WO2020112431A1

WO2020112431A1 - Method and system for roll-forming and laminating cover glass using pressure rollers

Info

Publication number: WO2020112431A1
Application number: PCT/US2019/062122
Authority: WO
Inventors: Robert Gordon Lawrence; Po Ki Yuen
Original assignee: Corning Incorporated
Priority date: 2018-11-29
Filing date: 2019-11-19
Publication date: 2020-06-04
Also published as: CN212765146U; TW202104103A

Abstract

Disclosed herein are embodiments of a method of forming a glass article in which a structural adhesive layer is applied to a frame that includes at least a first curvature. A substantially planar glass sheet is aligned with the frame, and the glass sheet is pressure rolled into conformity with the first curvature of the frame. A glass article made according to the disclosed method, such as for a vehicle interior system, is also provided. Also disclosed herein are embodiments of an alignment system for rolling a curved glass article having a glass sheet bonded to a frame. The alignment system includes a first alignment plate and a second alignment plate spatially disposed from the first alignment plate. The first alignment plate and the second alignment plate are configured to move laterally so as to maintain contact with the curved glass article as the curved glass article is rolled.

Description

METHOD AND SYSTEM FOR ROLL-FORMING AND LAMINATING COVER GLASS

USING PRESSURE ROLLERS

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of priority under 35 U.S.C. § 119 of U.S.

Provisional Application Serial No. 62/772,769 filed on November 29, 2018 the content of which is relied upon and incorporated herein by reference in its entirety.

BACKGROUND

[0002] The disclosure relates to glass articles and methods for forming same, and more particularly to vehicle interior systems including a glass article with a pressure-rolled cover glass and an alignment system for forming same.

[0003] Vehicle interiors include curved surfaces and can incorporate displays in such curved surfaces. The materials used to form such curved surfaces are typically limited to polymers, which do not exhibit the durability and optical performance as glass. As such, curved glass substrates are desirable, especially when used as covers for displays. Existing methods of forming such curved glass substrates, such as thermal forming, have drawbacks including high cost, optical distortion, and surface marking. Accordingly, Applicant has identified a need for vehicle interior systems that can incorporate a curved glass substrate in a cost- effective manner and without problems typically associated with glass thermal forming processes.

SUMMARY

[0004] According to an aspect, embodiments of the disclosure relate to a method of forming a glass article in which a structural adhesive layer is applied to a frame that includes at least a first curvature. A substantially planar glass sheet is aligned with the frame, and the glass sheet and the frame are pressure rolled between at least a first roller and a second roller so as to bend the glass sheet into conformity with the first curvature of the frame. At least one of the first roller and the second roller is configured to apply a pressure normal to the glass sheet and frame during pressure rolling.

[0005] According to another aspect, embodiments of the disclosure relate to an alignment system for rolling a curved glass article having a glass sheet bonded to a frame. The alignment system is configured for placement proximal to a set of rollers. The alignment system includes a first alignment plate and a second alignment plate. The second alignment plate is arranged parallel to the first alignment plate and is separated from the first alignment plate by a distance corresponding to a width of at least one of the frame or the glass substrate. The first alignment plate and the second alignment plate are configured to move parallel to the set of rollers so as to set the distance corresponding to the width prior to or during rolling of the curved glass article.

[0006] In embodiments, the alignment system is part of a pressure rolling system that also includes a set of pressure rollers.

[0007] According to still another aspect, embodiments of the disclosure relate to a glass article having a glass sheet with a first major surface and a second major surface. The second major surface includes at least a first curve. The glass article also includes a frame having a support surface and including at least a first complementary curve. The second major surface of the glass sheet faces the support surface of the frame, and the first complementary curve is complementary to the first curve. The glass article also includes a structural adhesive layer bonding the glass sheet to the frame, and the structural adhesive layer covers at least 80% of the support surface of the frame.

[0008] In embodiments, the glass article is part of a vehicle interior system.

[0009] Additional features and advantages will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the embodiments as described herein, including the detailed description which follows, the claims, as well as the appended drawings.

[0010] It is to be understood that both the foregoing general description and the following detailed description are merely exemplary, and are intended to provide an overview or framework to understanding the nature and character of the claims. The accompanying drawings are included to provide a further understanding, and are incorporated in and constitute a part of this specification.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention and, together with the description, serve to explain the principles of the invention. In the drawings:

[0012] FIG. 1 is a perspective view of a vehicle interior with vehicle interior systems, according to exemplary embodiments;

[0013] FIG. 2 is a cross-sectional view of a glass substrate following cold bending and attachment to a curved frame, according to an exemplary embodiment; [0014] FIG. 3 depicts a stage of the pressure rolling process, according to an exemplary embodiment;

[0015] FIG. 4 depicts another stage of the pressure rolling process, according to an exemplary embodiment;

[0016] FIG. 5 depicts a clamping mechanism, according to an exemplary embodiment;

[0017] FIG. 6 depicts an alignment jig for the glass substrate and frame, according to an exemplary embodiment;

[0018] FIG. 7 depicts an alignment system for the pressure rolling process, according to an exemplary embodiment;

[0019] FIG. 8 depicts an alignment system including a spring system, according to an exemplary embodiment; and

[0020] FIG. 9 is a front perspective view of a glass substrate, according to an exemplary embodiment.

DETAILED DESCRIPTION

[0021] Reference will now be made in detail to various embodiments, examples of which are illustrated in the accompanying drawings. In general, a vehicle interior system may include a variety of different curved surfaces that are designed to be transparent, such as curved display surfaces and curved non-display glass covers, and the present disclosure provides articles and methods for forming these curved surfaces from a glass material. Forming curved vehicle surfaces from a glass material provide a number of advantages compared to the typical curved plastic panels that are conventionally found in vehicle interiors. For example, glass is typically considered to provide enhanced functionality and user experience in many curved cover material applications, such as display applications and touch screen applications, compared to plastic cover materials.

[0022] Accordingly, as will be discussed in more detail below, Applicant has developed a glass article and related manufacturing processes that provide an efficient and cost-effective way to form an article, such as a display for a vehicle interior system, utilizing a pressure- rolled piece of glass substrate. As disclosed herein, the curved shape is maintained using an adhesive layer that is activated by the roller to hold the curved shape of the glass substrate.

[0023] FIG. 1 shows an exemplary vehicle interior 1000 that includes three different embodiments of a vehicle interior system 100, 200, 300. Vehicle interior system 100 includes a frame, shown as center console base 110, with a curved surface 120 including a display 130. Displays discussed herein are optically bonded to a cover glass, and can be curved or flat. Vehicle interior system 200 includes a frame, shown as dashboard base 210, with a curved surface 220 including a display 230. The dashboard base 210 typically includes an instrument panel 215 which may also include an optically bonded display.

Vehicle interior system 300 includes a frame, shown as steering wheel base 310, with a curved surface 320 and a display 330. In one or more embodiments, the vehicle interior system includes a frame that is an arm rest, a pillar, a seat back, a floor board, a headrest, a door panel, or any portion of the interior of a vehicle that includes a curved surface. In other embodiments, the frame is a portion of a housing for a free-standing display (i.e., a display that is not permanently connected to a portion of the vehicle).

[0024] The embodiments of the glass article described herein can be used in each of vehicle interior systems 100, 200 and 300. Further, the glass articles discussed herein may be used as curved cover glasses for any of the display embodiments discussed herein, including for use in vehicle interior systems 100, 200 and/or 300. Further, in various embodiments, various non-display components of vehicle interior systems 100, 200 and 300 may be formed from the glass articles discussed herein. In some such embodiments, the glass articles discussed herein may be used as the non-display cover surface for the dashboard, center console, door panel, etc. In such embodiments, glass material may be selected based on its weight, aesthetic appearance, etc. and may be provided with a coating (e.g., an ink or pigment coating) with a pattern (e.g., a brushed metal appearance, a wood grain appearance, a leather appearance, a colored appearance, etc.) to visually match the glass components with adjacent non-glass components. In specific embodiments, such ink or pigment coating may have a transparency level that provides for deadfront functionality.

[0025] FIG. 2 depicts a cross-sectional view of a glass article 10, such as the cover glass for display 130 (e.g., as shown in FIG. 1), according to exemplary embodiments. It should be understood that while FIG. 2 is described in terms of forming curved display 130, the glass article 10 of FIG. 2 may be used in any suitable curved glass application, including any curved or non-curved glass component of any of the vehicle interior systems of FIG. 1. Such glass components could be display or non-display regions, e.g., a flat display area and a curved non-display area, curved displays, and curved display and curved non-display areas.

[0026] In FIG. 2, a frame 12 includes a support surface 14 which has a curvature. Glass article 10 includes a glass substrate 16. Glass substrate 16 includes a first major surface 18 and a second major surface 20 opposite first major surface 18. A minor surface 22 connects the first major surface 18 and the second major surface 20, and in specific embodiments, minor surface 22 defines the outer perimeter of glass substrate 16.

