Display system with spacers disposed between a frame and a display back panel and related methods

Abstract

The display system includes a glass substrate, a frame with a curved support surface, an adhesive layer with an adhesive disposed between the curved support surface and the glass substrate, and a display module with a back panel. The adhesive layer holds the glass substrate in the shape of the curved support surface. A gap exists between a peripheral edge of the back panel and an inner edge of the frame. A spacer is disposed in the gap and extends the entire distance between the peripheral edge and the inner edge to maintain the gap during fabrication of the display system and facilitate the adhesive layer having a uniform thickness. Spacers for accommodating the adhesive during fabrication, methods for forming the adhesive layer, frame features for accommodating adhesive flow, schemes for forming the adhesive layer, and fabrication methods are also described.

Description

CROSS-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 / 443,079, filed February 3, 2023, and U.S. Provisional Application No. 63 / 523,699, filed June 28, 2023, the contents of which are herein relied upon and incorporated by reference in their entireties. [Background technology]

[0002] The present disclosure relates to glass articles for display systems including cold-formed glass substrates that are configured to address various problems that may arise from geometric mismatches between various components of the system. In a specific embodiment, the present disclosure relates to a display system comprising a spacer disposed within a gap between a display module and a frame within which the glass substrate is cold-formed.

[0003] Vehicle interiors may incorporate glass surfaces as part of the aesthetic and functional design of the vehicle. Such glass surfaces may be coupled to a frame system that attaches the glass surfaces to the vehicle interior. To facilitate the frame maintaining the glass in a curved shape that deviates from the equilibrium shape of the glass alone, the frame may be constructed of a suitable material (e.g., aluminum, magnesium) that is stiffer than glass. Fabrication methods for frames formed from such materials may not be completely consistent from part to part, resulting in some shape variation between frames. Such shape variation can create difficulties in fabricating systems incorporating curved glass.

[0004] Therefore, it is desirable to create a display system and manufacturing method that reduces the effects of variations in frame shape. Summary of the Invention

[0005] According to an embodiment of the present disclosure, a display system comprises: a glass substrate having a first major surface and a second major surface; a frame having a curved support surface, the frame having an inner edge defining an opening; an adhesive layer disposed between the curved support surface and the second major surface and attaching the glass substrate to the frame so as to conform to the curved support surface, the second major surface being unbonded to the frame and having an opening area overlapping the opening; a display module disposed within the opening and adhered to the opening area, the display module comprising a display layer and a back panel, wherein there is a gap disposed between a peripheral edge and an inner edge of the back panel, and the frame is not bolted to the back panel; and a spacer disposed in the gap and extending the entire distance between the peripheral edge and the inner edge.

[0006] According to another embodiment of the present disclosure, a method of forming a display system includes cold-forming a glass substrate against a curved support surface of a frame with an adhesive layer disposed between the curved support surface and the glass substrate, the frame including an opening; laminating a display module to the glass substrate in the opening via an optically clear adhesive layer, the display module including a back panel, a peripheral edge of the back panel being separated from an interior edge of the frame by a gap; disposing a spacer in the gap, the spacer bonding the back panel to the frame and maintaining the shape of the gap; and curing the adhesive layer such that the glass substrate is held in the curved shape by the frame.

[0007] According to another embodiment of the present disclosure, a display system includes a glass substrate having a first major surface and a second major surface; a frame having a curved support surface, the frame defining an opening; an adhesive layer disposed between the curved support surface and the second major surface and attaching the glass substrate to the frame so as to conform to the curved support surface, the second major surface being unbonded to the frame and having an opening region overlapping the opening; and a display module disposed within the opening and bonded to the opening region. Thus, the display module comprises a display layer and a back panel, with a gap disposed between a peripheral edge of the back panel and an inner edge of the frame, the frame not being bolted to the back panel; a spacer disposed in the gap and extending the entire distance between the peripheral edge and the inner edge; and at least one of a spacing element disposed between the curved support surface and the second major surface proximate to the periphery of the second major surface, a step or through-hole on the curved support surface, and a trough extending from the inner edge of the frame.

[0008] Additional features and advantages will be set forth in the following detailed description, and in part will be readily apparent to those skilled in the art from that description, or may be learned by practicing the embodiments described herein, including the following detailed description, the claims, and the accompanying drawings.

[0009] It is to be understood that both the foregoing general description and the following detailed description are exemplary only and are intended to provide an overview or framework for understanding the nature and character of the claims. The accompanying drawings are included to provide a further understanding, and are incorporated in and constitute a part of this specification.

[0010] The accompanying drawings, which are incorporated in and form a part of this specification, illustrate several aspects of the invention and, together with the description, serve to explain the principles of the invention. [Brief explanation of the drawings]

[0011] [Figure 1] 1 is a perspective view of a vehicle interior having a curved glass surface according to an exemplary embodiment. [Figure 2A] 2 depicts a side view of an embodiment of a curved glass article that may be used in the vehicle interior of FIG. 1 according to an exemplary embodiment. [Figure 2B] 2 depicts a side view of an embodiment of a curved glass article that may be used in the vehicle interior of FIG. 1 according to an exemplary embodiment. [Figure 3] 1A and 1B schematically depict a glass substrate being cold-formed to a frame via a vacuum chuck, according to an exemplary embodiment. [Figure 4A] 1 schematically depicts a rear view of a display system in accordance with one or more embodiments of the present disclosure. [Figure 4B] 4B-4B in accordance with one or more embodiments of the present disclosure. [Figure 4C] 4A-4B during its fabrication, where a spacer precursor material is injected into the gap between the back panel and the frame, according to one or more embodiments of the present disclosure. [Figure 4D] 4A-4B schematically depict the display system depicted in Figures 4A-4B during its fabrication, with spacers attached to the back panel before the display module is laminated to the glass substrate of the display system, according to one or more embodiments of the present disclosure. [Figure 5] 1 schematically depicts a display system including a spacing element disposed between a glass substrate and its frame, in accordance with one or more embodiments of the present disclosure. [Figure 6] 10A-10C schematically depict a display system comprising a step at an inner edge of a curved support surface of a frame and a trough extending from the inner edge, in accordance with one or more embodiments of the present disclosure. [Figure 7A]1A-1C schematically depict a display system positioned on a vacuum chuck having a removable adhesive forming element positioned in contact with a minor surface of a glass substrate, according to one or more embodiments of the present disclosure. [Figure 7B] 1A-1C schematically depict a display system positioned on a vacuum chuck having an adhesive-forming element forming a portion of the forming surface of the vacuum chuck and contacting a minor surface of a glass substrate, in accordance with one or more embodiments of the present disclosure. [Figure 8] FIG. 1 is a flow diagram of a process for making a display system in accordance with one or more embodiments of the present disclosure. [Figure 9A] 6A-6C schematically depict a cross-sectional view of a region of the display system depicted in FIG. 5 according to an exemplary embodiment, in accordance with one or more embodiments of the present disclosure. [Figure 9B] 9B schematically depicts the portion depicted in FIG. 9A during construction before adhesive layer 66 is compressed, in accordance with one or more embodiments of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0012] Reference will now be made in detail to various embodiments, examples of which are illustrated in the accompanying drawings. The present disclosure generally relates to displays including a cold-formed glass substrate adhered to a curved support surface of a frame via an adhesive layer. The curved support surface of the frame defines a bonding area where the adhesive layer can be disposed. However, the size and shape of the bonding area may not be precisely known during display fabrication, resulting in variable spacing between the curved support surface and the glass substrate and / or an insufficient amount of adhesive dispensed at each location within the bonding area. For example, certain areas of the curved support surface may deviate from the desired shape, resulting in a smaller depth of the space between the glass substrate and the curved support surface than other areas. Such areas of reduced depth may cause the adhesive to extrude outward from the bonding area (e.g., seep outward from the frame) and / or result in the adhesive layer having an uneven thickness, resulting in a wavy appearance of the adhesive layer. Aspects of the present disclosure aim to mitigate effects associated with variations in frame shape. By eliminating or reducing the adverse effects of frame-to-frame variations, the present disclosure enables frame constructions with less stringent manufacturing tolerances, thereby saving costs and streamlining the manufacturing process for curved displays.

[0013] According to aspects of the present disclosure, a display may include a display module with a rigid back panel. The rigid back panel may have a desired shape (e.g., a curvature that substantially matches the curved support surface of the frame). However, mechanical interaction between the frame and the rigid back panel may cause the back panel to deviate from this desired shape and / or the frame to bend unpredictably away from an expected configuration, thereby causing the precise spacing between the frame and the glass to be non-uniform. According to the present disclosure, to prevent such frame-to-back panel variations from unpredictably affecting the shape of the glass or adhesive, the back panel is not bolted to the frame, as in certain existing designs. Instead, a spacer is inserted between the back panel and the frame, the spacer configured to fix the shape of the gap between the back panel and the frame before any mechanical interaction occurs between the back panel and the frame. For example, the spacer may be a compliant material (e.g., a suitable adhesive or elastomeric material) that can accommodate geometric inconsistencies between the frame and the back panel. The presence of the spacers results in reduced unpredictable bending of the frame and back panel due to unknown geometric variations, and more controlled variations in adhesive thickness (by controlling the dimensions of the space between the frame and glass substrate during the fabrication process). In another example, the spacers can be a rigid material but have a shape that conforms to the shape of the gap between the back panel and frame, so that the shape of the gap is maintained throughout the fabrication process. The spacers facilitate greater control over the shape of the glass substrate, frame, and overall structure of the display module resulting from the manufacturing process.

[0014] In addition to the spacers between the back panel and frame described herein, various other aspects of the frame and fabrication process can be adjusted to control adhesive thickness and / or overflow. For example, in embodiments, spacing elements are disposed around the perimeter of the bond area before the adhesive layer is deposited. The spacing elements can determine the thickness of the adhesive layer and prevent the adhesive from overflowing during the fabrication process. Alternatively or additionally, feedback can be added to the adhesive dispensing process so that the volume of adhesive dispensed at a particular location in the bond area varies depending on at least one of the size of the frame (e.g., bezel width) at that location and the curvature of the curved support surface (e.g., areas where the curved support surface curves away from the desired shape may have more or less dispensed adhesive than areas where the curved support surface has the desired shape). Additionally or alternatively, at least the outer surface of the adhesive can be textured during or after adhesive dispensing to reduce the gloss and visibility of the adhesive. Additionally or alternatively, the curved support surface of the frame can include one or more steps or openings disposed inside the periphery of the frame. The steps or openings can create a space between the glass and the curved support surface for the adhesive to flow in and prevent overflow. Additionally or alternatively, an external dam can be disposed around the periphery of the glass substrate and frame to prevent overflow of the adhesive during cold forming. The external dam can be removably disposed around the periphery of the glass to both control the adhesive thickness and prevent overflow of the adhesive. In embodiments, the spacer can be a component of a vacuum chuck used during the fabrication process and can provide support for the glass substrate on the vacuum chuck. Any of these concepts can be used individually or in combination with any of the other concepts described herein to help provide a uniform adhesive layer despite unpredictable frame shapes.

