate to vehicle exterior components having convexly curved glass surfaces, such as a hood, a trunk lid, a windshield pillar, and a decorative element, among other possibilities.

[0022] Embodiments of the convexly curved glass articles described herein can be used, among other things, in each of vehicle interior components 20, 30, as well as in vehicle exterior components. In some such embodiments, the glass articles discussed herein can include a cover glass substrate that also covers a display surface or a non-display surface of an instrument panel, a center console, or the like. In such embodiments, the glass material can be selected based on its weight, aesthetic appearance, or the like, and can be provided with a coating (e.g., an ink or pigment coating) that includes a pattern (e.g., a brushed metal appearance, a wood grain appearance, a leather appearance, a color appearance, or the like) to visually match the glass component with an adjacent non-glass component. In particular embodiments for use with a display, such ink or pigment coatings can have a level of transparency that provides a deadfront or color matching function when display 22, 32 is inactive. Additionally, while exemplary embodiments relate to convexly curved glass articles, the present disclosure is not so limited, and embodiments of the present disclosure can also relate to concavely curved glass articles. Figure 1 While the vehicle of FIG. 1 is in the form of an automobile (e.g., a car, a truck, a bus, or the like), the glass articles disclosed herein can be incorporated into other vehicles, such as a train, a watercraft (a boat, a ship, a submarine, or the like), an aircraft (e.g., a drone, an airplane, a jet, a helicopter, or the like), and a spacecraft.

[0023] Figure 2A side view of a glass article 50 depicting a convexly curved surface 26, 36 of a vehicle interior component 20, 30 usable in a vehicle 10 is depicted. The glass article 50 includes a glass substrate 52 attached to a frame 54 using a first adhesive 56. The glass substrate 52 has a first major surface 58 and a second major surface 60. The second major surface 60 is opposite the first major surface 58. A minor surface 62 connects the first major surface 58 to the second major surface 60. The first major surface 58 and the second major surface 60 define a thickness T of the glass substrate 52 therebetween. In embodiments, the thickness T of the glass substrate 52 is 0.3 mm to 2 mm, particularly 0.5 mm to 1.1 mm. In vehicles, the first major surface 58 faces a passenger of the vehicle.

[0024] In embodiments, the first major surface 58 and / or the second major surface 60 include one or more surface treatments. Examples of surface treatments that can be applied to one or both of the first major surface 58 and the second major surface 60 include at least one of an anti-glare coating, an anti-reflective coating, a coating that provides touch functionality, a decorative (e.g., ink or pigment) coating, or an easy-to-clean coating. Additionally, in embodiments, a display module can be joined to the second major surface 60 of the glass substrate 52 (e.g., the display module can be laminated to the second major surface 60 within an opening defined by the frame 54). Exemplary display modules include at least one of a light emitting diode (LED) display, an organic LED (OLED) display, a micro-LED display, a liquid crystal display (LCD), or a plasma display.

[0025] The frame 54 includes a curved frame surface 64. According to the present disclosure, the curved frame surface 64 defines at least one convex curvature. In one or more embodiments, the convex curvature has a minimum radius of curvature of 200 mm to 10,000 mm, particularly 200 mm to 6000 mm. As Figure 2 As shown in the middle, the convex curvature extends from a first end 66 of the glass article 50 to a second end 68 of the glass article 50. However, in one or more embodiments, the convex curvature does not extend from end to end of the glass article 50, but rather only spans a portion of the distance between the ends 66, 68 of the glass article 50. Additionally, in one or more embodiments, the convex curvature is not centered between the first end 66 and the second end 68 (e.g., is positioned closer to the first end 66 or the second end 68), and in one or more embodiments, the frame 64 defines multiple curvatures, including at least one convex curvature.

[0026] For example, the frame 64 can be as Figure 2The C-shape (convex curvature extending from the first end 66 to the second end 68), V-shape (convex curvature between two flat regions), J-shape (convex curvature positioned closer to one end 66 than the other end 68), S-shape (convex curvature followed by a concave curvature), or U-shape (first convex curvature near the first end 66 and a second convex curvature near the second end 68), among other possibilities, are shown in the middle. Yet further, in one or more embodiments and depending on the shape of the glass article 50, the frame 54 can include multiple bending directions. For example, the frame 54 can have a profile defining a rectangle (as shown in the figures), a T-shape, an I-shape, or an L-shape, among other possibilities, and different portions of the frame 54 can bend in different directions.

