# US 11,993,148 B2 · Cold formed 3D product and processes using vacuum chuck

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- Number: US 11,993,148 B2
- Document ID: US11993148B2
- Status: Granted
- Kind: B2
- Application number: 17/606,490
- Filed: 2020-04-21
- Published: 2022-06-30
- Granted: 2024-05-28
- Earliest claimed: 2019-04-29
- Assignees: Corning Incorporated
- Applicants: Corning Incorporated
- Inventors: Peter Knowles; Christopher Mark Schweiger; Christopher Lee Timmons; Arlin Lee Weikel
- Web page: https://patentgrep.com/patent/US11993148B2

## CPC

- B60K 35/50: Instruments characterised by their means of attachment to or integration in the vehicle (B60K35/231 takes precedence)
- B60K 35/22: Display screens
- B60K 35/60: Instruments characterised by their location or relative disposition in or on vehicles (arrangements of lighting devices on dashboards B60Q3/10)
- B60K 2360/1523: Matrix displays
- B60K 2360/1526: Dual-view displays
- B60K 2360/688: Frames or decorative parts
- B60K 2360/691: Housings
- B60K 2360/692: Sealings
- B60K 2360/693: Cover plate features
- B60K 2360/774: on or in the centre console
- B60K 2360/816: Fastening of displays or touch screens
- B60K 2360/92: Manufacturing of instruments
- B60K 2360/96: by assembling
- B60Y 2200/11: Passenger cars; Automobiles
- G02F 1/133308: {Support structures for LCD panels, e.g. frames or bezels}
- G02F 1/133331: {Cover glasses}
- B60K: ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
- B60Y: INDEXING SCHEME RELATING TO ASPECTS CROSS-CUTTING VEHICLE TECHNOLOGY
- G02F: OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS

## Abstract

The disclosure relates to vacuum forming methods, apparatuses and resulting displays that represent improvements in various key areas. The methods, for example, greatly improve manufacturing throughput through reduced curing times. The methods further facilitate improved control of glass shape to a targeted shape and improved control of bond line thickness, which result in improved survivability and long-term reliability, for example.

## Claims

### Claim 1

An apparatus for housing a plurality of display modules within a vehicle interior system, comprising:
a frame having a curved central portion, a first wing portion connected to a first side of the curved central portion and defining a first opening configured to receive a first one of the plurality of display modules therein, and a second wing portion connected to an opposing second side of the curved central portion and defining a second opening configured to receive a second one of the plurality of display modules therein;
a glass substrate positioned on the frame and including a curved central portion interfacing with the curved central portion of the frame, 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; and
a bonding medium attaching the glass substrate to the frame, wherein the bonding medium has a thickness between the glass substrate and the frame that varies by less than 400 μm, wherein one or more of the first wing portion of the glass substrate, the first wing portion of the frame, the second wing portion of the glass substrate and the second wing portion of the frame each have at least one surface that is substantially flat with a curvature that varies by less than or equal to 0.250 units of Diopter in magnitude.

### Claim 2 (depends on 1)

The apparatus of claim 1, 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 0.100 Diopter in magnitude.

### Claim 3 (depends on 1)

The apparatus of claim 1, 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.

### Claim 4 (depends on 1)

The apparatus of claim 1, wherein one or more of the curved central portion of the frame and the curved central portion of the glass substrate each have a radius of curvature of at least 20 mm but less than 2000 mm.

### Claim 5 (depends on 1)

The apparatus of claim 1, wherein the bonding medium comprises a structural adhesive.

### Claim 6 (depends on 1)

The apparatus of claim 1, further comprising a spacer positioned between the frame and the glass substrate and positioned adjacent the bonding medium.

### Claim 7 (depends on 6)

The apparatus of claim 6, wherein the spacer comprises one or more of VHB tape, foam tape, rigid polymer, compliant polymer or fully or partially cured structural adhesive.

### Claim 8

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.

### Claim 9 (depends on 8)

The apparatus of claim 8, wherein the glass substrate is attached to the frame by a bonding medium, and wherein the bonding medium has a thickness between the glass substrate and the frame that varies by less than 400 μm.

### Claim 10

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.

### Claim 11 (depends on 10)

The method of claim 10, wherein the plurality of forming pieces includes a central forming piece that comprises the at least one of the plurality of forming pieces with the major surface with the radius of curvature.

### Claim 12 (depends on 11)

The method of claim 11, wherein the plurality of forming pieces further includes a first wing piece with the major surface thereof that is substantially flat and a second wing piece with the major surface thereof that is substantially flat.

### Claim 13 (depends on 10)

The method of claim 10, wherein the applying the desired force to the frame to compress the adhesive to the desired thickness is controlled by a mechanical stop.

### Claim 14 (depends on 10)

The method of claim 10, wherein applying the air pressure differential with the forming apparatus includes applying a different amount of the air pressure differential for one or more of the plurality of forming pieces.

### Claim 15 (depends on 10)

The method of claim 10, wherein the major surface of the forming apparatus defines a plurality of channels that communicate with the glass substrate to allow for applying the air pressure differential.