Method for forming thin, three-dimensional, near net shaped glass articles by gob pressing and glass articles formed using the same

Abstract

An enclosure for a consumer electronic device is disclosed. The enclosure comprises a glass body that has a three-dimension shape, an inside surface, and outside surface spaced from the inside surface. Each of the inside surface and the outside surface has a profile deviation within ± 200 µm from a target three-dimensional shape. A glass-containing material of the glass body comprises a marker indicative of high-velocity glass flow of the glass-containing material when in a molten state. The high-velocity glass flow radiates away from an origin within the glass body in directions that are substantially parallel to the inside and outside surfaces.

Description

METHOD FOR FORMING THIN, THREE-DIMENSIONAL, NEAR NET SHAPED GLASS ARTICLES BY GOB PRESSING AND GLASS ARTICLES FORMED USING THE SAMECROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of priority under 35 U.S.C. § 119 of U.S. Provisional Application No. 63 / 525,060 filed July 5, 2023, the content of which is incorporated herein by reference in its entirety.FIELD

[0002] The present disclosure relates to glass pressing and, more particularly, to forming thin, three-dimensional glass articles via gob pressing with said articles having a net or near net shape without subsequent processing.BACKGROUND

[0003] Glass cover articles for electronic devices, such as smart phones, smart watches, tablets, and other electronic devices, are desirably formed with three-dimensional (3D) shapes and non-uniform thicknesses. Such 3D glass cover articles may be formed using a variety of processes. One method of forming 3D glass cover articles includes machining the articles from thick pieces of glass that are initially provided as flat sheets of glass having uniform thickness. Another method of forming 3D glass cover articles includes using a 3D forming process with a glass blank / preform (e.g., sagging or sheet reforming) or with a glass sheet (e.g., vacuum sagging). However, these existing 3D forming processes may not be able to form 3D glass cover articles that meet designed thickness variations and / or designed thickness tolerances along the as-formed part without additional machining. Accordingly, these existing methods may involve significant material removal, leading to appreciable machining time and material waste.

[0004] Gob pressing is another 3D forming process that can be used to form 3D glass cover articles. In a gob pressing process, a volume of molten glass from a melt (known as a “gob”) is placed in a mold (e.g., typically at the center of the mold) through an opening at the top of the mold (known as “gathering”). A ring can be located on the top of the mold to cover a portion of the opening. A plunger is configured to be inserted through the ring and moved towards the mold to compress the gob against a shaped surface of the mold. The mold, the ring, and plunger define a closed volume into which the gob is compressed during the gob pressing process. Themovement of the plunger towards the mold reduces the closed (or compression) volume, thereby forcing the gob to conform to a desired 3D shape. It would be advantageous to provide as-formed (e.g., via gob pressing) near net shape components having three-dimensional shapes, precise surface profiles with minute profile deviations, and molded features that overcome the challenges of forming 3D glass cover articles using existing processes.SUMMARY

[0005] The following summary is a brief description of certain aspects of the present disclosure. The summary should not be considered as limiting of the breadth, scope, or applicability of the present disclosure.

[0006] According to aspect (1), an enclosure for a consumer electronic device is provided. The enclosure comprises: a glass body having a three-dimension shape, an inside surface, and outside surface spaced from the inside surface, each of the inside surface and the outside surface having a profde deviation within ± 200 pm from a target three-dimensional shape; wherein a glass-containing material of the glass body comprises a marker indicative of high-velocity glass flow of the glass-containing material when in a molten state, the high-velocity glass flow radiating away from an origin within the glass body in directions that are substantially parallel to the inside and outside surfaces.

[0007] According to aspect (2), the enclosure of aspect (1) is provided, wherein at least one of the inside surface and the outside surface has a profile deviation within ± 50 pm from a target three-dimensional shape.

[0008] According to aspect (3), the enclosure of aspect (1) or aspect (2) is provided, wherein the profile deviation is taken along a line extending across an entirety of the inside surface and / or the outside surface of the glass body.

[0009] According to aspect (4), the enclosure of aspect (3) is provided, wherein the glass body is non axisymmetric, and the profile deviation is taken parallel to the longest axis of the glass body.

[0010] According to aspect (5), the enclosure of any one of aspects (1) to (4) is provided, wherein the glass body has a wall thickness in a range of from about 0.5 mm to 4.0 mm.

[0011] According to aspect (6), the enclosure of aspect (5) is provided, wherein a total variation of the wall thickness is within ± 50 pm of an average wall thickness.

[0012] According to aspect (7), the enclosure of aspect (5) or aspect (6) is provided, wherein the glass body has at least two sections each with an average wall thickness that differs from the other by at least 150 pm.

[0013] According to aspect (8), the enclosure of any one of aspects (5) to (7) is provided, wherein the wall thickness is less than or equal to 1 mm.

[0014] According to aspect (9), the enclosure of aspect (5) or aspect (6) is provided, wherein the glass body has at least one section along which the wall thickness continuously increases or decreases.

[0015] According to aspect (10), the enclosure of aspect (9) is provided, wherein the wall thickness continuously increases or decreases for at least 1 mm along the at least one section.

[0016] According to aspect (11), the enclosure of any one of aspects (1) to (10) is provided, wherein the glass body has a flat section and a bend section adjacent to the flat section.

[0017] According to aspect (12), the enclosure of aspect (11) is provided, wherein the bend section surrounds a periphery of the flat section.

[0018] According to aspect (13), the enclosure of aspect (11) or aspect (12) is provided, wherein the bend section comprises at least one bend with a bend radius in a range of from about 0.5 mm to about 20 mm.

[0019] According to aspect (14), the enclosure of aspect (13) is provided, wherein the at least one bend has a bend angle greater than about 90°.

[0020] According to aspect (15), the enclosure of aspect (13) or aspect (14) is provided, wherein the bend section comprises at least two bends each with the bend radius.

[0021] According to aspect (16), the enclosure of aspect (13) or aspect (14) is provided, wherein the bend section comprises at least three bends each with the bend radius.

[0022] According to aspect (17), the enclosure of any one of aspects (1) to (16) is provided, wherein the glass-containing material has a composition that comprises a total amount of alkali metal oxides (R2O) equal to or greater than about 10 mol %.

[0023] According to aspect (18), the enclosure of any one of aspects (1) to (17) is provided, wherein the marker comprises a density of the glass-containing material, the density having a density gradient that is substantially symmetrical between the inside and outside surfaces.

[0024] According to aspect (19), the enclosure of aspect (18) is provided, wherein the density gradient comprises a surface density that increases from each of the inside and outside surfaces to a bulk density disposed centrally between the inside and outside surfaces.

[0025] According to aspect (20), the enclosure of any one of aspects ( 1) to ( 19) is provided, wherein the marker comprises elongate seeds dispersed throughout the glass-containing material, each elongate seed having a lengthwise axis that extends in a direction of elongation and is aligned substantially parallel to the high-velocity glass flow.

[0026] According to aspect (21), the enclosure of aspect (20) is provided, wherein the lengthwise axis of each elongate seed has a length in a range of from about 100 nm to about 50 pm.

[0027] According to aspect (22), the enclosure of any one of aspects (1) to (21) is provided, wherein the marker comprises acicular particles dispersed throughout the glass-containing material, each acicular particle having a lengthwise axis that is aligned substantially parallel to the high-velocity glass flow.

[0028] According to aspect (23), the enclosure of any one of aspects ( 1) to (22) is provided, wherein the marker comprises cords or striae disposed within the glass-containing material and aligned along the high-velocity glass flow.

[0029] According to aspect (24), the enclosure of aspect (23) is provided, wherein the cords or striae impart stress within the glass-containing material that results in a retardation of at least 5 nm.

[0030] According to aspect (25), the enclosure of any one of aspects ( 1) to (24) is provided, wherein the high-velocity glass flow comprises radial glass flow disposed proximate to the origin and radiating away from the origin and across at least a portion of the glass body in different directions.

[0031] According to aspect (26), a method is provided. The method comprises: depositing a glass-containing material in a molten state into a mold with a mold pattern; and actuating a plunger with a plunger pattern towards the mold, thereby pressing the glass-containing material between the plunger pattern and the mold pattern to form a near net shape component having a three-dimensional shape, an inside surface, and an outside surface spaced from the inside surface, wherein each of the inside surface and the outside surface has a profde deviation within ± 200 pm from a target three-dimensional shape after the pressing.

