Curved Glass Carrier Structure for Minimal Shape Deviation
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Solution Overview
Problem
Existing methods for forming curved glass substrates for vehicle interiors are costly, prone to optical distortion, and surface marking, limiting the use of glass in curved surfaces due to durability and optical performance issues.
Innovation Solution
A curved glass article with a carrier system comprising longitudinal and lateral strips that maintain the glass in a curved configuration, allowing for cold-forming at low temperatures, minimizing shape deviation to ±0.3 mm, and ensuring mechanical reliability through careful strip width and placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If thermal forming is used to form curved glass substrates, 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-temperature thermal forming to low-temperature cold-forming (below the glass transition temperature), thereby avoiding optical distortion and surface marking while achieving the desired curved shape through mechanical force applied via the carrier structure
Solution Approach 2:
The patent replaces the thermal field (heat-based forming) with a mechanical field (force-based forming), using a mechanically compliant carrier structure to apply distributed mechanical forces that bend the glass into the desired curved shape without thermal damage
2Shape
If thermal forming is used to form curved glass substrates, then the glass can be formed into curved shapes, but the process is costly
Solution Approach 1:
The patent changes the temperature parameter from high-temperature thermal forming to low-temperature cold-forming, eliminating the need for expensive thermal forming equipment and processes while achieving the same curved shape through mechanical means
Solution Approach 2:
The patent segments the forming process into a mechanical carrier structure that can be manufactured separately and then used to form the glass, allowing for standardized, reusable carriers that reduce per-unit manufacturing cost compared to single-use thermal forming processes
3Reliability
If the carrier strips are made wider to improve structural support, then mechanical reliability improves, but the bezel width increases and display area decreases
Solution Approach 1:
The patent transitions from using wide, shallow carrier structures to narrow, three-dimensional strips that extend vertically from the glass surface, utilizing the vertical dimension to provide mechanical support without occupying horizontal display area
Solution Approach 2:
The patent employs composite construction with the carrier strips made from materials that combine high stiffness and strength-to-weight ratios, allowing narrow strip dimensions to provide sufficient mechanical support while minimizing interference with the display area
4Shape
If the glass sheet is bent into a curved configuration, then the aesthetic and functional requirements are met, but shape deviation occurs in the flat sections
Solution Approach 1:
The patent applies local quality by designing the carrier structure with different strip configurations in different regions: narrow longitudinal strips in curved regions to allow bending, and wider lateral strips extending into flat sections to provide support and minimize shape deviation, with each region optimized for its specific functional requirement
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
The solution enables cost-effective incorporation of curved glass substrates in vehicle interiors with minimal shape deviation and enhanced mechanical reliability, providing a large display area while withstanding thermal and cold-forming stresses.
Implementation Method 1
a curved glass article includes a glass sheet having a first major surface and a second major surface opposite to the first major surface. The glass sheet is bent into a curved configuration defining a curved region disposed between a first flat section and a second flat section
Data Source
Figure 1~2B
Figure 3~4B
Figure 5A~5D
AI summary
Emobidments of a curved glass article are disclosed herein. The curved glass article includes a glass sheet first and second major surfaces. The glass sheet is bent to define a curved region disposed between flat sections. The curved glass article also includes a carrier adhered to the glass sheet. The carrier includes longitudinal strips and lateral strips. The longitudinal strips define the radius of curvature of the curved region. The lateral strips extend between the longitudinal strips. The glass sheet deviates 0.3 mm or less from planar in the flat sections. The longitudinal strips each have a width Wlong of 2 mm or less. The first lateral strips each have a width Wlat of 20 mm or less. At least a portion of the width Wlat of each lateral strip is located in the curved region and a flat section.