[0015] FIG. 1 illustrates an exemplary vehicle interior 10 including three different embodiments of vehicle interior systems 20, 30, and 40. Vehicle interior system 20 includes a base, shown as a center console base 22, with a curved surface 24 that includes a display 26. Vehicle interior system 30 includes a base, shown as a dashboard base 32, with a curved surface 34 that includes a display 36. Dashboard base 32 typically includes an instrument panel 38 that may also include a display. Vehicle interior system 40 includes a base, shown as a steering wheel base 42, with a curved surface 44 and a display 46. In one or more embodiments, the vehicle interior system includes a base that is an armrest, pillar, seatback, floorboard, headrest, door panel, or any part of the vehicle's interior that includes a curved surface. In other embodiments, the base is part of a housing for a freestanding display (i.e., a display that is not permanently connected to a part of the vehicle). While displays 26 and 36 and instrument panel 38 are depicted as separate from one another in FIG. 1 , it should be understood that embodiments are contemplated in which at least two displays 26 and 36 and instrument panel 38 are combined with one another. For example, in an embodiment, a single glass substrate extends the entire length of dashboard base 32 between pillars (not shown) of interior 10. As described herein, such a glass substrate can be curved to a desired shape and have one or more displays attached to it via methods described herein. In an example, a pillar-to-pillar display can be implemented in which a single display extends a substantial portion of the length of the glass substrate.

[0016] Embodiments of the curved glass articles described herein can be used in, among other things, each of the vehicle interior systems 20, 30, 40. In some such embodiments, the glass articles discussed herein may include a cover glass sheet that also covers non-display surfaces such as the dashboard, center console, steering wheel, door panels, etc. In such embodiments, the glass material may be selected based on its weight, aesthetic appearance, etc., and may be provided with a coating (e.g., an ink or pigment coating) having a pattern (e.g., a brushed metal appearance, a wood grain appearance, a leather appearance, a tinted appearance, etc.) that visually matches the glass component with adjacent non-glass components. In certain embodiments, such ink or pigment coatings may have a transparency level that provides dead-front or color-matching functionality when the displays 26, 36, 46 are inactive. Furthermore, while the vehicle interior of FIG. 1 depicts a vehicle in the form of an automobile (e.g., a car, truck, and bus), the glass articles disclosed herein may be incorporated into other vehicles, such as trains, watercraft (e.g., boats, ships, and submarines), and aircraft (e.g., drones, planes, jets, and helicopters).

[0017] In embodiments, the curved surfaces 24, 34, 44 can each have any of a variety of curved shapes, such as a V-shape or a C-shape, as shown in Figures 2A and 2B. Referring initially to Figure 2A, a side view of an embodiment of a V-shaped glass article 50 is shown. The glass article 50 includes a glass substrate 52 having a first major surface 54, a second major surface 56 opposite the first major surface 54, and a minor surface 58 joining the first major surface 54 to the second major surface 56. The first major surface 54 and the second major surface 56 define a thickness T of the glass substrate 52. In embodiments, the thickness T of the glass substrate 52 is between 0.3 mm and 2 mm, specifically between 0.5 mm and 1.1 mm. In a vehicle, the first major surface 54 faces the vehicle occupants.

[0018] In embodiments, first major surface 54 and / or second major surface 56 include one or more surface treatments. Examples of surface treatments that may be applied to one or both of first major surface 54 and second major surface 56 include anti-glare coatings, anti-reflective coatings, coatings that provide touch functionality, decorative (e.g., ink or pigment) coatings, and easy-to-clean coatings.

[0019] As can be seen in FIG. 2A , the glass substrate 52 has a curved region 60 disposed between a first flat section 62 a and a second flat section 62 b. In embodiments, the curved region 60 has a radius of curvature R of from 75 mm to a radius of curvature less than substantially flat or planar (e.g., R=10 mm). Specifically, the curved region 60 has a radius of curvature R of from 150 mm to 3000 mm. Furthermore, while as shown in FIG. 2A , the curved region 60 defines a concave curve relative to the first major surface 54, in other embodiments, the curved region 60 is instead a convex curve relative to the first major surface 54.

[0020] In the glass article 50 of FIG. 2A , the frame 64, and specifically its curved support surface 65, is adhered to the second major surface 56 of the glass substrate 52 using an adhesive layer 66. The adhesive layer 66 may be initially deposited on the glass substrate 52 or the frame 64 as a liquid adhesive bead and then cured. In embodiments, exemplary adhesives for the adhesive layer 66 include epoxies, acrylics, polyurethanes, polyurethane hot melts, silane-modified polymers, and / or silicones. In certain embodiments, the adhesive layer 66 comprises one or more toughened epoxies, such as EP21TDCHT-LO (available from MasterBond®, Hackensack, New Jersey), 3M™ Scotchweld™ Epoxy DP460 Off-White (available from 3M, Saint Paul, Minnesota), etc. In other embodiments, adhesive layer 66 comprises one or more flexible epoxies such as MasterBond EP21TDC-2LO (available from MasterBond®, Hackensack, New Jersey), 3M™ Scotchweld™ Epoxy 2216B / A Gray (available from 3M, St. Paul, Minnesota), and 3M™ Scotchweld™ Epoxy DP125.

[0021] In still other embodiments, adhesive layer 66 includes one or more acrylic resins, such as LORD® Adhesive 410 / Accelerator 19 with LORD® AP134 Primer, LORD® Adhesive 852 / LORD® Accelerator 25GB (both available from LORD Corporation, Cary, North Carolina), DELO PUR SJ9356 (available from DELO Industrial Adhesives, Windach, Germany), Loctite® AA4800, Loctite® HF8000, etc. In still others, the liquid adhesive includes, among others, a silane-modified polymer, such as TEROSON® MS9399, and TEROSON® MS647-2C (these latter four available from Henkel AG & Co. KGaA, Düsseldorf, Germany), or one or more silicones, such as Dow Corning® 995, Dow Corning® 7091 (available from Dow Corning Corporation, Midland, Michigan).

[0022] In yet other embodiments, adhesive layer 66 comprises one or more polyurethane hot melts, such as Loctite HHD3542 (available from Henkel AG & Co. KGaA, Düsseldorf, Germany). In yet other embodiments, adhesive layer 66 comprises one or more polyurethanes, such as 3M™ Scotchweld™ Urethane DP640 Brown, 3M™ Scotchweld™ Urethane DP604 (both available from 3M, St. Paul, Minnesota), Betamate™ 73100, Betaseal™ X2500, and Betalink™ K2 (these latter three available from The Dow Chemical Company, Midland, Michigan).

[0023] In embodiments, the material of adhesive layer 66 includes a modulus of elasticity between 0.1 MPa and 50 MPa. Furthermore, in embodiments, the material of adhesive layer 66 includes a viscosity between 1 kcp and 500 kcp upon deposition. In part, frame 64 facilitates mounting of glass article 50 to a vehicle interior base (such as center console base 22, dashboard base 32, and / or steering wheel base 42, as shown in FIG. 1 ). Additionally, through the shape of curved support surface 65 and bonding with adhesive layer 66, frame 64 holds the glass substrate in a curved state such that curved region 60 is not permanent. That is, if glass substrate 52 were not bonded to frame 64 using adhesive layer 66, glass substrate 52 would return to its planar, non-curved configuration. Therefore, glass substrate 52 is stressed to generate the curvature and remains stressed throughout the life of glass article 50. Curved support surface 65 can have a variety of sizes and shapes depending on the implementation. In embodiments, for example, the curved support surface 65 includes a peripheral shape that substantially matches the peripheral shape of the glass substrate 52 (when the glass substrate 52 is bent in the stress configuration). In such embodiments, the curved support surface can include a length that is greater than or equal to 500 mm and less than or equal to 3000 mm, a width that is less than half the length, and a minimum radius of curvature that is greater than or equal to 100 mm and less than or equal to 1500 mm.

[0024] Stress in the glass substrate 52 tends to pull the glass substrate 52 away from the frame 64, meaning that the adhesive layer 66 is also stressed. This stress can be further exacerbated by stress caused by thermal cycling. In particular, the glass substrate 52 has a thermal expansion coefficient that differs from that of the frame 64, which is typically a metal (e.g., aluminum or magnesium), composite, or plastic component. The difference in thermal expansion coefficients means that the glass substrate 52 and the frame expand or contract by different amounts during thermal cycling between temperature extremes (e.g., as low as -40°C and as high as 80°C), causing additional stress in the adhesive layer 66. While mechanical and thermal stresses can be addressed by expanding the adhesive layer 66 (in terms of thickness and / or surface area), aesthetic considerations constrain the size of the adhesive layer 66. In particular, it is desirable to minimize the area of ​​the adhesive layer 66 in contact with the glass substrate 52 to maximize the display area of ​​the glass article 50.

[0025] FIG. 2B depicts another embodiment of a glass article 50, specifically a C-shaped glass article 50. Compared to the V-shaped glass article 50 of FIG. 2A, the C-shaped glass article 50 of FIG. 2B has a larger curved region 60 and shorter flat sections 62a, 62b. The V-shape and C-shape are just two examples of curved glass articles 50 that can be produced in accordance with the present disclosure. In other embodiments, the glass article 50 can include, among other things, curved regions 60 with opposing curvatures to produce an S-shape, curved regions 60 followed by flat sections 62a to create a J-shape, and curved regions 60 separated by flat sections 62a to produce a U-shape. Embodiments are also contemplated in which the curved regions 60 are cylindrical with a constant minimum radius of curvature. Embodiments are also contemplated in which at least a portion of the curved region 60 includes a compound curvature (where the major surfaces 54 and 56 are curved along at least two axes of curvature that extend in different directions from one another).

[0026] A glass article 50 according to the present disclosure has been formed by a cold-forming technique. An exemplary cold-forming process involves applying a bending force to a glass substrate 52 while the glass substrate 52 is positioned on a chuck 68, as shown in FIG. 3 . As can be seen, the chuck 68 has a curved forming surface 70, and the glass substrate 52 is bent to conform to the curved forming surface 70. Advantageously, it is easier to apply a surface treatment to a flat glass substrate 52 before imparting a curvature to the glass substrate 52, and cold-forming allows the treated glass substrate 52 to be bent without destroying the surface treatment (compared to hot-forming techniques, where the high temperatures associated with hot-forming techniques tend to destroy the surface treatment, which therefore must be applied to curved articles in a more complicated process). In embodiments, the cold-forming process is carried out at a temperature below the glass transition temperature of the glass substrate 52. Specifically, the cold forming process can be carried out at room temperature (eg, about 20°C) or at a slightly elevated temperature, such as up to 200°C, up to 150°C, up to 100°C, or up to 50°C.