[0027] In various embodiments, first major surface 18 and/or the second major surface 20 of glass substrate 16 includes one or more surface treatments or layers. The surface treatment may cover at least a portion of the first major surface 18 and/or second major surface 20. Exemplary surface treatments include anti-glare surfaces/coatings, anti-reflective

surfaces/coatings, and an easy-to-clean surface coating/treatment. In one or more embodiments, at least a portion of the first major surface 18 and/or the second major surface 20 may include any one, any two or all three of an anti-glare surface, an anti-reflective surface, and easy-to-clean coating/treatment. For example, first major surface 18 may include an anti-glare surface and second major surface 20 may include an anti -reflective surface. In another example, first major surface 18 includes an anti-reflective surface and second major surface 20 includes an anti-glare surface. In yet another example, the first major surface 18 comprises either one of or both the anti-glare surface and the anti-reflective surface, and the second major surface 20 includes the easy-to-clean coating.

[0028] Further, many glass surface treatments (e.g., anti-glare coatings, anti-reflective coatings, easy-to-clean coating, etc.) are applied via deposition processes, such as sputtering processes that are typically ill-suited for coating curved glass articles. In addition, many surface treatments (e.g., anti-glare coatings, anti-reflective coatings, easy-to-clean coating, etc.) also are not able to survive the high temperatures associated with hot-bending processes. Thus, in particular embodiments discussed herein, one or more surface treatments are applied to the first major surface 18 and/or to the second major surface 20 of the glass substrate 16 prior to rolling, and the glass substrate 16 including the surface treatment is bent to a curved shape as discussed herein. Thus, Applicant believes that the pressure rolling processes and systems discussed herein allow for bending of glass after one or more coating materials have been applied to the glass, in contrast to typical hot-forming processes.

[0029] In embodiments, the glass substrate 16 may also include a pigment design on the first major surface 18 and/or second major surface 20. The pigment design may include any aesthetic design formed from a pigment (e.g., ink, paint and the like) and can include a wood- grain design, a brushed metal design, a graphic design, a portrait, or a logo. The pigment design may be printed onto the glass substrate. Further, in embodiments, the glass substrate 16 may include a tint film laminated to the first major surface 18 (e.g., a window film available from Scorption Window Film, Cloverdale, IN). In such embodiments, a pigment design may be applied to the tint film after the tint film is laminated to the first major surface 18 of the glass substrate 16. In one or more embodiments, the anti -glare surface includes an etched surface. In one or more embodiments, the anti-reflective surface includes a multi layer coating.

[0030] Advantageously, Applicant believes that pressure rolling allows for formation of a glass article 10 while preserving various coatings located on the glass substrate 16 that might otherwise be damaged or destroyed at high temperatures typically associated with conventional glass bending processes.

[0031] The glass substrate 16 is attached to the frame 12 via an adhesive layer 24. In embodiments, the adhesive layer 24 comprises a pressure sensitive adhesive. Exemplary pressure sensitive adhesives suitable for use in the adhesive layer 24 include at least one of 3M™ VHB™ (available from 3M, St. Paul, MN) or tesa® (available from tesa SE,

Norderstedt, Germany).

[0032] In embodiments, the adhesive layer 24 comprises a liquid adhesive. Exemplary liquid adhesives include toughened epoxy, flexible epoxy, acrylics, silicones, urethanes, polyurethanes, and silane modified polymers. In specific embodiments, the liquid adhesive includes one or more toughened epoxies, such as EP21TDCHT-LO (available from

Masterbond®, Hackensack, NJ), 3M™ Scotch-Weld™ Epoxy DP460 Off-White (available from 3M, St. Paul, MN). In other embodiments, the liquid adhesive includes one or more flexible epoxies, such as Masterbond EP21TDC-2LO (available from Masterbond®, Hackensack, NJ), 3M™ Scotch-Weld™ Epoxy 2216 B/A Gray (available from 3M, St. Paul, MN), and 3M™ Scotch-Weld™ Epoxy DP 125. In still other embodiments, the liquid adhesive includes one or more acrylics, such as LORD® Adhesive 410/Accelerator 19 w/ LORD® AP 134 primer, LORD® Adhesive 852/LORD® Accelerator 25 GB (both being available from LORD Corporation, Cary, NC), DELO PUR SJ9356 (available from DELO Industrial Adhesives, Windach, Germany), Loctite® AA4800, Loctite® HF8000.

TEROSON® MS 9399, and TEROSON® MS 647-2C (these latter four being available from Henkel AG & Co. KGaA, Diisseldorf, Germany), among others. In yet other embodiments, the liquid adhesive includes one or more urethanes, such as 3M™ Scotch-Weld™ Urethane DP640 Brown and 3M™ Scotch-Weld™ Urethane DP604, and in still further embodiments, the liquid adhesive includes one or more silicones, such as Dow Corning® 995 (available from Dow Coming Corporation, Midland, MI). [0033] In embodiments, the adhesive layer 24 covers substantially the entire support surface 14. In embodiments, the adhesive layer 24 covers at least 95% of the support surface 14. In other embodiments, the adhesive layer 24 covers at least 90% of the support surface 14, and in certain embodiments the adhesive layer 24 covers at least 80% of the support surface 14.

In embodiments, the adhesive layer 24 has a thickness of 0.1 mm to 2 mm.

[0034] In embodiments, a primer can be applied to prepare the surfaces of the glass substrate 16 and frame 12 for better adhesion to adhesive layer 24, especially for frames 12 made of metal or including metal surfaces and for the glass surface of the glass substrate 16. In addition to or instead of applying the primer, the support surface 14 of the frame 12 is roughened, in embodiments, to provide better adhesion between the adhesive layer 24 and the support surface 12. Further, in embodiments, an ink primer may be used in addition to or instead of the primer for metal and glass surfaces. The ink primer helps provide better adhesion between the adhesive layer 24 to ink covered surfaces (e.g., the pigment design mentioned above for deadfronting applications). An example of a primer is 3M™ Scotch- Weld™ Metal Primer 3901 (available from 3M, St. Paul, MN); other commercially available primers are also suitable for use in the present disclosure and can be selected based on surfaces involved in the bonding and on the adhesive used to create the bond.

[0035] In embodiments, the glass substrate 16 has a curved shape such that first major surface 18 and second major surface 20 each include at least one curved section having a radius of curvature. In the specific embodiments shown, support surface 14 of frame 12 is a convex curved surface. In such embodiments, the glass substrate 16 is bent such that first major surface 18 defines a concave shape that generally conforms to, or is complementary to, the convex curved shape of support surface 14, and second major surface 20 defines a convex shape that generally matches or mirrors the convex curved shape of support surface 14. In such embodiments, surfaces 18, 20 both define a first radius of curvature R1 that generally matches the radius of curvature of support surface 14 of frame 12.

[0036] In embodiments, R1 is between 30 mm and 5 m. Further, in embodiments, the glass substrate 16 has a thickness T1 (e.g., an average thickness measured between surfaces 18, 20) shown in FIG. 2 that is in a range from 0.05 mm to 2 mm. In specific embodiments, T1 is less than or equal to 1.5 mm and in more specific embodiments, T1 is 0.4 mm to 1.3 mm. Such thin glass substrates may be able to be pressure-rolled to a variety of curved shapes (including the relatively high curvature radii of curvature discussed herein) utilizing rolling without breakage while at the same time providing for a high quality cover layer for a variety of vehicle interior applications. In addition, such thin glass substrates 16 may deform more readily, which could potentially compensate for shape mismatches and gaps that may exist relative to support surface 14 and/or frame 12.

[0037] FIGS. 3 and 4 depict the pressure rolling process for applying the adhesive layer 24 and the glass substrate 16 to the frame 12 to form a glass article 10. In the embodiment shown in FIGS. 3 and 4, the frame 12 is S-shaped having a first curve 26 that is convex and proximal to a first end 28 and a second curve 30 that is concave and proximal to a second end 32. Disposed between the first curve 26 and the second curve 30 is a flat section 34. In embodiments, the radius of curvature for the first curve 26 is the same as the radius of curvature for the second curve 30, and in other embodiments, the radius of curvature for the first curve 26 is different from the radius of curvature for the second curve 30. Further, in embodiments, the curves 26, 30 can both be convex or concave, or in embodiments, such as the embodiment depicted in FIGS. 3 and 4, one curve 26 can be convex while the other curve 30 is concave.

[0038] In the pressure rolling process, the adhesive layer 24 is first pressure rolled onto the frame 12. In embodiments, the adhesive layer 24 is a sheet 36 having roughly the same size as the support surface 14 of the frame 12. In embodiments, the adhesive layer 24 is a sheet 36 having a size larger than the size of the support surface 14 of the frame, and after rolling, the sheet 36 is trimmed so that the adhesive layer 24 is no larger than the size of the support surface 14.

[0039] As depicted in FIG. 3, the sheet 36 is adhered at the first end 28 of the frame 12, and the sheet 36 and frame 12 are passed between rollers 37a, 37b in the direction of rolling (denoted by arrow 38). Pressure is maintained on the top roller 37a via a spring system 39. Thus, as the sheet 36 and frame 12 are passed between the rollers 37a, 37b, contact is maintained between the sheet 36 and the top roller 37a.

