Lamination of thin tempered glass to curved molded plastic surfaces for decorative and display cover applications

Abstract

To provide an article with a curved glass substrate that does not exhibit optical distortions and surface textures typically found in thermo-molded curved glass substrates while maintaining excellent display quality.SOLUTION: An article includes: a cold-molded glass substrate 120 including a non-planar shape, a first major surface 121 and an opposite second major surface 122; and a non-planar rigid support structure 130 coupled to the glass substrate and configured to hold the glass substrate in a non-planar shape. The non-planar rigid support structure is only coupled to the first major surface of the glass substrate so that the non-planar rigid support structure holds the cold-molded glass substrate in the non-planar shape even though the first major surface and the opposite second major surface have different surface compressive stresses from each other, and the non-planar rigid support structure is configured to be attached to a component of an automobile.SELECTED DRAWING: Figure 4

Description

Description of Related Applications

[0001] This application claims the benefit of priority under 35 U.S.C. §119 of U.S. Provisional Patent Application No. 62 / 444,470, filed January 10, 2017, and U.S. Provisional Patent Application No. 62 / 355,542, filed June 28, 2016, the contents of which are relied upon and incorporated herein by reference in their entireties. [Technical field]

[0002] FIELD OF THE DISCLOSURE The present disclosure relates to curved, cold-formed glass substrates, articles comprising such glass substrates, and related methods. [Background technology]

[0003] Curved glass substrates are desirable in many situations. One such situation is as a cover glass for curved displays that may be incorporated into appliances, architectural components (e.g., walls, windows, modular furniture, shower doors, mirrors, etc.), vehicles (e.g., automobiles, aircraft, ships, etc.), or other applications. Existing methods of forming such curved glass substrates, such as thermoforming, have drawbacks including optical distortion and surface markings. Summary of the Invention [Problem to be solved by the invention]

[0004] Therefore, there is a need for curved glass substrates that do not exhibit the optical distortions and surface patterns typically found in thermoformed curved glass substrates while maintaining excellent display quality. [Means for solving the problem]

[0005] SUMMARY The present disclosure relates to articles comprising a cold-formed glass substrate bonded to a non-planar rigid support structure and methods of making such articles.

[0006] A first aspect of the present disclosure relates to a method of forming the articles described herein, in one or more embodiments, the method includes cold forming a substantially flat glass substrate into a non-planar shape using a die.

[0007] In one or more embodiments, the method includes coupling the cold-formed glass substrate to a non-planar rigid support structure. In one or more embodiments, coupling the cold-formed glass substrate to a non-planar rigid support structure includes bonding the cold-formed glass substrate to the non-planar rigid support structure. In some examples, the cold-formed glass substrate may be coupled or bonded to the non-planar rigid support structure at a plurality of non-planar points. Such coupling or bonding may be performed using a die. In one or more embodiments, the method may include simultaneously cold-forming a substantially planar glass substrate and coupling the cold-formed glass substrate to the non-planar rigid support structure.

[0008] In some embodiments, the method includes cold forming a flat glass substrate into a non-planar shape using an injection molding die, in some embodiments, bonding is achieved by injection molding a non-planar rigid support structure onto the cold formed glass substrate while the die holds the cold formed glass substrate in the non-planar shape.

[0009] In some embodiments, the cold-formed glass substrate has opposing major surfaces and the non-planar rigid support structure is bonded to only one of the major surfaces.

[0010] In some embodiments, the method further includes, after the bonding step, applying an adhesive to at least a portion of the interface between the cold-formed glass substrate and the non-planar rigid support structure. In some embodiments, the interface is between an edge (or a microfacet perpendicular to a major surface) of the cold-formed glass substrate and the non-planar rigid support structure. In one or more embodiments, the method includes applying an adhesive to at least a portion of the edge or non-planar rigid support structure at the interface.

[0011] In some embodiments, the method includes cold forming the glass substrate into a non-planar shape. In some embodiments, the method includes directly bonding the cold formed glass substrate to a non-planar rigid support structure using a die. In one or more embodiments, the non-planar rigid support structure is shaped prior to bonding.

[0012] In some embodiments, the die includes a recess and the non-planar rigid support structure is placed in the recess prior to bonding.

[0013] In some embodiments, the method further comprises applying a coating and / or a surface treatment to the surface of the substantially flat glass substrate prior to cold forming. In one or more embodiments, the method further comprises applying a coating and / or a surface treatment to the surface of the substantially flat glass substrate after cold forming. In either case, the surface may include any one or more of opposing major faces and microfacets (forming edges) perpendicular to the major faces. In one or more embodiments, the coating may be an ink coating, an anti-reflective coating, an anti-glare coating, and / or any other suitable coating. In one or more embodiments, the surface treatment may include an anti-glare surface, a tactile surface providing tactile feedback, recesses and / or ridges providing indicia, and the like.

[0014] In some embodiments, the cold-formed glass substrate includes an open area that is not in direct contact with the non-planar rigid support structure when the cold-formed glass substrate is coupled to the non-planar rigid support structure. In one or more embodiments, the open area has a curved shape that is maintained by the non-planar rigid support structure. A display can be attached to at least one of the cold-formed glass substrate and the non-planar rigid support structure such that the display is at least partially visible through the open area of ​​the cold-formed glass substrate.

[0015] In some embodiments, during and after cold forming, the temperature of the glass substrate does not exceed its glass transition temperature, hi one or more embodiments, the temperature of the glass substrate does not exceed 800° F. (or about 427° C.).

[0016] In some embodiments, the method includes strengthening the substantially flat glass substrate. In one or more embodiments, the method includes chemically strengthening the substantially flat glass substrate, thermally strengthening the substantially flat glass substrate, mechanically strengthening the substantially flat glass substrate, or strengthening the substantially flat glass substrate using one or more of chemical strengthening, thermal strengthening, and mechanical strengthening.

[0017] In some embodiments, an article is formed by any of the methods described herein.

[0018] A second aspect of the present disclosure relates to an article comprising a cold-formed glass substrate having opposing major surfaces and a curved or non-planar shape, each of the opposing major surfaces having a different surface stress. In one or more embodiments, the cold-formed glass substrate is coupled to a rigid support structure having the curved or non-planar shape (i.e., the same curved or non-planar shape as the cold-formed glass substrate). In one or more embodiments, the cold-formed glass substrate is bonded to the non-planar rigid support structure. In some embodiments, the rigid support structure is bonded to only one of the major surfaces.

[0019] In one or more embodiments, the cold-formed glass substrate includes open areas that are not in direct contact with the rigid support structure, the open areas having a curved shape that is maintained by the rigid support structure.

[0020] In some embodiments, the rigid support structure has a spreadable surface. In one or more embodiments, the cold-formed glass substrate has a spreadable surface. In some embodiments, both the rigid support structure and the cold-formed glass substrate have spreadable surfaces.

[0021] In some embodiments, a display is attached to at least one of the cold-formed glass substrate and the non-planar rigid support structure. In one or more embodiments, the display is at least partially or completely visible through the open areas of the cold-formed glass substrate. In one or more embodiments, the cold-formed glass substrate may be free of open areas (i.e., the glass substrate may be a continuous sheet) and the display may be visible through the cold-formed glass substrate.

[0022] In some embodiments, the cold-formed glass substrate includes a coating and / or surface treatment on at least one of its major surfaces. The coating may be an ink coating, an anti-reflective coating, an anti-glare coating, and / or any other suitable coating. The surface treatment may include an anti-glare surface, a tactile surface to provide tactile feedback, recesses and / or ridges to provide indicia, and the like.

[0023] In some embodiments, the cold-formed glass substrate is a strengthened glass substrate, which may include chemically strengthened glass, thermally strengthened glass, mechanically strengthened glass, or glass that has been strengthened using one or more of chemically strengthened, thermally strengthened, and mechanically strengthened.

[0024] The embodiments in the previous paragraphs may be combined in any order.

[0025] The accompanying drawings are included herein and form a part of this specification and illustrate embodiments of the present disclosure. Together with the description, the drawings serve to explain the principles of the disclosed embodiments and to enable one of ordinary skill in the relevant art to make and use the disclosed embodiments. These drawings are intended to be illustrative, not limiting. Although the disclosure has been broadly described in terms of these embodiments, it should be understood that there is no intent to limit the scope of the disclosure to these particular embodiments. In the drawings, like reference numbers indicate identical or functionally similar elements. [Brief description of the drawings]