[0027] In embodiments, the bending force applied to the glass substrate 52 may be in the form of vacuum pressure pulled through the chuck 68. In embodiments, the chuck 68 includes an internal channel with a port in a forming surface 70 of the chuck 68. When the glass substrate 52 is positioned on the forming surface 70, a vacuum is drawn through the channel, pressing the glass substrate 52 against the chuck and keeping it conforming to the curvature of the forming surface 70. In other embodiments, the forming surface 70 may use other techniques to keep the glass substrate 52 conforming to the curvature. For example, the forming surface 70 may be a self-adhesive material configured to provide sufficient adhesion to keep the glass substrate 52 in a curved configuration during cold forming, or the chuck 68 may work in conjunction with a press or clamp that keeps the glass substrate 52 conforming to the forming surface 70 during cold forming. In embodiments, cold forming the glass substrate 52 may not use a vacuum chuck 68. For example, the glass substrate 52 may be bent into a frame 64 and secured to the frame 64 by clamps or other suitable securing means while the adhesive layer 66 cures.

[0028] In the embodiment shown in FIG. 3 , adhesive layer 66 is applied to second major surface 56 of glass substrate 52, and frame 64 is lowered onto glass substrate 52. However, in other embodiments, adhesive layer 66 may instead be applied to curved support surface 65 of frame 64. In either case, frame 64 compresses adhesive layer 66 between curved support surface 65 and second major surface 56 of glass substrate 52. As can be seen in FIG. 3 , adhesive layer 66 is applied to glass substrate 52 in a manner such that the shape followed by adhesive layer 66, i.e., the “bead path,” substantially matches the shape of frame 64. In embodiments, adhesive layer 66 defines a closed bead path, such that adhesive layer 66 is continuous on glass substrate 52. In other embodiments, adhesive layer 66 may have a discontinuous bead path, e.g., may have breaks between sections of adhesive layer 66. FIG. 3 depicts the uncured adhesive layer 66 material as applied in the form of an adhesive bead.

[0029] In an embodiment, adhesive layer 66 is applied through a nozzle 71 having a circular port 73, as shown in FIG. 3 . Advantageously, such a nozzle allows for ease of manufacturing because the orientation of the nozzle relative to glass substrate 52 is not limited, compared to, for example, a particular nozzle having a triangular-shaped port that is well-aligned in a specific orientation relative to the glass sheet to apply the formed adhesive bead in the appropriate location. Furthermore, while FIG. 3 depicts adhesive layer 66 being applied to glass substrate 52 when glass substrate 52 is in a curved configuration on chuck 68, adhesive layer 66 may instead be applied to glass substrate 52 when glass substrate 52 is in a flat configuration, thereby allowing glass substrate 52 with adhesive layer 66 applied thereto to then bend onto forming surface 70 of chuck 68. In an embodiment, nozzle 71 is connected to a movement system and a controller (not shown). The controller may include an imaging device that determines the shape of curved support surface 65 via image analysis techniques. The shape of the curved support surface 65 can be compared to an idealized surface (representing a designed curved shape for the curved support surface 65). Deviation between the actual shape and the idealized shape can be used to control the rate and / or volume of adhesive dispensed at specific locations on the glass substrate 52 or frame 64. Areas where the actual shape of the curved support surface 65 is farther from the second major surface 56 than the idealized surface can provide a larger volume of adhesive (by slowing the downward movement of the nozzle 71 or increasing the deposition rate), and areas where the actual shape of the curved support surface 65 is closer to the second major surface 56 than the idealized shape can provide a smaller volume of adhesive (by speeding up the upward movement of the nozzle 71 or decreasing the deposition rate). Such adhesive deposition control can reduce the amount of adhesive overflow.

[0030] Regardless of the particular process steps used, cold-forming the glass substrate generally involves applying a force to the glass substrate 52 to bend the glass substrate 52 into a shape that substantially conforms to the frame 64. For example, in embodiments, the forming surface 70 of the chuck 68 has a shape that substantially corresponds to the shape of the curved support surface 65 of the frame 64, such that applying a vacuum to the glass substrate 52 to cause the glass substrate 52 to conform to the forming surface 70 causes the second major surface 56 to bend to the shape of the curved support surface 65. Alternatively or additionally, a preform, roller, or other force-applying device can be used to press the glass substrate 52 directly against the curved support surface 65 to cause the second major surface 56 to bend to conform thereto.

[0031] Problems can arise when the frame 64 deviates from the desired shape. For example, when constructed of a metal such as aluminum or magnesium, the frame 64 may be fabricated in a casting process, which has some variability. In the depicted example, the curved support surface 65 may not precisely match the shape of the molding surface 70 of the chuck 68. As a result, the spacing between the curved support surface 65 and the second major surface 56 may be uneven, even when the positioning of the frame 64 is precisely controlled during the fabrication process. In addition, the dimensions of the frame 64 may vary, causing the dimensions of the curved support surface 65 to vary from expected values ​​at various locations, resulting in changes in the available bonding area where the adhesive layer 66 can be disposed between the glass substrate 52 and the frame 64. Such inconsistencies in the shape of the frame 64 can cause problems when dispensing the adhesive layer 66. By way of example, if adhesive layer 66 is dispensed to have a uniform volume throughout the bead path, regions of smaller-than-expected bond area and / or space between curved support surface 65 and second major surface 56 may result in adhesive overflowing (e.g., either outward from the periphery of frame 64 or inward toward the center of glass substrate 52). Variations in the curvature of curved support surface 65 may cause the thickness of adhesive layer 66 to vary because adhesive layer 66 may be compressed by curved support surface 65 before it hardens. Such thickness variations may give adhesive layer 66 a wavy appearance, which is undesirable.

[0032] Such problems associated with frame shape variations can be exacerbated when a display module is incorporated into a curved glass article to form the display system. Figures 4A and 4B schematically depict a display system 400 according to an exemplary embodiment of the present disclosure. Figure 4A schematically depicts a rear view of the display system 400 (e.g., from the side of the second major surface 56), and Figure 4B schematically depicts a cross-sectional view through line 4B-4B in Figure 4A. As shown, in the depicted embodiment, the curved support surface 65 of the frame 64 is curved to have a concave shape, and the glass substrate 52 is cold-formed and adhered to the curved support surface 65 via an adhesive layer 66, such that the first major surface 54 also has a concave shape. The glass substrate 52 is cold-formed to the curved support surface 65 via any suitable technique. For example, in an embodiment, a vacuum chuck 68 and a nozzle 71 depicted in Figure 3 may be used to bend the glass substrate 52 and dispense the adhesive layer 66.

[0033] As shown in FIG. 4B , the overlapping area between the curved support surface 65 and the second major surface 56 defines a bonding area 80 where an adhesive layer 66 can be disposed to attach the glass substrate 52 to the frame 64. In embodiments, the frame 64 is constructed to have a peripheral shape that substantially matches the peripheral shape of the glass substrate 52 after the glass substrate is bent. In such embodiments, or other embodiments in which the periphery of the frame 64 is inserted from the minor surface 58 (see FIG. 2A ), the bonding area 80 extends from the frame's periphery 415 to the frame's inner edge 416. That is, the shapes of the periphery 415 and the inner edge 416 determine the extent of the bonding area 80. Furthermore, the shape of the curved support surface 65, in combination with the bonding area 80, can determine the volume of the space between the curved support surface 65 and the second major surface 56 when the frame 64 is held in a fixed relationship relative to the glass substrate 52. Thus, the shape and size of the frame 64 determines the amount of adhesive that can be applied between the glass substrate 52 and the frame 64 at a particular location.

[0034] 4A and 4B , an inner edge 416 of the frame 64 may define an opening 402. As a result of the opening 402, the second major surface 506 includes an open area 403 that is not adhered to the frame 64 via the adhesive layer 66. The display module 404 is disposed within the opening 402 and adhered to the second major surface 56 via a layer of optically clear adhesive 405. The display module 404 can be attached to the glass substrate 52 via a suitable lamination technique during the cold-forming process (e.g., while the glass substrate 52 is disposed on the chuck 68 and before the adhesive layer 66 is cured or before the frame 64 is attached to the glass substrate 52).

[0035] The display module 404 may include a display layer 406 and a back panel 408. The display layer 406 may include a touch panel and other display components (e.g., a liquid crystal display panel, an organic light-emitting diode display panel). The back panel 408 may generally be more rigid than the display layer 406 and may be pre-curved to have a desired shape. For example, in embodiments where the display module 404 is a liquid crystal display, the back panel 408 may be a backlight unit and may include a light source and a light guiding layer. In embodiments where the display module 404 is an organic light-emitting diode display, the back panel 408 may be an integrated heat sink. The different components of the display module 404 may be attached to the glass substrate 52 in a variety of ways. For example, in embodiments, the display module 404 is a pre-assembled unit (e.g., as a curved display) and laminated to the glass substrate in a single processing step. In embodiments, the display layer 406 and the back panel 408 are sequentially attached to the glass substrate 52 in different steps of a cold-forming process. For example, the display layer 406 can be attached to the glass substrate 52 in a first step (when the glass is flat or curved), and the back panel 408 can be attached to the glass substrate 52 in a second step after the attachment of the display layer 406.

[0036] In embodiments, the back panel 408 is stiffer than the glass substrate 52 and is curved to have a shape that matches the desired shape of the opening area 403. For example, the back panel 408 can be curved to have a shape that substantially corresponds to the frame 64. However, variations in the shape of the frame 64 described herein can make it difficult to achieve a perfect fit. As a result, the curvature of the frame 64 may deviate from the curvature of the back panel 408, and / or the opening 402 may not be exactly the expected size. Such mismatches can create difficulties in attaching the back panel 408 to the frame 64. In certain existing display systems, the back panel 408 and the frame 64 are secured to one another by rigid fasteners (e.g., bolts) that utilize pressure to secure the frame 64 and the back panel 408 to one another and stabilize the system. Such fastener attachment mechanisms can introduce static indeterminate systems and cause less rigid components of the frame 64 and the back panel 408 to bend. Because the exact shape of the frame 64 may not be known, the frame 64 or back panel 408 may bend in an unpredictable manner, changing the spacing between the second major surface 56 and the curved support surface 65, thereby altering the thickness profile of the adhesive layer 66.