[0040] In embodiments, the sheet 36 forming the adhesive layer 24 is a double-sided adhesive having release layers. In particular, the sheet 36 has a first adhesive surface 40 and a second adhesive surface 42. Prior to application to the frame 12 and/or glass substrate 16, the first adhesive surface 40 is covered with a first release layer, and the second adhesive surface 42 is covered with a second release layer. During pressure rolling, the first release layer on the first adhesive surface 40 remains on the sheet 36 so that the first adhesive surface 40 does not stick to the top roller 37a. The second release layer on the second adhesive surface 42 is removed at least partially prior to pressure rolling so that the second adhesive surface 42 can be adhered to the support surface 14 of the frame 12. The release layer on the second adhesive surface 42 may be removed during rolling as the frame 12 and sheet 36 are passed between the rollers 37a, 37b.

[0041] As can be seen in FIG. 4, the sheet 36 has been applied (and trimmed, if necessary) to conform to the support surface 14. Thereafter, the first release layer on the first adhesive surface 40 is at least partially removed, and the glass substrate 16 is adhered at the first end 28 of the frame 12. The glass substrate 16, adhesive layer 24, and frame 12 are passed through the rollers 37a, 37b in rolling direction 38. The spring system 39 causes the top roller 37a to maintain pressure on the glass substrate 16, bending it into conformity with the frame 12. The adhesive layer 24 provides sufficient bonding strength to hold the glass substrate 16 in conformity with the frame 12. In embodiments, after the glass article 10 is passed through the rollers 37a, 37b, the glass substrate 16 is clamped to the frame 12 for a period of time for the adhesive layer 24 to fully bond the glass substrate 16 to the frame 12.

[0042] During the stages of pressure rolling, the rollers 37a, 37b may be maintained at room temperature (e.g., about 20 °C), or the rollers 37a, 37b may be at an elevated temperature, e.g., at 200 °C or less, 150 °C or less, 100 °C or less, or at 50 °C or less. Further, in embodiments, the pressure rollers 37a, 37b can be reversed so that the glass substrate 16 and frame 12 can be passed back-and-forth between the pressure rollers 37a, 37b multiple times to increase the resident time for applying heat or pressure from the pressure rollers 37a, 37b at a particular location of the glass article 10 or over the entire glass article 10.

[0043] FIG. 5 depicts an embodiment of a clamping mechanism 52 that hold glass substrate 16 in conformity with the frame 12 via a clamping force 53. In the embodiment shown in FIG. 5, the clamping mechanism 52 includes a support base 54 on which the frame 12 rests and a weight 56 that sits on the glass substrate 16. In other embodiments, the clamping mechanism 52 includes a series of clamps providing a clamping force 53 around the edges of the glass article 10 to hold the glass substrate 16 in place while the adhesive layer fully bonds to the glass substrate 16 and frame 12. In such embodiments, the clamps may be used in conjunction with the support base 54. In embodiments, toggle clamps are used to hold the glass substrate 16 into conformity with the frame 12. Example toggle clamps include hold down, push/pull, latch-style, C-clamps, and pliers-style toggle clamps. Further, in embodiments, the clamping mechanism 52 provides a clamping force 53 via a vacuum press or a mechanical press. In embodiments, the support base 54 is attached to the frame 12 prior to rolling such that the support base 54 is passed between the rollers 37a, 37b (as shown in FIG. 4) along with the frame 12 and glass substrate 16 during rolling. In such embodiments, the support base 54 may be thinner than the depiction of the support base 54 shown in FIG. 5.

[0044] During pressure rolling, the alignment between the glass substrate 16 and the frame 12 can be enhanced using a jig 58 as shown in FIG. 6 to provide initial alignment and an alignment system 60 as shown in FIGS. 7 and 8 to ensure alignment during pressure rolling. Referring first to FIG. 6, a jig 58 is provided to align the glass substrate 16 and the frame 12. The jig 58 includes a panel 62 having a plurality of alignment pins 64 that extend from the surface of the panel 62. The panel 62 also includes a further plurality of pinholes 66. In embodiments, the panel 62 includes more pinholes 66 than alignment pins 64 so that the alignment pins 64 may be configured to accommodate a variety of different frames 12. In other embodiments, each pinhole 66 has an alignment pin 64, but the alignment pin 64 is able to slide into a flush position with the panel 62. To use the jig 58, a first end 28 of the frame 12 with adhesive layer 24 applied thereon is placed on the panel 62 between alignment pins 64. If a release layer is still provided on the first adhesive surface 40, the release layer is at least partially removed from the first end 28. Thereafter, the glass substrate 16 (not shown in FIG. 6) is positioned over the adhesive layer 24 and frame 12 and between the alignment pins 64. The glass substrate 16 is brought into contact with the first adhesive surface 40 to provide an initial adherence to the frame 12. In this way, the glass substrate 16 is aligned with the frame 12 initially for pressure rolling. In embodiments, the jig 58 is inserted into the alignment system 60, which will be described with respect to FIGS. 7 and 8, below, and alignment pins 64 are removed or depressed (all at once or sequentially) until flush with the panel 62 so that the glass substrate 16 and the frame 12 are able to be fed across the jig 58 into the pressure rollers. In other embodiments, the jig 58 is removed prior to inserting the glass substrate 16 and frame 12 into the pressure rollers.

[0045] However, during pressure rolling, the glass substrate 16 and frame 12 may become unaligned. Thus, as shown in FIG. 7, an alignment system 60 is provided leading into the rollers 37a, 37b to maintain alignment between the glass substrate 16 and frame 12. The alignment system 60 includes a first alignment plate 68 and a second alignment plate 70 that are separated by a distance D corresponding to the width of the frame 12 and/or glass substrate 16. In embodiments, each alignment plate 68, 70 is supported by a slidable stanchion 72. The slidable stanchions 72 are disposed on a track 74 that allow for adjustment of the distance D between the alignment plates 68, 70 so as to accommodate frames 12 and/or glass substrate 16 of varying sizes. Additionally, as shown in FIG. 8, the alignment plates 68, 70 may be urged into contact with the glass substrate 16 and/or frame 12 by spring systems 76. Thus, for instance, the alignment system 60 is able to maintain constant contact with glass substrates 16 and/or frames 12 having an irregular width. That is, as the glass substrate 16 and frame 12 pressure rolled, changes in width going from the first end 28 to the second end 32 do not cause disruption of the alignment. In another embodiment, the alignment between the glass substrate 16 and frame 12 is monitored as it exits the pressure rollers, and a controller adjusts the spring pressure in the spring system 76 to re-align the glass substrate 16 with the frame 12.

[0046] In various embodiments, glass substrate 16 is formed from a strengthened glass sheet (e.g., a thermally strengthened glass material, a chemically strengthened glass sheet, etc.) In such embodiments, when glass substrate 16 is formed from a strengthened glass material, first major surface 18 and second major surface 20 are under compressive stress, and thus second major surface 20 can experience greater tensile stress during bending to the convex shape without risking fracture. This allows for strengthened glass substrate 16 to conform to more tightly curved surfaces.

[0047] A feature of a cold-formed glass substrate, such as a pressure-rolled glass substrate, is an asymmetric surface compressive between the first major surface 18 and the second major surface 20 once the glass substrate has been bent to the curved shape. In such embodiments, prior to the cold-forming process or being cold-formed, the respective compressive stresses in the first major surface 18 and the second major surface 20 of glass substrate 16 are substantially equal. After cold-forming, the compressive stress on concave first major surface 18 increases such that the compressive stress on the first major surface 18 is greater after cold-forming than before cold-forming. In contrast, convex second major surface 20 experiences tensile stresses during bending causing a net decrease in surface compressive stress on the second major surface 20, such that the compressive stress in the second major surface 20 following bending is less than the compressive stress in the second major surface 20 when the glass sheet is flat.

[0048] As noted above, in addition to providing processing advantages such as eliminating expensive and/or slow heating steps, the cold-forming processes discussed herein are believed to generate glass articles with a variety of properties that are superior to hot-formed glass articles, particularly for vehicle interior or display cover glass applications. For example, Applicant believes that, for at least some glass materials, heating during hot- forming processes decreases optical properties of curved glass sheets, and thus, the curved glass substrates formed utilizing the cold-bending processes/sy stems discussed herein provide for both curved glass shapes along with improved optical qualities not believed achievable with hot-bending processes.

[0049] In various embodiments, the glass substrate 16 may have a compound curve including a major radius and a cross curvature. A complexly curved glass substrate 16 may have a distinct radius of curvature in two independent directions. According to one or more embodiments, a complexly curved glass substrate 16 may thus be characterized as having “cross curvature,” where the glass substrate 16 is curved along an axis (i.e., a first axis) that is parallel to a given dimension and also curved along an axis (i.e., a second axis) that is perpendicular to the same dimension. The curvature of the glass substrate can be even more complex when a significant minimum radius is combined with a significant cross curvature, and/or depth of bend. In various embodiments, the glass substrate 16 can have more than two curved regions with the same or differing curved shapes. In some embodiments, the glass substrate 16 can have one or more region having a curved shape with a variable radius of curvature.