[0027] The first adhesive 56 attaches the second major surface 60 of the glass substrate 52 to the curved frame surface 64. In particular, the glass substrate 52 is cold-formed to conform to the convex curvature of the curved frame surface 64, and the first adhesive 56 holds the glass substrate 52 against the frame 54 so that the glass substrate 52 remains elastically deformed against the frame 54. In one or more embodiments, the glass substrate 52 conforms to the convex curvature (or curvatures) of the frame 54 to within 10%, particularly within 5%, and most particularly within 2%, of the radius of curvature of the curved frame surface 64. That is, if the curved frame surface 64 has a radius of curvature of X, then the glass substrate 52 has a radius of curvature, measured at the first major surface 58, in the range of 0.9X to 1.1X, particularly 0.95X to 1.05X, and most particularly 0.98X to 1.02X.

[0028] Advantageously, cold-forming the glass substrate 52 allows surface treatments to be applied to the glass substrate 52 while the glass substrate is in a flat configuration, and cold-forming the glass substrate 52 does not destroy or degrade the surface treatments. In contrast, hot-forming the glass substrate 52 (e.g., at or above the softening temperature of the glass) would degrade surface treatments applied prior to forming, and it would be more difficult to apply surface treatments after forming due to the bending of the glass substrate 52. Additionally, hot-forming can introduce defects that cause optical distortions of the glass substrate 52, while cold-forming does not introduce such defects to the glass substrate 52.

[0029] In one or more embodiments, the first adhesive 56 is selected so that it has a strength to hold the glass substrate 52 in the cold-formed configuration. However, the first adhesive 56 is also subjected to shear stresses applied during thermal expansion and contraction. In particular, the carrier is used in various environments where temperatures can reach -40°C or lower or 50°C or higher. The glass material of the glass substrate 52 and the material of the frame 54 (e.g., metal, plastic, or fiber composite) can have different coefficients of thermal expansion, which means that the glass substrate 52 and the frame 54 will expand and contract at different rates when exposed to temperature extremes. The different rates of thermal expansion cause the glass substrate 52 and the frame 54 to move laterally relative to each other. This creates shear stresses in the first adhesive 56, and the first adhesive 56 is selected so that it has a shear strength sufficient to withstand the shear stresses. However, in certain situations, the combination of the tensile stresses used to hold the glass substrate 52 and the shear stresses experienced during thermal expansion and contraction can be sufficient to overcome the strength of the first adhesive 56, particularly at the ends of the convex curvature where the tensile stresses of the convexly curved glass substrate 52 are highest and in situations where the convex curvature is positioned close to one of the ends 66, 68 of the glass substrate 52.

[0030] To avoid potential delamination of the glass substrate 52 from the frame 54, the glass article 50 is provided with one or more anchors 70. As shown in the cross-sectional view of FIG. 1, the anchors 70 are attached to the second major surface 60 of the glass substrate 52, and the anchors 70 extend through the frame 54. In particular, the frame 54 has a back frame surface 72 opposite the curved frame surface 64. In the embodiment shown in the figures, the frame 54 has a back frame surface 72 that has a curvature that matches that of the curved frame surface 64; however, in one or more other embodiments, the frame 54 has a back frame surface 72 that has a curvature that does not match or is opposite that of the curved frame surface 64 or is flat. Figure 3

[0031] In one or more embodiments, the frame 54 includes one or more slits 74 that extend through the frame 64, such as from the curved frame surface 64 to the back frame surface 72. Each anchor 70 is inserted through the slit 74 to attach the anchor 70 to the glass substrate 52. Referring now to FIG. 2, in one or more embodiments, each anchor 70 includes a first portion 76 attached to the glass substrate 52 and a second portion 78 that abuts the frame 54. In particular, the second portion 78 abuts the frame 54 without bonding or attaching to the frame, such as by using an adhesive, a cement, or a fastener. In this way, the second portion 78 of the anchor 70 is able to translate over the back frame surface 72 while remaining in contact with the back frame surface 72. Figure 4

[0032] ​​In one or more embodiments, the anchor 70 is formed of plastic or a composite material. For example, the anchor 70 is formed of plastic, such as polycarbonate, acrylonitrile butadiene styrene, polypropylene, polyamide, polyethylene, or a blend of two or more thereof. In embodiments, the plastic can be filled with a reinforcing material, such as glass or carbon fibers, to provide a composite material.

[0033] In one or more embodiments, the first portion 76 of the anchor 70 is joined to the second portion 78 by an intermediate portion 80. The first portion 76 and the intermediate portion 80 are sized to be inserted through the slit 74, but the second portion 78 is sized such that it cannot pass through the slit 74. In this way, after the frame 54 is joined to the glass substrate 52, the first portion 76 and the intermediate portion 80 can be inserted through the slit to attach the first portion 76 to the glass substrate 52, and the second portion 78 abuts the frame 54. In embodiments, the length of the intermediate portion 80 can be sized to be less than or equal to the thickness of the first adhesive 54, as measured between the curved frame surface 64 and the back frame surface 72 (in a direction perpendicular to the back frame surface 72), to facilitate the second portion 78 contacting the back frame surface 72 after the anchor 70 is attached to the glass substrate 52.

