Cold-Formed Curved Glass Assembly With Hidden Mechanical Retainers
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Solution Overview
Problem
Existing methods for forming curved glass substrates, such as thermal forming, result in high costs, optical distortion, and surface marking, which are undesirable for applications like curved displays and architectural elements.
Innovation Solution
The use of cold-formed glass substrates with separate mechanical retainers attached to maintain the curved shape, allowing for the application of coatings and surface treatments without thermal stress, and the retainers are designed to be hidden from view, providing a cost-effective and distortion-free solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If thermal forming is used to create curved glass substrates, then the glass can be formed into curved shapes, but optical distortion and surface marking occur
Solution Approach 1:
The patent changes the temperature parameter from high (thermal forming) to low (cold forming), forming the glass at temperatures below its transition point. This parameter change eliminates thermal stress and associated defects while maintaining the ability to achieve curved shapes through mechanical force alone.
Solution Approach 2:
The patent replaces the thermal system (heating and cooling cycles) with a mechanical system (applying force to bend the glass). By using mechanical bending instead of thermal processing, the method achieves curved shapes without the optical distortion and surface marking caused by thermal expansion and contraction.
2Shape
If thermal forming is used to create curved glass substrates, then curved shapes can be achieved, but high costs are incurred
Solution Approach 1:
The patent uses a disposable or reusable forming tool that applies mechanical force to bend the glass temporarily during the forming process. This tool does not require expensive thermal processing equipment, thereby reducing manufacturing costs while still achieving the desired curved shape.
Solution Approach 2:
The patent replaces expensive thermal processing equipment and energy-intensive heating systems with simpler mechanical bending devices. This substitution significantly reduces equipment costs, energy consumption, and overall manufacturing expenses while maintaining the ability to produce curved glass substrates.
3Shape
If thermal forming is used to create curved glass substrates, then curved shapes can be formed, but surface marking occurs
Solution Approach 1:
The patent changes the temperature parameter to remain below the glass transition temperature throughout the forming process. This parameter change prevents the thermal expansion and contraction that cause surface marking, while mechanical bending still achieves the desired curved shape without surface defects.
4Manufacturing precision
If cold-formed glass substrates are used, then optical distortion and surface marking are reduced, but additional mechanical retainers are required
Solution Approach 1:
The patent introduces mechanical retainers as intermediary components that hold the cold-formed glass substrate in its curved shape. These retainers act as mediators between the glass and the final application, providing the necessary structural support without interfering with the optical properties of the glass since they are positioned at the edges or behind the viewing area.
Data Source
AI summary
Embodiments of an article comprising a cold-formed glass substrate in a curved shape, a plurality of separate mechanical retainers, and a frame are disclosed. The cold-formed glass substrate has a first major surface, and a second major surface opposing the first major surface. In one more embodiments, the plurality of separate mechanical retainers are attached to the second major surface of the cold-formed glass substrate. The mechanical retainers may be attached to the frame to define a position for each of the plurality of mechanical retainers, such that the mechanical retainers define the curved shape. Embodiments of processes to form such articles are also provided. Such processes can include attaching a plurality of separate mechanical retainers to a flexible glass substrate such that the glass substrate maintains its flexibility, and attaching the mechanical retainers to a frame, such that the mechanical retainers attached to the frame define a cold-formed curved shape for the flexible glass substrate.