[0050] Referring to FIG. 9, additional structural details of the glass substrate 16 are shown and described. As noted above, the glass substrate 16 has a thickness T1 that is substantially constant and is defined as a distance between the first major surface 18 and the second major surface 20. In various embodiments, T1 may refer to an average thickness or a maximum thickness of the glass substrate. In addition, the glass substrate 16 includes a width W1 defined as a first maximum dimension of one of the first or second major surfaces 18, 20 orthogonal to the thickness Tl, and a length LI defined as a second maximum dimension of one of the first or second major surfaces 18, 20 orthogonal to both the thickness and the width. In other embodiments, W1 and LI may be the average width and the average length of the glass substrate 16, respectively, and in other embodiments, W1 and LI may be the maximum width and the maximum length of the glass substrate 16, respectively (e.g., for glass substrates 16 having a variable width or length).

[0051] In various embodiments, thickness Tl is 2 mm or less and specifically is 0.3 mm to 1.1 mm. For example, thickness Tl may be in a range 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 1.2 mm, from about 0.1 mm to about 1.1 mm, from about 0.1 mm to about 1.05 mm, from about 0.1 mm to about 1 mm, from about 0.1 mm to about 0.95 mm, from about 0.1 mm to about 0.9 mm, from about 0.1 mm to about 0.85 mm, from about 0.1 mm to about 0.8 mm, from about 0.1 mm to about 0.75 mm, from about 0.1 mm to about 0.7 mm, from about 0.1 mm to about 0.65 mm, from about 0.1 mm to about 0.6 mm, from about 0.1 mm to about 0.55 mm, from about 0.1 mm to about 0.5 mm, from about 0.1 mm to about 0.4 mm, or from about 0.3 mm to about 0.7 mm. In other embodiments, the T1 falls within any one of the exact numerical ranges set forth in this paragraph.

[0052] In various embodiments, width W1 is in a range from 5 cm to 250 cm, from about 10 cm to about 250 cm, from about 15 cm to about 250 cm, from about 20 cm to about 250 cm, from about 25 cm to about 250 cm, from about 30 cm to about 250 cm, from about 35 cm to about 250 cm, from about 40 cm to about 250 cm, from about 45 cm to about 250 cm, from about 50 cm to about 250 cm, from about 55 cm to about 250 cm, from about 60 cm to about 250 cm, from about 65 cm to about 250 cm, from about 70 cm to about 250 cm, from about 75 cm to about 250 cm, from about 80 cm to about 250 cm, from about 85 cm to about 250 cm, from about 90 cm to about 250 cm, from about 95 cm to about 250 cm, from about 100 cm to about 250 cm, from about 110 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 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. In other embodiments, W1 falls within any one of the exact numerical ranges set forth in this paragraph.

[0053] In various embodiments, length LI is in a range from about 5 cm to about 1500 cm, from about 50 cm to about 1500 cm, from about 100 cm to about 1500 cm, from about 150 cm to about 1500 cm, from about 200 cm to about 1500 cm, from about 250 cm to about 1500 cm, from about 300 cm to about 1500 cm, from about 350 cm to about 1500 cm, from about 400 cm to about 1500 cm, from about 450 cm to about 1500 cm, from about 500 cm to about 1500 cm, from about 550 cm to about 1500 cm, from about 600 cm to about 1500 cm, from about 650 cm to about 1500 cm, from about 650 cm to about 1500 cm, from about 700 cm to about 1500 cm, from about 750 cm to about 1500 cm, from about 800 cm to about 1500 cm, from about 850 cm to about 1500 cm, from about 900 cm to about 1500 cm, from about 950 cm to about 1500 cm, from about 1000 cm to about 1500 cm, from about 1050 cm to about 1500 cm, from about 1100 cm to about 1500 cm, from about 1150 cm to about 1500 cm, from about 1200 cm to about 1500 cm, from about 1250 cm to about 1500 cm, from about 1300 cm to about 1500 cm, from about 1350 cm to about 1500 cm, from about 1400 cm to about 1500 cm, or from about 1450 cm to about 1500 cm. In other embodiments, LI falls within any one of the exact numerical ranges set forth in this paragraph.

[0054] In various embodiments, one or more radius of curvature (e.g., R1 shown in FIG. 2) of glass substrate 16 is about 60 mm or greater. For example, R1 may be in a range from about 60 mm to about 10,000 mm, from about 70 mm to about 10,000 mm, from about 80 mm to about 10,000 mm, from about 90 mm to about 10000 mm, from about 100 mm to about 10000 mm, from about 120 mm to about 10000 mm, from about 140 mm to about 10000 mm, from about 150 mm to about 10000 mm, from about 160 mm to about 10000 mm, from about 180 mm to about 10000 mm, from about 200 mm to about 10000 mm, from about 220 mm to about 10000 mm, from about 240 mm to about 10000 mm, from about 250 mm to about 10000 mm, from about 260 mm to about 10000 mm, from about 270 mm to about 10000 mm, from about 280 mm to about 10000 mm, from about 290 mm to about 10000 mm, from about 300 mm to about 10000 mm, from about 350 mm to about 10000 mm, from about 400 mm to about 10000 mm, from about 450 mm to about 10000 mm, from about 500 mm to about 10000 mm, from about 550 mm to about 10000 mm, from about 600 mm to about 10000 mm, from about 650 mm to about 10000 mm, from about 700 mm to about 10000 mm, from about 750 mm to about 10000 mm, from about 800 mm to about 10000 mm, from about 900 mm to about 10000 mm, from about 950 mm to about 10000 mm, from about 1000 mm to about 10000 mm, from about 1250 mm to about 10000 mm, from about 60 mm to about 9000 mm, from about 60 mm to about 8000 mm, from about 60 mm to about 720000 mm, from about 60 mm to about 6000 mm, from about 60 mm to about 5000 mm, from about 60 mm to about 4000 mm, from about 60 mm to about 3000 mm, from about 60 mm to about 2500 mm, from about 60 mm to about 2000 mm, from about 60 mm to about 1800 mm, from about 60 mm to about 1600 mm, from about 60 mm to about 1500 mm, from about 60 mm to about 1400 mm, from about 60 mm to about 1300 mm, from about 60 mm to about 1200 mm, from about 60 mm to about 1100 mm, from about 60 mm to about 1000 mm, from about 60 mm to about 950 mm, from about 60 mm to about 900 mm, from about 60 mm to about 850 mm, from about 60 mm to about 800 mm, from about 60 mm to about 750 mm, from about 60 mm to about 700 mm, from about 60 mm to about 650 mm, from about 60 mm to about 600 mm, from about 60 mm to about 550 mm, from about 60 mm to about 500 mm, from about 60 mm to about 450 mm, from about 60 mm to about 400 mm, from about 60 mm to about 350 mm, from about 60 mm to about 300 mm, or from about 60 mm to about 250 mm. In other embodiments, R1 falls within any one of the exact numerical ranges set forth in this paragraph.

[0055] The various embodiments of the vehicle interior system may be incorporated into vehicles such as trains, automobiles (e.g., cars, trucks, buses and the like), sea craft (boats, ships, submarines, and the like), and aircraft (e.g., drones, airplanes, jets, helicopters and the like).

Strengthened Glass Properties

[0056] As noted above, glass substrate 16 may be strengthened. In one or more

embodiments, glass substrate 16 may be strengthened to include compressive stress that extends from a surface to a depth of compression (DOC). The compressive stress regions are balanced by a central portion exhibiting a tensile stress. At the DOC, the stress crosses from a positive (compressive) stress to a negative (tensile) stress.

[0057] In various embodiments, glass substrate 16 may be strengthened mechanically by utilizing a mismatch of the coefficient of thermal expansion between portions of the article to create a compressive stress region and a central region exhibiting a tensile stress. In some embodiments, the glass substrate may be strengthened thermally by heating the glass to a temperature above the glass transition point and then rapidly quenching.

[0058] In various embodiments, glass substrate 16 may be chemically strengthened by ion exchange. In the ion exchange process, ions at or near the surface of the glass substrate are replaced by - or exchanged with - larger ions having the same valence or oxidation state. In those embodiments in which the glass substrate comprises an alkali aluminosilicate glass, ions in the surface layer of the article and the larger ions are monovalent alkali metal cations, such as Li⁺, Na⁺, K⁺, Rb⁺, and Cs⁺. Alternatively, monovalent cations in the surface layer may be replaced with monovalent cations other than alkali metal cations, such as Ag⁺ or the like. In such embodiments, the monovalent ions (or cations) exchanged into the glass substrate generate a stress.

[0059] Ion exchange processes are typically carried out by immersing a glass substrate in a molten salt bath (or two or more molten salt baths) containing the larger ions to be exchanged with the smaller ions in the glass substrate. It should be noted that aqueous salt baths may also be utilized. In addition, the composition of the bath(s) may include more than one type of larger ions (e.g., Na+ and K+) or a single larger ion. It will be appreciated by those skilled in the art that parameters for the ion exchange process, including, but not limited to, bath composition and temperature, immersion time, the number of immersions of the glass substrate in a salt bath (or baths), use of multiple salt baths, additional steps such as annealing, washing, and the like, are generally determined by the composition of the glass substrate (including the structure of the article and any crystalline phases present) and the desired DOC and CS of the glass substrate that results from strengthening. Exemplary molten bath compositions may include nitrates, sulfates, and chlorides of the larger alkali metal ion. Typical nitrates include KNO3, NaN03, L1NO3, NaS04 and combinations thereof. The temperature of the molten salt bath typically is in a range from about 380°C up to about 450°C, while immersion times range from about 15 minutes up to about 100 hours depending on glass substrate thickness, bath temperature and glass (or monovalent ion) diffusivity. However, temperatures and immersion times different from those described above may also be used.