[0026] [Figure 1] FIG. 1 is an illustration of an injection molding die designed with an exemplary curved shape and a substantially flat glass substrate, according to one or more embodiments. [Diagram 2] Illustration of the die in Figure 1 for cold forming a glass substrate into a non-planar shape. [Diagram 3] FIG. 3 is an illustration of the die of FIG. 2 after material has been injection molded into the cavity in the die to form a non-planar rigid support structure that is bonded to the backside of the cold-formed glass substrate. [Figure 4] 4 is an illustration of the die of FIG. 3 and the resulting article after the die has been separated. The resulting article is a cold-formed glass substrate bonded to a non-planar rigid support structure. The cold-formed cover glass substrate maintains its designed curvature due to the rigidity of the non-planar rigid support structure coupled to a major surface of the cold-formed glass substrate. [Diagram 5] FIG. 5 is an illustration of a cold-formed glass substrate bonded to the non-planar rigid support structure of FIG. 4 by an adhesive. [Figure 6] FIG. 1 is a perspective view of a cold-formed glass substrate bonded to a non-planar rigid support structure according to one or more embodiments. [Figure 7] 1 illustrates a top view of a cold-formed glass substrate bonded to a non-planar rigid support structure, the curvature of which is not visible due to viewing angle, in accordance with one or more embodiments. [Figure 8]FIG. 1 is an illustration of a direct bond die designed into a particular desired curved shape, a flat glass substrate, and a non-planar rigid support structure inserted into a recess in the die, according to one or more embodiments. [Figure 9] 9 is an illustration of the die of FIG. 8 for cold forming a glass substrate into a non-planar shape and bonding a non-planar rigid support structure to the cold-formed glass substrate. [Figure 10] 10 is an illustration of the die of FIG. 9 and the resulting article after the die has been separated. The resulting article is a cold-formed glass substrate bonded to a non-planar rigid support structure. The cold-formed cover glass substrate maintains its designed curvature due to the rigidity of the non-planar rigid support structure coupled to a major surface of the cold-formed glass substrate. [Figure 11] FIG. 11 is an illustration of a cold-formed glass substrate bonded by an adhesive to the non-planar rigid support structure of FIG. [Figure 12] FIG. 6 is a flow chart of the process corresponding to the process shown in FIGS. 1 to 5. [Figure 13] FIG. 11 is a flow chart of a process corresponding to the process shown in FIGS. [Figure 14] FIG. 1 is an illustration of a die having ridges that position a glass substrate within the die, according to one or more embodiments. [Figure 15] FIG. 1 is an illustration of an automotive interior display comprising a cold-formed glass substrate bonded to a non-planar rigid support structure, according to one or more embodiments. [Figure 16] 1 is a top view of a cold-formed glass substrate bonded to a non-planar rigid support structure with a display bonded to the cold-formed glass substrate according to one or more embodiments, where the curvature is not visible due to the viewing angle. [Figure 17] FIG. 1 is a side view of a glass substrate being applied to a rigid support structure having a spreadable surface using a single roller, according to one or more embodiments. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0027] Vehicle manufacturers are creating interiors that better connect, protect, and safely inform today's drivers and passengers. Moreover, as the industry moves toward autonomous driving, there is a need to create large, eye-catching displays. There is already a trend toward larger displays with touch capabilities in new models from several OEMs. Such trends are also emerging in appliances, architectural components (e.g., walls, windows, modular furniture, shower doors, mirrors, etc.), and other vehicles (e.g., aircraft, ships, etc.). However, most of these displays consist of two-dimensional plastic cover lenses.

[0028] Because of these trends in the automotive interior and related industries, there is a need to develop low-cost techniques for producing three-dimensional transparent surfaces. Strengthened glass materials, such as chemically, thermally and / or mechanically strengthened glass materials, are particularly desirable for use as such surfaces, especially when the glass materials are used as curved cover glass for displays.

[0029] However, many methods for forming curved glass surfaces involve subjecting a glass substrate to a thermoforming process, including a thermoforming process that involves heating the glass substrate to a temperature above the transition temperature of the glass. Such processes can be energy intensive due to the high temperatures involved, and such processes add significant cost to the product. Additionally, thermoforming processes can degrade the strength or damage any coatings present on the glass substrate, such as anti-reflective (AR) coatings or ink coatings. Additionally, thermoforming processes can impart undesirable characteristics to the glass itself, such as distortions and patterns.

[0030] Various aspects of the present disclosure relate to articles comprising cold-formed glass substrates capable of assuming and maintaining a curved shape. As used herein, "cold-forming" refers to bending a glass substrate to obtain a curved or non-planar shape at a temperature below the glass transition temperature of the glass. In one or more embodiments, this temperature is less than about 800°F (or 427°C). The resulting curved or non-planar glass substrate is a cold-formed glass substrate.

[0031] In some embodiments, a portion of a major surface of a cold-formed glass substrate may include a "developable" surface. A developable surface has a surface with zero Gaussian curvature. In one or more embodiments, the developable surface means that all points of the cold-formed glass substrate have a Gaussian curvature (GC) equal to zero (GC is equal to Kmax x Kmin, where Kmax and Kmin are the principal curvatures defined as Kmax = 1 / R' and Kmin = 1 / R"), and one of Kmax and Kmin is non-zero. R' is the maximum radius of curvature and R" is the minimum radius of curvature. In one or more embodiments, the surface of the cold-formed glass substrate can be flattened into a plane without stretching or compressing within the plane of the surface.

[0032] Examples of developable surfaces include cones, cylinders, oloids, tangent developable surfaces, and parts thereof. A surface that projects onto a single curve is a developable surface.

[0033] In one or more embodiments, the article comprises a cold-formed glass substrate having a non-planar shape, a first major surface and a second major surface opposite the first major surface, the cold-formed glass substrate coupled to the non-planar rigid support structure. In one or more embodiments, the cold-formed glass substrate is coupled to the non-planar rigid support structure by bonding. In one or more embodiments, an adhesive is used to bond the cold-formed glass substrate coupled to the non-planar rigid support structure. In one or more embodiments, the non-planar rigid support structure is injection molded onto the cold-formed glass substrate.

[0034] In one or more embodiments, the non-planar rigid support structure is coupled to the first major surface of the cold-formed glass substrate at one or more points, which may be non-planar points, hi some embodiments, the non-planar rigid support structure is coupled to the first major surface at multiple non-planar points.

[0035] In one or more embodiments, each of the first and second opposing major surfaces exhibits a different surface stress. Such difference in stress is caused by cold forming. The stress may include surface compressive stress caused by the cold forming process in addition to any surface stress that may be present due to a strengthening process applied to the glass substrate. These stresses are not thermally relieved because the glass substrate is maintained at a temperature well below the glass transition temperature. In some embodiments, the cold formed glass substrate exhibits different surface compressive stresses on its first and second major surfaces at, near, or adjacent to the one or more non-planar locations. As shown in FIG. 4, the first and second major surfaces 121 and 122 are under tension or compression depending on the orientation of the curvature. The first major surface 121 at a first location 121A adjacent to the non-planar rigid support structure 130 is under tension, while the second major surface 122 at a second location 122A adjacent to the same non-planar rigid support structure 130 is under compression. Thus, the second major surface 122 at the second location 122A exhibits a greater surface compressive stress than the first major surface 121 at the first location 121A. This asymmetric surface compressive stress is exhibited even if the glass substrate 120 exhibits surface compressive stress before being tempered and cold formed as described herein. In one or more embodiments, the first location 121A and the second location 122A of each of the first and second major surfaces 121, 122 are adjacent to the same non-planar rigid support structure such that either or both of the first and second locations are located at a distance of 5 centimeters or less from the non-planar rigid support structure 130. In one or more embodiments, either or both of the first and second locations are located at a distance of 4 centimeters or less, 3 centimeters or less, 2 centimeters or less, 1 centimeter or less, or 0.5 centimeters or less from the non-planar rigid support structure 130. The distances of the first and second locations relative to the non-planar rigid support structure 130 are measured from a center 131 of the non-planar rigid support structure 130 to the respective first and second locations. In some embodiments, the first location 121A and the second location 122A are located directly opposite one another, as shown in FIG. 5, exhibiting the asymmetric surface compressive stresses described herein.

[0036] In some embodiments, either or both of the first and second major surfaces of the glass substrate may include a coating or surface treatment. In one or more embodiments, the coating may be an ink coating, an anti-reflective coating, an anti-glare coating, and / or any other suitable coating. In one or more embodiments, the surface treatment may include an anti-glare surface, a tactile surface to provide tactile feedback, recesses and / or ridges to provide indicia, and the like.

[0037] In some instances, the article may include an adhesive disposed at an interface between the cold-formed glass substrate and the non-planar rigid support structure. In one or more embodiments, the interface is between one or more microsurfaces of the cold-formed glass substrate and the non-planar rigid support structure. In one or more embodiments, the interface may be substantially free of adhesive or other materials such that one or more microsurfaces are exposed.

[0038] In some examples, the cold-formed glass substrate includes an open area that is not in direct contact with the non-planar rigid support structure, the open area having a curved shape maintained by the non-planar rigid support structure. In some examples, the article includes a display disposed on at least one of the glass substrate and the non-planar rigid support structure, where the display is at least partially or completely visible through the cold-formed glass substrate. In some examples, the display is disposed between the glass substrate and the non-planar rigid support structure. In some examples, the display may be attached to at least one of the glass substrate and the non-planar rigid support structure.

[0039] In some embodiments, the cold-formed glass substrate has a developable surface as described herein. In some examples, the cold-formed glass substrate may include a complex developable surface, which is a combination of two or more developable surfaces, such as a cone, a cylinder, an oloid, a plane, and a tangent developable surface. For example, the complex developable surface may be a combination of at least a plane and at least a concave surface, or at least a plane and at least a convex surface, or at least a concave and at least a convex surface.

[0040] In some embodiments, complex developable surfaces may also be formed by a combination of flat, conical, cylindrical, and other developable surfaces and may include both inward and outward bending. In some embodiments, the combination of flat, conical, cylindrical, and other developable surfaces may be in a manner such that no sharp edges are formed while progressing from one developable surface to another.

[0041] In some embodiments, a complex developable surface or a complex developable surface may include one or more planar portions, one or more conical portions, one or more cylindrical portions, and / or one or more other developable surface portions.