[0037] In consideration of the above problems caused by variations in the shape of the frame 64, the frame 64 is not secured to the back panel 408 through rigid fasteners such as bolts. Instead, a spacer 418 is disposed in a gap 410 extending between a periphery 414 of the back panel 408 and an inner edge 416 of the frame 64. The size and shape of the gap 410 are generally determined by the respective sizes and shapes of the frame 64 and the back panel 408. In an embodiment, the opening 402 is larger in size than the back panel 408, and the gap 410 surrounds the entire periphery 414. In an alternative embodiment, the gap 410 does not completely surround the back panel 408 (e.g., the gap 410 may extend to only one side of the back panel 408). The gap 410 is shown having a width 412 extending perpendicular to the inner edge 416 of the frame 64. In an embodiment, width 412 is 2 mm or less (e.g., 0.01 mm or more and 2.0 mm or less, 0.2 mm or more and 2.0 mm or less). In an embodiment, back panel 408 is disposed (e.g., centered) within opening 402 such that width 412 is circumferentially uniform (varying by less than 5% from the average as a function of azimuthal position). Minimizing the size of gap 410 beneficially maximizes the portion of opening 402 filled by display module 404.

[0038] The spacers 418 are configured to maintain the relative positioning of the frame 64 and the back panel 408 throughout the fabrication process to prevent deformation of the frame 64 and / or the back panel 408. For illustrative purposes, FIG. 4C depicts an example in which a display system 400 is being fabricated. As shown, the glass substrate 52 is disposed on a forming surface 70 of a chuck 68. The chuck 68 can apply negative pressure to the glass substrate 52 to bend the glass substrate 52. Furthermore, the frame 64 is aligned with the glass substrate 52, with an adhesive layer 66 disposed between the frame 64 and the glass substrate 52. The frame 64 is disposed a certain distance from the glass substrate 52 based on the desired thickness of the adhesive layer 66 after curing (the frame 64 can be held in such position by a suitable holding device, not shown). When the adhesive layer 66 is not yet fully cured, the display module 404 is laminated to the glass substrate 52 via a layer of optically clear adhesive 405 so as to form a gap 410 between the frame 64 and the back panel 408. In an embodiment, the periphery of the frame 64 is aligned with the minor surface 58 (see FIG. 2A ) to maximize the size of the opening 402 and the display area. In an embodiment, the periphery of the frame 64 is disposed inward of the minor surface 58. Such a structure may help hide variations in the adhesive layer 66.

[0039] The exact geometry and dimensions of the gap 410 vary depending on the geometry of the frame 64. That is, because the structure of the frame 64 may vary for reasons described herein, the exact geometry of the gap 410 varies from part to part. Accordingly, the spacer 418 (see FIG. 4B ) is designed to accommodate such part-to-part variations by precisely filing the gap 410. Various methods of providing such a spacer 418 are contemplated and are within the scope of this disclosure. FIG. 4C illustrates an example in which a spacer precursor material 422 is dispensed into the gap 410 via a dispensing system 420 (e.g., an applicator gun, a print head, a nozzle). The spacer precursor material 422 is beneficially a liquid material, allowing the material to assume the exact shape of the gap 410. After application of the spacer precursor material 422, the spacer precursor material 422 cures and solidifies into the spacer 218, and beneficially extends the entire distance between the periphery 414 and the inner edge 416.

[0040] A variety of materials can be used as the spacer precursor material 422. For example, in embodiments, the spacer 218 is relatively rigid. For example, in embodiments, the spacer 218 (after the spacer precursor material 422 has cured) comprises a Young's modulus greater than that of the adhesive layer 66. In such embodiments, the spacer precursor material 422, when cured, can comprise a Young's modulus of 100 MPa or greater, 300 MPa or greater, 500 MPa or greater, or 800 MPa or greater, such that the size of the gap 410 is maintained throughout the manufacturing process, and application of force to either the frame 64 or the back panel 408 does not change the size of the gap 410 (after the spacer precursor material 422 has sufficiently cured). Suitable rigid materials include acrylic or epoxy adhesives.

[0041] As will be appreciated, the curing of the spacer precursor material 422 depends on the type of material used to form the spacer precursor material 422. In certain embodiments, the spacer precursor material 422 is a room temperature or thermally cured material, and the curing step involves the application of temperature / heat to harden the spacer precursor material 422. In other certain embodiments, depending on the spacer precursor material 422, the curing mechanism may include radiation curing, a change in pH, a catalyst, an activator, or the use of moisture. 1K moisture-curing adhesives or 2K adhesives may be particularly beneficial in that they can be cured without the application of heat, thereby minimizing any deleterious effects of heat on the components of the display module 404.

[0042] In embodiments, it may be beneficial if the spacer precursor material 422 includes a relatively high viscosity (e.g., 1 kcp or more, 100 kcp or more, 300 kcp or more) when initially deposited. Such a high viscosity facilitates the spacer precursor material 422 maintaining its shape before fully curing, thereby allowing control of the shape of the spacers 218.

[0043] In embodiments, the spacer precursor material 422 may include a reaction injection molding material. As used herein, "reaction injection molding material" includes a thermosetting polymer that hardens in a mold during an injection molding procedure (in which case the gap 410 serves as the mold). In embodiments, reaction injection molding materials include polyurethane, polyurea, polyisocyanurate, polyester, polyphenol, polyepoxide, and nylon 6. In embodiments, the spacer precursor material 422 may include a reinforcing agent such as glass fiber or mica. Such two-component systems of materials may react and harden to form the spacer 418 with a fast cure time. In embodiments, the spacer precursor material 422 may include a hot melt adhesive containing a suitable thermoplastic polymer, resin, plasticizer, and other additives. Such hot melt adhesives may be beneficial in that they harden relatively quickly after dispensing and may maintain the shape of the gap 410 for the remaining time it takes for the adhesive layer 66 to harden.

[0044] In embodiments, instead of being rigid, the spacers 218 may be constructed of a relatively conformable material that can be compressed to the size of the gap 410. In such embodiments, the spacers 218 may be molded of a material having a Young's modulus of less than 100 MPa (e.g., 80 MPa or less, 50 MPa or less, 30 MPa or less, 10 MPa or less). In such embodiments, instead of being injected directly into the gap 410 as described above with respect to the rigid embodiments, the spacers 218 may first be molded onto one of the back panel 408 and the frame 64 before the back panel 408 is attached to the glass substrate 52. For illustrative purposes, FIG. 4D depicts an example in which the back panel 408 has not yet been attached to the glass substrate 52. While FIG. 4D depicts the display layer 406 disposed on the glass substrate 52 without the back panel 408, it should be understood that embodiments are also contemplated in which the spacers 218 may be attached in a manner similar to the entire display module 404 (see FIG. 4B ) before the display module 404 is laminated to the glass substrate 52 via a layer of optically clear adhesive 405. As described with respect to FIG. 4C, a force may be applied to the glass substrate 52 via a chuck 68 to maintain the glass in a bent state before the adhesive layer 66 hardens.

[0045] As shown in FIG. 4D , the spacers 218 are attached to the periphery 414 of the back panel 408 before the back panel 408 is lowered onto the glass substrate 52. In an alternative embodiment, the spacers 218 can be attached to the inner edge 416 of the frame 64 rather than the periphery 414. In such an embodiment, a variety of materials are contemplated for the spacers 218. For example, the spacers 218 can be strips of pressure-sensitive adhesive (e.g., 3M™, VHB™, e.g., #8412BLACK, #5909, #4611, #4930, #5952, Tesa®, e.g., #7805, #61057, or DAITAC STA400 or TRYCK). In an embodiment, the spacers 218 can be first deposited as a liquid precursor material and cured on the back panel 408 before the back panel 408 is lowered onto the glass substrate 52. In such embodiments, a suitable mold may be used to harden the liquid precursor material in the desired shape. Any suitable material may be used that is conformable and can be compressed to fit the shape of the gap 410, including the materials described above with respect to the adhesive layer 66 and the spacer precursor material 422.

[0046] In an embodiment, when initially molded or deposited on the back panel 408, the spacers 218 include a thickness 424 measured in a direction perpendicular to the periphery 414. The thickness 424 can be selected to be greater than the width 412 of the gap 410 (the width 412 is the same width as the back panel 408 when disposed on the glass substrate 52, because it is aligned with the position the back panel 408 will eventually assume on the glass substrate 52). As a result, lowering the back panel 408 onto the glass substrate 52 (e.g., in the depicted embodiment, contacting the display layer 406) compresses the spacers 218, causing them to assume the exact shape of the gap 410 (as shown in FIG. 4B ). After such compression, the spacers 218 can apply an outward force that tends to maintain the size of the gap 410 and prevent deformation of the frame 64 and / or the back panel 408 caused by relative movement throughout the fabrication process. In such an embodiment, using a pressure-sensitive adhesive for the spacer 218 can be beneficial in that the spacer 218 can bond to both the peripheral edge 414 and the inner edge 416 without creeping during use of the display system 400.

[0047] 4A-4D , the spacer 218 can have a variety of geometric shapes. In embodiments, the spacer 218 only partially fills the gap 410. Such embodiments may include an air gap between the spacer 218 and the glass substrate 52, which may help hide the appearance of the spacer 218 when the display system 400 is viewed from the first major surface 54. In embodiments, the spacer 218 is a continuous body that entirely surrounds the back panel 408. In embodiments, the spacer 218 comprises one or more discrete segments of material that are disposed within the gap 410 and extend the entire distance between the periphery 414 and the inner edge 416. Any amount of material sufficient to maintain the dimensions and shape of the gap 410 when the back panel 408 is initially disposed on the glass substrate 52 can be used.

[0048] In embodiments, after the spacers 218 are molded into the gaps 410 (and the precursor material for the spacers 218 is cured), the back panel 408 can maintain the glass substrate 52 in a desired curved shape even if the adhesive layer 66 is not fully cured. This can be particularly true in embodiments in which the material of the spacers 218 cures before the adhesive layer 66. As a result, the force applied to the glass substrate 52 to initially bend the glass substrate 52 can be removed before the adhesive layer 66 is fully cured. This is aided by the spacers 218 maintaining the relative positioning between the frame 64 and the display module 404. Such early removal can free up equipment used in fabrication and increase process throughput. In the depicted embodiment, for example, the display system 400 can be removed from the chuck 68 and placed in a staging area to allow the adhesive layer 66 to cure. This allows another system to be fabricated using the chuck 68 while the adhesive layer 66 cures.

[0049] In addition to the spacers described herein, various other features can be incorporated into display system 400 and its fabrication to mitigate problems caused by variations in the shape of the frame. Several such features are described below. It should be understood that such features can be used in addition to spacers 218 or individually to provide even greater control over the adhesive during the fabrication process. While display system 400 described with respect to FIGS. 4A-4D is used as an exemplary system that can incorporate the features described below, it should be understood that other display systems (having different components, forms, and / or shapes) can also incorporate these features.