[0032] According to aspect (27), the method of aspect (26) is provided, wherein the near net shape component comprises a molded feature formed by one or more of the plunger pattern and the mold pattern during the pressing.

[0033] According to aspect (28), the method of aspect (26) is provided, wherein the molded feature comprises one or more of a hole, a slot, a stepped edge, an indented portion, a raised portion, a non-uniform thickness, a thick portion, a thick comer, a thick edge, a thin portion, a thin edge, an inner surface pattern, an outer surface pattern, an edge surface pattern, an embossed feature, a varying radii of at least one of: an inside comer, and outside comer, an inside edge and an outside edge, a contoured outer edge, and a contoured inner surface.

[0034] According to aspect (29), the method of aspect (26) is provided, further comprising preheating a portion of the mold, a portion of the plunger, or both.

[0035] According to aspect (30), the method of aspect (26) is provided, further comprising cooling a portion of the mold.

[0036] According to aspect (31), the method of aspect (26) is provided, further comprising cooling the glass-containing material during the pressing to form the near net shape component.

[0037] According to aspect (32), the method of aspect (26) is provided, further comprising preparing the glass-containing material prior to the depositing, wherein the glass-containing material is prepared with one or more of a target temperature, a target shape, a target weight, and a target viscosity based on a size of the near net shape component, a complexity of the mold pattern, a complexity of the plunger pattern, and a composition of the glass-containing material.

[0038] According to aspect (33), the method of aspect (26) is provided, wherein, during the pressing, a portion of the glass-containing material is directed out of the mold and into a glass -containing material overflow channel via an outlet formed by one or more of the mold pattern and the plunger pattern.

[0039] According to aspect (34), the method of aspect (26) is provided, wherein the mold is a monolithic component.

[0040] According to aspect (35), the method of aspect (26) is provided, wherein the mold comprises multiple components.

[0041] According to aspect (36), the method of aspect (26) is provided, wherein the near net shape component has a wall thickness in a range of between about 0.5 mm and about 4.0 mm.

[0042] According to aspect (37), the method of aspect (26) is provided, wherein the glasscontaining material is a glass.

[0043] According to aspect (38), the method of aspect (37) is provided, wherein, if the profde deviation of one or more of the inside surface and the outside surface exceeds ± 200 pm and the glass has a short working range, the method further comprises applying a process modification.

[0044] According to aspect (39), the method of aspect (38) is provided, wherein the process modification comprises preheating a surface of the mold with a low-intensity flame prior to depositing the glass-containing material thereon.

[0045] According to aspect (40), the method of aspect (38) or aspect (39) is provided, wherein the process modification comprises increasing a number of pressing cycles during the pressing.

[0046] According to aspect (41), the method of aspect (26) is provided, wherein the glasscontaining material is a glass-ceramic.

[0047] According to aspect (42), the method of aspect (41) is provided, wherein if the profile deviation of one or more of the inside surface and the outside surface exceeds ± 200 pm and the glass-ceramic has a long working range, the method further comprises applying a process modification.

[0048] According to aspect (43), the method of aspect (42) is provided, wherein the process modification comprises increasing a dwell time during the pressing.

[0049] According to aspect (44), the method of any one of aspects (26) to (43) further comprising post-processing the near net shape component after the pressing.

[0050] According to aspect (45), the method of aspect (44) is provided, wherein the postprocessing comprises machining a region of the near net shape component to define a machined feature.

[0051] According to aspect (46), the method of aspect (44) is provided, wherein the postprocessing comprises surface polishing a region of the near net shape component to define a polished region.

[0052] According to aspect (47), the method of aspect (44) is provided, wherein, when the glass-containing material is a glass-ceramic, the post-processing comprises directing a laser beam from a laser into portions of the near net shape component to impart a ceram feature into the near net shape component.

[0053] According to aspect (48), the method of aspect (47) is provided, wherein the ceram feature comprises a symbol, a text, a numeric portion, a design, a pattern, an image, or combinations thereof.

[0054] According to aspect (49), the method of aspect (44) is provided, wherein, when the glass -containing material is a glass, the post-processing comprises performing an ion exchange process on the near net shape component.

[0055] According to aspect (50), the method of any one of aspects (26) to (49) is provided, wherein the near net shape component is annealed after the pressing to stabilize the three- dimensional shape.

[0056] According to aspect (51), the method of any one of aspects (26) to (50) is provided, wherein the near net shape component is configured as a consumer electronics component, a phone cover, a phone back, a wearable device component, a smart watch, component, or an enclosure.

[0057] According to aspect (52), an enclosure for a consumer electronic device is provided. The enclosure comprises: a glass body having a three-dimension shape, an inside surface, and outside surface spaced from the inside surface, the glass body comprising a glass-containing material with a composition that includes a total amount of alkali metal oxides (R2O) greater than or equal to about 10 mol %, wherein the glass-containing material comprises a marker indicative of high-velocity glass flow of the glass-containing material when in a molten state, the high-velocity glass flow radiating away from an origin within the glass body in directions that are substantially parallel to the inside and outside surfaces.

[0058] According to aspect (53), a method is provided. The method comprises: depositing a molten gob of glass-containing material into a mold; pressing the molten gob against the mold to form an enclosure for a consumer electronic device, the enclosure having a three- dimensional shape,

[0059] According to aspect (54), the method of aspect (53) is provided, wherein a composition of the glass-containing material comprises a total amount of alkali metal oxides (R2O) greater than or equal to about 10 mol%.BRIEF DESCRIPTION OF THE DRAWINGS

[0060] Various exemplary embodiments of the present disclosure are described in detail below with reference to the following drawings. The drawings are provided for purposes of illustration only and merely depict exemplary embodiments of the present disclosure to facilitate the understanding of the present disclosure. Therefore, the drawings should not be considered as limiting of the breadth, scope, or applicability of the present disclosure. It should be noted that for clarity and ease of illustration these drawings are not necessarily drawn to scale.

[0061] FIG. 1 is a schematic perspective view of an embodiment of a near net shape component formed “as is” using a glass gob-pressing process according to embodiments of the present disclosure;

[0062] FIG. 2 is a schematic perspective view of another embodiment of a near net shape component formed “as is” using a glass gob-pressing process according to embodiments of the present disclosure;

[0063] FIG. 3 is a schematic perspective view of yet another embodiment of a near net shape component formed “as is” using a glass gob-pressing process according to embodiments of the present disclosure;

[0064] FIG. 4 is a cross sectional view along line A-A through a portion of a glass body of the component of FIG. 3;

[0065] FIGS. 5 and 6 are example profde deviations of inside surfaces of sample enclosures formed using a gob-pressing process that did not include a process modification;

[0066] FIGS. 7 and 8 are example profile deviations of inside surfaces of sample enclosures formed using a gob-pressing process that includes one or more process modifications;

[0067] FIG. 9 is a flow chart of various steps of a method for forming a thin, near net shape component according to embodiments of the present disclosure;

[0068] FIG. 10 is a schematic cross-sectional representation of a mold assembly configured to be used with embodiments of the method of FIG. 9;

[0069] FIGS. 11 and 12 are digital images of components of a mold assembly configured to be used with embodiments of the method of FIG. 9;

[0070] FIGS. 13 and 14 are schematic top views depicting example high-velocity glass flow of molten glass-containing material within a closed volume defined by a mold and a plunger of a mold assembly during gob pressing;

[0071] FIGS. 15A-15C schematically depict an embodiment of post-processing of a near net shape component that has an example configuration; and

[0072] FIGS. 16A-16C schematically depict another embodiment of post-processing of a near net shape component that has an example configuration.DETAILED DESCRIPTION

[0073] For the purposes of promoting an understanding of the principles of the disclosure, reference will now be made to the embodiments illustrated in the drawings and described in the following written specification. It is understood that no limitation to the scope of the disclosure is thereby intended. It is further understood that the present disclosure includes any alterations and modifications to the illustrated embodiments and includes further applications of the principles disclosed herein as would normally occur to one skilled in the art to which this disclosure pertains.

[0074] As used herein, the term “and / or,” when used in a list of two or more items, means that any one of the listed items can be employed by itself, or any combination of two or more of the listed items can be employed. For example, if a composition is described as containing components A, B, and / or C, the composition can contain A alone; B alone; C alone; A and B in combination; A and C in combination; B and C in combination; or A, B, and C in combination.