[0042] In the illustrated embodiment, the cold-formed glass substrate has a thickness (t) that is substantially constant and is defined as the distance between the opposing major surfaces. As used herein, thickness (t) refers to the maximum thickness of the glass substrate. In one or more embodiments, the cold-formed glass substrate has a thickness (t) of about 1.5 mm or less. For example, the thickness may be from about 0.1 mm to about 1.5 mm, from about 0.15 mm to about 1.5 mm, from about 0.2 mm to about 1.5 mm, from about 0.25 mm to about 1.5 mm, from about 0.3 mm to about 1.5 mm, from about 0.35 mm to about 1.5 mm, from about 0.4 mm to about 1.5 mm, from about 0.45 mm to about 1.5 mm, from about 0.5 mm to about 1.5 mm, from about 0.55 mm to about 1.5 mm, from about 0.6 mm to about 1.5 mm, from about 0.65 mm to about 1.5 mm, from about 0.7 mm to about 1.5 mm, from about 0.1 mm to about 1.4 mm, from about 0.1 mm to about 1.3 mm, from about 0.1 mm to about 1.5 mm, The diameter of the slit may be in the range of about 1.2 mm, about 0.1 mm to about 1.1 mm, about 0.1 mm to about 1.05 mm, about 0.1 mm to about 1 mm, about 0.1 mm to about 0.95 mm, about 0.1 mm to about 0.9 mm, about 0.1 mm to about 0.85 mm, about 0.1 mm to about 0.8 mm, about 0.1 mm to about 0.75 mm, about 0.1 mm to about 0.7 mm, about 0.1 mm to about 0.65 mm, about 0.1 mm to about 0.6 mm, about 0.1 mm to about 0.55 mm, about 0.1 mm to about 0.5 mm, about 0.1 mm to about 0.4 mm, or about 0.3 mm to about 0.7 mm.

[0043] In one or more embodiments, the cold-formed glass substrate may have a thickness of about 5 cm to about 250 cm, about 10 cm to about 250 cm, about 15 cm to about 250 cm, about 20 cm to about 250 cm, about 25 cm to about 250 cm, about 30 cm to about 250 cm, about 35 cm to about 250 cm, about 40 cm to about 250 cm, about 45 cm to about 250 cm, about 50 cm to about 250 cm, about 55 cm to about 250 cm, about 60 cm to about 250 cm, about 65 cm to about 250 cm, about 70 cm to about 250 cm, about 75 cm to about 250 cm, about 80 cm to about 250 cm, about 85 cm to about 250 cm, about 90 cm to about 250 cm, about 95 cm to about 250 cm, about 100 cm to about 250 cm, about 11 The range may be from 0 cm to about 250 cm, from about 120 cm to about 250 cm, from about 130 cm to about 250 cm, from about 140 cm to about 250 cm, from about 150 cm to about 250 cm, from about 5 cm to about 240 cm, from about 5 cm to about 230 cm, from about 5 cm to about 220 cm, from about 5 cm to about 210 cm, from about 5 cm to about 200 cm, from about 5 cm to about 190 cm, from about 5 cm to about 180 cm, from about 5 cm to about 170 cm, from about 5 cm to about 160 cm, from about 5 cm to about 150 cm, from about 5 cm to about 140 cm, from about 5 cm to about 130 cm, from about 5 cm to about 120 cm, from about 5 cm to about 110 cm, from about 5 cm to about 100 cm, from about 5 cm to about 90 cm, from about 5 cm to about 80 cm, or from about 5 cm to about 75 cm.

[0044] In one or more embodiments, the cold-formed glass substrate may have a thickness of about 5 cm to about 250 cm, about 10 cm to about 250 cm, about 15 cm to about 250 cm, about 20 cm to about 250 cm, about 25 cm to about 250 cm, about 30 cm to about 250 cm, about 35 cm to about 250 cm, about 40 cm to about 250 cm, about 45 cm to about 250 cm, about 50 cm to about 250 cm, about 55 cm to about 250 cm, about 60 cm to about 250 cm, about 65 cm to about 250 cm, about 70 cm to about 250 cm, about 75 cm to about 250 cm, about 80 cm to about 250 cm, about 85 cm to about 250 cm, about 90 cm to about 250 cm, about 95 cm to about 250 cm, about 100 cm to about 250 cm, about 110 cm to about 250 cm, about 120 cm to about 250 cm, about 130 cm to about 250 cm, about 140 cm to about 250 cm, about 150 cm to about 250 cm, about 160 cm to about 250 cm, about 170 cm to about 250 cm, about 180 cm to about 250 cm, about 190 cm to about 250 cm, about 200 cm to about 250 cm, about 210 cm to about 250 cm, about 220 cm to about 250 cm, about 230 cm to about 250 cm, about 240 cm to about 250 cm, about 250 cm to about 250 cm, about 260 cm to about 250 cm, about 270 cm to about cm to about 250 cm, about 120 cm to about 250 cm, about 130 cm to about 250 cm, about 140 cm to about 250 cm, about 150 cm to about 250 cm, about 5 cm to about 240 cm, about 5 cm to about 230 cm, about 5 cm to about 220 cm, about 5 cm to about 210 cm, about 5 cm to about 200 cm, about 5 cm to about 190 cm, about 5 cm to about 180 cm, about 5 cm to about 170 cm, about 5 cm to about 160 cm, about 5 cm to about 150 cm, about 5 cm to about 140 cm, about 5 cm to about 130 cm, about 5 cm to about 120 cm, about 5 cm to about 110 cm, about 5 cm to about 100 cm, about 5 cm to about 90 cm, about 5 cm to about 80 cm, or about 5 cm to about 75 cm.

[0045] In one or more embodiments, a portion of one or both major surfaces includes a convex shape, and the convex shape has an R' in the range of about 37.5 mm to about 500 mm. In some embodiments having a convex surface, the substrate may have a thickness of 0.4 mm and R' may be in the range of about 100 mm to about 200 mm, about 125 mm to about 200 mm, about 150 mm to about 200 mm, about 175 mm to about 200 mm, about 100 mm to about 175 mm, about 100 mm to about 150 mm, or about 100 mm to about 125 mm. In some embodiments having a convex surface, the thickness of the substrate may be 0.55 mm and R' may range from about 150 mm to about 250 mm, about 175 mm to about 250 mm, about 200 mm to about 250 mm, about 225 mm to about 250 mm, about 150 mm to about 225 mm, about 150 mm to about 200 mm, or about 150 mm to about 175 mm. In some embodiments having a convex surface, the thickness of the substrate may be 0.7 mm and R' may range from about 200 mm to about 300 mm, about 225 mm to about 300 mm, about 250 mm to about 300 mm, about 275 mm to about 300 mm, about 200 mm to about 275 mm, about 200 mm to about 250 mm, or about 200 mm to about 225 mm. In some embodiments having a convex surface, the thickness of the substrate may be 1.1 mm and R' may range from about 350 mm to about 450 mm, about 375 mm to about 450 mm, about 300 mm to about 450 mm, about 325 mm to about 450 mm, about 350 mm to about 425 mm, about 350 mm to about 400 mm, or about 350 mm to about 375 mm. In some embodiments having a convex surface, the thickness of the substrate may be 1.3 mm and R' may range from about 450 mm to about 550 mm, about 475 mm to about 550 mm, about 400 mm to about 550 mm, about 425 mm to about 550 mm, about 450 mm to about 525 mm, about 450 mm to about 500 mm, or about 450 mm to about 475 mm.

[0046] In one or more embodiments, a portion of one or both major surfaces includes a concave shape, and the concave shape has an R' (maximum radius of curvature) in the range of about 20 mm to about 500 mm. In some embodiments having a concave surface, the substrate may have a thickness of 0.4 mm and R' may be in the range of about 15 mm to about 100 mm, about 30 mm to about 100 mm, about 50 mm to about 100 mm, about 75 mm to about 100 mm, about 15 mm to about 75 mm, about 15 mm to about 50 mm, or about 15 mm to about 30 mm. In some embodiments having a concave surface, the substrate may have a thickness of 0.55 mm and R' may range from about 20 mm to about 150 mm, about 40 mm to about 150 mm, about 50 mm to about 150 mm, about 75 mm to about 150 mm, about 20 mm to about 125 mm, about 20 mm to about 100 mm, or about 20 mm to about 75 mm. In some embodiments having a concave surface, the substrate may have a thickness of 0.7 mm and R' may range from about 25 mm to about 175 mm, about 50 mm to about 175 mm, about 75 mm to about 175 mm, about 100 mm to about 175 mm, about 150 mm to about 175 mm, about 25 mm to about 150 mm, about 25 mm to about 125 mm, about 25 mm to about 100 mm, or about 25 mm to about 75 mm. In some embodiments having a concave surface, the substrate may have a thickness of 1.1 mm and R' may range from about 40 mm to about 225 mm, about 50 mm to about 225 mm, about 75 mm to about 225 mm, about 100 mm to about 225 mm, about 150 mm to about 225 mm, about 40 mm to about 200 mm, about 40 mm to about 175 mm, about 40 mm to about 150 mm, or about 40 mm to about 100 mm. In some embodiments having a concave surface, the substrate may have a thickness of 1.3 mm and R' may range from about 150 mm to about 250 mm, about 175 mm to about 250 mm, about 200 mm to about 250 mm, about 225 mm to about 250 mm, about 150 mm to about 225 mm, about 150 mm to about 200 mm, or about 150 mm to about 175 mm.