[0050] In embodiments, a material can be incorporated between the glass substrate 52 and the frame 64 to control the adhesive. Figure 5 illustrates an embodiment incorporating a spacing element 500 between the glass substrate 52 and the frame 64. The spacing element 500 is disposed around the periphery of the curved support surface 65 and serves to perform at least one of the following functions: (a) to conceal the adhesive layer 66 from view so as to obscure the wavy appearance caused by the variable shape of the frame 64; (b) to act as a dam to prevent the material of the adhesive layer 66 from spilling outward when compressed during the fabrication process; and (c) to set the thickness of the adhesive layer 66.

[0051] A variety of materials may be used to construct the spacing element 500. In embodiments, the spacing element 500 may be formed from and function as a strip of pressure-sensitive adhesive, as described in U.S. patent application Ser. No. 17 / 295,742, entitled "Adhering Glass Cover Sheet to a Frame," the entirety of which is incorporated herein by reference. In such embodiments, the spacing element 500 may help maintain the curved shape of the glass substrate 52 as the adhesive layer 66 cures, thereby allowing cold-forming processes other than a vacuum chuck to be used. For example, rollers, preforms, molds, clamping structures, or other suitable structures may be used to press the glass substrate 52 against the frame 64, and the spacing element 500 may bond the glass substrate 52 to the frame 64 and hold the glass substrate 52 in its curved shape as the adhesive layer 66 cures.

[0052] In embodiments, the spacing element 500 is positioned adjacent to the adhesive layer 66 and can be used to apply a force to the glass substrate 52 when the frame 64 is positioned on the glass substrate 52 during cold forming (e.g., the spacing element 500 can cause the glass substrate 52 to bend to conform to the forming surface 70 of the chuck 68 depicted in FIGS. 4C and 4D ). The use of the spacing element 500 can provide a uniform application of force and control the thickness of the adhesive layer 66 regardless of irregularities in the frame. In embodiments, for example, the spacing element 500 can be a rigid material (e.g., metal, ceramic, composite, polymer) bonded to at least one of the glass substrate 52 or the frame 64. In embodiments, the spacing element 500 is a protrusion of the curved support surface 65 of the frame 64 (e.g., the spacing element 500 can be integrally molded with the frame 64 during the casting process). In embodiments, the spacer is a compliant material such as rubber or a gasket material.

[0053] Instead of, or in addition to, spacing element 500, frame 64 can be modified to accommodate adhesive overflow toward the interior of display system 400 (inward of inner edge 416). FIG. 6 shows an example in which curved support surface 65 includes a step 600 extending outward from inner edge 416. Step 600 provides space for excess adhesive to flow in to prevent overflow into gap 410. In an embodiment, instead of step 600, frame 64 can include a recess or through-hole offset from inner edge 416 to provide space for excess adhesive flow. Step 600, hole, or recess can function in the manner of an opening described in U.S. Patent Application No. 17 / 263,378, entitled "Cold-Formed Curved Glass Articles and Methods of Making the Same," the entirety of which is incorporated herein by reference. In particular, the steps 600, holes, or depressions can improve the bond between the glass substrate 52 and the frame 64 and improve impact performance.

[0054] In addition to, or instead of, the step 600, the display system 400 may further include a trough 602 disposed inwardly of the inner edge 416. The trough 602 may collect any inward adhesive spillage and prevent the adhesive from interacting with other components of the display system 400. In embodiments, the trough 602 is integrally molded with the frame 64. In embodiments, the trough is a separate component from the frame 64 (e.g., molded from a different material than the body of the frame 64). In embodiments, the trough 602 extends over the curved support surface 65 to completely prevent any inward adhesive spillage. In embodiments, the trough 602 is an extension (e.g., a protrusion, ridge, cantilever) of the inner edge 416 and prevents excess adhesive droplets from reaching other components.

[0055] In embodiments, the adhesive can be controlled through modification of the fabrication process. The adhesive forming element can be added to the components used to cold-form the glass substrate. For example, FIG. 7A illustrates an example in which a forming element 700 is disposed on the forming surface 70 of the chuck 68. In an embodiment, the forming element 700 contacts the minor surface 58 of the glass substrate 52 and extends beyond the second major surface 56, thereby damming the adhesive layer 66 and preventing overflow. In an embodiment, the forming element 700 extends from the forming surface 70 to the curved support surface 65 (e.g., in such an embodiment, the minor surface 58 can be offset from the periphery of the frame to provide space for the forming element 700 to contact the curved support surface 65). In such an embodiment, the forming element 700 can function as a dam to prevent overflow of the adhesive and as a spacer to control the thickness of the adhesive layer 66. The forming element 700 may be removable from the chuck 68 (and from between the frame 64 and the molding surface 70), which produces a uniform-looking adhesive layer after the adhesive layer 66 has hardened, and the forming element 700 does not add thickness to the display system 400.

[0056] In embodiments, the forming element 700 is integrated into or attached to the chuck 68. For example, FIG. 7B depicts an embodiment in which a forming element 702 forms at least a portion of the forming surface 70 of the vacuum chuck 68. As shown, the forming element 702 includes a support portion 704 and a side portion 706. The support portion 704 is disposed on the body of the chuck 68 and may form the forming surface 70 that contacts the glass substrate 52. The side portion 706 may extend from the support portion 704 and define a cavity in which the glass substrate 52 is disposed during cold forming. The side portion 706 may have a shape that corresponds to the peripheral shape of the glass substrate 52, thereby facilitating alignment of the glass substrate 52. The side portion 706 may contact the minor surface 58 of the glass substrate 52 and extend beyond the second major surface 56 to form a dam for the adhesive layer 66. Integrating forming element 702 into chuck 68 may allow for consistent alignment of components from part to part and reduce process variability.

[0057] 4A-4C in combination with at least one of the spacing element 500, the step 600, the trough 602, and the forming element 700 and the forming element 702, it is believed that adhesive overflow can be prevented during fabrication and the adhesive layer 66 can have a uniform thickness despite variations in the shape of the frame 64. As described herein, the spacer 218 prevents deformation of the frame 64 and the back panel 408 during the fabrication process and allows for more uniform spacing between the frame 64 and the glass substrate 52. The spacing element 500 and / or the forming elements 700 and 702 can further aid in the formation of the adhesive layer by preventing adhesive overflow and controlling the thickness of the adhesive layer 66. The step 600 and / or the trough 602 can be used in combination with the spacer 218 (and optionally in combination with the spacing element 500 and / or one of the forming elements 700 and the forming element 702) to prevent adhesive overflow inside the frame 64. Thus, any number of the features described herein can be incorporated in combination with each other to provide varying amounts of adhesive control.

[0058] Referring now to Figure 8, a process 800 for fabricating a display system is shown, according to an exemplary embodiment. Process 800 may be used to fabricate display system 400 described herein, according to any of the embodiments described with respect to Figures 2A-7B. Accordingly, reference will be made to the various components depicted in Figures 2A-7B to aid in describing the method. It should be understood that process 800 can be used to fabricate display systems having shapes and configurations different from display system 400 described herein.

[0059] At block 802, the glass substrate 52 is cold-formed against the curved support surface 65 of the frame 64, with the adhesive layer 66 disposed between the glass substrate 52 and the curved support surface 65. As described herein, a variety of different processes can be used to cold-form the glass substrate 52. Generally, cold-forming involves applying a bending force to the glass substrate 52 to bend the glass substrate 52 into a curved shape (the glass substrate 52 may initially be a flat sheet of glass cut to a suitable size and shape). In embodiments, the bending force is applied via a vacuum chuck, such as the chuck 68 described herein. In embodiments, a spacing element 500 may be disposed between the glass substrate 52 and the frame 64. For example, the spacing element 500 may be disposed on and attached to one of the second major surface 56 and the curved support surface 65 before the glass substrate 52 is pressed against the frame 64. The spacing element 500 determines the spacing between the glass substrate 52 and the frame 64 and allows the bending force to be applied through the frame 64 rather than through the chuck 68 (although embodiments are envisioned in which the spacing element 500 is used in conjunction with the chuck 68, such that the adhesive layer 66 has a uniform thickness after curing). In embodiments including the spacing element 500 (or other spacing element that controls the distance between the frame 64 and the glass substrate 52), the bending force can be applied through a vacuum bag (e.g., the glass substrate 52 and frame 64 can be inserted into a vacuum bag with adhesive disposed on one of the glass substrate 52 and the frame). Alternatively, the bending force can be applied by contacting the glass substrate 52 with a roller, preform, or mold to conform the glass substrate 52 to the curved support surface 65. Alternatively, the bending force can be applied by clamping the glass substrate 52 to the frame 64 using multiple clamps. Rollers, preforms, molds, and clamps can also be used in combination with the chuck 68.

[0060] Prior to cold-forming, adhesive of adhesive layer 66 can be dispensed onto curved support surface 65 or second major surface 56. For example, nozzle 71 can be moved along the bead path in a shape corresponding to frame 64 to dispense adhesive in a desired pattern. As described herein, the rate of adhesive deposition along the bead path can be controlled based on the shape of frame 64. Areas where frame 64 is smaller than expected and / or where there are ridges on curved support surface 65 can be provided with a smaller volume of adhesive than larger areas of frame 64 and / or areas where there are troughs on curved support surface 65.

[0061] At block 804, adhesive layer 66 is shaped and / or modified in appearance. In embodiments, when adhesive layer 66 is compressed between frame 64 and glass substrate 52, excess adhesive material may spill either outward or inward from frame 64 (particularly in embodiments not including spacing element 500, where the adhesive is not formed by one of forming elements 700 and 702, steps 600, or troughs 602). Such excess adhesive can be removed (e.g., scraped off) from frame 64 before curing and before interacting with any other additional components. In embodiments, excess adhesive can be cut off after curing to control the appearance of adhesive layer 66. In embodiments, adhesive layer 66 can be formed through the incorporation of spacing element 500, steps 600, and / or troughs 602 described herein with respect to FIGS. 5-6 . In embodiments, adhesive layer 66 can be formed through external forming elements, such as forming elements 700 and 702 described herein with respect to FIGS. 7A-7B .

[0062] In embodiments, the appearance of adhesive layer 66 can be modified to reduce gloss and visibility, thereby reducing the appearance of waviness in display system 400. In embodiments, adhesive layer 66 can be textured to provide a matte finish after it is cured. Adhesive layer 66 can be textured via any suitable method. In embodiments, adhesive layer 66 can be textured by treating the adhesive while it is not cured, for example, by jetting air onto adhesive layer 66, spraying adhesive layer 66 with water, applying a textured roller or sponge to adhesive layer 66, or other suitable technique. Such treatment can cause adhesive layer 66 to scatter incident light (e.g., have a reflective haze of 20% or more), reducing gloss and visibility.