[0075] In this document, relational terms, such as first and second, top and bottom, and the like, are used solely to distinguish one entity or action from another entity or action, without necessarily requiring or implying any actual such relationship or order between such entities or actions.

[0076] As used herein, the term “about” means that amounts, sizes, formulations, parameters, and other quantities and characteristics are not and need not be exact, but may be approximate and / or larger or smaller, as desired, reflecting tolerances, conversion factors, rounding off, measurement error and the like, and other factors known to those of skill in the art. When the term “about” is used in describing a value or an end-point of a range, thedisclosure should be understood to include the specific value or end-point referred to. Whether or not a numerical value or end-point of a range in the specification recites “about,” the numerical value or end-point of a range is intended to include two embodiments: one modified by “about,” and one not modified by “about.” It will be further understood that the end-points of each of the ranges are significant both in relation to the other end-point, and independently of the other end-point.

[0077] The terms “substantial,” “substantially,” and variations thereof as used herein, unless defined elsewhere in association with specific terms or phrases, are intended to note that a described feature is equal or approximately equal to a value or description. For example, a “substantially planar” surface is intended to denote a surface that is planar or approximately planar. Moreover, “substantially” is intended to denote that two values are equal or approximately equal. In some embodiments, “substantially” may denote values within about 10% of each other, such as within about 5% of each other, or within about 2% of each other.

[0078] Directional terms as used herein — for example up, down, right, left, front, back, top, bottom, above, below, and the like — are made only with reference to the figures as drawn and are not intended to imply absolute orientation.

[0079] As used herein the terms "the," "a," or "an," mean "at least one," and should not be limited to "only one" unless explicitly indicated to the contrary. Thus, for example, reference to "a component" includes embodiments having two or more such components unless the context clearly indicates otherwise.

[0080] The present disclosure is directed generally towards embodiments of as-formed (e.g., via gob pressing) near net shape components having three-dimensional shapes, surfaces with minute profile deviations, and molded features (e.g., hole, slot, non-uniform edge (stepped edge), non-uniform thickness, or surface texturing (on an inner surface or outer surface)) and methods of making such near net shaped components.

[0081] Referring to FIGS. 1-4, various embodiments of a near net shape component 100 formed “as is” using a gob-pressing process (as disclosed herein) are depicted. In the embodiments shown, the near net shape component is configured as a three-dimensional (3D) enclosure for a consumer electronic device. A 3D enclosure according to one aspect of the present disclosure can be used to cover an electronic device having a display. In embodiments, the display area is flat or planar. The 3D enclosure will protect the display while allowing viewing of and interaction with the display. The 3D enclosure has a front section (also referredto as a central portion or a flat section herein) for covering the front side of the electronic device, where the display is located, and one or more side sections (also referred to as bend section(s) herein) for wrapping around the peripheral side of the electronic device. The front section is contiguous with the side section(s).

[0082] Another aspect comprises a 3D enclosure for use as a cover for at least part of the back and side portions of an electronic device, referred to as a backplate. In embodiments, the backplate is flat or planar. The backplate can protect the electronic components in the device and / or provide a scratch or damage resistant surface. The electronic device can also have a display on part or all of the back of the device, and in such cases, the backplate can have a planar surface (also referred to as a central portion or a flat section herein) over that region and may function as a second cover for the second display area. The backplate can also have one or more side sections (also referred to as bend section(s) herein) for wrapping around the peripheral side of the electronic device. The backplate is contiguous with the side section(s). It should be appreciated that other configurations for the near net shape component 100 are contemplated.

[0083] Referring still to FIGS. 1-4, the enclosure 100 includes a glass body 104 having a three -dimension (3D) shape, an inside surface 108, and outside surface 112 spaced from the inside surface 108. In embodiments, the spacing between the inside surface 108 and the outside surface defines a thickness t of the enclosure 100. In embodiments in which the enclosure 100 is positioned on or adjacent to an electronic device, the inside surface 108 would be on the inside of the assembly, whereas the outside surface 112 would be on the outside of the assembly. Each of the inside surface 108 and the outside surface 112 is smooth, and this smoothness can be characterized by surface roughness. In embodiments, the inside surface 108 and the outside surface 112 can have the same surface roughness or each can have a different surface roughness. In embodiments, the surface roughness of one or both of the inside surface 108 and the outside surface 112 can be imparted by the method of forming the enclosure 100 (e.g., gob pressing using a mold assembly) as described herein.

[0084] In embodiments, a portion (e.g., a central portion) of the glass body 104 includes a flat or planar section 116. The portions of the inside surface 108 and the outside surface 112 defined by the flat section 116 of the glass body 104 are generally flat or planar. The flat section 116 in embodiments can be configured to cover at least part of a display area of an electronic device. The glass body 104 can also include a bend or curved section 120 disposed adjacent to at least a portion of the flat section 116. In embodiments, the bend section 120 is adjacent toone side (e.g., a long or elongated side) of the flat section 116, giving the enclosure 100 a slide shape. In embodiments, the glass body 104 includes two, separate bend sections 120 adjacently disposed on opposite sides of the flat section 116, giving the enclosure article 100 a sled shape. In embodiments, the bend section 120 surrounds a periphery of the flat section 116, giving the enclosure 100 a dish shape. The portions of the inside surface 108 and the outside surface 112 defined by the bend section 120 of the glass body 104 are generally curved. In embodiments, the central portion of the glass body 104 is curved (instead of flat or planar) and the glass body does not contain abend section 120, giving the enclosure 100 a contour shape. In any of these embodiments, the glass body 104 can have an edge surface or edge 124 that extends between the inside surface 108 and the outside surface 112.

[0085] The bend section 120 comprises at least one bend with a bend radius or curvature. In embodiments, the bend section 120 can include at least two bends, at least three bends, or greater than three bends with each bend having the same bend radius or a different bend radius. For example, FIG. 4 depicts a cross section along line A-A through a portion of the glass body 104 of the enclosure 100 of FIG. 3. As shown in FIG. 4, the bend section 120 has two bends, including a first bend Bi and a second bend B2. The bend radius can be constant having a fixed radius with a constant center point, or the bend radius can be variable, as in the case of a spline structure. In embodiments, the bend can be a complex bend that has a changing radius, such as described by a Burmester curve. The bend can also have a bend angle. In embodiments, the bend angle can be measured using the inside surface 108, the outside surface 112, or a central plane disposed along a midpoint between the inside and outside surfaces of the glass body 104, or the bend angle can be measured using a centerline disposed between the inside and outside surfaces if the glass body 104 is viewed in cross-section. In embodiments, the bend angle and the bend radius can be selected based on a peripheral side geometry of the electronic device.

[0086] In embodiments, the bend angle is from greater than 0° to 90°. In embodiments, the bend angle can be greater than 90°. In embodiments, the bend radius is about 1 mm or greater. In some embodiments, the bend radius is from about 0.25 mm to about 20 mm, about 0.5 mm to about 20 mm, about 1 mm to about 20 mm, about 1 to about 15 mm, about 1 mm to about 10 mm, about 1 mm to about 5 mm, about 2 mm to about 20 mm, about 2 to about 15 mm, about 0.75 mm to about 10 mm, about 2 mm to about 10 mm, about 2 mm to about 5 mm, about 5 to about 15 mm, about 5 mm to about 10 mm, or about 1 mm to about 20 mm, and also comprising all sub-ranges and sub-values between these range endpoints. In embodiments, thebend radius is about 0.25, 0.5, 0.75, 1.0, 1.25, 1.5, 1.75, 2.0, 2.25, 2.5, 2.75, 3.0, 3.5, 4.0, 4.5, 5.0, 6.0, 7.0, 8.0, 9.0, 10.0, 15.0, 20.0 mm or more.

[0087] As described above, the spacing between the inside surface 108 and the outside surface can define the thickness t of the enclosure 100. In embodiments, the thickness t is measured as the shortest distance between the inside surface 108 and the outside surface 112. In embodiments, the thickness t is measured in a direction normal to one or both of the inside surface 108 and the outside surface 112. In embodiments, the thickness t is measured relative to a centerline (e.g., two-dimensional cross section) or a central plane (e.g., three-dimensional region) disposed at a midpoint between the inside surface 108 and the outside surface 112.