[0047] In some embodiments, the cold-formed glass substrate is strengthened (prior to cold-forming). For example, the glass substrate may be strengthened by one or more of thermal strengthening, chemical strengthening, mechanical strengthening, or a combination thereof. In some embodiments, the strengthened glass substrate has a compressive stress (CS) layer that extends from the surface of the substrate to a compressive stress depth (or depth of compressive stress layer or DOL). The compressive depth is the depth at which compressive stress switches to tensile stress. The region within the glass substrate that exhibits tensile stress is often referred to as the central tension or CT layer.

[0048] As used herein, "thermally strengthened" refers to a glass substrate that has been heat treated to improve the strength of the substrate. In a thermally strengthened glass substrate, the CS layer is formed by heating the substrate to an elevated temperature above the glass transition temperature (i.e., at or near the softening point of the glass) and then cooling the surface region of the glass more rapidly than the interior region of the glass. The difference in cooling rate between the surface and interior regions results in a residual CS layer on the surface.

[0049] Factors that influence the degree of surface compression caused by the thermal strengthening process include air-cooling temperature, volume, and other variables that result in a surface compression of at least 10,000 pounds per square inch (psi) (about 69 MPa). In a chemically strengthened glass substrate, the replacement of smaller ions with larger ions at a temperature below the temperature at which the glass network can relax results in a distribution of ions across the surface of the glass, which creates a stress profile. The larger volume of incoming ions results in a CS layer extending from the surface and a CT layer in the center of the glass.

[0050] Chemical strengthening can be accomplished by an ion exchange process that includes immersing the glass substrate in a molten salt bath for a predetermined period of time such that ions at or near the surface of the glass substrate are exchanged with larger metal ions from the molten salt bath. In some embodiments, the temperature of the molten salt bath is about 375° C. to about 450° C., and the predetermined period of time is in the range of about 4 to about 8 hours. In one example, sodium ions in the glass substrate are exchanged with potassium ions from a salt bath, such as a potassium nitrate salt bath, but other alkali metal ions with larger atomic radii, such as rubidium or cesium, may exchange for the smaller alkali metal ions in the glass. In another example, lithium ions in the glass substrate are exchanged with potassium and / or sodium ions from a molten salt bath that may include potassium nitrate, sodium nitrate, or a combination thereof, but other alkali metal ions with larger atomic radii, such as rubidium or cesium, may exchange for the smaller alkali metal ions in the glass. In some embodiments, the smaller alkali metal ions in the glass substrate are exchanged with Ag ions from a salt bath, such as a potassium nitrate salt bath, but other alkali metal ions with larger atomic radii, such as rubidium or cesium, may exchange for the smaller alkali metal ions in the glass. + ions. Similarly, other alkali metal salts, such as, but not limited to, sulfates, phosphates, halides, etc., may be used in the ion exchange process. The glass substrate may be immersed in a single bath or multiple successive baths, which may have the same or different compositions and / or temperatures. In some embodiments, such immersions in multiple baths may be for different durations.

[0051] In mechanically strengthened glass substrates, the CS layer arises due to the mismatch of thermal expansion coefficients between portions of the glass substrate.

[0052] For tempered glass substrates, the DOL can be approximated as follows (Equation 1): CS ≒ (CS × DOL) / (Thickness - (2 × DOL)) (1) is related to the CT value by: where thickness is the total thickness of the tempered glass substrate. Unless otherwise specified, CT and CS are expressed herein in megapascals (MPa), whereas thickness and DOL are expressed in millimeters or micrometers. Unless otherwise specified, CS values ​​are values ​​measured at the surface and CT values ​​are tensile stress values ​​(as determined by Equation 1). CS and CT values ​​given herein are given as absolute values.

[0053] In some embodiments, the tempered cold-formed glass substrate may have a surface CS of 300 MPa or more, e.g., 400 MPa or more, 450 MPa or more, 500 MPa or more, 550 MPa or more, 600 MPa or more, 650 MPa or more, 700 MPa or more, 750 MPa or more, or 800 MPa or more. In some embodiments, the surface CS is the maximum CS of the cold-formed glass substrate. The tempered cold-formed glass substrate may have a DOL of 15 micrometers or more, 20 micrometers or more (e.g., 25, 30, 35, 40, 45, 50 micrometers or more). In one or more embodiments, the tempered cold-formed glass substrate may have a maximum CT value of 10 MPa or more, 20 MPa or more, 30 MPa or more, 40 MPa or more (e.g., 42 MPa, 45 MPa, or 50 MPa or more), but less than 100 MPa (e.g., 95, 90, 85, 80, 75, 70, 65, 60, 55 MPa or less). In one or more particular embodiments, the tempered cold-formed glass substrate has one or more of the following: a surface CS of greater than 500 MPa, a DOL of greater than 15 micrometers, and a maximum CT of greater than 18 MPa.

[0054] The CS and DOL can be determined by a surface stress measuring instrument such as the commercially available FSM-6000 instrument manufactured by Orihara Manufacturing Co., Ltd. (Tokyo, Japan). Surface stress measurement relies on precise measurement of the stress optical coefficient (SOC), which is related to the birefringence of the glass. The SOC is then measured by methods known in the art such as the fiber and four-point bend method and the bulk cylinder method described in ASTM standard C770-98 (2013), entitled "Standard Test Method for Measurement of Glass Stress-Optical Coefficient," both of which are incorporated herein by reference in their entirety.

[0055] The material of the glass substrate may vary. The glass substrate used to form the articles described herein may be amorphous or crystalline. In this regard, the use of the term "glass" is intended to be general and encompass materials that are not strictly amorphous. Amorphous glass substrates according to some embodiments may be selected from soda-lime glass, alkali aluminosilicate glass, alkali-containing borosilicate glass, and alkali aluminoborosilicate glass. Examples of crystalline glass substrates include glass ceramics, sapphire, or spinel. Examples of glass ceramics include Li2O·Al2O3·SiO2-based (i.e., LAS-based) glass ceramics, MgO·Al2O3·SiO2-based (i.e., MAS-based) glass ceramics, mullite, spinel, α-quartz, β-quartz solid solution, petalite, lithium disilicate, β-spodumene, nepheline, and glass ceramics containing one or more crystalline phases of alumina.

[0056] Glass substrates may be provided using a variety of different processes. For example, exemplary glass substrate forming processes include float glass and down-draw processes such as fusion draw and slot draw. Glass substrates prepared by float glass processes can be characterized by a smooth surface and uniform thickness created by floating molten glass on a bed of molten metal, typically tin. In an exemplary process, molten glass dispensed onto the surface of a molten tin bed forms a floating glass ribbon. As this glass ribbon flows along the tin bath, its temperature gradually decreases until the glass ribbon solidifies into a solid glass substrate that is lifted from the tin onto rollers. Once away from the bath, the glass substrate can be further cooled and annealed to reduce internal stresses.

[0057] The downdraw process produces glass substrates of uniform thickness with relatively pristine surfaces. A pristine surface with minimal contact has higher initial strength, since the average bending strength of the glass substrate is controlled by the amount and size of surface scratches. Downdrawn glass substrates may be drawn into sheets having thicknesses of less than about 2 millimeters. Moreover, downdrawn glass substrates have very flat and smooth surfaces that can be used in end applications without costly grinding and polishing.

[0058] The fusion draw process, for example, employs a drawing tank having a passageway for receiving molten glass raw material. The passageway has weirs open at the top along the length of the passageway on either side of the passageway. When the passageway is filled with molten material, the molten glass spills over the weirs. The molten glass flows down the exterior surface of the drawing tank as two flowing glass films due to gravity. These exterior surfaces of the drawing tank extend downward and inward to meet at a lower edge of the drawing tank. The two flowing glass films meet at this edge and fuse to form a single flowing glass sheet. The fusion draw process offers the advantage that because the two glass films flowing over the passageway fuse together, the exterior surface of the resulting glass sheet does not come into contact with any part of the apparatus. Thus, the surface properties of the glass sheet formed by the fusion draw process are not affected by such contact.

[0059] The slot draw process differs from the fusion draw process in that molten raw glass is provided to a draw tank that has an open slot at the bottom with a nozzle extending the length of the slot. The molten glass flows through the slot / nozzle and is drawn downward as a continuous sheet to the annealing area.

[0060] In one or more embodiments, the article comprises a glass substrate. In one or more embodiments, the article may comprise a second glass substrate. In such embodiments, the second glass substrate forms a laminate with the cold-formed glass substrate. In one or more embodiments, the second glass substrate is cold-formed to have the same curved or non-planar shape as the cold-formed glass substrate. In some embodiments, the glass substrates may be separated by an interlayer, and thus, a laminate according to some embodiments comprises at least two glass substrates bonded together by an interlayer. In such embodiments, one major surface of the cold-formed glass substrate is coupled to the non-planar rigid support structure, and an opposite major surface of the cold-formed glass substrate is in contact with an interlayer, which may be disposed between the cold-formed glass substrate and the second glass substrate. Examples of suitable interlayers include poly(vinyl butyral) (PVB), ethylene vinyl acetate (EVA), polyvinyl chloride (PVA), ionomers, and thermoplastic polyurethanes (TPUs). This second glass substrate can be reinforced (chemically, thermally, and / or mechanically) as previously described.

[0061] The second glass substrate may face a user, while the cold-formed glass substrate may face in the opposite direction. For example, if the article is used in a vehicle interior, appliance, or architectural component, the second glass substrate may form a user interface. In vehicle applications, such as automobile glazing, the cold-formed glass substrate may be exposed to the interior of the vehicle or automobile, and the second glass substrate may face the exterior environment of the automobile, or vice versa. In automobile interiors, the cold-formed glass substrate is not exposed, but faces onto an underlying support (e.g., display, dashboard, center console, instrument panel, seat back, seat front, floor panel, door panel, pillar, armrest, etc.) (and rigid non-planar support structures), and the second glass substrate is exposed to the interior of the vehicle or automobile, and thus to the user. In architectural applications, the second glass substrate is exposed to the interior of a building, room, or furniture, and the first layer faces the exterior environment of the building, room, or furniture.