[0063] At block 806, the display module 404 is laminated to the glass substrate 52 within the opening 402 defined by the frame 64, such that a gap 410 is disposed between the frame 64 and the back panel 408 of the display module 404. Any suitable method may be used to apply the layer of optically clear adhesive 405 and press the display module 404 against the second major surface 56. At block 808, the spacers 218 are disposed within the gap 410 via any of the methods described herein.

[0064] Provided below is a discussion of the attributes of embodiments of the glass substrate 52. Accordingly, in the following paragraphs, various geometric, mechanical, and strengthening attributes of the glass substrate 52, as well as the composition of the glass substrate 52, are provided.

[0065] In various embodiments, the average thickness T of the glass substrate 52 between the first major surface 54 and the second major surface 56 ranges from 0.3 mm to 2 mm. In various embodiments, the width of the glass substrate 52 ranges from 5 cm to 250 cm. Furthermore, in various embodiments, the length of the glass substrate 52 ranges from 5 cm to 1500 cm. The length is the largest dimension of the glass substrate 52 perpendicular to the thickness T. The width is the largest dimension of the glass substrate 52 perpendicular to the thickness T and the length. In various embodiments, one or more radii of curvature of the glass substrate 52 (e.g., R shown in FIGS. 2A-2B ) range from 75 mm to 10,000 mm.

[0066] In one or more embodiments, the glass substrate 52 can be strengthened to contain compressive stresses extending from the surface to a depth of compression (DOC). The compressive stress regions are balanced by a central portion exhibiting tensile stress. At the DOC, the stress crosses from positive (compressive) to negative (tensile). In various embodiments, the glass substrate 52 can be mechanically strengthened by exploiting a mismatch in thermal expansion coefficients between portions of the article to create compressive stress regions and a central region exhibiting tensile stress. In some embodiments, the glass sheet can be thermally strengthened by heating the glass to a temperature above its glass transition temperature and then rapidly quenching.

[0067] In yet other embodiments, the glass substrate 52 is chemically strengthened through an ion exchange process. In an ion exchange process, ions at or near the surface of the glass sheet are replaced by or exchanged with larger ions having the same valence or oxidation state. In those embodiments in which the glass sheet comprises an aluminosilicate glass, the ions in the surface layer of the article and the larger ions are Li + , Na + , K. + , Rb + , and Cs + Alternatively, the monovalent cation in the surface layer may be, for example, Ag +In such embodiments, the monovalent ions (or cations) exchanged into the glass sheet generate stress.

[0068] The ion exchange process is typically carried out by immersing the glass sheet in a molten salt bath (or two or more molten salt baths) containing larger ions to be exchanged for smaller ions in the glass sheet. Note that aqueous salt baths may also be utilized. Additionally, the composition of the bath(s) may include two or more types of larger ions (e.g., Na+ and K+) or a single larger ion. Those skilled in the art will appreciate that the parameters of the ion exchange process, including but not limited to the bath composition and temperature, immersion time, number of immersions of the glass in the salt bath(s), use of multiple salt baths, additional steps such as annealing and washing, etc., are generally determined by the composition of the glass sheet (including the structure of the article and any crystalline phases present), and the desired DOC and compressive stress (CS) of the glass sheet resulting from tempering. Exemplary molten bath compositions may include nitrates, sulfates, and chlorides of larger alkali metal ions. Typical nitrates include KNO, NaNO, LiNO, NaSO, and combinations thereof. The temperature of the molten salt bath typically ranges from about 380°C up to about 450°C, and the immersion time ranges from about 15 minutes up to about 100 hours, depending on the thickness of the glass sheet, the bath temperature, and the diffusivity of the glass (or monovalent ions). However, temperatures and immersion times other than those stated above may also be used.

[0069] In one or more embodiments, the glass sheet may be immersed in a molten salt bath of 100% NaNO, 100% KNO, or a combination of NaNO and KNO having a temperature of about 370°C to about 480°C. In some embodiments, the glass sheet may be immersed in a molten mixed salt bath containing about 5% to about 90% KNO and about 10% to about 95% NaNO. In one or more embodiments, the glass sheet may be immersed in a first bath followed by a second bath. The first and second baths may have different compositions and / or temperatures. The immersion times in the first and second baths may vary. For example, the immersion times in the first and second baths may be longer than the immersion time in the second bath.

[0070] In one or more embodiments, the glass sheet may be immersed in a molten mixed salt bath comprising NaNO and KNO (e.g., 49% / 51%, 50% / 50%, 51% / 49%) having 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 less than about 4 hours.

[0071] Ion exchange conditions can be adjusted to provide a "spike" or increase the slope of the stress profile at or near the surface of the resulting glass sheet. The spike can result in a larger surface CS value. This spike can be achieved by a single bath or multiple baths with bath(s) having a single composition or mixed compositions due to the unique attributes of the glass compositions used in the glass sheets described herein.

[0072] In one or more embodiments in which two or more monovalent ions are exchanged into the glass sheet, the different monovalent ions may be exchanged to different depths within the glass sheet (and may generate different amounts of stress within the glass sheet at different depths), which can determine the relative depths of the resulting stress-generating ions and cause different characteristics of the stress profile.

[0073] CS can be measured using means known in the art, such as a surface stress meter (FSM) using commercially available equipment, 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), which is related to the birefringence of the glass. SOC is then measured by methods known in the art, such as the fiber and four-point bending methods, and the bulk cylinder method, as described in ASTM Standard C770-98 (2013), entitled "Standard Test Method for Measurement of Glass Stress-Optical Coefficient," the entire contents of which are incorporated herein by reference.

[0074] Depending on the strengthening method and conditions, DOC can be measured by FSM or a scattered light polarimeter (SCALP) (such as the SCALP-04 scattered light polarimeter available from GlassStress Ltd., Tallinn, Estonia). When a glass sheet is chemically strengthened by an ion exchange process, either FSM or SCALP can be used depending on which ions are exchanged into the glass sheet. When stress in a glass sheet is generated by exchanging potassium ions into the glass sheet, FSM is used to measure DOC. When stress in a glass sheet is generated by exchanging sodium ions into the glass sheet, SCALP is used to measure DOC. When stress in a glass sheet is generated by exchanging both potassium and sodium ions into the glass, DOC is measured by SCALP because the depth of exchange of sodium ions is believed to indicate DOC, and the depth of exchange of potassium ions in such glass sheets is measured by FSM because it is believed that the depth of exchange of sodium ions indicates DOC, and the depth of exchange of potassium ions indicates a change in the magnitude of compressive stress (but not a change in stress from compressive to tensile). CT is the maximum tensile stress and is measured by SCALP.

[0075] Suitable glass compositions for use in the glass substrate 52 include soda-lime glass, aluminosilicate glass, borosilicate glass, boroaluminosilicate glass, alkali-containing aluminosilicate glass, alkali-containing borosilicate glass, and alkali-containing boroaluminosilicate glass.

[0076] In one or more embodiments, the glass composition may include SiO in an amount ranging from about 66 mol% to about 80 mol%, AlO in an amount ranging from about 4 mol% to about 15 mol%, BO in an amount ranging from about 0 mol% to about 5 mol%, PO in an amount ranging from about 0 mol% to about 2 mol%, RO in an amount ranging from about 0 mol% to about 2 mol%, RO in an amount ranging from about 0 mol% to about 2 mol%, ZrO in an amount ranging from about 0 mol% to about 0.2 mol%, and SnO in an amount ranging from about 0 mol% to about 0.2 mol%. In the above compositions, RO refers to the total amount of alkali metal oxides, such as LiO, NaO, KO, RbO, and CsO. Specifically, NaO may be present in an amount ranging from about 8 mol% to about 20 mol%, and KO may be present in an amount ranging from about 0 mol% to about 4 mol%. Furthermore, in the above composition, RO refers to the total amount of alkaline earth metal oxides such as CaO, MgO, BaO, ZnO, and SrO. Specifically, CaO may be present in an amount ranging from about 0 mol % to about 1 mol %, and MgO may be present in an amount ranging from about 0 mol % to about 7 mol %.

[0077] In embodiments, the glass composition may include other oxides of metals such as Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Ce, W, and Mo. Specifically, Fe in the form of Fe2O3 may be present in an amount ranging from about 0 mol % to about 1 mol %, and TiO2 may be present in an amount ranging from about 0 mol % to about 5 mol %.

[0078] Exemplary glass compositions include SiO in an amount ranging from about 65 mol% to about 75 mol%, AlO in an amount ranging from about 8 mol% to about 14 mol%, NaO in an amount ranging from about 12 mol% to about 17 mol%, KO in an amount ranging from about 0 mol% to about 0.2 mol%, and MgO in an amount ranging from about 1.5 mol% to about 6 mol%. Optionally, SnO may be included in amounts otherwise disclosed herein. ***

[0079] Embodiments of the present disclosure may be further understood in view of the following information.

[0080] As described herein with respect to FIG. 5 , embodiments of the present disclosure may include a spacing element 500 disposed on one of the frame 64 or the glass substrate 52, which may be configured to act as a dam to prevent overflow of the material of the adhesive layer 66 when compressed to bond the frame 64 to the glass substrate 52. Further aspects of an exemplary embodiment of such a spacing element 500 are described herein with respect to FIGS. 9A-9B . FIG. 9A schematically depicts a cross-sectional view of a region 900 of the display system 400 depicted in FIG. 5 , according to an exemplary embodiment. In this embodiment, the spacing element 500 comprises a secondary adhesive bead 902 disposed proximate the periphery of the frame 64 and / or the minor surface 58 of the glass substrate 52. The secondary adhesive bead 902 contacts the adhesive layer 66 and helps prevent the material of the adhesive layer 66 from flowing outward when the material of the adhesive layer 66 is compressed during any of the manufacturing processes described herein. 9A depicts secondary adhesive bead 902 and adhesive layer 66 in a fully cured state. As shown, when fully cured, adhesive layer 66 includes a thickness 904 that corresponds to the separation distance between second major surface 56 and frame 64, such that adhesive layer 66 bonds glass substrate 52 to frame 64 and maintains the separation distance therebetween.

