Cold-Forming Curved Glass with Self-Adhesive Mold
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Solution Overview
Problem
Existing methods for forming curved glass sheets for vehicle interiors are costly and prone to optical distortion and surface marking, limiting the use of durable and optically superior glass materials.
Innovation Solution
A method involving a self-adhesive layer on a curved mold to bend glass sheets at temperatures below their transition temperature, followed by bonding a frame and curing, allowing for the efficient and cost-effective production of curved glass articles with improved optical qualities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If thermal forming is used to form curved glass sheets, then the glass can be formed into curved shapes, but the process results in high cost, optical distortion, and surface marking
Solution Approach 1:
The patent changes the temperature parameter from high (thermal forming) to low (cold forming below glass transition temperature), and changes the forming mechanism from thermal softening to mechanical bending with adhesive support, thereby eliminating optical distortion and surface marking while achieving curved shapes
Solution Approach 2:
The patent introduces a self-adhesive layer as an intermediary between the mold and the glass sheet. This adhesive layer enables cold forming by providing the necessary bonding during bending at low temperatures, eliminating the need for thermal forming while achieving the desired curved shape without optical defects
2Shape
If thermal forming is used to form curved glass sheets, then the glass can be formed into curved shapes, but the process incurs high cost
Solution Approach 1:
The patent changes the temperature parameter from high (thermal forming) to low (cold forming), eliminating expensive heating equipment and energy consumption, thereby reducing manufacturing cost while still achieving curved glass shapes
Solution Approach 2:
The patent extracts the thermal processing step from the forming process, replacing it with cold forming using a self-adhesive layer. This eliminates the need for expensive thermal forming equipment and reduces energy costs while maintaining the ability to produce curved glass articles
3Ease of manufacture
If glass is bent at temperatures above glass transition temperature, then the glass becomes formable, but optical distortion and surface marking occur
Solution Approach 1:
The patent inverts the temperature approach by bending glass at temperatures below the glass transition temperature rather than above it. The self-adhesive layer provides the necessary formability assistance, enabling bending at low temperatures without optical distortion or surface marking
Solution Approach 2:
The self-adhesive layer acts as an intermediary that enables glass bending at low temperatures by providing bonding support during the forming process, eliminating the need to heat the glass above its transition temperature and thereby preventing optical defects
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the production of curved glass articles with enhanced durability and optical performance, avoiding the drawbacks of traditional thermal forming methods while maintaining the benefits of glass materials in vehicle interiors.
Implementation Method 1
A self-adhesive layer is disposed on the curved surface. A glass sheet is bent into conformity with the curved surface... The first major surface is adhered to the self-adhesive layer
Implementation Method 2
The glass sheet is bent into conformity with the curved surface at a temperature less than the glass transition temperature of the glass sheet
Implementation Method 3
A frame is bonded to the second major surface of the glass sheet
Data Source
AI summary
Disclosed are embodiments of a method of forming a curved glass article. In the method, a mold having a curved surface is provided. A self-adhesive layer is disposed on the curved surface. A glass sheet is bent into conformity with the curved surface at a temperature less than the glass transition temperature of the glass sheet. The glass sheet includes a first major surface and a second major surface in which the second major surface is opposite to the first major surface. The first major surface is adhered to the self-adhesive layer. A frame is bonded to the second major surface of the glass sheet, and the glass sheet is removed from the self-adhesive layer. A system for performing the method and a mold having a self-adhesive layer are also disclosed.