[0062] Some embodiments of the articles disclosed herein are useful for automotive interiors because such articles provide curved covers that fit curved displays. To fit curved displays, the covers should closely conform to the shape of the curved display to ensure optimal fit and allow high quality viewing. It is also desirable to provide covers that are high optical quality and cost-effective. Thermoforming the cover to a precise shape presents challenges in obtaining the desired shape. Moreover, when glass is used, it is challenging to minimize the adverse effects (e.g., distortion and markings) of heating the cover to its softening point. The concept of cold forming addresses these challenges and allows the use of glass, but creates new challenges in maintaining the cold formed shape and providing sufficient support to provide rigidity. The ability to cold form thin glass substrates to defined shapes presents an opportunity for a high quality, cost-effective solution.

[0063] Embodiments of the articles described herein include a cold-formed glass substrate supported by a non-planar rigid support structure such that the cold-formed glass substrate maintains a curved shape while minimizing stresses induced by cold-forming. In embodiments in which the article incorporates a display, the surface of the cold-formed glass substrate conforms to the shape of the display.

[0064] In terms of high quality, the articles described herein allow for excellent conformance to curved displays and exhibit high optical quality. Cold-formed glass substrates may have flexible features that can accommodate curved displays. Cold-forming maintains the high quality of flat glass substrates that may be compromised during the thermoforming process. This concept also allows for excellent stress management, minimizing cold-forming stresses by providing support over a large area.

[0065] Additionally, the articles described herein are compatible with coatings and surface treatments, which are often desirable. More specifically, the articles described herein can easily incorporate high-quality coatings and surface treatments on curved substrate surfaces, where such coatings are typically limited to flat portions. For example, AR and AG coatings and AG surfaces will improve the visibility of displays in a variety of challenging ambient lighting conditions; however, high-quality multi-layer AR coating processes are typically performed utilizing vapor deposition or sputtering coating techniques. These techniques are typically limited to vapor deposition on flat surfaces due to the nature of the process. Providing these coatings on curved, three-dimensional surfaces is difficult, further increasing the cost of the process. According to one or more embodiments, coatings and / or surface treatments may be applied to the glass substrate prior to cold forming, and then cold forming the coated and / or treated glass substrate avoids problems associated with thermoforming (i.e., damage to the coatings and / or surface treatments due to handling and / or high processing temperatures). In one or more embodiments, the coatings may be ink coatings, anti-reflective coatings, anti-glare coatings, and / or any other suitable coatings. In one or more embodiments, the surface treatment may include an anti-glare surface, a tactile surface that provides tactile feedback, recesses and / or ridges that provide indicia, and the like. Although decorative ink coatings can be applied to various shaped / curved surfaces, the process of applying these coatings to flat surfaces is simpler, better established, and more cost-effective. Additionally, surface treatments (typically formed by etching processes) are also typically applied to flat surfaces. Thus, the articles described herein allow for the application of coatings and / or surface treatments onto a substantially flat glass substrate, which is then cold-formed into a curved shape. The cold-forming process does not degrade the coating or surface treatment in the same manner as a thermal process.

[0066] Another aspect of the present disclosure relates to a method of forming the articles described herein. In one or more embodiments, the method comprises transforming a substantially flat glass substrate (such as a glass substrate as described herein), which may optionally include a coating or surface treatment as described above, into a cold-formed glass substrate that is sufficiently supported to exhibit and maintain a desired shape. In one or more embodiments, the method comprises cold-forming the substantially flat glass substrate into a shape that conforms to or approximates the shape of a curved display.

[0067] In some embodiments, a die is used to cold-form the glass substrate into a desired shape. As used herein, a die includes a structure used to impart a desired shape to a glass substrate and to attach a non-planar rigid support structure to the glass substrate. The die itself is not part of the finished article, but rather may be used repeatedly to create many finished articles. In one or more embodiments, the term "die" refers to an apparatus used to impart a desired shape to an object. In such embodiments, a "die" includes at least two parts, a first part and a second part, that can be pressed together to impart a desired shape to a flexible object disposed between the first and second parts. In one or more embodiments, while the die is imparting the desired shape, the die is also used to bond a non-planar rigid support structure to the cold-formed glass substrate. Once the non-planar rigid support structure is bonded to the cold-formed glass substrate, the die can be removed and the non-planar rigid support structure will maintain the desired shape of the cold-formed glass substrate. The die may be reused multiple times to repeatably and accurately produce the same shape on multiple articles comprising a non-planar rigid support structure bonded to a cold-formed glass substrate.

[0068] In some embodiments, an injection molding process is used to transform the substantially flat glass substrate described herein into a cold-formed glass substrate having a curved shape. In one or more embodiments, a support structure is injection molded onto a major surface of the glass substrate. In one or more embodiments, the glass substrate may be cold-formed prior to injection molding the support structure. The injection-molded support structure forms a non-planar rigid support structure that holds the cold-formed glass substrate in a defined shape. In some embodiments, injection molding is used to form the non-planar rigid support structure bonded to the surface of the cold-formed glass substrate. Any suitable injection molding process and material may be used. For example, polyvinyl chloride (PVC) and thermoplastic polyurethane (TPU) are two common materials used to injection mold the non-planar rigid support structure. In some embodiments, reaction injection molding (RIM) may be used. Common materials used for RIM include polyurethane, polyurea, polyisocyanurate, polyester, polyphenol, polyepoxide, and nylon 6. Different materials will have different operating parameters. Equipment, operating parameters (e.g., pressure, flow rate, temperature), and mold designs will vary for different materials. Typical injection molding temperatures can range from 300°F to 450°F (about 150°C to about 230°C), and typical processing pressures can range from 200 psi to greater than 1000 psi (about 1.38 MPa to greater than about 6.9 MPa); however, any suitable process parameters may be used.

[0069] In some embodiments, a direct bonding process is used to cold-form a substantially flat glass substrate and bond it to a non-planar rigid support structure, where the non-planar rigid support structure provides rigidity to the cold-formed glass substrate and holds the cold-formed glass substrate in a desired curved or non-planar shape.

[0070] A variety of techniques other than direct bonding or injection molding may be used to obtain the articles described herein.

[0071] Embodiments of the process are illustrated in drawings, which are not necessarily drawn to scale: different parts of the various drawings may not be drawn to scale relative to other parts in order to better illustrate concepts.

[0072] FIG. 1 illustrates an injection molding die 110 designed with a particular desired curved shape, and a flat glass substrate 120 having opposing major surfaces 121 and 122. The injection molding die 110 includes two parts, a first die part 111 and a second die part 112. The first and second die parts 111 and 112 have curved shapes corresponding to those desired for the cold-formed glass substrate. The first die part 111 includes a recess 113 configured to receive molten material as part of the injection molding process. The flat glass substrate 120 is disposed between the first and second die parts 111 and 112, but has not yet been cold-formed.

[0073] Figure 2 shows the die 110 of Figure 1 cold forming a substantially flat glass substrate 120 into a non-planar shape by forcing first and second die parts 111 and 112 together while the glass substrate 120 is disposed therebetween. In Figure 2, the recess 113 is left empty.

[0074] FIG. 3 shows the die of FIG. 2 after material has been injection molded into recesses 113 to form a non-planar rigid support structure 130 that is bonded to the back surface of the cold-formed glass substrate 120.

[0075] FIG. 4 shows the die of FIG. 3 and the resulting article after the first and second die parts 111 and 112 are separated. The resulting article is a cold-formed glass substrate 120 bonded to a non-planar rigid support structure 130. The cold-formed glass substrate 120 maintains the curvature imparted by the first and second die parts 111 and 112 due to the rigidity of the non-planar rigid support structure 130. Each of the opposing major surfaces (first major surface 121 and second major surface 122) is under tension or compression depending on the orientation of the curvature. In FIG. 4, the first major surface 121 at a first location 121A adjacent the non-planar rigid support structure 130 is under tension, while the second major surface 122 at a second location 122A adjacent the non-planar rigid support structure 130 is under compression. Thus, second major surface 122 at second location 122A exhibits a greater surface compressive stress than first major surface 121 at first location 121A. This is shown even though substrate 120 exhibits surface compressive stress prior to being strengthened and cold formed as described herein.

[0076] 5 shows the cold-formed glass substrate 120 bonded to the non-planar rigid support structure 130 of FIG. 4 with additional adhesive 140 added along the interface where the cold-formed glass substrate 120 is bonded to the non-planar rigid support structure 130. The additional adhesive 140 is optional and may help improve the bond between the cold-formed glass substrate 120 and the non-planar rigid support structure 130. The additional adhesive 140 may be applied without a mold, although the overall structure still benefits from the precision gained by using a mold to bond the cold-formed glass substrate 120 to the non-planar rigid support structure 130.

[0077] FIG. 6 shows a perspective view of a cold-formed glass substrate 120 bonded to a non-planar rigid support structure 130.

[0078] Figure 7 shows a top view of a cold-formed glass substrate 120 bonded to a non-planar rigid support structure 130. The curvature is not visible due to the viewing angle. Line 7-7' shows the cross section shown in Figures 1-5. Figures 8-11 show similar cross sections.