[0034] The slit 74 is sized in a manner such that the anchor 70 is allowed to move laterally in the slit 74 while limiting movement of the anchor 70 perpendicular to the second major surface 60 of the glass substrate 52. That is, the anchor 70 is configured to move relative to the frame 54 in at least one degree of freedom in response to a thermal dimensional change in at least one of the frame 54 and the glass substrate 62, while limiting or preventing the ability of the glass substrate 52 to move in a direction away from the frame 54. Providing lateral movement of the anchor 70 allows for relative motion between the glass substrate 52 and the frame 54 during thermal expansion and contraction. Limiting vertical movement of the anchor 70 prevents the first adhesive 56 from experiencing tensile stresses sufficient to overcome the strength of the first adhesive 56.

[0035] In the embodiment shown in Figure 4 , the slit 74 has a first width W1, the first portion 76 has a second width W2, the intermediate portion 80 has a third width W3, and the second portion 78 has a fourth width W4. As shown in Figure 4 , the widths W1, W2, W3, W4 are measured parallel to the second major surface 60 of the glass substrate 52 in a direction of bending (i.e., in a direction from the first end 66 to the second end 68). However, in one or more embodiments, the relevant width measurements can be parallel to the second major surface but in a direction transverse to the bending (e.g., for the elongated slit 74 shown in Figure 6 ).

[0036] The second width W2 and the third width W3 are less than the first width W1 to allow the anchor 70 to be inserted through the slit 74. The fourth width W4 is greater than the first width W1 such that the second portion 78 cannot enter the slit 74, resulting in the second portion 78 abutting the back frame surface 72 when the anchor 70 is inserted into the slit 74. In one or more embodiments, the second width W2 is greater than the third width W3 to provide a larger area of engagement for the first portion 76 against the glass substrate 52. However, in one or more other embodiments, the second width W2 is equal to the third width W3 such that the first portion 76 and the middle portion 80 substantially define a post extending from the second portion 78.

[0037] As shown in FIG. 1, the anchor 70 is attached to the glass substrate 52 using a first adhesive 56. In one or more embodiments, the first adhesive 56 is selected to provide a strong bond between the anchor 70 and the glass substrate 52. The first adhesive 56 is also selected to have a certain flexibility to withstand shear forces caused by differential thermal expansion between the glass substrate 52 and the frame 54. In one or more embodiments, the first adhesive 56 is a pressure sensitive adhesive tape. In one or more embodiments, the first adhesive 56 has a Young's modulus in the range of 0.5 MPa to 200 MPa. Figure 4 As shown in FIG. 1, the anchor 70 is attached to the glass substrate 52 using a first adhesive 56. In one or more embodiments, the first adhesive 56 is selected to provide a strong bond between the anchor 70 and the glass substrate 52. The first adhesive 56 is also selected to have a certain flexibility to withstand shear forces caused by differential thermal expansion between the glass substrate 52 and the frame 54. In one or more embodiments, the first adhesive 56 is a pressure sensitive adhesive tape. In one or more embodiments, the first adhesive 56 has a Young's modulus in the range of 0.5 MPa to 200 MPa.

[0038] In one or more embodiments, the second adhesive 82 is selected to have a higher Young's modulus than the first adhesive 56. However, in one or more other embodiments, the second adhesive 82 can have the same Young's modulus as the first adhesive 56 or a lower Young's modulus than the first adhesive. For example, the first adhesive 56 can be a pressure sensitive adhesive tape (relatively low Young's modulus) and the second adhesive 82 can be an epoxy (relatively high Young's modulus). In another example, both the first adhesive 56 and the second adhesive 82 can be pressure sensitive adhesive tapes or epoxies. In one or more embodiments, the first adhesive 56 has a Young's modulus in the range of 0.5 MPa to 200 MPa. In one or more embodiments, the second adhesive 82 has a Young's modulus in the range of 0.5 MPa to 5 GPa. Generally, a lower Young's modulus corresponds to greater compliance in an adhesive, which means that the adhesive is less rigid compared to an adhesive with a higher Young's modulus. Additionally, generally, an adhesive with a higher Young's modulus tends to be a liquid adhesive that provides faster bond times and higher rigidity compared to an adhesive with a lower Young's modulus.

