Patent Description:
The disclosure relates to a vacuum chuck and a method of forming a curved glass article using same and, more particularly, to a vacuum chuck having a plurality of elongate groves, connected by a cross conduit, that are configured to hold a glass sheet in a cold-bent configuration.

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 sheets are desirable, especially when used as covers for displays. Existing methods of forming such curved glass sheets, such as thermal forming, have drawbacks including high cost, optical distortion, and surface marking. Additionally, to meet manufacturing demands, several forming apparatuses are needed for each processing line, and because of the number of forming apparatuses needed, the forming apparatuses are preferably relatively inexpensive to manufacture and use. Accordingly, Applicant has identified a need for vehicle interior systems that can incorporate a curved glass sheet in a cost-effective manner and without problems typically associated with glass thermal forming processes.

<CIT> discloses a method of forming a shaped glass article and includes placing a glass sheet on a mold such that a first glass area of the glass sheet corresponds to a first mold surface area of the mold and a second glass area of the glass sheet corresponds to a second mold surface area of the mold. The first glass area and the second glass area are heated such that the viscosity of the second glass area is <NUM> poise or more lower than the viscosity of the first glass area. A force is applied to the glass sheet to conform the glass sheet to the mold surface. During the heating of the second glass area, the first mold surface area is locally cooled to induce a thermal gradient on the mold.

<CIT> discloses a laser irradiation device for heating by irradiating at least one laser beam having a shape corresponding to a specific region of the glass material to be molded to the specific region of the glass material; And a forming mold on which the glass material is loaded and configured to vacuum-adsorb and shape a specific region of the glass material heated by the laser beam.

The present disclosure relates to a vacuum chuck and a method as set out in the appended set of claims. According to an aspect, embodiments of the disclosure relate to a vacuum chuck. The vacuum chuck includes a forming surface having a first longitudinal end, a second longitudinal end, and a curved region. The first longitudinal end and the second longitudinal end define a longitudinal axis, and the curved region defines a radius of curvature along the longitudinal axis. A plurality of elongate grooves are formed into the forming surface in the curved region. Each elongate groove of the plurality of elongate grooves has a length, a width, and a depth extending into the forming surface. The length of each elongate groove is greater than the width. The plurality of elongate grooves extend parallel to one another and are spaced apart from one another by a spacing of <NUM> to <NUM> in a direction perpendicular to the length. At least one conduit is configured for connection to a vacuum source and is disposed beneath the forming surface. The at least one conduit extends transversely across the plurality of elongate grooves, and the at least one conduit is in fluid communication with the plurality of elongate grooves.

According to another aspect, embodiments of the disclosure relate to a method in which a glass sheet is bent over a forming surface. The glass sheet has a first major surface and a second major surface. The second major surface opposes the first major surface, and the first major surface and the second major surface define a thickness of the glass sheet. The forming surface has a curved region and a plurality of elongate grooves. The curved region defines a first radius of curvature. The plurality of elongate grooves extend parallel to one another and are spaced apart from one another by a spacing of <NUM> to <NUM> in a direction perpendicular to the length. The second major surface of the glass sheet conforms to the curved region of the forming surface. In the method, a vacuum is drawn through the plurality of elongate grooves to hold the glass sheet against the forming surface.

According to still another aspect, embodiments of the disclosure relate to a vacuum chuck. The vacuum chuck includes a resin body having a forming surface. The forming surface defines a curvature having a first radius of curvature. A plurality of elongate grooves are formed into the forming surface. At least one conduit is formed in the resin body. The plurality of elongate grooves are in fluid communication with the at least one conduit, and the at least one conduit is configured for connection to a vacuum source. A gasket extends around a periphery of the forming surface. The gasket is seated within a channel formed into the forming surface.

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.

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. The drawings illustrate one or more embodiment(s), and together with the description serve to explain principles and operation of the various embodiments.

Reference will now be made in detail to various embodiments of a vacuum chuck and embodiments of cold-forming a curved glass article using same. Exemplary embodiments 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 a vacuum chuck for forming such curved surfaces. Forming curved vehicle surfaces from a glass material provides 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. Thus, glass is being incorporated into more systems of a vehicle interior. As such, new tools are needed to efficiently, accurately, and inexpensively form curved glass articles for incorporation into the vehicle interior systems.

Accordingly, as will be discussed in more detail below, Applicant has developed a vacuum chuck for cold-forming curved glass articles. In particular, the vacuum chuck includes a plurality of elongate grooves through which a vacuum is drawn to hold a glass sheet in a bent configuration when cold-forming the curved glass article. Advantageously, the elongate grooves provide greater vacuum pressure and is easier to manufacture than conventional vacuum chucks that include vacuum holes in fluid communication with a hollowed-out interior.