[0079] FIG. 8 shows a direct bonding die 810 designed with a particular desired curved shape, and a flat glass substrate 820. The direct bonding die 810 comprises two parts, a first die part 811 and a second die part 812. The first and second die parts 811 and 812 have a curved shape corresponding to that desired for the cold formed glass substrate. The first die part 811 includes a recess 813 configured to receive a non-planar rigid support structure 830 formed by a separate process. The non-planar rigid support structure 830 may be formed by any suitable process, such as injection molding. The non-planar rigid support structure 830 is inserted into the recess 813 in the first die part 811. If desired, an adhesive layer 831 may be applied to the non-planar rigid support structure 830 by any suitable process, either before or after the non-planar rigid support structure 830 is inserted into the recess 813. A flat glass substrate 820 is disposed between the first and second die parts 811 and 812, but has not yet been cold formed.

[0080] 9 shows the die 810 of FIG. 8 cold forming the glass substrate 820 into a non-planar shape and bonding a non-planar rigid support structure to the cold formed glass substrate. The cold forming is performed by forcing the first and second die parts 811 and 812 together while the glass substrate 820 is disposed therebetween. This forcing of the first and second die parts 811 and 812 together brings the non-planar rigid support structure 830 into contact with the glass substrate 820 and bonds the non-planar rigid support structure 830 to the glass substrate 820. The recesses 813 ensure precise positioning of the non-planar rigid support structure 830 relative to the glass substrate 820.

[0081] Figure 10 shows the die 810 of Figure 9 and the resulting article after the die 810 has been pulled apart. The resulting article is a cold-formed glass substrate 820 bonded to a non-planar rigid support structure 830. Optionally, an adhesive layer 831 may aid in such bonding. The cold-formed glass substrate 820 maintains the curvature imparted by the first and second die parts 811 and 812 due to the rigidity of the non-planar rigid support structure 830.

[0082] 11 shows the cold-formed glass substrate 820 bonded to the non-planar rigid support structure 830 of FIG. 10 with additional adhesive 840 added along the interface where the cold-formed glass substrate 820 is bonded to the non-planar rigid support structure 830. The additional adhesive 840 is optional and may help improve the bond between the cold-formed glass substrate 820 and the non-planar rigid support structure 830. The additional adhesive 840 may be applied without a mold, but the overall structure still benefits from the precision gained by using a mold to bond the cold-formed glass substrate 820 to the non-planar rigid support structure 830.

[0083] Figure 12 shows a process flow diagram corresponding to the processes shown in Figures 1 to 5. The following steps are performed in order:

[0084] Step 1210 - The die 110 is used to cold form the glass substrate 120 into the desired shape.

[0085] Step 1220 - Forming a rigid support structure 130 in the recess 113 and bonding it to the cold-formed glass substrate 120 by injection molding.

[0086] Step 1230-Remove the die 110.

[0087] Step 1240 - If necessary, additional adhesive 140 is applied.

[0088] Figure 13 shows a process flow diagram corresponding to the processes shown in Figures 8 to 10. The following steps are performed in order:

[0089] Step 1310 - Placing a rigid support structure 830 within the recess 113.

[0090] Step 1320 - Die 810 is used to cold form glass substrate 820 into a desired shape while bonding rigid support structure 830 directly to the cold formed glass substrate 820.

[0091] Step 1330-Remove the die 810.

[0092] Step 1340 - If necessary, additional adhesive 840 is applied.

[0093] FIG. 14 illustrates a die 1410 having a first die part 1411 and a second die part 1412. The first die part 1411 includes a recess 1413. As can be seen, both the first die part 1411 and the second die part 1412 include ridges 1414 that are useful for precisely positioning the glass substrate 1420 relative to the first and second die parts 1411 and 1412. This allows for precise placement of the rigid support structure relative to the glass substrate 1420, whether by injection molding, direct bonding, or other die based processes. In some embodiments, the ridges may be present on only one of the first die part 1411 and the second die part 1412. In some embodiments, the ridges 1414 may be absent.

[0094] FIG. 15 illustrates an example of an automotive interior display component, including, but not limited to, an instrument cluster, console display, or center stack display having a monitor, that may be manufactured in some embodiments. A cold-formed glass substrate is bonded to a rigid support structure 1530. The cold-formed glass substrate 1510 includes an open area 1550 that is not in direct contact with the non-planar rigid support structure 1530. The open area 1550 has a curved shape that is maintained by the non-planar rigid support structure 1530. A monitor or display may be laminated to the open area 1550. The rigid support structure 1530 may be designed to be attached to other portions of the automobile (dashboard, center console, instrument panel, seat back, seat front, floor panel, door panel, pillar, armrest, etc.) or architectural applications (walls, windows, wall panels, furniture, appliances, doors, etc.). The embodiment of FIG. 15 may be formed by any of the various processes disclosed herein, including the embodiment of FIG. 12 and the embodiment of FIG. 13.

[0095] FIG. 16 shows a top view of a cold-formed glass substrate 120 bonded to a non-planar rigid support structure 130. The curvature is not visible due to the viewing angle. The interior of the non-planar rigid support structure 130 defines an open region 1610 of the cold-formed glass substrate that is not in direct contact with the non-planar rigid support structure. The open region 1610 has a curved shape that is maintained by the non-planar rigid support structure. A display 1620 is attached to the cold-formed glass substrate 120. The display 1620 is visible through the open region 1610 of the cold-formed glass substrate 120.

[0096] In some embodiments, the glass substrate is cold-formed into a curved shape, which may include a developable surface or a complex developable surface. A force to hold the cold-formed glass substrate in such a shape is applied and maintained across different portions or the entirety of a major surface of the cold-formed glass substrate that is coupled to the non-planar rigid support structure. In one or more embodiments, the force is applied and maintained at multiple non-planar points until the coupling is sufficient to maintain the shape. For example, in the embodiment of FIGS. 1-5, the injection molding die 110 can be maintained in the position shown in FIG. 3 until the material of the non-planar rigid support structure 130 is sufficiently solidified and bonded to the glass substrate 120 to maintain the cold-formed shape of the glass substrate 120 without the injection molding die 110. Similarly, in the embodiment shown in Figures 8-10, the direct bonding die 810 can be maintained in the position shown in Figure 9 until the adhesive layer 831 has sufficiently cured and the glass substrate 820 is sufficiently bonded to the rigid support structure 830 to maintain the cold-formed shape of the glass substrate 820 even in the absence of the direct bonding die 810.

[0097] A force would be "maintained" in an area by applying the force over spaced or periodic portions of that area. For example, the direct bonding die 810 would contact the glass substrate 820 everywhere except where there is a rigid support structure 830, as shown in Figure 9. Alternatively, such contact could be gapped, in which case the contact would be maintained at a point sufficient to hold the glass substrate 820 in place until the adhesive layer 831 can cure.

[0098] Complications will arise if force is not applied and maintained across different regions of a complex developable surface. For example, it will be difficult to bond a glass substrate to a rigid support structure with a complex developable surface if a single roller is used instead of using a die process or other process that applies and maintains force. Poor yields are expected, to say the least. Without being bound by theory, there is an internal stress in cold-formed glass. In the absence of external constraints, this stress will drive the glass to its original shape.

[0099] For example, as shown in FIG. 17, a single roller 1790 is used to press an initially planar glass substrate 1720 against a rigid support structure 1730 with a complex developable surface - three adjacent cylindrical surfaces, with the middle surface having an opposite concavity to the outer two surfaces. On the rigid support structure 1730, there is an adhesive layer 1731. As the roller 1790 passes from left to right, stresses in the cold-formed glass substrate 1720 to the left of the roller 1790 tend to return the glass substrate 1720 to a planar shape, as indicated by arrow 1780. These stresses may result in delamination or low yield. For simple shapes, this phenomenon may not exist (e.g., a flat surface) or may be addressed in other ways (e.g., when glass is glued to the inside of a cylinder with adhesive, slight compressive stresses across the plane of the glass will everywhere press the glass against the adhesive as the adhesive hardens). However, for complex developable surfaces, especially those having different but distinct areas of concavity, application and maintenance of the force is preferred.

[0100] Another aspect relates to a vehicle interior system that includes a base including a non-planar rigid support structure, and a cold-formed glass substrate (or a laminate including a cold-formed substrate, as described herein) disposed on the non-planar support structure. In one or more embodiments, the base includes a display disposed between the non-planar support structure and the cold-formed substrate (or a laminate including a cold-formed substrate). The display can be curved. In one or more embodiments, the cold-formed glass substrate has a thickness of 1.5 mm or less (or from about 0.4 mm to about 1.3 mm).

[0101] In one or more embodiments, the cold-formed glass substrate used in such vehicle interior systems includes a glass surface, all points of which have a Gaussian curvature (GC) equal to zero (GC=K×K, where K and K are the principal curvatures defined as K=1 / R' and K=1 / R"), one of K and K is non-zero, R' is the maximum radius of curvature, and R" is the minimum radius of curvature. The glass surface may be one or both of the opposing major surfaces of the cold-formed glass substrate.

[0102] In one or more embodiments, the base includes one of a center console, a dashboard, an armrest, a pillar, a seat back, a floorboard, a headrest, a door panel, and a steering wheel. The vehicle may be one of an automobile, a watercraft, and an aircraft.