[0039] In one or more embodiments, the second adhesive 82 has a thickness of 0.1 mm to 2 mm between the first portion 76 and the glass substrate 52. In one or more embodiments, the first adhesive 56 has a thickness of 0.1 mm to 2 mm between the glass substrate 52 and the frame 54. In one or more embodiments, the thickness of the first adhesive 56 is greater than the thickness of the second adhesive 82. In such embodiments, the thicker first adhesive 56 allows for greater compliance between the glass substrate 52 and the frame 54 to accommodate differences in thermal expansion and contraction between the glass substrate 52 and the frame 54. Additionally, in such embodiments, the thinner second adhesive 82 may correspond to a more rigid bond between the anchor 70 and the glass substrate 52, which limits or prevents relative movement between the anchor 70 and the glass substrate 52. Nevertheless, different sections of the glass article 50 may still include areas where the first adhesive 56 has a higher Young's modulus and / or a lower thickness than the second adhesive 82. In one or more embodiments, the glass substrate 52 is attached to the frame 54 with the first adhesive 56, and the anchor 70 is attached to the glass substrate 52 with the second adhesive 82, without the use of a primer.

[0040] Figure 5 An embodiment of the glass article 50 as viewed from the rear frame surface 72 is depicted. In one or more embodiments, the frame 54 of the glass article 50 defines a boundary 84 surrounding the periphery of the glass substrate 52. In one or more such embodiments, anchors 70 and corresponding slits 74 (not visible below the anchors 70) are positioned around the boundary 84 of the frame 54. Figure 5 As shown in the embodiments, the anchor 70 and slit 74 are positioned on the longitudinal side of the boundary 84 of the frame 54; however, in one or more other embodiments, the anchor 70 and slit 74 may alternatively or additionally be positioned along the lateral side of the boundary 84 of the frame 54.

[0041] In one or more embodiments, the frame 54 includes struts 86 extending between two opposite sides of the boundary 84. Figure 5 As shown in the embodiments, the strut 86 extends between opposite longitudinal sides of the boundary 84; however, in one or more other embodiments, the strut 86 may alternatively or additionally extend between opposite lateral sides of the boundary 84. In one or more embodiments, the anchor 70 and the slit 74 may also be positioned along the strut 86.

[0042] In one or more embodiments, the frame 54, including the border 84 and the post 86 if present, defines one or more openings 88. In one or more embodiments, the openings 88 are configured to accommodate a display module, such as a light emitting diode (LED) display, an organic LED (OLED) display, a micro-LED display, a liquid crystal display (LCD), or a plasma display, among other possibilities. In one or more embodiments, the display module is attached to the second major surface 60 of the glass substrate 52 (e.g., using a third adhesive, such as an optically clear adhesive). In one or more embodiments, the frame 54 does not have any openings 88 and is a solid backing piece. In such embodiments, the display module can be disposed between the glass substrate 52 and the frame 54.

[0043] Figure 6 Another embodiment of the frame 54 is depicted. In one or more embodiments, the frame 54 includes at least one elongated slit 74 formed in the border 84. A plurality of anchors 70 can be inserted through the elongated slit 74. In this way, the anchors 70 are able to move laterally in response to thermal expansion and contraction of the glass substrate 52 and the frame 54 while remaining constrained from moving in a direction perpendicular to the glass substrate 52. In one or more embodiments, the elongated slit 74 is formed in the border 84, but in one or more other embodiments, the elongated slit 74 can alternatively or additionally be formed along the lateral sides and / or along the post 86 if present. Figure 6 In the embodiment depicted in FIG. 1, the elongated slit 74 is formed in the longitudinal sides of the border 84, but in one or more other embodiments, the elongated slit 74 can alternatively or additionally be formed along the lateral sides and / or along the post 86 if present.

[0044] Figure 7 A flowchart of a method 100 for forming the glass article 50 according to the present disclosure is depicted. In the method 100, a first step 101 involves cold-forming (or elastically bending) the glass substrate 52 over a forming surface (e.g., a chuck). For example, in one or more embodiments, the glass substrate 52 is bent over a vacuum chuck at a temperature below the softening point of the glass material of the glass substrate (e.g., 200°C or less, particularly 100°C or less, and most particularly at or about room temperature). A vacuum is drawn through the chuck to hold the glass substrate 52 in the cold-formed configuration. In one or more embodiments, the forming surface can define a concave curvature such that the first major surface 58 of the glass substrate 52 defines a convex curvature when elastically deformed against the forming surface.

[0045] Thereafter, in a second step 102, a first adhesive 56 is applied to one or both of the second major surface 60 of the glass substrate 52 and the curved frame surface 64 of the frame 54. In a third step 103, the frame 54 is pressed to the glass substrate 52 to attach the frame 54 to the glass substrate 52. The first adhesive 56 is allowed to cure, which can occur under ambient conditions or can be facilitated using, for example, UV, moisture, or heat. In a fourth step 104, the anchors 70 are inserted through the frame 54 and attached to the glass substrate 52 to form the glass article 50, which is then removed from the forming surface.

[0046] During performance of the method, other steps can be involved. For example, the method can involve attaching one or more display modules to the glass substrate 52 and / or the frame 54. In one or more embodiments, the display modules are attached to the glass substrate 52 prior to cold forming, such that the glass substrate 52 and display modules are cold formed together. In one or more embodiments, the display modules are attached to the glass substrate 52 after cold forming. In either case, the display modules can be attached to the glass substrate 52 using an optically transparent adhesive. Additionally, the method can involve applying a surface treatment to the glass substrate 52, particularly prior to the cold forming step.