[0088] In embodiments, the thickness t of the glass body (e.g., wall thickness) is in a range of from about 0.3 mm to about 4.0 mm, about 0.5 mm to about 4.0 mm, about 0.75 mm to about 3.0 mm, or about 0.9 mm to about 2. 1 mm, and also comprising all sub-ranges and subvalues between these range endpoints. In embodiments, the wall thickness is about 0.3, 0.4, 0.5, 0.6, 0.7, 0.75, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, or 4.0 mm. In embodiments, a total variation of the wall thickness is within ± 200 pm, ± 175 pm, ± 150 pm, ± 125 pm, ± 100 pm, ± 75 pm, ± 50 pm, ± 20 pm, or ± 20 pm. In embodiments, the total variation in the wall thickness of the glass body 104 is within ± 10 pm, ± 20 pm, ± 30 pm, ± 40 pm, ± 50 pm, ± 60 pm, ± 70 pm , ± 80 pm, ± 90 pm, ± 100 pm, ± 125 pm, ± 150 pm ± 200 pm, or ± 250 pm of an average wall thickness of the glass body 104.

[0089] In embodiments, the glass body has at least two sections each with an average wall thickness t that differs from the other (e.g., by at least 20 pm, 25 pm, 50 pm, 75 pm, 100 pm, 150 pm, 175 pm, 200 pm, 225 pm, 250 pm, or more). For example, the glass body 104 of FIG. 4 has first section (e.g., the flat section 116) with a first thickness ti and a second section (e.g., the bend section 120) with a second thickness 12 that is different (e.g., greater) than the first thickness 0. The second section (e.g., the bend section 120) also has a third thickness ts that is different (e.g., greater) than the first thickness ti and the second thickness / j. As used herein, a “section” of the glass body 104 refers to portion of the glass body 104 that includes the inside surface 108, the outside surface 112, and the glass-containing material disposed therebetween. The sections can have any size and shape sufficient to define and / or describe the different attributes and features associated with the sections as described herein.

[0090] In embodiments, in each section of the glass body 104 that is configured to have a constant wall thickness (even if one or more other sections of the glass body are configured to have different constant wall thicknesses), the total variation of the wall thickness along a given section of the glass body is ± 10% of the average wall thickness of that given section. In embodiments, the total variation of the wall thickness along a given section of the glass body is ±3% of the average wall thickness of that given section. In embodiments, the total variation in the wall thickness along a given section of the glass body is ± 20%, ± 15%, ± 10%, ± 9%, ± 8%, ± 7%, ± 6%, ± 5%, ± 4%, ± 3%, ± 2%, or ±1 % of the average wall thickness of that given section.

[0091] In embodiments, the glass body 104 has at least one section along which the wall thickness t continuously increases or decreases (e.g., for at least 1, 2, 3, 4, 5, 6, 7 mm, or more mm along the at least one section. For example, the glass body 104 of FIG. 4 has a section (e.g., the section disposed after the third bend B3 and adjacent to the edge surface 124) along which the third thickness ts continuously increases as the section extends towards the edge surface 124. The third thickness increases because the portion of the outer surface 112 defined by the section has an outward angle a relative to a vertical direction (e.g., indicated by the vertical construction line defining the angle). Thus, the portions of the inner surface 108 and the outer surface 112 defined by the section are not parallel. In embodiments, one or both of the inner surface 108 and the outer surface can be configured with an angle a (e.g., inward or outward) such that the wall thickness continuously increases or decreases along an extent of the section.

[0092] In embodiments, the enclosure 100 is transparent and has an optical transmission greater than 85% in a wavelength range of 400 nm to 800 nm. In embodiments, the enclosure 100 is transparent and has an optical transmission greater than 75%, 80%, 85%, 87%, 90%, 93%, or 95% in a wavelength range of 400 nm to 800 nm.

[0093] The inside surface 108 and the outside surface 112 of the glass body 104 can have a profile deviation from a target three-dimensional shape. As used herein, a “target three- dimensional shape” refers to an intended or designed shape, such as a three-dimensional shape defined electronically as a computer-aided design (CAD) solid model or rendering of the enclosure 100. In embodiments, each of the inside surface 108 and the outside surface 112 has a profile deviation within ± 200 pm from the target three-dimensional shape. In embodiments, each of the inside surface 108 and the outside surface 112 of the glass body 104 can have a larger or smaller profile deviation, such as within ± 250 pm, ± 225 pm, ± 200 pm, ± 150 pm,± 125 pm, ± 75 pm, ± 50 pm, ± 45 pm, ± 40 pm, ± 35 pm, ± 30 pm, ± 25 pm, ± 20 pm, ± 15 pm, ± 10 irn, or less. In embodiments, at least one of the inside surface 108 and the outside surface 112 has a profile deviation within ± 50 pm (e.g., ± 40 pm, ± 30 pm, ± 20 pm, ± 10 pm, or less) from the target three-dimensional shape.

[0094] Referring now to FIG. 3, further aspects of the profile deviation are depicted. The profile deviation is taken along a line that extends across the inside surface 108 and / or the outside surface 112 of the glass body 104. In embodiments, the line along which the profile deviation is taken extends across an entirety ofthe inside surface 108 and / orthe outside surface 112, such as the line 128 extending across the inside surface 108 of the glass body 104 shown in FIG. 3. In embodiments, the glass body 104 is non axisymmetric such that the glass body 104 has a first dimension (e.g., a length) along a first axis (e.g., x axis) that is different (e.g., longer in FIG. 3) than a second dimension (e.g., a width) along a second axis (e.g., y axis) orthogonal to the first direction. In embodiments, the profile deviation is taken parallel to the longest axis of the glass body 104.

[0095] Referring now to FIGS. 5-8, example profile deviations of inside surfaces 108 of sample enclosures are depicted. The profile deviations shown in FIGS. 5 and 6 are taken from sample enclosures formed using a gob-pressing process that did not include a process modification to account for profile deviations that may exceed specifications. The profile deviations shown in FIGS. 7 and 8 are taken from sample cover glass articles using a gobpressing process that includes one or more process modifications. The gob-pressing process and one or more process modifications used to reduce or eliminate profile deviations are described later in this disclosure.

[0096] The example profile deviations include a solid line that represents the target three- dimensional shape of the profile of the inside surface and a colored and / or dashed line that represents the as-measured shape of the profile of the inside surface. The example profile deviations also include balloon text that indicates the direction of the profile deviation (e.g., positive “+” or negative “-”) and the amount of the profile deviation in millimeters at various points along the inside surface. The profile deviations illustrated in FIGS. 5 and 6 have maximum deviations from the target three-dimensional shape of + 0.19 mm and - 0.22 mm, respectively. The profile deviations illustrated in FIGS. 7 and 8 have maximum deviations from the target three-dimensional shape of + 0.06 mm and + 0.08 mm, respectively. Thus, the profile deviations illustrated in FIGS. 5 and 6 are larger than the profile deviations illustrated in FIGS.7 and 8. This comparison underscores the advantage or gob-pressing near net shape components using the one or more process modifications described hereinbelow.

[0097] In embodiments, the enclosure 100 can include one or more features (e.g., molded feature(s) 132) that are formed in situ during the gob-pressing process. Referring again to FIG. 1, an embodiment of the near net shape component or enclosure 100 is depicted. The enclosure 100 includes the outer surface 112 (generally planar) having a molded feature 132 thereon. The molded feature is a raised geometric shape (square) 132a, such that the enclosure is configured with a non-uniform or variable thickness (e.g., thicker at the molded feature 132a). The molded feature 132 in the embodiment shown also includes a curved portion or surface 132b that extends from the outer surface 112 to the raised, thicker portion 132a.

[0098] Referring again to FIG. 2, an embodiment of the enclosure 100 is depicted. The enclosure 100 includes the inner surface 108 (e.g., inner side wall of a hand-held consumer electronics device) with the bend portion 120 of the glass body 104 configured as a raised, perimetrical wall or edge surrounding the flat section 116 of the glass body 104. The enclosure 100 includes two different molded features 132. One molded feature comprises a discontinuous edge 132c located along the edge of the bend portion 120 (e.g., shown as a stepped, or cut-out feature imparted during gob-pressing). Another molded feature comprises two holes 132d configured to extend entirely through the glass body 104 from the inside surface 108 to the outside surface 112. In embodiments, the holes 132d may be positioned to correspond to locations of lens or apertures of a cell phone camera.