[0060] In one or more embodiments, the glass substrates may be immersed in a molten salt bath of 100% NaNCh, 100% KNO3, or a combination of NaNCh and KNO3 having a temperature from about 370 °C to about 480 °C. In some embodiments, the glass substrate may be immersed in a molten mixed salt bath including from about 5% to about 90% KNO3 and from about 10% to about 95% NaNCh. In one or more embodiments, the glass substrate may be immersed in a second bath, after immersion in a first bath. The first and second baths may have different compositions and/or temperatures from one another. The immersion times in the first and second baths may vary. For example, immersion in the first bath may be longer than the immersion in the second bath.

[0061] In one or more embodiments, the glass substrate may be immersed in a molten, mixed salt bath including NaNCh and KNO3 (e.g., 49%/51%, 50%/50%, 51 %/49%) having a temperature less than about 420 °C (e.g., about 400 °C or about 380 °C). for less than about 5 hours, or even about 4 hours or less. [0062] Ion exchange conditions can be tailored to provide a“spike” or to increase the slope of the stress profile at or near the surface of the resulting glass substrate. The spike may result in a greater surface CS value. This spike can be achieved by a single bath or multiple baths, with the bath(s) having a single composition or mixed composition, due to the unique properties of the glass compositions used in the glass substrates described herein.

[0063] In one or more embodiments, where more than one monovalent ion is exchanged into the glass substrate, the different monovalent ions may exchange to different depths within the glass substrate (and generate different magnitudes stresses within the glass substrate at different depths). The resulting relative depths of the stress-generating ions can be determined and cause different characteristics of the stress profile.

[0064] CS is measured using those means known in the art, such as by surface stress meter (FSM) using commercially available instruments such as the FSM-6000, manufactured by Orihara Industrial Co., Ltd. (Japan). Surface stress measurements rely upon the accurate measurement of the stress optical coefficient (SOC), which is related to the birefringence of the glass. SOC in turn is measured by those methods that are known in the art, such as fiber and four point bend methods, both of which are described in ASTM standard C770-98 (2013), entitled“Standard Test Method for Measurement of Glass Stress-Optical

Coefficient,” the contents of which are incorporated herein by reference in their entirety, and a bulk cylinder method. As used herein CS may be the“maximum compressive stress” which is the highest compressive stress value measured within the compressive stress layer.

In some embodiments, the maximum compressive stress is located at the surface of the glass substrate. In other embodiments, the maximum compressive stress may occur at a depth below the surface, giving the compressive profile the appearance of a“buried peak.”

[0065] DOC may be measured by FSM or by a scattered light polariscope (SCALP) (such as the SCALP-04 scattered light polariscope available from Glasstress Ltd., located in Tallinn Estonia), depending on the strengthening method and conditions. When the glass substrate is chemically strengthened by an ion exchange treatment, FSM or SCALP may be used depending on which ion is exchanged into the glass substrate. Where the stress in the glass substrate is generated by exchanging potassium ions into the glass substrate, FSM is used to measure DOC. Where the stress is generated by exchanging sodium ions into the glass substrate, SCALP is used to measure DOC. Where the stress in the glass substrate is generated by exchanging both potassium and sodium ions into the glass, the DOC is measured by SCALP, since it is believed the exchange depth of sodium indicates the DOC and the exchange depth of potassium ions indicates a change in the magnitude of the compressive stress (but not the change in stress from compressive to tensile); the exchange depth of potassium ions in such glass substrates is measured by FSM. Central tension or CT is the maximum tensile stress and is measured by SCALP.

[0066] In one or more embodiments, the glass substrate may be strengthened to exhibit a DOC that is described as a fraction of the thickness T1 of the glass substrate (as described herein). For example, in one or more embodiments, the DOC may be equal to or greater than about 0.05T1, equal to or greater than about 0.1T1, equal to or greater than about 0.11T1, equal to or greater than about 0.12T1, equal to or greater than about 0.13T1, equal to or greater than about 0.14T1, equal to or greater than about 0.15T1, equal to or greater than about 0.16T1, equal to or greater than about 0.17T1, equal to or greater than about 0.18T1, equal to or greater than about 0.19T1, equal to or greater than about 0.2T1 , equal to or greater than about 0.21T1. In some embodiments, the DOC may be in a range from about 0.08T1 to about 0.25T1, from about 0.09T1 to about 0.25T1, from about 0.18T1 to about 0.25T1, from about 0.11T1 to about 0.25T1, from about 0.12T1 to about 0.25T1, from about 0.13T1 to about 0.25T1, from about 0.14T1 to about 0.25T1, from about 0.15T1 to about 0.25T1, from about 0.08T1 to about 0.24T1, from about 0.08T1 to about 0.23T1, from about 0.08T1 to about 0.22T1, from about 0.08T1 to about 0.21T1, from about 0.08T1 to about 0.2T1, from about 0.08T1 to about 0.19T1, from about 0.08T1 to about 0.18T1, from about 0.08T1 to about 0.17T1, from about 0.08T1 to about 0.16T1, or from about 0.08T1 to about 0.15T1. In some instances, the DOC may be about 20 pm or less. In one or more embodiments, the DOC may be about 40 pm or greater (e.g., from about 40 pm to about 300 pm, from about 50 pm to about 300 pm, from about 60 pm to about 300 pm, from about 70 pm to about 300 pm, from about 80 pm to about 300 pm, from about 90 pm to about 300 pm, from about 100 pm to about 300 pm, from about 110 pm to about 300 pm, from about 120 pm to about 300 pm, from about 140 pm to about 300 pm, from about 150 pm to about 300 pm, from about 40 pm to about 290 pm, from about 40 pm to about 280 pm, from about 40 pm to about 260 pm, from about 40 pm to about 250 pm, from about 40 pm to about 240 pm, from about 40 pm to about 230 pm, from about 40 pm to about 220 pm, from about 40 pm to about 210 pm, from about 40 pm to about 200 pm, from about 40 pm to about 180 pm, from about 40 pm to about 160 pm, from about 40 pm to about 150 pm, from about 40 pm to about 140 pm, from about 40 pm to about 130 pm, from about 40 pm to about 120 pm, from about 40 mih to about 110 mih, or from about 40 mih to about 100 mih. In other embodiments, DOC falls within any one of the exact numerical ranges set forth in this paragraph.

[0067] In one or more embodiments, the strengthened glass substrate may have a CS (which may be found at the surface or a depth within the glass substrate) of about 200 MPa or greater, 300 MPa or greater, 400 MPa or greater, about 500 MPa or greater, about 600 MPa or greater, about 700 MPa or greater, about 800 MPa or greater, about 900 MPa or greater, about 930 MPa or greater, about 1000 MPa or greater, or about 1050 MPa or greater.

[0068] In one or more embodiments, the strengthened glass substrate may have a maximum tensile stress or central tension (CT) of about 20 MPa or greater, about 30 MPa or greater, about 40 MPa or greater, about 45 MPa or greater, about 50 MPa or greater, about 60 MPa or greater, about 70 MPa or greater, about 75 MPa or greater, about 80 MPa or greater, or about 85 MPa or greater. In some embodiments, the maximum tensile stress or central tension (CT) may be in a range from about 40 MPa to about 100 MPa. In other embodiments, CS falls within the exact numerical ranges set forth in this paragraph.

Glass Compositions

[0069] Suitable glass compositions for use in glass substrate 16 include soda lime glass, aluminosilicate glass, borosilicate glass, boroaluminosilicate glass, alkali-containing aluminosilicate glass, alkali-containing borosilicate glass, and alkali-containing

boroaluminosilicate glass.

[0070] Unless otherwise specified, the glass compositions disclosed herein are described in mole percent (mol%) as analyzed on an oxide basis.

[0071] In one or more embodiments, the glass composition may include SiC in an amount in a range from about 66 mol% to about 80 mol%, from about 67 mol% to about 80 mol%, from about 68 mol% to about 80 mol%, from about 69 mol% to about 80 mol%, from about 70 mol% to about 80 mol%, from about 72 mol% to about 80 mol%, from about 65 mol% to about 78 mol%, from about 65 mol% to about 76 mol%, from about 65 mol% to about 75 mol%, from about 65 mol% to about 74 mol%, from about 65 mol% to about 72 mol%, or from about 65 mol% to about 70 mol%, and all ranges and sub-ranges therebetween.