[0103] Embodiments of the present disclosure are described in detail herein with reference to the embodiments thereof as illustrated in the accompanying drawings, in which like reference numerals are used to indicate identical or functionally similar elements. References to "one embodiment," "an embodiment," "several embodiments," "particular embodiments," and the like indicate that the described embodiments may include a particular feature, structure, or characteristic, but all embodiments may not necessarily include that particular feature, structure, or characteristic. Moreover, such phrases do not necessarily refer to the same embodiment. Furthermore, when a particular feature, structure, or characteristic is described with respect to one embodiment, it is contemplated that it is within the knowledge of one of ordinary skill in the art to affect such feature, structure, or characteristic with respect to other embodiments, whether or not expressly described.

[0104] As used herein, "comprising" is an open-ended transitional phrase. The list of elements following the transitional phrase "comprising" is a non-exclusive list, so elements may be present in addition to those specifically recited in the list.

[0105] The following examples are illustrative rather than limiting of the disclosure. Other suitable modifications and adaptations of the variety of conditions and parameters normally encountered in the art and which would be obvious to those skilled in the art are within the spirit and scope of the disclosure.

[0106] Aspect (1) of the present disclosure relates to a method comprising using a die to cold-form a flat glass substrate into a non-planar shape, and using the die to bond the cold-formed glass substrate to a non-planar rigid support structure at a plurality of non-planar points.

[0107] Aspect (2) of the present disclosure relates to the method of aspect (1), wherein the die is an injection molding die and the bonding step is performed by injection molding a non-planar rigid support structure onto the cold-formed glass substrate while the die holds the cold-formed glass substrate in the non-planar shape.

[0108] An aspect (3) of the present disclosure relates to the method of aspect (1), wherein the non-planar rigid support structure is formed prior to the bonding step, and the bonding step includes using the die to directly bond a cold-formed glass substrate onto the non-planar rigid support structure.

[0109] An aspect (4) of the present disclosure relates to the method of aspect (3), further comprising the step of disposing a non-planar rigid support structure within the recess of the die prior to the bonding step.

[0110] An embodiment (5) of the present disclosure relates to the method of embodiment (3) or embodiment (4), further comprising the step of applying an adhesive to at least one of the non-planar rigid support structure and the flat glass substrate prior to the bonding step.

[0111] An embodiment (6) of the present disclosure relates to the method of any one of embodiments (1) to (5), further comprising, after the bonding step, applying an adhesive to an edge of the interface between the cold-formed glass substrate and the non-planar rigid support structure.

[0112] An embodiment (7) of the present disclosure relates to the method of any one of embodiments (1) to (6), further comprising the step of applying a coating to the flat glass substrate prior to the cold forming step.

[0113] An embodiment (8) of the present disclosure relates to the method of embodiment (7), wherein the coating is an ink coating.

[0114] An embodiment (9) of the present disclosure relates to the method of embodiment (7), wherein the coating is an antireflective coating.

[0115] Aspect (10) of the present disclosure relates to the method of any one of aspects (7) to (9), wherein the cold-formed glass substrate includes an open area that is not in direct contact with the non-planar rigid support structure after being bonded to the non-planar rigid support structure, the open area having a curved shape maintained by the non-planar rigid support structure.

[0116] An embodiment (11) of the present disclosure relates to the method of embodiment (10), further comprising attaching a display to at least one of the cold-formed glass substrate and the non-planar rigid support structure such that the display is visible through the open area of ​​the cold-formed glass substrate.

[0117] An embodiment (12) of the present disclosure relates to the method of any one of the embodiments (1) to (11), wherein the temperature of the glass substrate does not exceed 800° F. (about 427° C.) during or after the cold forming step.

[0118] An embodiment (13) of the present disclosure relates to the method of any one of embodiments (1) to (12), wherein the glass substrate comprises tempered glass.

[0119] An embodiment (14) of the present disclosure relates to the method of any one of embodiments (1) to (13), wherein the cold-formed glass substrate has opposing major surfaces, one of the major surfaces being free of a non-planar rigid support structure.

[0120] Embodiment (15) relates to an article comprising: a cold-formed glass substrate including a non-planar shape and a first major surface and an opposing second major surface, the first and second major surfaces having different surface compressive stresses; and a non-planar rigid support structure bonded to the first major surface at a plurality of non-planar points.

[0121]

[0023] Aspect (16) relates to the article of aspect (15), wherein the non-planar rigid support structure is injection molded onto the cold-formed glass substrate while the cold-formed glass substrate includes the non-planar shape.

[0122] Example (17) relates to the article of example (15), wherein the cold-formed glass substrate has a second major surface opposite the first major surface, the second major surface including a coating or surface treatment.

[0123] An embodiment (18) of the present disclosure relates to the article of any one of embodiments (15) to (17), further comprising an edge adhesive applied to an edge of the interface between the cold-formed glass substrate and the non-planar rigid support structure.

[0124] Embodiment (19) of the present disclosure relates to the article of any one of embodiments (15) to (18), wherein the cold-formed glass substrate includes an open area that is not in direct contact with a non-planar rigid support structure, the open area having a curved shape maintained by the non-planar rigid support structure.

[0125]

[0023] Aspect (20) relates to the article of aspect (19), further comprising a display attached to at least one of the cold-formed glass substrate and the non-planar rigid support structure, the display being visible through the cold-formed glass substrate.

[0126] An embodiment (21) of the present disclosure relates to the article of any one of embodiments (15) to (20), further comprising a coating disposed on the cold-formed glass substrate.

[0127] An embodiment (22) of the present disclosure relates to the article of embodiment (21), wherein the coating is an ink coating.

[0128] An embodiment (23) of the present disclosure relates to the article of embodiment (21), wherein the coating is an antireflective coating.

[0129] Aspect (24) of the present disclosure relates to an article comprising a glass substrate having opposing major surfaces and a curved shape, the opposing major surfaces having different surface stresses, the glass substrate being attached to a rigid support structure having the curved shape, the glass substrate including an open region not in direct contact with the non-planar rigid support structure, the open region having a curved shape maintained by the non-planar rigid support structure.

[0130] Aspect (25) of the present disclosure relates to an article comprising: a non-planar rigid support structure having a complex developable surface; and a cold-formed glass substrate coupled to the non-planar rigid support structure, the cold-formed glass substrate having the complex developable surface.

[0131] Aspect (26) of the present disclosure relates to the article of aspect (25) or aspect (24), further comprising a display attached to at least one of the glass substrate and the non-planar rigid support structure, the display being visible through the open area of ​​the glass substrate.

[0132] An embodiment (27) of the present disclosure relates to the article of any one of embodiments (24) to (26), further comprising a coating disposed on the glass substrate.

[0133] An embodiment (28) of the present disclosure relates to the article of embodiment (27), wherein the coating is an ink coating.

[0134] An embodiment (29) of the present disclosure relates to the article of embodiment (27), wherein the coating is an antireflective coating.

[0135] An embodiment (30) of the present disclosure relates to the article of any one of embodiments (24) to (29), wherein the glass substrate is a chemically strengthened glass substrate.

[0136] An embodiment (31) of the present disclosure relates to the article of any one of embodiments (24) to (30), wherein one major surface is free of the non-planar rigid support structure.

[0137] An embodiment (32) of the present disclosure relates to the article of any one of embodiments (24) to (31), wherein the cold-formed glass substrate has a complex developable surface.

[0138] An aspect (33) of the present disclosure relates to a vehicle interior system including a base having a curved surface and an article comprising a cold-formed glass substrate disposed on the curved surface, the glass substrate having a surface, all points of the surface having a Gaussian curvature (GC) equal to zero (GC=Kmax×Kmin, where Kmax and Kmin are the principal curvatures defined as Kmax=1 / R' and Kmin=1 / R"); one of Kmax and Kmin is non-zero, R' is the maximum radius of curvature, and R" is the minimum radius of curvature.

[0139] An embodiment (34) relates to the vehicle interior system of embodiment (33), wherein the glass substrate has a thickness of about 1.5 mm or less.

[0140]

[0039] Embodiment (35) relates to the vehicle interior system of embodiment (33) or embodiment (34), wherein a portion of the surface has a concave shape, and R' of the concave shape is in the range of about 37.5 mm to about 500 mm.

[0141]

[0036] Embodiment (36) relates to the vehicle interior system of embodiment (33) or embodiment (34), wherein a portion of the surface has a convex shape, and R' of the convex shape is in the range of about 20 mm to about 500 mm.

[0142] An embodiment (37) relates to the vehicle interior system of any one of embodiments (33) to (36), further comprising a display.

[0143] Aspect (38) relates to the vehicle interior system of aspect (37), wherein the display is disposed between the base and the item.

[0144] Aspect (39) relates to the vehicle interior system of aspect (37) or aspect (38), wherein the display is curved.

[0145] An embodiment (40) relates to the vehicle interior system of any one of embodiments (33) to (39), wherein the glass substrate is reinforced.

[0146] While various embodiments have been described herein, they have been presented by way of example only, and not limitation. It will be apparent that adaptations and modifications within the meaning and range of equivalents of the disclosed embodiments are intended based on the teaching and guidance presented herein. Thus, it will be apparent to those skilled in the art that various changes in form and detail can be made in the embodiments disclosed herein without departing from the spirit and scope of the present disclosure. Elements of the embodiments presented herein are not necessarily mutually exclusive and may be interchanged to meet various requirements, as will be recognized by those skilled in the art.

[0147] The embodiments described herein may be combined in any order.

[0148] It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. The breadth and scope of the present disclosure should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.

[0149] Preferred embodiments of the present invention will be described below in detail.