[0081] In an embodiment, the secondary adhesive bead 902 is formed of the same material as the adhesive layer 66 and is dispensed and cured by a similar process. In an embodiment, the nozzle 71 depicted in FIG. 3 can be used to dispense both the secondary adhesive bead 902 and the adhesive layer 66. FIG. 9B schematically depicts a work-in-progress 900 before the adhesive layer 66 is compressed, according to an exemplary embodiment. As shown in FIG. 9B, the nozzle 71 can be used to dispense the secondary adhesive bead 902 along a first bead path at the periphery of one of the glass substrate 52 and the frame 64. In an embodiment, the nozzle 71 can also be used to dispense a primary adhesive bead 908 (an uncured precursor of the adhesive layer 66 depicted in FIG. 9A) along a second bead path inward from the first bead path after the secondary adhesive bead 902 has at least partially cured. In embodiments, an active step (e.g., heating, exposure to radiation, time delay, exposure to a curing component) is taken to cure the secondary adhesive bead 902 before dispensing the primary adhesive bead 908. In embodiments, the secondary adhesive bead 902 is at least partially cured after its dispensing is complete (e.g., the initially dispensed portion may be partially cured before the secondary adhesive bead 902 is disposed along the entire first bead path), and dispensing of the primary adhesive bead 908 can begin immediately after dispensing of the secondary adhesive bead 902 is complete. Using the same material for the primary adhesive bead 908 and the secondary adhesive bead 902 may beneficially allow the same dispensing equipment to be used for each bead and may streamline the fabrication process.

[0082] Nozzle 71 can be controlled during dispensing of primary adhesive bead 908 and secondary adhesive bead 902 so that each bead has a desired volume. As depicted in FIG. 9B , when uncured, primary adhesive bead 908 has a thickness 910 measured in a direction perpendicular to the surface onto which it is dispensed (second major surface 56 in this example) and a width 912 measured in a direction parallel to the surface, and secondary adhesive bead 902 has a thickness 914 and a width 916. In embodiments, secondary adhesive bead 902 comprises a smaller volume than primary adhesive bead 908, such that width 916 is less than width 912 and thickness 914 is less than thickness 910. As described herein, during assembly of display system 400, it is beneficial to compress primary adhesive bead 908 so that the adhesive material contacts a relatively large area of ​​glass substrate 52 and frame 64 before curing, facilitating the formation of a reliable bond. To facilitate such compression, the thickness 910 of the primary adhesive bead 908 may be greater than the thickness 904 of the adhesive layer 66 after its creation (see FIG. 9A).

[0083] In embodiments, the thickness 914 of the secondary adhesive bead 902 is equal to or less than the thickness 904 (see FIG. 9A ) to allow for compression of the primary adhesive bead 908. In order for the secondary adhesive bead 902 to effectively function as a dam to prevent uncured adhesive in the primary adhesive bead 908 from flowing outward after compression of the primary adhesive bead 908, the secondary adhesive bead 902 is partially cured when the primary adhesive bead 908 is dispensed, and therefore has a degree of rigidity. As a result of being cured, the secondary adhesive bead 902 may prevent compression of the primary adhesive bead 908 to some extent. Thus, the height of the secondary adhesive bead 902 is equal to or less than the thickness 904 to allow the primary adhesive bead 908 to achieve the desired thickness 904 after compression. In embodiments, thickness 914 is greater than or equal to 50% of thickness 910 and less than or equal to 80% of thickness 910 to provide a dam of sufficient height to effectively prevent spillover of material from primary adhesive bead 908 upon compression while allowing a sufficient amount of compression of primary adhesive bead 908. When thickness 914 is equal to thickness 904, secondary adhesive bead 902 may function to determine thickness 904 by limiting the amount that primary adhesive bead 908 can be compressed. Such a configuration may beneficially provide a uniform thickness for adhesive layer 66 regardless of irregularities in the shape of frame 64.

[0084] Various configurations for the primary adhesive bead 908 and the secondary adhesive bead 902 are contemplated and within the scope of the present disclosure. In embodiments, the primary adhesive bead 908 and the secondary adhesive bead 902 include a uniform cross-sectional dimension around the perimeter of the frame 64. For example, the primary adhesive bead 908 and the secondary adhesive bead 902 may each include multiple linear segments that follow corresponding segments of the perimeter shape of the glass substrate 52 and the frame 64. Any suitable cross-sectional dimension may be used for the beads. For example, in embodiments, the width 912 is greater than the thickness 910, and the width 916 is greater than the thickness 914. Having relatively larger widths may promote a reliable bond through an increased bond area. In embodiments, the width 912 is greater than the width 916. The secondary adhesive bead 902 may not bond to both the frame 64 and the glass substrate 52, and therefore, its width 916 is not particularly limited. However, making width 916 as small as possible while still achieving the desired thickness 914 can beneficially conserve adhesive material and maximize the available bond area of ​​adhesive layer 66. In embodiments, thickness 910 of primary adhesive bead 908 is at least 110% of thickness 904 of adhesive layer 66 (e.g., no less than 120% of thickness 904 and no more than 130% of thickness 904) after the fabrication process is completed (see FIG. 9A) to allow for a sufficient amount of compression.

[0085] 9A , as a result of the secondary adhesive bead 902 being at least partially cured when the primary adhesive bead 908 is compressed, the secondary adhesive bead 902 may include a non-bonding surface 918 that is not directly bonded to either the glass substrate 52 or the frame 64. In the depicted example, the non-bonding surface 918 is not in contact with the frame 614 (thus there is an air gap between the secondary adhesive bead 902 and the frame 64). It has been found that such an air gap does not prevent the secondary adhesive bead 902 from effectively functioning as a dam to prevent overflow of the primary adhesive bead 908 upon compression, provided that the thickness 906 of the secondary adhesive bead 902 after the fabrication process is at least 50% of the thickness 904 of the adhesive layer 66. It has been found that the secondary adhesive bead 902 tends to force the adhesive of the primary adhesive bead 908 inward and prevents overflow even in the presence of the air gap. In embodiments, thickness 906 can be equal to thickness 904, indicating contact between non-bonding surface 918 and frame 64 or glass substrate 52. Such embodiments without an air gap may imply the use of a secondary adhesive bead 902 in setting the desired thickness 904 by limiting compression of primary adhesive bead 908.

[0086] Embodiments of the present disclosure may be further understood in view of the following aspects.

[0087] Aspect (1) of the present disclosure relates to a display system comprising: a glass substrate having a first major surface and a second major surface; a frame having a curved support surface, the frame having an inner edge defining an opening; an adhesive layer disposed between the curved support surface and the second major surface and attaching the glass substrate to the frame so as to conform to the curved support surface, the second major surface being not adhered to the frame and having an opening region overlapping the opening; a display module disposed within the opening and adhered to the opening region, the display module comprising a display layer and a back panel, wherein there is a gap disposed between a peripheral edge and an inner edge of the back panel, and the frame is not bolted to the back panel; and a spacer disposed in the gap and extending the entire distance between the peripheral edge and the inner edge.

[0088] Aspect (2) of the present disclosure relates to the display system according to aspect (1), wherein the gap surrounds the entire peripheral edge of the back panel.

[0089] Aspect (3) of the present disclosure relates to a display system according to any one of aspects (1) to (2), wherein the back panel comprises a curved backlight unit or heat sink and comprises a surface having a minimum radius of curvature that is within 10% of the curvature of the curved support surface.

[0090] Aspect (4) of the present disclosure relates to the display system according to any one of aspects (1) to (3), in which the spacer partially fills the gap.

[0091] Aspect (5) of the present disclosure relates to a display system according to any one of aspects (1) to (4), wherein the spacer comprises at least one of polyurethane, polyurea, polyisocyanurate, polyester, polyphenol, polyepoxide, nylon 6, a 1K component adhesive or sealant, and a 2K component adhesive or sealant.

[0092] Aspect (6) of the present disclosure relates to the display system according to any one of aspects (1) to (5), wherein the spacer comprises a Young's modulus greater than 100 MPa.

[0093] A seventh aspect of the present disclosure relates to the display system according to any one of the first to fifth aspects, wherein the spacer includes a Young's modulus of 50 MPa or less and is compressed inside the gap.

[0094] Aspect (8) of the present disclosure relates to a display system according to any of aspects (1) to (7), wherein the curved support surface comprises a length of 500 mm or more and 3000 mm or less, a width that is less than half the length, and a minimum radius of curvature of 100 mm or more and 1500 mm or less.

[0095] Aspect (9) of the present disclosure relates to a display system according to any of aspects (1) to (8), further comprising at least one of a spacing element disposed between the curved support surface and the second major surface proximate to the periphery of the second major surface, a step or through-hole on the curved support surface, and a trough extending from the inner edge of the frame.

[0096] A tenth aspect of the present disclosure relates to a display system according to any one of the first to ninth aspects, wherein the outer surface of the adhesive layer is textured.

[0097] Aspect (11) of the present disclosure relates to a method of molding a display system, the method including: cold-forming a glass substrate against a curved support surface of a frame with an adhesive layer disposed between the curved support surface and the glass substrate, the frame including an opening; laminating a display module to the glass substrate in the opening via an optically clear adhesive layer, the display module including a back panel, a peripheral edge of the back panel being separated from an interior edge of the frame by a gap; disposing a spacer in the gap, the spacer bonding the back panel to the frame and maintaining the shape of the gap; and curing the adhesive layer such that the glass substrate is held in the curved shape by the frame.

[0098] Aspect (12) of the present disclosure relates to the method according to aspect (11), wherein the cold-forming includes applying a negative pressure to the glass substrate via a vacuum chuck to conform the glass substrate to the vacuum chuck, and pressing a curved support surface against the glass substrate after the negative pressure is applied to the glass substrate.

[0099] Aspect (13) of the present disclosure relates to the method according to aspect (12), wherein the back panel is curved before being laminated to the glass substrate, and a spacer bonds the back panel to the frame before the adhesive layer is cured.

[0100] Aspect (14) of the present disclosure relates to the method according to aspect (13), wherein the method further includes removing the glass substrate, the frame, and the display module from the vacuum chuck before the adhesive layer is cured, and the back panel holds the glass substrate in a curved shape before the adhesive is fully cured.

[0101] Aspect (15) of the present disclosure relates to the method according to any one of aspects (11) to (14), wherein disposing the spacer includes injecting a spacer precursor material into the gap and curing the spacer precursor material.

[0102] Aspect (16) of the present disclosure relates to the method according to any one of aspects (11) to (14), wherein disposing the spacers includes attaching the spacers to the peripheral or inner edges before laminating the display module to the glass substrate.

[0103] Aspect (17) of the present disclosure relates to a method according to any of aspects (11) to (16), wherein the cold-forming includes dispensing adhesive of the adhesive layer along a bead path onto one of the curved support surface of the frame and the glass substrate, the bead path having a shape corresponding to the shape of the curved support surface of the frame.