[0072] In one or more embodiments, the glass composition includes AI2O3 in an amount greater than about 4 mol%, or greater than about 5 mol%. In one or more embodiments, the glass composition includes AI2O3 in a range from greater than about 7 mol% to about 15 mol%, from greater than about 7 mol% to about 14 mol%, from about 7 mol% to about 13 mol%, from about 4 mol% to about 12 mol%, from about 7 mol% to about 11 mol%, from about 8 mol% to about 15 mol%, from about 9 mol% to about 15 mol%, from about 10 mol% to about 15 mol%, from about 11 mol% to about 15 mol%, or from about 12 mol% to about 15 mol%, and all ranges and sub-ranges therebetween. In one or more embodiments, the upper limit of AI2O3 may be about 14 mol%, 14.2 mol%, 14.4 mol%, 14.6 mol%, or 14.8 mol%.

[0073] In one or more embodiments, the glass article is described as an aluminosilicate glass article or including an aluminosilicate glass composition. In such embodiments, the glass composition or article formed therefrom includes S1O2 and AI2O3 and is not a soda lime silicate glass. In this regard, the glass composition or article formed therefrom includes AI2O3 in an amount of about 2 mol% or greater, 2.25 mol% or greater, 2.5 mol% or greater, about 2.75 mol% or greater, about 3 mol% or greater.

[0074] In one or more embodiments, the glass composition comprises B2O3 (e.g., about 0.01 mol% or greater). In one or more embodiments, the glass composition comprises B2O3 in an amount in a range from about 0 mol% to about 5 mol%, from about 0 mol% to about 4 mol%, from about 0 mol% to about 3 mol%, from about 0 mol% to about 2 mol%, from about 0 mol% to about 1 mol%, from about 0 mol% to about 0.5 mol%, from about 0.1 mol% to about 5 mol%, from about 0.1 mol% to about 4 mol%, from about 0.1 mol% to about 3 mol%, from about 0.1 mol% to about 2 mol%, from about 0.1 mol% to about 1 mol%, from about 0.1 mol% to about 0.5 mol%, and all ranges and sub-ranges therebetween. In one or more embodiments, the glass composition is substantially free of B2O3.

[0075] As used herein, the phrase“substantially free” with respect to the components of the composition means that the component is not actively or intentionally added to the composition during initial batching, but may be present as an impurity in an amount less than about 0.001 mol%.

[0076] In one or more embodiments, the glass composition optionally comprises P2O5 (e.g., about 0.01 mol% or greater). In one or more embodiments, the glass composition comprises a non-zero amount of P2O5 up to and including 2 mol%, 1.5 mol%, 1 mol%, or 0.5 mol%. In one or more embodiments, the glass composition is substantially free of P2O5.

[0077] In one or more embodiments, the glass composition may include a total amount of R2O (which is the total amount of alkali metal oxide such as L12O, Na₂0, K2O, Rb₂0, and CS2O) that is greater than or equal to about 8 mol%, greater than or equal to about 10 mol%, or greater than or equal to about 12 mol%. In some embodiments, the glass composition includes a total amount of R2O in a range from about 8 mol% to about 20 mol%, from about 8 mol% to about 18 mol%, from about 8 mol% to about 16 mol%, from about 8 mol% to about 14 mol%, from about 8 mol% to about 12 mol%, from about 9 mol% to about 20 mol%, from about 10 mol% to about 20 mol%, from about 11 mol% to about 20 mol%, from about 12 mol% to about 20 mol%, from about 13 mol% to about 20 mol%, from about 10 mol% to about 14 mol%, or from 11 mol% to about 13 mol%, and all ranges and sub-ranges therebetween. In one or more embodiments, the glass composition may be substantially free of Rb₂0, CS2O or both Rb₂0 and CS2O. In one or more embodiments, the R2O may include the total amount of LfrO, Na20 and K2O only. In one or more embodiments, the glass composition may comprise at least one alkali metal oxide selected from L12O, Na₂0 and K2O, wherein the alkali metal oxide is present in an amount greater than about 8 mol% or greater.

[0078] In one or more embodiments, the glass composition comprises Na₂0 in an amount greater than or equal to about 8 mol%, greater than or equal to about 10 mol%, or greater than or equal to about 12 mol%. In one or more embodiments, the composition includes Na₂0 in a range from about from about 8 mol% to about 20 mol%, from about 8 mol% to about 18 mol%, from about 8 mol% to about 16 mol%, from about 8 mol% to about 14 mol%, from about 8 mol% to about 12 mol%, from about 9 mol% to about 20 mol%, from about 10 mol% to about 20 mol%, from about 11 mol% to about 20 mol%, from about 12 mol% to about 20 mol%, from about 13 mol% to about 20 mol%, from about 10 mol% to about 14 mol%, or from 11 mol% to about 16 mol%, and all ranges and sub-ranges therebetween.

[0079] In one or more embodiments, the glass composition includes less than about 4 mol% K2O, less than about 3 mol% K2O, or less than about 1 mol% K2O. In some instances, the glass composition may include K2O in an amount in a range from about 0 mol% to about 4 mol%, from about 0 mol% to about 3.5 mol%, from about 0 mol% to about 3 mol%, from about 0 mol% to about 2.5 mol%, from about 0 mol% to about 2 mol%, from about 0 mol% to about 1.5 mol%, from about 0 mol% to about 1 mol%, from about 0 mol% to about 0.5 mol%, from about 0 mol% to about 0.2 mol%, from about 0 mol% to about 0.1 mol%, from about 0.5 mol% to about 4 mol%, from about 0.5 mol% to about 3.5 mol%, from about 0.5 mol% to about 3 mol%, from about 0.5 mol% to about 2.5 mol%, from about 0.5 mol% to about 2 mol%, from about 0.5 mol% to about 1.5 mol%, or from about 0.5 mol% to about 1 mol%, and all ranges and sub-ranges therebetween. In one or more embodiments, the glass composition may be substantially free of K2O.

[0080] In one or more embodiments, the glass composition is substantially free of LriO. [0081] In one or more embodiments, the amount of Na₂0 in the composition may be greater than the amount of LfrO. In some instances, the amount of Na20 may be greater than the combined amount of LfrO and K2O. In one or more alternative embodiments, the amount of L12O in the composition may be greater than the amount of Na₂0 or the combined amount of Na₂0 and K2O.

[0082] In one or more embodiments, the glass composition may include a total amount of RO (which is the total amount of alkaline earth metal oxide such as CaO, MgO, BaO, ZnO and SrO) in a range from about 0 mol% to about 2 mol%. In some embodiments, the glass composition includes a non-zero amount of RO up to about 2 mol%. In one or more embodiments, the glass composition comprises RO in an amount from about 0 mol% to about 1.8 mol%, from about 0 mol% to about 1.6 mol%, from about 0 mol% to about 1.5 mol%, from about 0 mol% to about 1.4 mol%, from about 0 mol% to about 1.2 mol%, from about 0 mol% to about 1 mol%, from about 0 mol% to about 0.8 mol%, from about 0 mol% to about 0.5 mol%, and all ranges and sub-ranges therebetween.

[0083] In one or more embodiments, the glass composition includes CaO in an amount less than about 1 mol%, less than about 0.8 mol%, or less than about 0.5 mol%. In one or more embodiments, the glass composition is substantially free of CaO.

[0084] In some embodiments, the glass composition comprises MgO in an amount from about 0 mol% to about 7 mol%, from about 0 mol% to about 6 mol%, from about 0 mol% to about 5 mol%, from about 0 mol% to about 4 mol%, from about 0.1 mol% to about 7 mol%, from about 0.1 mol% to about 6 mol%, from about 0.1 mol% to about 5 mol%, from about 0.1 mol% to about 4 mol%, from about 1 mol% to about 7 mol%, from about 2 mol% to about 6 mol%, or from about 3 mol% to about 6 mol%, and all ranges and sub-ranges therebetween.

[0085] In one or more embodiments, the glass composition comprises ZrC>2 in an amount equal to or less than about 0.2 mol%, less than about 0.18 mol%, less than about 0.16 mol%, less than about 0.15 mol%, less than about 0.14 mol%, less than about 0.12 mol%. In one or more embodiments, the glass composition comprises ZrC in a range from about 0.01 mol% to about 0.2 mol%, from about 0.01 mol% to about 0.18 mol%, from about 0.01 mol% to about 0.16 mol%, from about 0.01 mol% to about 0.15 mol%, from about 0.01 mol% to about 0.14 mol%, from about 0.01 mol% to about 0.12 mol%, or from about 0.01 mol% to about 0.10 mol%, and all ranges and sub-ranges therebetween. [0086] In one or more embodiments, the glass composition comprises SnC in an amount equal to or less than about 0.2 mol%, less than about 0.18 mol%, less than about 0.16 mol%, less than about 0.15 mol%, less than about 0.14 mol%, less than about 0.12 mol%. In one or more embodiments, the glass composition comprises Sn02 in a range from about 0.01 mol% to about 0.2 mol%, from about 0.01 mol% to about 0.18 mol%, from about 0.01 mol% to about 0.16 mol%, from about 0.01 mol% to about 0.15 mol%, from about 0.01 mol% to about 0.14 mol%, from about 0.01 mol% to about 0.12 mol%, or from about 0.01 mol% to about 0.10 mol%, and all ranges and sub-ranges therebetween.