[0047] In the following paragraphs, various geometric, mechanical, and strengthening properties of the glass substrate 52 are provided, as well as compositions of the glass substrate. Reference is made to Figure 8 As noted above, the thickness T of the glass substrate 52 is substantially constant and is defined as the distance between the first major surface 58 and the second major surface 60. In various embodiments, T can refer to the average thickness or the maximum thickness of the glass substrate. Additionally, the glass substrate 52 includes a width W, defined as a first maximum dimension of one of the first major surface 58 or the second major surface 60 that is orthogonal to the thickness T, and a length L, defined as a second maximum dimension of one of the first major surface 58 or the second major surface 60 that is orthogonal to both the thickness and the width. In other embodiments, W and L can be the average width and average length, respectively, of the glass substrate 52.

[0048] In various embodiments, the average or maximum thickness T is in the range of 0.3 mm to 2 mm. In various embodiments, the width W is in the range of 5 cm to 250 cm, and the length L is in the range of about 5 cm to about 1500 cm. As mentioned above, the radius of curvature of the convexly curved glass substrate 52 is about 200 mm to about 10,000 mm.

[0049] In embodiments, the glass substrate 52 can be strengthened. In one or more embodiments, the glass substrate 52 can be strengthened to include compressive stress extending from the surface to a depth of compression (DOC). The compressive stress region is balanced by a central portion exhibiting tensile stress. At the DOC, the stress transitions from positive (compressive) stress to negative (tensile) stress.

[0050] In various embodiments, the glass substrate 52 can be mechanically strengthened by utilizing a mismatch in the coefficient of thermal expansion between portions of the article to create a compressive stress region and a central region exhibiting tensile stress. In some embodiments, the glass substrate can be thermally strengthened by heating the glass to a temperature above the glass transition point and then rapidly quenching.

[0051] In various embodiments, the glass substrate 52 can be chemically strengthened by ion exchange. In the ion exchange process, ions at or near the surface of the glass substrate are replaced with or exchanged for larger ions of the same valence or oxidation state. In those embodiments where the glass substrate includes an alkali-aluminosilicate glass, the ions and larger ions in the surface layer of the article are monovalent alkali metal cations, such as Li + , Na + , K + , Rb + , and Cs + . Alternatively, the monovalent cations in the surface layer can be replaced by monovalent cations other than alkali metal cations (e.g., Ag + , etc.). In such embodiments, the exchange of monovalent ions (or cations) into the glass substrate creates stress.

[0052] The ion exchange process is typically carried out by immersing the glass substrate in a molten salt bath (or two or more molten salt baths) containing the larger ions to be exchanged for the smaller ions in the glass substrate. It should be noted that aqueous salt baths can also be utilized. Additionally, the composition of one or more of the baths can include more than one type of larger ion (e.g., Na + and K +) or single larger ions. 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 substrate in the salt bath (or baths), use of multiple salt baths, additional steps such as annealing, washing, etc., are generally determined by the composition of the glass substrate, including the structure of the article and any crystalline phases present, and the desired DOC and CS of the glass substrate resulting from strengthening. Exemplary molten bath compositions can 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 generally in the range of about 380 °C to about 450 °C, while the immersion time is in the range of about 15 minutes to about 100 hours, depending on the glass substrate thickness, bath temperature, and glass (or monovalent ion) diffusivity. However, temperatures and immersion times different from those described above can also be used.

[0053] In one or more embodiments, the glass substrate 52 can be immersed in a molten salt bath of 100% NaNO3, 100% KNO3, or a combination of NaNO3and KNO3at a temperature of about 370 °C to about 480 °C. In some embodiments, the glass substrate can be immersed in a molten mixed salt bath comprising about 5% to about 90% KNO3and about 10% to about 95% NaNO3. In one or more embodiments, the glass substrate can be immersed in a second bath after being immersed in a first bath. The first and second baths can have different compositions and / or temperatures from one another. The immersion times in the first and second baths can vary. For example, the immersion in the first bath can be longer than the immersion in the second bath.

[0054] In one or more embodiments, the glass substrate can be immersed in a molten mixed salt bath comprising NaNO3and 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.

[0055] The 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 substrate. The spike can result in a larger surface CS value. Due to the unique properties of the glass compositions used in the glass substrates described herein, this spike can be achieved by a single bath or multiple baths, with one or more of the baths having a single composition or a mixed composition.

[0056] In one or more embodiments, where more than one monovalent ion is exchanged into the glass substrate, different monovalent ions can be exchanged to different depths within the glass substrate (and produce different magnitudes of stress at different depths within the glass substrate). The resulting relative depths of the stress-producing ions can be determined and lead to different characteristics of the stress profile.