[0099] Various other molded features 132 can be formed in or on the enclosure 100 during the gob-pressing process. In embodiments, the molded feature is selected from a hole, a slot, a stepped edge, an indented portion, a raised portion, a non-uniform thickness, a thick portion, a thick comer, a thick edge, a thin portion, a thin edge, an inner surface pattern, an outer surface pattern, an edge surface pattern, an embossed feature, a varying radii of at least one of: an inside comer, and outside comer, an inside edge and an outside edge, a contoured outer edge, and a contoured inner surface. In some embodiments in which the enclosure 100 includes one or more molded features 132, the determination of an average wall thickness along a section configured with a constant wall thickness (e.g., except for a thickness contribution from the molded feature) may exclude the molded feature from the average wall thickness. In other embodiments in which the enclosure 100 includes one or more molded features 132, the determination of an average wall thickness along a section configured with a constant wall thickness may include the molded feature as a portion of the average wall thickness.

[0100] A method for forming a thin, near net shape component, such as the 3D enclosure 100 of FIGS. 1-8, via gob pressing is now described. FIG. 9 is a flow chart depicting various steps of the method according to embodiments. The method is further described with reference to FIGS. 10-16C, which include schematic cross-sectional representations and digital images of components and additional processing steps associated with embodiments of the method.

[0101] The method includes use of a mold assembly such as the mold assembly 1000 shown in FIGS. 10-12. The mold assembly 1000 includes a mold 1004 that is configured to retain an initial deposit of glass-containing material 1006 in a molten state (also referred to as a “gob”). The mold 1004 comprises a bottom end 1008 and a top end 1012 disposed opposite the bottom end 1008. In embodiments, the mold 1004 has an open cavity 1016 within which one or more mold surfaces of the mold 1004 are configured to define the mold pattern. The open cavity 1016 opens to the top end 1012 of the mold 1004 in embodiments.

[0102] The mold assembly 1000 also includes a plunger 1020 that is configured to actuate towards or with the mold 1004 to press the glass-containing material between the mold 1004 and the plunger 1008. The plunger 1020 has one or more plunger surfaces that define a plunger pattern. Each of the mold pattern and the plunger pattern is configured to impart or form features (e.g., in the negative) into respective areas of the glass-containing material 1006 during the pressing to form the near net shape component 100 with an accurate, as-formed 3D shape having minimal to no deviation from a target 3D shape.

[0103] Referring now to FIGS. 9-12, the method comprises depositing the glass-containing material 1006 in the molten state into (the open cavity 1016 of) the mold 1004 of the mold assembly 1000. The glass-containing material 1006 (e.g., glass or glass ceramic) can be placed at a center of the mold 1004 (also referred to as gathering), though in embodiments the glasscontaining material 1006 can be placed approximately at the center (e.g., FIGS. 12 and 13) or spaced from the center (e.g., FIG. 14).

[0104] In embodiments, the glass-containing material 1006 is deposited into the mold 1004 according to predetermined gathering conditions. For example, the glass-containing material (e.g., glass or glass-ceramic) can be configured with a target temperature, target shape, target mass / weight / volume, and target viscosity prior to deposition or delivery into the mold. There are several considerations for determining the target temperature, target shape, target mass / weight / volume, and target viscosity of the glass -containing material 1006. For instance,temperature will dictate the viscosity of the glass-containing material as it enters the mold and, thus, its ability to fdl out the mold (if desired) prior to pressing the glass-containing material with the plunger. Another consideration is the die design (e.g., the mold pattern and the plunger pattern), which includes the thickness, tightness of tolerances and / or scale of the features in the die design (e.g., how far the glass has to travel and / or the size or smallness of the features). Another consideration is the amount of pressure utilized in the pressing force. Additional consideration can include a size of the near net shape component, a complexity of the mold pattern, a complexity of the plunger pattern, and a composition of the glass-containing material . The gathering conditions are configured to be compatible with the specifications of the mold assembly 1000.

[0105] In embodiments, the glass-containing material 1006 is deposited into the mold 1004 in the form of a gob (e.g., amounded form) or a stream (e.g., a flattened form). In embodiments, the gob or stream has a viscosity in a range of from about 1500 P to about 7000 P or from about 10 P to about 500 P. In embodiments, the gob or stream can have a smaller or a larger viscosity range. The glass-containing material 1006 can include various materials. In embodiments, the glass -containing material is a glass, such as soda lime glass or a multi-component silicate glass. In embodiments, the glass-containing material is a glass-ceramic.

[0106] The method further comprises actuating the plunger 1020 of the mold assembly 1000 towards the mold 1004 and into the open cavity 1016 to press the glass-containing material 1006 into a closed volume 1024 to form the enclosure 100. In embodiments, the plunger 1020 is configured to translate along an axis (arrow 1028 in FIG. 10) towards the mold 1004 in a first direction when actuated to press the glass-containing material 1006 into the closed volume 1024. The plunger 1020 is configured to translate along the axis 1028 away from the mold 1004 in a second direction opposite the first direction when actuated to release the enclosure 100 from the mold assembly 1000 or to perform a process modification (e.g., to account for profile deviations as described herein). As shown in FIG. 10, the closed volume 1024 is defined by the mold 1004 (e.g., the mold pattern) and the plunger 1020 (e.g., the plunger pattern).

[0107] In embodiments, the closed volume 1024 has a three-dimensional shape such that when the glass-containing material 1006 is pressed into the closed volume 1024, the glass body 104 of the enclosure 100 is formed with a three-dimensional shape corresponding to the three- dimensional shape of the closed volume 1024. The enclosure 100, after the pressing, has thethree -dimensional shape, an inside surface 108, and an outside surface 112 spaced from the inside surface 108.

[0108] Each of the mold pattern and the plunger pattern has a configuration of features that is imparted / formed (e.g., in the negative) into respective areas or regions of the glasscontaining material 1006 when pressed by the plunger 1020 so as the form the enclosure 100 with a near net or net three-dimensional shape (i.e., with minimal or no post-processing). The surfaces of the enclosure 100 imparted / formed via the mold pattern and the plunger pattern can be planar (e.g., the flat section 116) and / or curved (e.g., the bend section(s) 120) in portions though the surfaces are configured with the three-dimensional shape exemplary embodiments.

[0109] The near net shape component 100 further includes molded features or attributes that are imparted / formed via the mold pattern and / or the plunger pattern during the pressing. In embodiments, the molded features included one or more of holes (circular, rectangular, elliptical, etc.), a stepped edge (e.g., a cut-out through which device buttons are positioned), curved sides (e.g., extending upward from a generally flat portion of the component and / or curving inwardly over itself), among other features. Other molded features include non- uniform thickness, including a thicker edge, a thicker comer, a thicker portion or a thinner portion of the component (e.g., raised shape or raised region (thicker), an embedded shape or embedded region (thinner), among other configurations). Another non-limiting example of a molded feature includes textured surface finishes that can be embossed from pressing contact with the mold pattern and / or plunger pattern.

[0110] The mold assembly 1000 in embodiments can further comprise a ring portion 1032 configured to cover a portion (e.g., a peripheral portion) of the open cavity 1016 of the mold 1004. The ring portion 1032 is configured to define a portion of the closed volume 1024. For example, when the plunger 1020 is actuated towards the mold 1004 and presses the glasscontaining material 1006, the glass-containing material 1006 is squeezed between the plunger pattern of the plunger 1020 (e.g., the plunger pattern) and the mold 1004 (e.g., the mold pattern) with portions of the glass-containing material 1006 radiating away from an origin of the initially deposited gob in directions that are substantially parallel to the surfaces defining the plunger and mold patterns until contact with the ring portion 1032.

[0111] In embodiments, the ring portion 1032 is separate from (i.e., not an integral part of) the mold 1004 and the plunger 1020. In such embodiments, the ring portion 1032 is disposed on the mold 1004 (e.g., on the top end 1012 of the mold 1004) and configured to define a ringopening through which the plunger 1020 moves and makes sliding contact with the ring portion 1032 when the plunger 1020 is actuated during a pressing operation. In other embodiments, the ring portion is an integral part of the mold 1004 such that the mold is a monolithic component.