[0087] In one or more embodiments, the glass composition may include an oxide that imparts a color or tint to the glass articles. In some embodiments, the glass composition includes an oxide that prevents discoloration of the glass article when the glass article is exposed to ultraviolet radiation. Examples of such oxides include, without limitation oxides of: Ti, V,

Cr, Mn, Fe, Co, Ni, Cu, Ce, W, and Mo.

[0088] In one or more embodiments, the glass composition includes Fe expressed as Fe2C>3, wherein Fe is present in an amount up to (and including) about 1 mol%. In some

embodiments, the glass composition is substantially free of Fe. In one or more embodiments, the glass composition comprises Fe₂C>₃ in an amount equal to or less than about 0.2 mol%, less than about 0.18 mol%, less than about 0.16 mol%, less than about 0.15 mol%, less than about 0.14 mol%, less than about 0.12 mol%. In one or more embodiments, the glass composition comprises Fe2C>3 in a range from about 0.01 mol% to about 0.2 mol%, from about 0.01 mol% to about 0.18 mol%, from about 0.01 mol% to about 0.16 mol%, from about 0.01 mol% to about 0.15 mol%, from about 0.01 mol% to about 0.14 mol%, from about 0.01 mol% to about 0.12 mol%, or from about 0.01 mol% to about 0.10 mol%, and all ranges and sub -ranges therebetween.

[0089] Where the glass composition includes T1O2, T1O2 may be present in an amount of about 5 mol% or less, about 2.5 mol% or less, about 2 mol% or less or about 1 mol% or less. In one or more embodiments, the glass composition may be substantially free of T1O2.

[0090] An exemplary glass composition includes S1O2 in an amount in a range from about 65 mol% to about 75 mol%, AI2O3 in an amount in a range from about 8 mol% to about 14 mol%, Na₂0 in an amount in a range from about 12 mol% to about 17 mol%, K2O in an amount in a range of about 0 mol% to about 0.2 mol%, and MgO in an amount in a range from about 1. 5 mol% to about 6 mol%. Optionally, Sn0₂ may be included in the amounts otherwise disclosed herein. It should be understood, that while the preceding glass composition paragraphs express approximate ranges, in other embodiments, glass substrate 16 may be made from any glass composition falling with any one of the exact numerical ranges discussed above.

[0091] Aspect (1) pertains to a method of forming a glass article, comprising the steps of: applying an adhesive layer to a frame, the frame comprising at least a first curvature; aligning a substantially planar glass sheet with the frame; and pressure rolling the glass sheet and the frame between at least a first roller and a second roller so as to bend the glass sheet into conformity with the first curvature of the frame, wherein at least one of the first roller and the second roller is configured to apply a pressure normal to the glass sheet and frame during pressure rolling.

[0092] Aspect (2) pertains to the method of Aspect (1), wherein the adhesive layer comprises at least one of a toughened adhesive, a flexible epoxy, an acrylic, a urethane, a silicone, or a pressure sensitive adhesive tape and wherein the adhesive layer bonds the glass sheet to the frame to maintain the glass sheet in conformity with the first curvature of the frame.

[0093] Aspect (3) pertains to the method of Aspect (1), wherein the adhesive layer comprises a double-sided adhesive sheet comprising a release layer and wherein the step of applying the adhesive layer to the frame further comprises pressure rolling the adhesive layer onto the frame with the release layer facing away from the frame.

[0094] Aspect (4) pertains to the method of Aspect (3), wherein the adhesive layer has a larger area than a surface of the frame and wherein the method further comprises the step of trimming the adhesive layer to match the surface of the frame.

[0095] Aspect (5) pertains to the method of Aspect (4), wherein the frame comprises at least one opening for a display device and wherein the step of trimming the adhesive layer further comprises removing a region of the adhesive layer corresponding to each of the at least one opening.

[0096] Aspect (6) pertains to the method of any one of Aspects (1) through (5), wherein the step of aligning further comprises positioning the glass sheet and the frame between a first adjustable alignment plate and a second adjustable alignment plates prior to or during the step of pressure rolling.

[0097] Aspect (7) pertains to the method of Aspect (6), wherein the step of aligning further comprises positioning the glass sheet and the frame on an alignment jig comprising a plurality of alignment pins, inserting the alignment jig between the first adjustable alignment plate and the second adjustable alignment plate, and moving at least some of the alignment pins so that the glass sheet and frame are able to be fed across the alignment jig during pressure rolling.

[0098] Aspect (8) pertains to the method of Aspect (6) or Aspect (7), wherein the glass sheet and frame each have a non-uniform width and wherein the first adjustable alignment plate and the second adjustable alignment plate are configured to move laterally during pressure rolling such that the first adjustable alignment plate and the second adjustable alignment plate remain in contact with the glass sheet and the frame.

[0099] Aspect (9) pertains to the method of any one of Aspects (1) through (8), further comprising the step of applying a clamping force to the glass sheet and the frame after the step of pressure rolling.

[00100] Aspect (10) pertains to the method of any one of Aspects (1) through (9), further comprising the step of curing the adhesive layer with ultraviolet light or at elevated temperature.

[00101] Aspect (11) pertains to the method of any one of Aspects (1) through (10), wherein the frame further comprises a second curvature.

[00102] Aspect (12) pertains to the method of Aspect (11), wherein the first curvature is concave, and the second curvature is convex.

[00103] Aspect (13) pertains to the method of Aspect (11) or Aspect (12), wherein at least one of the first curvature or the second curvature has a bend radius of less than 100 mm.

[00104] Aspect (14) pertains to the method of any one of Aspects (1) through (13), wherein the glass sheet comprises a chemically strengthened aluminosilicate glass composition.

[00105] Aspect (15) pertains to the method of any one of Aspects (1) through (14), wherein the glass sheet has a thickness of from 0.4 mm to 2.0 mm.

[00106] Aspect (16) pertains to the method of any one of Aspects (1) through (15), wherein the method further comprises the step of applying a surface treatment to the second side of the glass sheet prior to the step of pressure rolling.

[00107] Aspect (17) pertains to the method of Aspect (16), wherein the surface treatment is at least one of a tint film, an ink or pigment design, an anti-glare treatment, an anti-reflective coating, and easy-to-clean coating.

[00108] Aspect (18) pertains to an alignment system for rolling a curved glass article comprising a glass sheet bonded to a frame, the alignment system configured for placement proximal to a set of rollers, the alignment system comprising: a first alignment plate; and a second alignment plate arranged parallel to the first alignment plate, the second alignment plate being separated from the first alignment plate by a distance corresponding to a width of at least one of the frame or the glass substrate; wherein the first alignment plate and the second alignment plate are configured to move parallel to the set of rollers so as to set the distance corresponding to the width prior to or during rolling of the curved glass article.

[00109] Aspect (19) pertains to the alignment system of Aspect (18), further comprising an alignment jig comprising a plurality of alignment pins, the alignment jig positioned between the first alignment plate and the second alignment plate, wherein the alignment jig is configured to align the glass sheet with the frame using the plurality of alignment pins.

[00110] Aspect (20) pertains to the alignment system of Aspect (19), wherein alignment jig has a first end and a second end, wherein the plurality of alignment pins comprises a row of alignment pins across the first end, and wherein the row of alignment pins is configured move so that the glass sheet and the frame are able to pass across the alignment jig from the second end to the first end during rolling.

[00111] Aspect (21) pertains to the alignment system of any one of Aspects (18) through (20), wherein the first alignment plate and the second alignment plate apply pressure on the glass article.

[00112] Aspect (22) pertains to the alignment system of Aspect (21), wherein springs apply spring force on the first alignment plate and on the second alignment plate to cause the first alignment plate and the second alignment plate to apply pressure on the glass article.

[00113] Aspect (23) pertains to a pressure rolling system, comprising: the alignment system according to any one of Aspects (18) through (22); and a set of pressure rollers.

[00114] Aspect (24) pertains to the pressure rolling system of Aspect (23), wherein the set of pressure rollers are configured to apply heat to the glass article during rolling.

[00115] Aspect (25) pertains to the alignment system of Aspect (23) or Aspect (24), wherein at least one pressure roller of the set of pressure rollers is mechanically linked to a spring mechanism that allows for adjustment of the height of the at least one pressure roller during rolling while applying a constant force on the at least one pressure roller.

[00116] Aspect (26) pertains to the alignment system of any one of Aspects (23) through (25), further comprising a clamping mechanism configured to apply a clamping force to the glass article after the glass article exits the set of pressure rollers.

[00117] Aspect (27) pertains to a glass article, comprising: a glass sheet comprising a first major surface and a second major surface, the second major surface comprising at least a first curve; a frame comprising a support surface, the support surface comprising at least a first complementary curve, wherein the second major surface of the glass sheet faces the support surface of the frame and wherein the first complementary curve is complementary to the first curve; and an adhesive layer bonding the glass sheet to the frame; wherein the structural adhesive layer covers at least 80% of the support surface of the frame.

[00118] Aspect (28) pertains to the glass article of Aspect (27), wherein the adhesive layer is a sheet of pressure-sensitive adhesive tape.

[00119] Aspect (29) pertains to the glass article of Aspect (27), wherein the adhesive layer comprises at least one of a toughened adhesive, a flexible epoxy, an acrylic, a urethane, or a silicone.