[0057] CS is measured using those means known in the art, such as by using a surface stress meter (FSM) of a commercially available instrument, such as the FSM-6000, manufactured by Orihara Industrial Co., Ltd. (Japan). Surface stress measurement relies on accurate measurement of the stress-optical coefficient (SOC) associated with the birefringence of the glass. SOC is in turn measured by those methods known in the art, such as the fiber method and the four-point bend 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, as well as the bulk cylinder method. As used herein, CS can be the "maximum compressive stress," which is the highest compressive stress value measured within the compressive stress layer. In some embodiments, the maximum compressive stress is at the surface of the glass substrate. In other embodiments, the maximum compressive stress can occur at a depth below the surface, giving the compressive profile the appearance of a "buried peak."

[0058] Depending on the strengthening method and conditions, the DOC can be measured by FSM or by a scattered light polariscope (SCALP), such as a SCALP-04 scattered light polariscope available from Glas Stress Ltd. located in Tallinn Estonia. When a glass substrate is chemically strengthened by an ion exchange treatment, FSM or SCALP can be used depending on which ions are exchanged into the glass substrate. In the case where stresses in the glass substrate are created by exchanging potassium ions into the glass substrate, FSM is used to measure the DOC. In the case where stresses are created by exchanging sodium ions into the glass substrate, SCALP is used to measure the DOC. In the case where stresses in the glass substrate are created by exchanging both potassium and sodium ions into the glass, the DOC is measured by SCALP because it is believed that the exchange depth of sodium is indicative of the DOC and the exchange depth of potassium is indicative of a change in the magnitude of the compressive stress (but not a change in the stress from compressive to tensile); the exchange depth of potassium in such glass substrates is measured by FSM. The central tension or CT is the maximum tensile stress and is measured by SCALP.

[0059] In one or more embodiments, the glass substrate can be strengthened to exhibit a DOC described as a fraction of the thickness T of the glass substrate (as described herein). For example, in one or more embodiments, the DOC can be in a range from about 0.05T to about 0.25T. In some cases, the DOC can be in a range from about 20 pm to about 300 pm. In one or more embodiments, the strengthened glass substrate 52 can have a CS (which can be found at a surface or depth within the glass substrate) of about 200 MPa or greater, about 500 MPa or greater, or about 1050 MPa or greater. In one or more embodiments, the strengthened glass substrate can have a maximum tensile stress or central tension (CT) in a range from about 20 MPa to about 100 MPa.

[0060] Suitable glass compositions suitable for use as the glass substrate 52 include soda-lime glasses, alumino-silicate glasses, borosilicate glasses, boro-alumino-silicate glasses, alkali-containing alumino-silicate glasses, alkali-containing borosilicate glasses, and alkali-containing boro-alumino-silicate glasses.

[0061] Unless otherwise specified, the glass compositions disclosed herein are described in terms of mole percent (mol%) on an oxide analysis basis.

[0062] In one or more embodiments, the glass composition can include Si02in an amount ranging from about 66 mol% to about 80 mol%. In one or more embodiments, the glass composition includes Al203in an amount ranging from about 3 mol% to about 15 mol%. In one or more embodiments, the glass article is described as an aluminosilicate glass article or includes an aluminosilicate glass composition. In such embodiments, the glass composition or article formed therefrom includes Si02and Al203and is not a soda-lime silicate glass.

[0063] In one or more embodiments, the glass composition includes B203in an amount ranging from about 0.01 mol% to about 5 mol%. However, in one or more embodiments, the glass composition is substantially free of B203. As used herein, the phrase "substantially free of" with respect to a component of a composition means that the component is not intentionally or actively added to the composition during the initial batching, but can be present as an impurity in an amount less than about 0.001 mol%.

[0064] In one or more embodiments, the glass composition optionally includes P205in an amount ranging from about 0.01 mol% to 2 mol%. In one or more embodiments, the glass composition is substantially free of P205.

[0065] In one or more embodiments, the glass composition can include R20 (which is the total amount of alkali metal oxides such as Li20, Na20, K20, Rb20, and Cs20) in a total amount ranging from about 8 mol% to about 20 mol%. In one or more embodiments, the glass composition can be substantially free of Rb20, Cs20, or both Rb20 and Cs20. In one or more embodiments, the R20 can include only the total amount of Li20, Na20, and K20. In one or more embodiments, the glass composition can include at least one alkali metal oxide selected from Li20, Na20, and K20, wherein the alkali metal oxide is present in an amount greater than about 8 mol% or more.