[0104] An aspect (18) of the present disclosure relates to the method according to aspect (17), wherein dispensing the adhesive includes controlling a dispensing rate of the adhesive as a function of the shape of the curved support surface.

[0105] Aspect (19) of the present disclosure relates to a method according to any of aspects (17) to (18), wherein the method further includes attaching a spacing element to one of the frame and the glass substrate before dispensing the adhesive, the spacing element being configured to prevent the adhesive from flowing outward from the frame when the adhesive is compressed between the glass substrate and the frame.

[0106] Aspect (20) of the present disclosure relates to a method according to any of aspects (17) to (18), wherein the method further includes forming an adhesive via an adhesive-forming element disposed outside the glass substrate when the adhesive is compressed between the glass substrate and the frame.

[0107] An aspect (21) of the present disclosure relates to a display system, the display system including a glass substrate having a first major surface and a second major surface, a frame having a curved support surface, the frame defining an opening, an adhesive layer disposed between the curved support surface and the second major surface and attaching the glass substrate to the frame so as to conform to the curved support surface, the second major surface being not adhered to the frame and having an opening region overlapping the opening, and a display module disposed within the opening and adhered to the opening region. a display module comprising a display layer and a back panel, with a gap disposed between a periphery of the back panel and an inner edge of the frame, the frame not being bolted to the back panel; a spacer disposed in the gap and extending the entire distance between the periphery and the inner edge; and at least one of a spacing element disposed between the curved support surface and the second major surface proximate a periphery of the second major surface, a step or through-hole on the curved support surface, and a trough extending from the inner edge of the frame.

[0108] Aspect (22) of the present disclosure relates to a display system according to aspect (21), wherein the back panel comprises a curved backlight unit or heat sink and comprises a surface having a minimum radius of curvature that is within 10% of the curvature of the curved support surface.

[0109] An aspect (23) of the present disclosure relates to a display system according to any one of aspects (21) to (22), wherein the spacer partially fills the gap.

[0110] Aspect (24) of the present disclosure relates to a display system according to any one of aspects (21) to (23), wherein the spacer comprises at least one of polyurethane, polyurea, polyisocyanurate, polyester, polyphenol, polyepoxide, nylon 6, a 1K component adhesive or sealant, and a 2K component spacer or sealant.

[0111] Aspect (25) of the present disclosure relates to the display system according to any one of aspects (21) to (24), wherein the spacer comprises a Young's modulus greater than 100 MPa.

[0112] An aspect (26) of the present disclosure relates to the display system according to any one of the aspects (21) to (24), wherein the spacer includes a Young's modulus of 50 MPa or less and is compressed inside the gap.

[0113] Aspect (27) of the present disclosure relates to a display system according to any of aspects (21) to (26), wherein the curved support surface comprises a length of 500 mm or more and 3000 mm or less, a width that is less than half the length, and a radius of curvature of 100 mm or more and 1500 mm or less.

[0114] Aspect (28) of the present disclosure relates to a display system according to any one of aspects (21) to (27), wherein the outer surface of the adhesive layer is textured.

[0115] Aspect (29) of the present disclosure relates to a display system according to aspect (9), wherein the display system includes a spacing element, the spacing element including a secondary adhesive bead having a non-bonding surface that is not directly bonded to either the curved support surface or the second major surface.

[0116] Aspect (30) of the present disclosure relates to a method according to any of aspects (17) to (18), wherein the adhesive of the adhesive layer is disposed in the form of a primary adhesive bead along a first bead path, the primary adhesive bead having a first thickness measured in a direction perpendicular to the surface on which the primary adhesive bead is disposed and a first width measured in a direction parallel to the surface, and the method further includes, before dispensing the adhesive of the adhesive layer, dispensing a secondary adhesive bead along a second bead path surrounding the first bead path, the secondary adhesive bead having a second thickness that is less than the first thickness of the primary adhesive bead when the primary adhesive bead is dispensed, and the secondary adhesive bead is at least partially cured when the adhesive of the adhesive layer is dispensed.

[0117] Aspect (31) of the present disclosure relates to the method according to aspect (30), wherein the second thickness is equal to or less than the thickness of the adhesive layer after the adhesive is cured.

[0118] Aspect (32) of the present disclosure relates to a display system according to any of aspects (21) to (28), wherein the display system includes a spacing element, the spacing element including a secondary adhesive bead having a non-bonding surface that is not directly bonded to either the curved support surface or the second major surface.

[0119] Unless otherwise expressly stated, any method set forth herein is in no way intended to be construed as requiring that its steps be performed in a particular order. Thus, unless a method claim actually recites the order in which its steps are to be followed or the claim or description specifically states that the steps are to be limited to a particular order, no particular order is intended to be inferred. Additionally, as used herein, the article "a" is intended to include one or more components or elements and is not intended to be construed as meaning only one.

[0120] It will be apparent to those skilled in the art that various modifications and variations can be made without departing from the scope of the embodiments of the present disclosure. Since modifications, combinations, subcombinations, and variations of the disclosed embodiments incorporating the spirit and content of the embodiments may occur to those skilled in the art, the disclosed embodiments should be construed as including all within the scope of the appended claims and their equivalents.

Claims

1. 1. A display system comprising: a glass substrate having a first major surface and a second major surface; a frame having a curved support surface, the frame having an inner edge defining an opening; an adhesive layer disposed between the curved support surface and the second major surface and attaching the glass substrate to the frame so as to conform the glass substrate to the curved support surface, the second major surface being not adhered to the frame and including an open area overlapping the opening; and a display module disposed within the opening and adhered to the opening area, the display module including a display layer and a back panel, a gap disposed between a peripheral edge and the inner edge of the back panel, and the frame not bolted to the back panel; a spacer disposed in the gap and extending the entire distance between the peripheral edge and the inner edge.

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

3. 3. The display system of claim 1, wherein the back panel comprises a curved backlight unit or heat sink and comprises a surface having a minimum radius of curvature that is within 10% of the curvature of the curved support surface.

4. 4. The display system of claim 1, wherein the spacers partially fill the gaps.

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

6. 6. The display system of claim 1, wherein the spacers comprise a Young's modulus greater than 100 MPa.

7. 6. The display system of claim 1, wherein the spacer comprises a Young's modulus of 50 MPa or less and is compressed inside the gap.

8. The curved support surface comprises: A length of 500 mm or more and 3000 mm or less; a width that is less than half of said length; A display system according to any one of claims 1 to 7, comprising a minimum radius of curvature of 100 mm or more and 1500 mm or less.

9. a spacing element disposed between the curved support surface and the second major surface adjacent a periphery of the second major surface; a step or through-hole on the curved support surface; and A display system according to any preceding claim, further comprising at least one of: a trough extending from the inner edge of the frame.

10. the display system comprises the spacing element; 10. The display system of claim 9, wherein the spacing element comprises a secondary adhesive bead having a non-bonding surface that is not directly bonded to either the curved support surface or the second major surface.

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

12. 1. A method of molding a display system, the method comprising: cold-forming a glass substrate against a curved support surface of a frame with an adhesive layer disposed between the curved support surface and the glass substrate, the frame including an opening; laminating a display module to the glass substrate within the opening via a layer of optically clear adhesive, the display module including a back panel, a peripheral edge of the back panel being separated from an inner edge of the frame by a gap; disposing a spacer in the gap, the spacer connecting the back panel to the frame and maintaining the shape of the gap; and curing the adhesive layer such that the glass substrate is held in a curved shape by the frame.

13. The cold forming is applying a negative pressure to the glass substrate through the vacuum chuck to conform the glass substrate to the vacuum chuck; and pressing the curved support surface against the glass substrate after the negative pressure is applied to the glass substrate.

14. the back panel is curved before being laminated to the glass substrate; The method of claim 13 , wherein the spacer bonds the back panel to the frame before the adhesive layer is cured.

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

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

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

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

19. 20. The method of claim 18, wherein dispensing the adhesive includes controlling a dispensing rate of the adhesive as a function of a shape of the curved support surface.

20. 20. The method of claim 18 or 19, further comprising attaching a spacing element to one of the frame and the glass substrate before dispensing the adhesive, the spacing element configured to prevent the adhesive from flowing outward from the frame when the adhesive is compressed between the glass substrate and the frame.

21. 20. The method of claim 18 or 19, further comprising forming the adhesive through an adhesive forming element disposed outside the glass substrate when the adhesive is compressed between the glass substrate and the frame.

22. the adhesive of the adhesive layer is disposed in the form of a primary adhesive bead along a first bead path, the primary adhesive bead having a first thickness measured in a direction perpendicular to a surface on which the primary adhesive bead is disposed and a first width measured in a direction parallel to the surface; The method further includes dispensing a secondary adhesive bead along a second bead path surrounding the first bead path before dispensing the adhesive of the adhesive layer; the secondary adhesive bead includes a second thickness that is less than the first thickness of the primary adhesive bead when the primary adhesive bead is dispensed; 20. The method of claim 18 or 19, wherein the secondary adhesive bead is at least partially cured as the adhesive of the adhesive layer is dispensed.

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

24. 1. A display system comprising: a glass substrate having a first major surface and a second major surface; a frame having a curved support surface, the frame defining an opening; an adhesive layer disposed between the curved support surface and the second major surface and attaching the glass substrate to the frame so as to conform the glass substrate to the curved support surface, the second major surface being not adhered to the frame and including an open area overlapping the opening; and a display module disposed within the opening and adhered to the opening area, the display module comprising a display layer and a back panel having a stiffness greater than that of the display layer, a gap disposed between a periphery of the back panel and an inner edge of the frame, the frame not being bolted to the back panel, and the gap having a width of 2 mm or less; a spacer disposed within the gap and extending the entire distance between the peripheral edge and the inner edge; a spacing element disposed between the curved support surface and the second major surface adjacent a periphery of the second major surface; a step or through-hole on the curved support surface; and a trough extending from the inner edge of the frame.

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

26. 26. A display system according to claim 24 or 25, wherein the spacers partially fill the gaps.

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

28. A display system according to any one of claims 24 to 27, wherein the spacers comprise a Young's modulus greater than 100 MPa.

29. 28. A display system according to any one of claims 24 to 27, wherein the spacer comprises a Young's modulus of 50 MPa or less and is compressed inside the gap.

30. The curved support surface comprises: A length of 500 mm or more and 3000 mm or less; a width that is less than half of said length; A display system according to any one of claims 24 to 29, comprising a minimum radius of curvature of 100 mm or more and 1500 mm or less.

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

32. the display system includes the spacing element; 32. A display system as claimed in any one of claims 24 to 31, wherein the spacing element comprises a secondary adhesive bead having a non-bonding surface that is not directly bonded to either the curved support surface or the second major surface.

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