Cold-Formed Curved Glass With Independent Multi-Bend Regions
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Solution Overview
Problem
Current methods for forming complexly curved glass articles are limited by the need for high-temperature hot forming processes, which are energy-intensive and costly, and cold bending is restricted to single-axis bends with potential for permanent strain and stress, failing to meet the demand for three-dimensional automotive interior displays with independent bends.
Innovation Solution
A cold forming process that shapes glass articles with multiple independent bend regions using a preform configuration, where first and second bend line segments are non-parallel and non-intersecting, allowing for complex curvatures without heating the glass to its transition temperature, thus reducing manufacturing time and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If hot forming process is used to form complexly curved glass articles, then three-dimensional shapes with multiple bends can be achieved, but energy consumption and manufacturing cost increase significantly
Solution Approach 1:
The patent changes the temperature parameter from high (hot forming) to low (cold forming), enabling glass to be formed at room temperature or near room temperature. This is achieved by using a preform with specific mechanical properties that allow cold deformation, fundamentally changing the thermal state parameter of the glass during forming
Solution Approach 2:
The patent performs preliminary action by creating a preform with specific bend line segment patterns before final forming. The preform contains embedded bend lines that guide the cold forming process, allowing complex curvatures to be achieved through controlled cold deformation rather than hot forming
2Shape
If hot forming process is used to form complexly curved glass articles, then three-dimensional shapes with multiple bends can be achieved, but manufacturing cost increases due to heating operations and coating challenges
Solution Approach 1:
The patent changes the temperature parameter from high (hot forming) to low (cold forming), eliminating the need for expensive heating equipment, energy consumption, and complex cooling/downstream processing. Cold forming at or near room temperature significantly reduces manufacturing cost while achieving the same complex three-dimensional shapes
Solution Approach 2:
The patent extracts the heating operation from the forming process, separating the thermal step from the mechanical forming step. By using cold forming, the expensive thermal processing equipment, energy infrastructure, and associated operational costs are eliminated, leaving only the essential mechanical forming operation
3Use of energy by moving object
If cold bending process is used to form glass articles, then energy consumption is reduced, but the process is limited to single-axis bends with large radius
Solution Approach 1:
The patent segments the continuous glass sheet into discrete bend regions by introducing bend line segments at specific locations. Each bend line segment can be independently controlled to create bends in different directions and radii, transforming cold bending from a single-axis limitation to a multi-axis versatile process capable of complex three-dimensional shapes
Solution Approach 2:
The patent adds dimensional complexity by using non-parallel, non-intersecting bend line segments that extend in multiple directions across the glass surface. This transforms the process from single-axis (one dimension of bending) to multi-axis (multiple dimensions of bending simultaneously), enabling anticlastic and other complex curvatures while maintaining cold forming energy efficiency
4Ease of manufacture
If cold bending process is used to form glass articles, then manufacturing cost is reduced, but permanent strain and stress are induced in the glass
Solution Approach 1:
The patent changes the temperature parameter to enable cold forming at or near room temperature, avoiding the thermal stresses of hot forming. By carefully controlling the cold deformation parameters and using a preform with optimized bend line segment distribution, the glass is formed without inducing excessive permanent strain or stress, maintaining structural integrity and reliability
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
Enables the production of complexly curved glass articles with reduced energy consumption and costs, while avoiding permanent strain and stress, facilitating the creation of three-dimensional automotive interior displays with multiple independent bends.
Implementation Method 1
A cold forming process that shapes glass articles with multiple independent bend regions
Implementation Method 2
Cold bending procedure induces a permanent strain, and consequently a permanent stress, in the glass pane
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
The principles and embodiments of the present disclosure relate generally to complexly curved glass articles and methods of cold forming complexly curved glass articles, such as complexly curved glass articles having a first bend region with a set of first bend line segments, and a second bend region with a set of second bend line segments, wherein the first bend line segments and the second bend line segments are independent, are not parallel, and do not intersect.