[0066] In one or more embodiments, the glass composition includes Na20 in an amount ranging from about 8 mol% to about 20 mol%. In one or more embodiments, the glass composition includes K20 in an amount ranging from about 0 mol% to about 4 mol%. In one or more embodiments, the glass composition is substantially free of K20. In one or more embodiments, the glass composition is substantially free of Li20. In one or more embodiments, the amount of Na20 in the composition can be greater than the amount of Li20. In some cases, the amount of Na20 can be greater than the combined amount of Li20 and K20. In one or more alternative embodiments, the amount of Li20 in the composition can be greater than the amount of Na20 or the combined amount of Na20 and K20.

[0067] In one or more embodiments, the glass composition can include RO (which is the total amount of alkaline earth metal oxides such as CaO, MgO, BaO, ZnO, and SrO) in a total amount ranging from about 0 mol% to about 2 mol%. In one or more embodiments, the glass composition includes CaO in an amount less than about 1 mol%. In one or more embodiments, the glass composition is substantially free of CaO. In some embodiments, the glass composition includes MgO in an amount ranging from about 0 mol% to about 7 mol%.

[0068] In one or more embodiments, the glass composition includes Zr02in an amount equal to or less than about 0.2 mol%. In one or more embodiments, the glass composition includes Sn02in an amount equal to or less than about 0.2 mol%.

[0069] In one or more embodiments, the glass composition can include oxides that impart color or tint to the glass article. In some embodiments, the glass composition includes oxides that prevent discoloration of the glass article when the glass article is exposed to ultraviolet radiation. Examples of such oxides include, but are not limited to, oxides of Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Ce, W, and Mo.

[0070] In one or more embodiments, the glass composition includes Fe represented as Fe203, where Fe is present in an amount up to 1 mol%. In the event the glass composition includes Ti02, the Ti02may be present in an amount of about 5 mol% or less.

[0071] Exemplary glass compositions include Si02in an amount ranging from about 65 mol% to about 75 mol%, AI2O3in an amount ranging from about 8 mol% to about 14 mol%, Na20 in an amount ranging from about 12 mol% to about 17 mol%, K20 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, Sn02may be included in the amounts otherwise disclosed herein. It should be understood that while the foregoing glass composition paragraphs recite approximate ranges, in other embodiments, the glass substrate 52 can be made from any glass composition falling within any of the precise numerical ranges discussed above.

[0072] No method steps described herein are intended to be performed in any particular order, unless otherwise explicitly stated in the claims. Hence, under no circumstances can any of the method steps be inferred as being performed in a particular order unless the claim specifically states otherwise. Furthermore, as used herein the article "a" is intended to include one or more than one item recited. Thus, for example, "a" can be interpreted to mean "one or more."

[0073] It will be apparent to those skilled in the art that various modifications and variations can be made in the disclosed embodiments without departing from the spirit or scope of the disclosed embodiments. Since modifications, combinations, sub-combinations and variations of the disclosed embodiments incorporating the spirit and substance of the disclosed embodiments can occur to those skilled in the art, the disclosed embodiments should be construed to encompass all such variations as being within the scope of the following claims and their equivalents.

Claims

1. A glass article comprising: A frame having a curved frame surface and a rear frame surface, the curved frame surface defining at least one convex bend and the rear frame surface being opposite to the curved frame surface; A glass substrate having a first main surface, a second main surface opposite to the first main surface, a first end, and a second end; A first adhesive attaches the second main surface of the glass substrate to the surface of the curved frame, causing the glass substrate to elastically deform, and the first main surface defines a convex bend between the first end and the second end. The first anchor has a first portion attached to the second main surface of the glass substrate and a second portion abutting the surface of the rear frame; The frame and the first anchor are configured such that the first anchor is laterally movable in the direction of the first end or the second end, and the first anchor is restricted from moving in a direction perpendicular to the second main surface.

2. The glass article of claim 1, wherein the first portion of the first anchor is attached to the second main surface of the glass substrate with a second adhesive.

3. The glass article according to claim 2, wherein the first adhesive comprises a first Young's modulus, wherein the second adhesive comprises a second Young's modulus, and wherein the second Young's modulus is greater than the first Young's modulus.

4. The glass article according to claim 2, wherein the first adhesive comprises a first Young's modulus, wherein the second adhesive comprises a second Young's modulus, and wherein the second Young's modulus is equal to or less than the first Young's modulus.

5. The glass article according to any one of claims 1 to 4, wherein the frame includes a second frame surface opposite to the first frame surface, wherein the frame includes a first slit extending from the first frame surface to the second frame surface, and wherein the anchor extends through the first slit.

6. The glass article of claim 5, wherein the first slit includes a first width measured in a direction parallel to the second main surface of the glass substrate, wherein the second portion of the first anchor includes a second width, and wherein the second width is greater than the first width.

7. The glass article of claim 6, wherein the first anchor includes an intermediate portion disposed between the first portion and the second portion, wherein the intermediate portion includes a third width, and wherein the third width is smaller than the first width.