[0112] During the pressing operation while the plunger 1020 is actuated towards the mold 1004, the closed volume 1024 (also referred to as a compression volume) decreases or reduces until the plunger 1020 is actuated to or reaches a predetermined distance from the mold 1004, such as position of the plunger 1020 shown in FIG. 10. The plunger 1020 is actuated with a pressing speed and a pressing force configured to ensure the plunger 1020 reaches the predetermined distance and the glass-containing material 1006 is pressed so as to completely fill the closed volume 1024.

[0113] In embodiments, one or both of the mold 1004 (e.g., the mold pattern) and the plunger 1008 (e.g., plunger pattern) can individually or collectively define an outlet through which excess glass (e.g., extra glass not needed in the near net shape component) can be directed out of the mold 1004 into a glass-containing overflow channel or region during the pressing. The excess glass in the overflow channel can be machined or otherwise removed from the near net-shape component 100 after the pressing.

[0114] In embodiments, prior to depositing the glass-containing material 1006 in the mold 1004, the method can include applying a lubricant (e.g., solid lubricant, coating, soot, etc.) to the surfaces of the mold 1004 and / or the surfaces of the plunger 1020 to improve flow of the molten glass-containing material and / or operation of the mold assembly 1000 during pressing and facilitate removal of the enclosure 100 from the mold 1004 after pressing. The method described herein can include the lubricants and corresponding application methods described in International Application Publication No. WO 2023 / 096736 Al (Coming Incorporated, “MOLD RELEASE COATINGS FOR GLASS FORMING OR PROCESSING EQUIPMENT AND RELATED METHODS”) and U.S. Provisional Application Serial No. 63 / 400,491 (Coming Incorporated, “SYSTEM AND METHOD FOR FORMING THIN, THREE- DIMENSIONAL SHAPED GLASS ARTICLES BY PRESSING”), the disclosures of each of which are herein incorporated by reference in their entirety .

[0115] In embodiments, the method further comprises preheating a portion of the mold 1004. In embodiments, the method further comprises preheating (an entirety of) the mold 1004. In embodiments, the method further comprises preheating a portion of the plunger 1020. In embodiments, the method further comprises preheating (an entirety of) the plunger 1020. Inembodiments, at least one of the mold 1004 and the plunger 1020 are preheated to a temperature of at least 250 °C. In embodiments, the mold 1004 is preheated to a temperature of not greater than 500 °C. In embodiments, the plunger 1020 is preheated to a temperature of not greater than 500 °C. In embodiments, a portion of at least one of the mold 1004 and the plunger 1020 are (selectively) cooled. In embodiments, the mold 1004 can be (selectively) heated and (selectively) cooled in different areas or regions. In embodiments, the method further comprises cooling the glass-containing material 1006 during the pressing to form the near net shape component 100.

[0116] After the glass-containing material 1006 is pressed to form the enclosure 100, one or more of the inside surface 108 and the outside surface 112 of the glass body 104 of the as- formed enclosure 100 are configured to have a profile deviation that is within a predetermined tolerance (e.g., ± 200 pm) from a target three-dimensional shape. The profile deviation and corresponding predetermined tolerances are discussed hereinabove with respect to the enclosure 100 of FIGS. 1-8. The glass body 104 of the as-formed enclosure 100 is further configured to have the wall thickness (e.g., total variation, section-to-section thickness difference, per section continuous thickness variation, etc.) and the section configurations (e.g., flat section 116 and / or bend section 120) discussed hereinabove with respect to the enclosure 100 of FIGS. 1-8.

[0117] In embodiments, if the inside surface 108 and / or the outside surface 112 of the near net shape component 100 formed by the method has a profile deviation from the target 3D shape that exceeds the predetermined tolerance (e.g., ± 200 pm), the method can include applying a process modification based on one or more current process parameters of the method.

[0118] In embodiments, the process modification comprises adjusting the pressing (e.g., increasing a number of pressing cycles or increasing a dwell time of the pressing) of the glasscontaining material 1006 and is based on a composition of the glass-containing material 1006. Through experiments, the inventors have discovered a correlation between the profile deviation (i.e., warp) of the as-formed enclosure 100 and the dwell time during pressing (e.g., the time the mold 1004 and the plunger 1020 are in contact with the glass-containing material 1006 under pressure during the pressing). In particular, it has been discovered that a longer dwell time can help reduce the profile deviation of the as-formed enclosure 100. However, increased dwell time may lead to defects, such as sticking, high stress, and / or cracking.

[0119] The effects of dwell time relate to the viscosity curve of the glass-containing material. If the composition of the glass-containing material has a long working range or shallow slope (such as with some glass-ceramics), the dwell time during the pressing can be increased to allow for more heat extraction from the glass-containing material to the plunger and the mold. Such heat extraction can improve the profde deviation of the as-formed enclosures. The plunger can be retracted before the temperature of the glass-containing material approaches or decreases below the strain point; otherwise, the pressing may induce stress in the glass body, causing cracks or other defects before or during annealing. Thus, if the inside surface 108 and / or the outside surface 112 of the near net shape component 100 formed by the method has a profile deviation from the target 3D shape that exceeds the predetermined tolerance and the glass-containing material has a long working range, the process modification comprises increasing the dwell time during the pressing. In embodiments, the increased dwell time is applied while a viscosity of the glass-containing material during the pressing is in a range of from about 102P and 109P, enabling varying dwell time without defects, such as sticking, high stress, and / or cracking.

[0120] If the composition of the glass-containing material has a short working range or steep slope (such as with some amorphous glasses), the dwell time during the pressing may need to be decreased. In embodiments, preheating the surface of the mold with a low -intensity flame prior to depositing the glass-containing material thereon can mitigate or prevent small cracks on the inside and outside surfaces after the pressing. Depending on the wall thickness of the glass body 104 after a first pressing, the glass body 104 can be pressed again (e.g., a second pressing) subsequent to a first retracting of the plunger after the first pressing.

[0121] It has been observed that after the plunger is retracted and is not in contact with the glass body 104 after the first pressing, the glass-containing material will reheat since the center of the glass body is hotter than the inside and outside surfaces of the glass body, which were in contact with the mold and the plunger during the first pressing. At this point, the glass body can be pressed again (e.g., a second pressing) to reduce the profile deviation, if needed, while not inducing stress in the glass body as long as the temperature of the glass-containing material during the second pressing is above the strain point. Thus, if the inside surface 108 and / or the outside surface 112 of the near net shape component 100 formed by the method has a profile deviation from the target 3D shape that exceeds the predetermined tolerance and the glasscontaining material has a short working range, the process modification comprises one or moreof (i) preheating the surface of the mold with a low-intensity flame prior to depositing the glasscontaining material thereon and (ii) increasing a number of pressing cycles during the pressing.

[0122] In embodiments, the glass-containing material 1006 of the near net shape component 100 formed via the (gob-pressing) method disclosed herein may contain defects within acceptable limits. As used herein, “defects” include, but are not limited to, indentations (or dimples - depressions in the surface of the glass body), surface checks / cracks, blisters, chips, cords, dice, observable crystals, laps, seeds, stones, and stria. In embodiments, there are less than an average of 50, 40, 30, 20, 10, 5, 4, 3, 2, or 1 defect(s) that are 150 pm in the largest dimension in a 25 mm x 25 mm area on any of the surfaces and / or within a bulk of the glasscontaining material, as measured by optical microscopy. In embodiments, there are less than an average of 50, 40, 30, 20, 10, 5, 4, 3, 2, or 1 defect(s) that are 150 pm in the largest dimension in a 25 mm x 25 mm area on one of the surfaces - inside or outside - as measured by optical microscopy. In embodiments, there are less than an average of 50, 40, 30, 20, 10, 5, 4, 3, 2, or 1 defect(s) that are 150 pm in the largest dimension in a 25 mm x 25 mm area within the bulk as measured by optical microscopy. In embodiments, the defect is 1, 2, 3, 5, 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 125, or 150 pm in the largest dimension.