[0150] EMBODIMENT 1 In the method, cold forming a flat glass substrate into a non-planar shape using a die; and using the die to bond the cold-formed glass substrate to a non-planar rigid support structure at a plurality of non-planar points; The method comprising:

[0151] EMBODIMENT 2 the die is an injection molding die, the bonding step is performed by injection molding the non-planar rigid support structure onto the cold-formed glass substrate while the die holds the cold-formed glass substrate in the non-planar shape. 2. The method of embodiment 1.

[0152] EMBODIMENT 3 the non-planar rigid support structure is formed prior to the bonding step; the bonding step includes using the die to directly bond the cold-formed glass substrate onto the non-planar rigid support structure. 2. The method of embodiment 1.

[0153] EMBODIMENT 4 4. The method of embodiment 3, further comprising the step of disposing the non-planar rigid support structure within a recess in the die prior to the bonding step.

[0154] EMBODIMENT 5 5. The method of claim 3 or 4, further comprising applying an adhesive to at least one of the non-planar rigid support structure and the flat glass substrate prior to the bonding step.

[0155] EMBODIMENT 6 6. The method of any one of claims 1 to 5, further comprising, after the bonding step, applying an adhesive to an edge of the interface between the cold-formed glass substrate and the non-planar rigid support structure.

[0156] EMBODIMENT 7 7. The method of any one of claims 1 to 6, further comprising applying a coating to the flat glass substrate prior to the cold forming step.

[0157] EMBODIMENT 8 8. The method of embodiment 7, wherein the coating is an ink coating.

[0158] EMBODIMENT 9 8. The method of embodiment 7, wherein the coating is an antireflective coating.

[0159] EMBODIMENT 10 10. The method of any one of claims 1 to 9, wherein the cold-formed glass substrate includes an open area that is not in direct contact with the non-planar rigid support structure after being bonded to the non-planar rigid support structure, the open area having a curved shape maintained by the non-planar rigid support structure.

[0160] EMBODIMENT 11 11. The method of claim 10, further comprising attaching a display to at least one of the cold-formed glass substrate and the non-planar rigid support structure such that the display is visible through the open area of ​​the cold-formed glass substrate.

[0161] EMBODIMENT 12 12. The method of any one of the preceding claims, wherein the temperature of the glass substrate does not exceed 800°F (about 427°C) during or after the cold forming step.

[0162] EMBODIMENT 13 13. The method of any one of claims 1 to 12, wherein the glass substrate is made of tempered glass.

[0163] EMBODIMENT 14 14. The method of any one of claims 1 to 13, wherein the cold-formed glass substrate has opposing major surfaces, one of the major surfaces being free of the non-planar rigid support structure.

[0164] EMBODIMENT 15 In the case of goods, a cold-formed glass substrate including a non-planar shape and a first major surface and an opposing second major surface, the first and second major surfaces having different surface compressive stresses; a non-planar rigid support structure coupled to the first major surface at a plurality of non-planar points; An article equipped with the above.

[0165] EMBODIMENT 16 16. The article of claim 15, wherein the non-planar rigid support structure is injection molded onto the cold-formed glass substrate while the cold-formed glass substrate comprises the non-planar shape.

[0166] EMBODIMENT 17 16. The article of claim 15, wherein the cold-formed glass substrate has a second major surface opposite the first major surface, the second major surface comprising a coating or surface treatment.

[0167] EMBODIMENT 18 18. The article of any one of claims 15 to 17, further comprising an edge adhesive applied to an edge of an interface between the cold-formed glass substrate and the non-planar rigid support structure.

[0168] EMBODIMENT 19 19. The article of any one of claims 15 to 18, wherein the cold-formed glass substrate includes an open area that is not in direct contact with the non-planar rigid support structure, the open area having a curved shape maintained by the non-planar rigid support structure.

[0169] EMBODIMENT 20 20. The article of claim 19, further comprising a display attached to at least one of the cold-formed glass substrate and the non-planar rigid support structure, the display being visible through the cold-formed glass substrate.

[0170] EMBODIMENT 21 21. The article of any one of claims 15 to 20, further comprising a coating disposed on the cold-formed glass substrate.

[0171] EMBODIMENT 22 22. The article of embodiment 21, wherein the coating is an ink coating.

[0172] EMBODIMENT 23 22. The article of embodiment 21, wherein the coating is an antireflective coating.

[0173] EMBODIMENT 24 1. An article comprising a glass substrate having opposed major surfaces and a curved shape, the opposing major surfaces have different surface stresses; the glass substrate is attached to a rigid support structure having the curved shape; The article, wherein the glass substrate includes an open area that is not in direct contact with the non-planar rigid support structure, the open area having a curved shape maintained by the non-planar rigid support structure.

[0174] EMBODIMENT 25 A non-planar rigid support structure having a complex deployable surface; a cold-formed glass substrate coupled to the non-planar rigid support structure, the cold-formed glass substrate having the complex developable surface; An article equipped with the above.

[0175] EMBODIMENT 26 26. The article of claim 24 or 25, further comprising a display attached to at least one of the glass substrate and the non-planar rigid support structure, the display being visible through an open area of ​​the glass substrate.

[0176] EMBODIMENT 27 27. The article of any one of claims 24 to 26, further comprising a coating disposed on the glass substrate.

[0177] EMBODIMENT 28 28. The article of embodiment 27, wherein the coating is an ink coating.

[0178] EMBODIMENT 29 28. The article of embodiment 27, wherein the coating is an antireflective coating.

[0179] EMBODIMENT 30 30. The article of any one of claims 24 to 29, wherein the glass substrate is a chemically strengthened glass substrate.

[0180] EMBODIMENT 31 31. The article of any one of claims 24 to 30, wherein one major surface is free of the non-planar rigid support structure.

[0181] EMBODIMENT 32 32. The article of any one of claims 24 to 31, wherein the cold-formed glass substrate has a complex developable surface. [Explanation of symbols]

[0182] 110 Injection molding die 111, 811, 1411 First die part 112, 812, 1412 Second die part 113 Recess 120, 820, 1420 glass substrate 121 First main surface 122 Second main surface 130, 830, 1530 Non-Planar Rigid Support Structure 140, 840 Adhesive 810 Direct Bonding Die 831 Adhesive layer 1410 Die 1414 Ridge 1510 Cold-formed glass substrate 1550, 1610 aperture area 1620 Display

Claims

1. 1. A system having an article and a display, The article, a cold-formed glass substrate including a non-planar shape, a first major surface and an opposing second major surface, and having a thickness between the first major surface and the second major surface of greater than or equal to 0.4 mm and less than or equal to 1.3 mm; a non-planar rigid support structure coupled to the glass substrate and configured to hold the glass substrate in a non-planar shape; Equipped with the non-planar rigid support structure is coupled to the first major surface of the glass substrate such that the non-planar rigid support structure holds the cold-formed glass substrate in a non-planar shape even though the first major surface and the opposing second major surface have different surface stresses; the cold-formed glass substrate is the only glass substrate in the article; the cold-formed glass substrate comprises a single sheet of chemically strengthened glass including one or more coatings or surface treatments; the non-planar rigid support structure is a base component of an automotive interior; the base of the interior of the automobile includes a dashboard, a center console, an instrument panel, a seat back, a seat front, a floor panel, a door panel, a pillar, and an armrest; the display is attached to at least one of the cold-formed glass substrate and the non-planar rigid support structure such that the display is visible through the cold-formed glass substrate; The system, wherein the display has touch capabilities.

2. The system of claim 1 , wherein the display is a curved display and the non-planar shape conforms to a shape of the display.

3. The system of claim 1 , wherein the display is laminated to an open area of ​​the first major surface that is not in direct contact with the non-planar rigid support structure.

4. The system of claim 1 , wherein the cold-formed glass substrate has zero Gaussian curvature.

5. The system of claim 1 , wherein the non-planar rigid support structure is formed on and coupled to the first major surface without an adhesive.

6. 5. The system of claim 1 , wherein an outer edge of the non-planar rigid support structure is disposed within a microfacet of the cold-formed glass substrate that extends between the first major surface and the second major surface.

7. 1. A system having an article and a curved display, comprising: The article, a cold-formed glass substrate including a curved shape, a first major surface and an opposing second major surface, and having a thickness between the first major surface and the second major surface of greater than or equal to 0.4 mm and less than or equal to 1.3 mm; a non-planar rigid support structure having a deployable surface bonded to the first major surface of the cold-formed glass substrate; Equipped with the non-planar rigid support structure holds the cold-formed glass substrate in a curved shape even though the first major surface and the opposing second major surface have different surface stresses; the cold-formed glass substrate is the only glass substrate in the article; the cold-formed glass substrate comprises a single sheet of chemically strengthened glass including one or more coatings or surface treatments; the non-planar rigid support structure is a base component of an automotive interior; the base of the interior of the automobile includes a dashboard, a center console, an instrument panel, a seat back, a seat front, a floor panel, a door panel, a pillar, and an armrest; the curved display is laminated to an area of ​​the first major surface that is not in direct contact with the non-planar rigid support structure; the cold-formed glass substrate is bent to form a curvature, the shape of the curvature conforming to the shape of the curved surface of the curved display in the region; The system wherein the curved display has touch capabilities.

8. The system of claim 7 , wherein the cold-formed glass substrate has zero Gaussian curvature.

9. The system of claim 7 , wherein the non-planar rigid support structure is formed on and coupled to the first major surface without an adhesive.

10. The system of claim 7 , further comprising: an adhesive provided at an edge interface between one or more microfacets of the cold-formed glass substrate and the non-planar rigid support structure.

Images