8. The glass article according to any one of claims 1 to 7, further comprising a second anchor having a fourth portion attached to the second main surface of the glass substrate and a fifth portion abutting the frame.

9. The glass article of claim 8, wherein the first anchor is positioned closer to the first end than the second anchor, and the second anchor is positioned closer to the second end than the first anchor.

10. The glass article according to any one of claims 1 to 9, wherein the first anchor is formed of plastic or composite material.

11. The glass article according to any one of claims 1 to 10, wherein the distance between the first main surface and the second main surface defines the thickness of the glass substrate, and wherein the thickness is from 0.3 mm to 2 mm.

12. The glass article according to any one of claims 1 to 11, wherein the glass substrate comprises at least one of soda-lime glass, aluminosilicate glass, borosilicate glass, borosilicate glass, alkali aluminosilicate glass, alkali borosilicate glass or alkali borosilicate glass.

13. The glass article according to any one of claims 1 to 12, wherein the frame comprises at least one of metal, plastic or composite material.

14. The glass article according to any one of claims 1 to 13, wherein the first anchor is directly attached to the frame without adhesive or fasteners.

15. A method comprising: A glass substrate is elastically bent above a molding surface at a temperature of less than 200°C. The glass substrate includes a first main surface, a second main surface opposite to the first main surface, a first end, and a second end. The second main surface of the glass substrate is bonded to the frame using a first adhesive; The first portion of the first anchor is attached to the second main surface of the glass substrate; as well as The second portion of the first anchor is brought close to the frame, such that the first anchor prevents the second main surface from moving away from the frame, wherein, after the close contact, the first anchor is configured to move relative to the frame with at least one degree of freedom in response to thermal dimensional changes in at least one of the frame and the glass substrate.

16. The method of claim 15, wherein the attachment further comprises using a second adhesive to bond the first portion of the first anchor to the second main surface of the glass substrate.

17. The method of claim 16, wherein the first adhesive comprises a first Young's modulus, wherein the second adhesive comprises a second Young's modulus, and wherein the second Young's modulus is greater than the first Young's modulus.

18. The method of claim 16, wherein the first adhesive comprises a first Young's modulus, wherein the second adhesive comprises a second Young's modulus, and wherein the second Young's modulus is greater than the first Young's modulus.

19. The method of any one of claims 15 to 18, wherein the frame includes a curved frame surface and a rear frame surface opposite to the curved frame surface, wherein the frame includes a first slit extending from the curved frame surface to the rear frame surface, and wherein the method further includes inserting the anchor through the first slit prior to the attachment.

20. The method of claim 19, wherein the first slit includes a first width measured in a direction parallel to the second main surface of the glass substrate, wherein the second portion of the first anchor includes a second width, and wherein the second width is greater than the first width.

21. The method of claim 20, wherein the first anchor includes a third portion disposed between the first portion and the second portion, wherein the third portion includes a third width, and wherein the third width is smaller than the first width.

22. The method according to any one of claims 15 to 21, further comprising attaching a fourth portion of the second anchor to the second main surface of the glass substrate and bringing a fifth portion of the second anchor against the frame.

23. The method of claim 22, further comprising positioning the first anchor member closer to the first end than the second anchor member and positioning the second anchor member closer to the second end than the first anchor member.

24. The method according to any one of claims 15 to 23, wherein bringing the second portion of the first anchor against the frame does not involve directly attaching the second portion of the first anchor to the frame with adhesives or fasteners.

25. A glass article comprising: A frame, which includes a convex curved surface; A cold-formed glass substrate, which is bonded to the convex curved surface; At least one anchor is attached to the cold-formed glass substrate; The at least one anchor is engaged with the frame in such a way that it restricts the movement of the cold-formed glass substrate in a direction away from the convex curved surface.

26. The glass article of claim 25, wherein the cold-formed glass substrate includes a first main surface and a second main surface, the second main surface being opposite to the first main surface and bonded to the convex curved surface, and wherein the at least one anchor is attached to the second main surface of the cold-formed glass substrate.

27. The glass article of claim 26, wherein the cold-formed glass substrate is bonded to the convex curved surface with a first adhesive, and the at least one anchor is attached to the cold-formed glass substrate with a second adhesive.

28. The glass article of claim 27, wherein the first adhesive comprises a first Young's modulus and the second adhesive comprises a second Young's modulus, and wherein the second Young's modulus is greater than the first Young's modulus.

29. The glass article of claim 27, wherein the first adhesive comprises a first Young's modulus and the second adhesive comprises a second Young's modulus, and wherein the second Young's modulus is greater than the first Young's modulus.

30. The glass article according to any one of claims 25 to 29, wherein the at least one anchor is configured to move relative to the frame with at least one degree of freedom in response to a thermal dimensional change in at least one of the frame and the glass substrate.

Images