[0123] The method for forming the near net shape component 100 via gob pressing as disclosed herein results in high-velocity glass flow of the glass-containing material 1006 when in the molten state during the pressing, especially during the initial portion of the pressing. FIGS. 13 and 14 are top views schematically depicting the high-velocity glass flow of the molten glass-containing material 1006 within the closed volume 1024 (e.g., defined by the mold 1004 and the plunger 1020) during the pressing. The plunger 1020 is omitted from the depiction of the closed volume 1024 in FIGS. 13 and 14 for ease of understanding. The solid line indicated by reference number 1024 demarks a boundary of the closed volume. The dashed lines illustrate gob flow front evolution at different times (e.g., an initial time To when the gob is first deposited in the mold, a first time Ti when the gob is initially pressed and expands within the closed volume 1024, a second time T2 when the gob is pressed more and further expands within the closed volume, and so on. The arrows indicate glass flow paths from different starting positions about an origin of the gob 1006. As illustrated in each of FIGS. 13 and 14, the high-velocity glass flow comprises radial glass flow disposed proximate to the origin (e.g., at To) and radiating away from the origin and across at least a portion of the glass body in different directions. Once the gob flow front meets an edge or boundary of the closedvolume 1024, the radial glass flow transitions to axial glass flow (e.g., the arrows are substantially parallel to one another).

[0124] Without being bound by theory, it is believed that the glass-containing material of the glass body of the enclosure comprises a marker indicative of the high-velocity glass flow of the glass-containing material when in a molten state during the pressing. More specifically, it is believed that the defects (e.g., even when within acceptable numbers, sizes, types, limits, etc.) in the glass-containing material may indicate the high-velocity flow glass flow of the glass -containing material.

[0125] In embodiments, the marker comprises elongate seeds dispersed throughout the glass -containing material. Each of the elongate seeds has a lengthwise axis that extends in a direction of elongation and is aligned substantially parallel to the high-velocity glass flow. In embodiments, the seeds (e.g., prior to elongation by the high velocity glass flow) may arise from typical melting processes associating with the glass-containing material. In embodiments, the seeds could be introduced into the melt (e.g., either prior to elongation or as elongated seeds) such that the glass-containing material can be “tagged” with the seeds. In embodiments, the lengthwise axis of each elongate seed has a length in a range of from about 100 run to about 50 pm.

[0126] In embodiments, the marker comprises acicular particles dispersed throughout the glass -containing material. Each acicular particle has a lengthwise axis that is aligned substantially parallel to the high-velocity glass flow. In embodiments, the lengthwise axis of each acicular particle has a length in a range of from about 100 run to about 50 pm.

[0127] In embodiments, the marker comprises cords or striae disposed within the glasscontaining material and aligned along the high-velocity glass flow. In embodiments, the cords or striae impart stress within the glass-containing material that results in a retardation of at least 5 nm for detection using polarized light.

[0128] In embodiments, aspects of the glass-containing material other than defects may indicate the high-velocity flow glass flow of the glass -containing material. For example, in embodiments, the marker comprises a density of the glass-containing material. Without being bound by theory, it is believed there will be a gradient with a lower density closest to the inside and outside surfaces where the cooling is faster and higher density within the bulk where the cooling is slower. Thus, in embodiments, the density can have a density gradient that is substantially symmetrical between the inside and outside surfaces. In embodiments, the densitygradient comprises a surface density that increases from each of the inside and outside surfaces to a bulk density disposed centrally between the inside and outside surfaces.

[0129] In embodiments, the method further comprises (e.g., before optional postprocessing) removing the near net shape component 100 from the mold 1004. In embodiments, the near net shape component 100 is removed from the mold 1004 by gravity after the pressing . In embodiments, the near net shape component 100 is removed from the mold 1004 via a vacuum cup. In some embodiments, the removing is automated whereas the removing is manual in other embodiments.

[0130] In embodiments, the method optionally comprises post-processing the near net shape component to form a final part. In some embodiments, post-processing includes annealing, machining, surface finishing, performing an ion exchange (chemically strengthening), laser processing (e.g., ceramming, imparting indicia, selectively strengthening portions or regions of the final part), and / or combinations thereof.

[0131] In embodiments, the post-processing comprises machining a region of the near net shape component to define a machined feature (or region). In embodiments, the postprocessing comprises surface polishing a region of the near net shape component to define a polished region.

[0132] In embodiments, when the glass-containing material is a glass-ceramic, the postprocessing comprises directing a laser beam from a laser (e.g., a CO2 laser) into portions of the near net shape component to nucleate the glass-containing material and promote crystal growth in specific locations of the near net shape component. In embodiments, when the glasscontaining material is a photo sensitive glass-ceramic, the post-processing comprises directing a laser beam from a laser (e.g., a UV laser) to ceram (e.g., impart a cerammed feature) in a specific location of the near net shape component.

[0133] In embodiments, when the glass-containing material is a glass-ceramic, the postprocessing comprises reheating the glass -containing material to promote nucleation and crystal growth within the bulk of the glass-containing material.

[0134] In embodiments, when the glass-containing material is a glass-ceramic, the glasscontaining material undergoes ceramming followed by exposure to a UV laser to impart indicia (e.g., letters, numbers, symbols, or combinations thereof) beneath the inside and / or outside surfaces. For example, a focal point of the UV laser is directed below the inside and / or outside surfaces to selectively heat a portion of an inner layer of the glass-ceramic, promoting crystalgrowth in this region. In embodiments, the cerammed features comprise: a symbol, a text, a numeric portion, a design, a pattern, an image, and combinations thereof.

[0135] In embodiments, when the glass-containing material is a glass-ceramic, the glasscontaining material undergoes ceramming, followed by exposure to a UV laser to impart strengthening in specific locations of the final part. For example, a focal point of the UV laser is directed below the inside and / or outside surfaces to selectively heat a portion of an inner layer of the glass-ceramic, promoting crystal growth in this region to impart strengthening.

[0136] In embodiments, when the glass-containing material is a glass, the post-processing comprises performing an ion exchange process on the near net shape component to provide a strengthened final part. In embodiments, after the pressing, the near net shape component is annealed (e.g., for a sufficient time and sufficient temperature) to impart part stability (e.g., dimensional stability) in the near net shape component. In embodiments, the final part is a consumer electronics component, a phone cover, a phone back, or an enclosure.

[0137] Referring to FIGS. 15A-15C, an embodiment of the post-processing of a near net shape component 100 having a genericized molded feature 132 is depicted, where FIG. 15A depicts the near net shape component 10 (with the inside surface 108 and the bend section 120 configured as the perimetrical edge depicted); FIG. 15B illustrates the area of post-processing, machining, completed to transform the near net shape component 100 of FIG. 15B into the final part 200 of FIG. 15C. The genericized molded feature(s) 132 remains in near net shape component 100 and in the final part 200.

[0138] Referring to FIGS. 16A-16C, another embodiment of the post-processing of a near net shape component 100 having a genericized molded feature 132 is depicted, where FIG. 16A depicts the near net shape component 100 (with inside surface 108 and the bend section 120 configured as aperimetrical edge depicted); FIG. 16B illustrates selected, narrowly molded regions where post-processing machining is completed to transform the near net shape component 100 of FIG. 16B into the final part 200 of FIG. 16C. Genericized molded feature(s) 132 remains in near net shape component 100 and in the final part 200. Additional areas of machining are shown in FIG. 16B as compared to FIG. 15B, though both processes provide a near net shape component that results in a final part 200 which generally correspond to one another. While FIG. 15B and FIG. 16B are both embodiments of near net shape components, the corresponding method of FIGS. 15A-15C can provide a tighter tolerance near net shape component, which more closely corresponds to the final part than the method of FIGS. 16A-16C (which requires more post-processing, as indicated by additional arrows in additional areas along FIG. 16B).

[0139] The pressing methods described herein to make near net shape glass-containing forms provide both technical and commercial advantages: speed (e.g., pressing takes seconds, near net shape requires less grinding and polishing), flexibility (e.g., mold pattern and plunger pattern variable to provide multiple combinations and permutations of near net shape components having molded features thereon), material utilization (e.g., lower loss of material to make near net shape component or final part), and machining time (e.g., if any, on select regions or smaller areas).

[0140] While the disclosure has been illustrated and described in detail in the drawings and foregoing description, the same should be considered as illustrative and not restrictive in character. It is understood that only the preferred embodiments have been presented and that all changes, modifications, and further applications that come within the spirit of the disclosure are desired to be protected.

Claims

CLAIMSWhat is claimed is:1 . An enclosure for a consumer electronic device, comprising: a glass body having a three-dimension shape, an inside surface, and outside surface spaced from the inside surface, each of the inside surface and the outside surface having a profde deviation within ± 200 pm from a target three-dimensional shape; wherein a glass-containing material of the glass body comprises a marker indicative of high-velocity glass flow of the glass-containing material when in a molten state, the high- velocity glass flow radiating away from an origin within the glass body in directions that are substantially parallel to the inside and outside surfaces.

