Cold formed 3D product and processes using vacuum chuck

An apparatus for housing a plurality of display modules within an interior of a vehicle, comprising:

• a frame having a curved central portion and configured to house at least one of the plurality of display modules therein;
• a glass substrate attached to and positioned on the frame and including a curved central portion interfacing with the curved central portion of the frame, wherein the curved central portion of the glass substrate has a radius of curvature that is within 100 μm of a radius of curvature of the curved central portion of the frame, wherein the frame further comprises:
• a first wing portion connected to a first side of the central portion and defining a first opening configured to receive one of the plurality of display modules therein, and
• a second wing portion connected to an opposing second side of the central portion and defining a second opening configured to receive another of the plurality of display modules therein,
• wherein the glass substrate further comprises:
• a first wing portion interfacing with the first wing portion of the frame and covering the first opening, and
• a second wing portion interfacing with the second wing portion of the frame and covering the second opening,
• wherein the first wing portion of the glass substrate and the second wing portion of the glass substrate each have at least one major surface that is substantially flat with a curvature that varies by less than or equal to 0.150 Diopter in magnitude.

A method of forming a display for mounting one or more display modules in a vehicle interior system, the method comprising:

• positioning a glass substrate on a forming apparatus, wherein the forming apparatus has a plurality of forming pieces each with a major surface configured to interface with the glass substrate, wherein the major surface of at least one of the plurality of forming pieces has a radius of curvature;
• applying an air pressure differential with the forming apparatus to cause the glass substrate to deform and assume a shape along a major surface thereof corresponding to that of each major surface of the forming apparatus, wherein a portion of the major surface of the glass substrate deforms to have a radius of curvature corresponding with the radius of curvature of the major surface at least one of the plurality of forming pieces;
• applying a structural adhesive to one or more of a frame and the glass substrate;
• positioning the frame on the glass substrate with the structural adhesive positioned therebetween;
• applying a desired force to the frame to compress the structural adhesive to a desired thickness;
• removing the glass substrate from one or more of the plurality of forming pieces of the forming apparatus while maintaining the glass substrate clamped to the at least one of the plurality of forming pieces;
• and
• maintaining applying the desired force to compress the structural adhesive to the desired thickness for a desired duration of time with the glass substrate clamped to the at least one of the plurality of forming pieces and with the glass substrate removed from one or more of the plurality of forming pieces of the forming apparatus.