[00120] Aspect (30) pertains to the glass article of any one of Aspects (27) through (29), further comprising at least one display device bonded to the frame using optically clear adhesive.

[00121] Aspect (31) pertains to the glass article of any one of Aspects (27) through (30), wherein the glass sheet comprises a chemically strengthened aluminosilicate glass composition.

[00122] Aspect (32) pertains to the glass article of any one of Aspects (27) through (31), wherein the glass sheet has a thickness of from 0.4 mm to 2.0 mm.

[00123] Aspect (33) pertains to the glass article of any one of Aspects (27) through (32), further comprising a surface treatment on the first major surface of the glass sheet.

[00124] Aspect (34) pertains to the glass article of any one of Aspects (27) through (33), wherein the surface treatment is at least one of a tint film, an ink or pigment design, an anti glare treatment, an anti-reflective coating, and easy-to-clean coating.

[00125] Aspect (35) pertains to the glass article of any one of Aspects (27) through (34), wherein the second major surface of the glass sheet comprises a second curve and the support surface of the frame comprises a second complementary curve.

[00126] Aspect (36) pertains to the glass article of Aspect (35), wherein at least one of the first curve or the second curve has a radius of curvature of 100 mm or less.

[00127] Aspect (37) pertains to the glass article of any one of Aspect (35) or Aspect (36), wherein the first curve is concave and the second curve is convex.

[00128] Aspect (38) pertains to a vehicle interior comprising the glass article according to any one of Aspects (27) through (37).

[00129] Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is in no way intended that any particular order be inferred. In addition, as used herein, the article "a" is intended to include one or more than one component or element, and is not intended to be construed as meaning only one.

[00130] It will be apparent to those skilled in the art that various modifications and variations can be made without departing from the spirit or scope of the disclosed

embodiments. Since modifications, combinations, sub-combinations and variations of the disclosed embodiments incorporating the spirit and substance of the embodiments may occur to persons skilled in the art, the disclosed embodiments should be construed to include everything within the scope of the appended claims and their equivalents.

Claims

What is claimed is:

1. A method of forming a glass article, comprising the steps of: applying an adhesive layer to a frame, the frame comprising at least a first curvature; aligning a substantially planar glass sheet with the frame; and pressure rolling the glass sheet and the frame between at least a first roller and a second roller so as to bend the glass sheet into conformity with the first curvature of the frame, wherein at least one of the first roller and the second roller is configured to apply a presssure normal to the glass sheet and frame during pressure rolling.

2. The method of claim 1, wherein the adhesive layer comprises at least one of a

toughened adhesive, a flexible epoxy, an acrylic, a urethane, a silicone, or a pressure sensitive adhesive tape and wherein the adhesive layer bonds the glass sheet to the frame to maintain the glass sheet in conformity with the first curvature of the frame.

3. The method of claim 1, wherein the adheisve layer comprises a double-sided adhesive sheet comprising a release layer and wherein the step of applying the adhesive layer to the frame further comprises pressure rolling the adhesive layer onto the frame with the release layer facing away from the frame.

4. The method of claim 3, wherein the adhesive layer has a larger area than a surface of the frame and wherein the method further comprises the step of trimming the adhesive layer to match the surface of the frame.

5. The method of claim 4, wherein the frame comprises at least one opening for a

display device and wherein the step of trimming the adhesive layer further comprises removing a region of the adhesive layer corresponding to each of the at least one opening.

6. The method of any one of the preceding claims, wherein the step of aligning further comprises positioning the glass sheet and the frame between a first adjustable alignment plate and a second adjustable alignment plates prior to or during the step of pressure rolling.

7. The method of claim 6, wherein the step of aligning further comprises positioning the glass sheet and the frame on an alignment jig comprising a plurality of alingment pins, inserting the alignment jig between the first adjustable alignment plate and the second adjustable alignment plate, and moving at least some of the alignment pins so that the glass sheet and frame are able to be fed across the alignment jig during pressure rolling.

8. The method of claim 6 or claim 7, wherein the glass sheet and frame each have a non- uniform width and wherein the first adjustable alignment plate and the second adjustable alignment plate are configured to move laterally during pressure rolling such that the first adjustable alignment plate and the second adjustable alignment plate remain in contact with the glass sheet and the frame.

9. The method of any one of the preceding claims, further comprising the step of

applying a clamping force to the glass sheet and the frame after the step of pressure rolling.

10. The method of any one of the preceding claims, further comprising the step of curing the adhesive layer with ultraviolet light or at elevated temperature.

11. The method of any one of the preceding claims, wherein the frame further comprises a second curvature.

12. The method of claim 11 , wherein the first curvature is concave and the second

curvature is convex.

13. The method of claim 11 or claim 12, wherein at least one of the first curvature or the second curvature has a bend radius of less than 10000 mm.

14. The method of any one of the preceding claims, wherein the glass sheet comprises a chemically strengthened aluminosilicate glass composition.

15. The method of any one of the preceding claims, wherein the glass sheet has a

thickness of from 0.4 mm to 2.0 mm.

16. The method of any one of the preceding claims, wherein the method further comprises the step of applying a surface treatment to the second side of the glass sheet prior to the step of pressure rolling.

17. The method of claim 16, wherein the surface treatment is at least one of a tint film, an ink or pigment design, an anti-glare treatment, an anti-reflective coating, and easy-to- clean coating.

18. An alignment system for rolling a curved glass article comprising a glass sheet

bonded to a frame, the alignment system configured for placement proximal to a set of rollers, the alignment system comprising: a first alignment plate; and a scond aligment plate arranged parallel to the first alignment plate, the second alignment plate being separated from the first alignment plate by a distance corresponding to a width of at least one of the frame or the glass substrate; wherein the first alignment plate and the second alignment plate are configured to move parallel to the set of rollers so as to set the distance corresponding to the width prior to or during rolling of the curved glass article.

19. The alignment system of claim 18, further comprising an alignment jig comprising a plurality of alignment pins, the alignment jig positioned between the first alignment plate and the second alignment plate, wherein the alignment jig is configured to align the glass sheet with the frame using the plurality of alignment pins.

20. The alignment system of claim 19, wherein alignment jig has a first end and a second end, wherein the plurality of alignment pins comprises a row of alignment pins across the first end, and wherein the row of alignment pins are configured move so that the glass sheet and the frame are able to pass across the alignment jig from the second end to the first end during rolling.

21. The alignment system according to any one of claims 18-20, wherein the first

alignment plate and the second alignment plate apply pressure on the glass article.

22. The alignment system of claim 21, wherein springs apply spring force on the first alignment plate and on the second alignment plate to cause the first alignment plate and the second alignment plate to apply pressure on the glass article.

23. A presure rolling system, comprising: the alignment system according to any one of claims 18-22; and a set of pressure rollers.

24. The pressure rolling system of claim 23, wherein the set of pressure rollers are

configured to apply heat to the glass article during rolling.

25. The pressure rolling system of claim 23 or claim 24, wherein at least one pressure roller of the set of pressure rollers is mechanically linked to a spring mechanism that allows for adjustment of the height of the at least one pressure roller during rolling while applying a constant force on the at least one pressure roller.

26. The pressure rolling system according to any one of claims 23-25, further comprising a clamping mechanism configured to apply a clamping force to the glass article after the glass article exits the set of pressure rollers.

27. A glass article, comprising: a glass sheet comprising a first major surface and a second major surface, the second major surface comprising at least a first curve; a frame comprising a support surface, the support surface comprising at least a first complementary curve, wherein the second major surface of the glass sheet faces the support surface of the frame and wherein the first complementary curve is complementary to the first curve; and an adhesive layer bonding the glass sheet to the frame; wherein the structural adhesive layer covers at least 80% of the support surface of the frame.

28. The glass article of claim 27, wherein the adhesive layer is a sheet of pressure- senstive adhesive tape.

29. The glass article of claim 27, wherein the adhesive layer comprises at least one of a toughened adhesive, a flexible epoxy, an acrylic, a urethane, or a silicone.

30. The glass article according to any one of claims 27-29, further comprising at least one display device bonded to the frame using optically clear adhesive.

31. The glass article according to any one of claims 27-30, wherein the glass sheet

comprises a chemically strengthened aluminosilicate glass composition.

32. The glass article according to any one of claims 27-31, wherein the glass sheet has a thickness of from 0.4 mm to 2.0 mm.

33. The glass article according to any one of claims 27-32, further comprising a surface treatment on the first major surface of the glass sheet.

34. The glass article according to any one of claims 27-33, wherein the surface treatment is at least one of a tint film, an ink or pigment design, an anti-glare treatment, an anti- reflective coating, and easy-to-clean coating.

35. The glass article according to any one of claims 27-34, wherein the second major surface of the glass sheet comprises a second curve and the support surface of the frame comprises a second complementary curve.

36. The glass article according to claim 35, wherein at least one of the first curve or the second curve has a radius of curvature of 10,000 mm or less.

37. The glass article according to any one of claim 35 or claim 36, wherein the first curve is concave and the second curve is convex.

38. A vehicle interior comprising the glass article according to any one of claims 27-37.