2. The enclosure of claim 1, wherein at least one of the inside surface and the outside surface has a profde deviation within ± 50 pm from a target three-dimensional shape.

3. The enclosure of claim 1 or claim 2, wherein the profde deviation is taken along a line extending across an entirety of the inside surface and / or the outside surface of the glass body.

4. The enclosure of claim 3, wherein the glass body is non axisymmetric, and the profde deviation is taken parallel to the longest axis of the glass body.

5. The enclosure of any one of claims 1-4, wherein the glass body has a wall thickness in a range of from about 0.5 mm to 4.0 mm.

6. The enclosure of claim 5, wherein a total variation of the wall thickness is within ± 50 pm of an average wall thickness.

7. The enclosure of claim 5 or claim 6, wherein the glass body has at least two sections each with an average wall thickness that differs from the other by at least 150 pm.

8. The enclosure of any one of claims 5-7, wherein the wall thickness is less than or equal to 1 mm.

9. The enclosure of claim 5 or claim 6, wherein the glass body has at least one section along which the wall thickness continuously increases or decreases.

10. The enclosure of claim 9, wherein the wall thickness continuously increases or decreases for at least 1 mm along the at least one section.

11. The enclosure of any one of claims 1-10, wherein the glass body has a flat section and a bend section adjacent to the flat section.

12. The enclosure of claim 11, wherein the bend section surrounds a periphery of the flat section.

13. The enclosure of claim 11 or claim 12, wherein the bend section comprises at least one bend with a bend radius in a range of from about 0.5 mm to about 20 mm.

14. The enclosure of claim 13, wherein the at least one bend has a bend angle greater than about 90°.

15. The enclosure of claim 13 or claim 14, wherein the bend section comprises at least two bends each with the bend radius.

16. The enclosure of claim 13 or claim 14, wherein the bend section comprises at least three bends each with the bend radius.

17. The enclosure of any one of claims 1-16, wherein the glass-containing material has a composition that comprises a total amount of alkali metal oxides (R2O) equal to or greater than about 10 mol %.

18. The enclosure of any one of claims 1-17, wherein the marker comprises a density of the glass-containing material, the density having a density gradient that is substantially symmetrical between the inside and outside surfaces.

19. The enclosure of claim 18, wherein the density gradient comprises a surface density that increases from each of the inside and outside surfaces to a bulk density disposed centrally between the inside and outside surfaces.

20. The enclosure of any one of claims 1-19, wherein the marker comprises elongate seeds dispersed throughout the glass-containing material, each elongate seed having a lengthwise axis that extends in a direction of elongation and is aligned substantially parallel to the high-velocity glass flow.

21. The enclosure of claim 20, wherein the lengthwise axis of each elongate seed has a length in a range of from about 100 nm to about 50 pm.

22. The enclosure of any one of claims 1-21, wherein the marker comprises acicular particles dispersed throughout the glass-containing material, each acicular particle having a lengthwise axis that is aligned substantially parallel to the high-velocity glass flow.

23. The enclosure of any one of claims 1-22, wherein the marker comprises cords or striae disposed within the glass-containing material and aligned along the high-velocity glass flow.

24. The enclosure of claim 23, wherein the cords or striae impart stress within the glasscontaining material that results in a retardation of at least 5 nm.

25. The enclosure of any one of claims 1-24, wherein the high-velocity glass flow comprises radial glass flow disposed proximate to the origin and radiating away from the origin and across at least a portion of the glass body in different directions.

26. A method, comprising: depositing a glass-containing material in a molten state into a mold with a mold pattern; and actuating a plunger with a plunger pattern towards the mold, thereby pressing the glass -containing material between the plunger pattern and the mold pattern to form a near net shape component having a three-dimensional shape, an inside surface, and an outside surface spaced from the inside surface,wherein each of the inside surface and the outside surface has a profde deviation within ± 200 pm from a target three-dimensional shape after the pressing.

27. The method of claim 26, wherein the near net shape component comprises a molded feature formed by one or more of the plunger pattern and the mold pattern during the pressing.

28. The method of claim 26, wherein the molded feature comprises one or more of a hole, a slot, a stepped edge, an indented portion, a raised portion, a non-uniform thickness, a thick portion, a thick comer, a thick edge, a thin portion, a thin edge, an inner surface pattern, an outer surface pattern, an edge surface pattern, an embossed feature, a varying radii of at least one of: an inside comer, and outside comer, an inside edge and an outside edge, a contoured outer edge, and a contoured inner surface.

29. The method of claim 26, further comprising preheating a portion of the mold, a portion of the plunger, or both.

30. The method of claim 26, further comprising cooling a portion of the mold.

31. The method of claim 26, further comprising cooling the glass-containing material during the pressing to form the near net shape component.

32. The method of claim 26, further comprising preparing the glass-containing material prior to the depositing, wherein the glass-containing material is prepared with one or more of a target temperature, a target shape, a target weight, and a target viscosity based on a size of the near net shape component, a complexity of the mold pattern, a complexity of the plunger pattern, and a composition of the glass-containing material.

33. The method of claim 26, wherein, during the pressing, a portion of the glasscontaining material is directed out of the mold and into a glass-containing material overflow channel via an outlet formed by one or more of the mold pattern and the plunger pattern.

34. The method of claim 26, wherein the mold is a monolithic component.

35. The method of claim 26, wherein the mold comprises multiple components.

36. The method of claim 26, wherein the near net shape component has a wall thickness in a range of between about 0.5 mm and about 4.0 mm.

37. The method of claim 26, wherein the glass-containing material is a glass.

38. The method of claim 37, wherein, if the profile deviation of one or more of the inside surface and the outside surface exceeds ± 200 pm and the glass has a short working range, the method further comprises applying a process modification.

39. The method of claim 38, wherein the process modification comprises preheating a surface of the mold with a low-intensity flame prior to depositing the glass-containing material thereon.

40. The method of claim 38 or claim 39, wherein the process modification comprises increasing a number of pressing cycles during the pressing.

41. The method of claim 26, wherein the glass-containing material is a glass-ceramic.

42. The method of claim 41, wherein if the profile deviation of one or more of the inside surface and the outside surface exceeds ± 200 pm and the glass-ceramic has a long working range, the method further comprises applying a process modification.

43. The method of claim 42, wherein the process modification comprises increasing a dwell time during the pressing.

44. The method of any one of claims 26-43 further comprising post-processing the near net shape component after the pressing.

45. The method of claim 44, wherein the post-processing comprises machining a region of the near net shape component to define a machined feature.

46. The method of claim 44, wherein the post-processing comprises surface polishing a region of the near net shape component to define a polished region.

47. The method of claim 44, wherein, when the glass-containing material is a glassceramic, the post-processing comprises directing a laser beam from a laser into portions of the near net shape component to impart a ceram feature into the near net shape component.

48. The method of claim 47, wherein the ceram feature comprises a symbol, a text, a numeric portion, a design, a pattern, an image, or combinations thereof.

49. The method of claim 44, wherein, when the glass-containing material is a glass, the post-processing comprises performing an ion exchange process on the near net shape component.

50. The method of any one of claims 26-49, wherein the near net shape component is annealed after the pressing to stabilize the three-dimensional shape.

51. The method of any one of claims 26-50, wherein the near net shape component is configured as a consumer electronics component, a phone cover, a phone back, a wearable device component, a smart watch, component, or an enclosure.

52. An enclosure for a consumer electronic device, comprising: a glass body having a three-dimension shape, an inside surface, and outside surface spaced from the inside surface, the glass body comprising a glass-containing material with a composition that includes a total amount of alkali metal oxides (R2O) greater than or equal to about 10 mol %, wherein the glass-containing material comprises a marker indicative of high-velocity glass flow of the glass-containing material when in a molten state, the high-velocity glass flow radiating away from an origin within the glass body in directions that are substantially parallel to the inside and outside surfaces.

53. A method, comprising: depositing a molten gob of glass-containing material into a mold; pressing the molten gob against the mold to form an enclosure for a consumer electronic device, the enclosure having a three-dimensional shape,54. The method of claim 53, wherein a composition of the glass-containing material comprises a total amount of alkali metal oxides (R2O) greater than or equal to about 10 mol%.

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