In order to provide context for the vacuum chuck, exemplary embodiments of curved glass articles that can be formed thereon will be described in relation to the particular application of a vehicle interior system. <FIG> shows an exemplary vehicle interior <NUM> that includes three different embodiments of a vehicle interior system <NUM>, <NUM>, <NUM>. Vehicle interior system <NUM> includes a frame, shown as center console base <NUM>, with a curved surface <NUM> including a curved display <NUM>. Vehicle interior system <NUM> includes a frame, shown as dashboard base <NUM>, with a curved surface <NUM> including a curved display <NUM>. The dashboard base <NUM> typically includes an instrument panel <NUM> which may also include a curved display. Vehicle interior system <NUM> includes a frame, shown as steering wheel base <NUM>, with a curved surface <NUM> and a curved display <NUM>. 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). In embodiments, the display <NUM>, <NUM>, <NUM> may be at least one of a light-emitting diode display, an organic light-emitting diode display, a quantum dot display, a plasma display, or a liquid crystal display bonded to a rear surface (e.g., using an optically clear adhesive) of a curved glass article <NUM> disclosed herein. Further, the displays <NUM>, <NUM>, <NUM> may be provided with touch functionality using a wire resistive sensor, a capacitive sensor, an acoustic wave sensor, an infrared sensor, etc..

The embodiments of the curved glass article described herein can be used in each of vehicle interior systems <NUM>, <NUM> and <NUM>. Further, the curved glass articles discussed herein may be used as curved cover glasses for any of the curved display embodiments discussed herein, including for use in vehicle interior systems <NUM>, <NUM> and/or <NUM>. Further, in various embodiments, various non-display components of vehicle interior systems <NUM>, <NUM> and <NUM> 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.

<FIG> depicts a curved glass article <NUM>, such as the cover glass for curved display <NUM>, <NUM>, <NUM> according to exemplary embodiments. It should be understood that, while <FIG> is described in terms of forming curved display <NUM>, <NUM>, <NUM>, the curved glass article <NUM> of <FIG> may be used in any suitable curved glass application, including any curved glass component of any of the vehicle interior systems of <FIG> or other curved glass surfaces of the vehicle interior <NUM>. Such curved 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.

As shown in <FIG>, the curved glass article <NUM> includes a glass sheet <NUM> and a frame <NUM>. The frame <NUM> holds the glass sheet <NUM> in a curved configuration. As shown in the side view of <FIG>, the glass sheet <NUM> includes a first major surface <NUM> and a second maj or surface <NUM> opposite first major surface <NUM>. A minor surface <NUM> connects the first major surface <NUM> and the second major surface <NUM>, and in specific embodiments, minor surface <NUM> defines the outer perimeter of glass sheet <NUM>. The glass sheet <NUM> is attached to the frame <NUM> via an adhesive layer <NUM>.

The adhesive layer <NUM> provides long term strength after curing over the course of, e.g., about an hour at ambient temperature. In embodiments, exemplary adhesives for the adhesive layer <NUM> include toughened epoxy, flexible epoxy, acrylics, silicones, urethanes, polyurethanes, and silane modified polymers.

The glass sheet <NUM> has a curved shape such that first major surface <NUM> and second major surface <NUM> each include at least one curved section having a radius of curvature R1. In embodiments, R1 is between <NUM> and <NUM>. Further, in embodiments, the glass sheet <NUM> has a thickness (e.g., an average thickness measured between surfaces <NUM>, <NUM>) that is in a range from <NUM> to <NUM>. In specific embodiments, the thickness is less than or equal to <NUM> and in more specific embodiments, the thickness is <NUM> to <NUM>. Applicant has found that such thin glass sheets can be cold formed to a variety of curved shapes (including the relatively tight radii of curvature discussed herein) utilizing cold forming 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 sheets <NUM> may deform more readily, which could potentially compensate for shape mismatches and gaps that may exist relative to the frame <NUM>.

In various embodiments, first major surface <NUM> and/or the second major surface <NUM> of glass sheet <NUM> includes one or more surface treatments or layers. The surface treatment may cover at least a portion of the first major surface <NUM> and/or second major surface <NUM>. 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 <NUM> and/or the second major surface <NUM> 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 <NUM> may include an anti-glare surface and second major surface <NUM> may include an anti-reflective surface. In another example, first major surface <NUM> includes an anti-reflective surface and second major surface <NUM> includes an anti-glare surface. In yet another example, the second major surface <NUM> comprises either one of or both the anti-glare surface and the anti-reflective surface, and the first major surface <NUM> includes the easy-to-clean coating. 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.

In embodiments, the glass sheet <NUM> may also include a pigment design on the first major surface <NUM> and/or second major surface <NUM>. 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 leather design, a brushed metal design, a graphic design, a portrait, or a logo. The pigment design may be printed onto the glass sheet.

In general, glass sheet <NUM> is cold formed or cold bent to the desired curved shape via application of a bending force to the glass sheet <NUM> while it is situated on a vacuum chuck <NUM>, such as shown in <FIG>. Advantageously, it is easier to apply surface treatments to a flat glass sheet <NUM> prior to creating the curvature in the glass sheet <NUM>, and cold-forming allows the treated glass sheet <NUM> to be bent without destroying the surface treatment (as compared to the tendency of high temperatures associated with hot-forming to destroy surface treatments, which requires surface treatments to be applied to the curved article in a more complicated process). In embodiments, the cold forming process is performed at a temperature less than the glass transition temperature of the glass sheet <NUM>. In particular, the cold forming process may be performed at room temperature (e.g., about <NUM>) or a slightly elevated temperature, e.g., at <NUM> or less, <NUM> or less, <NUM> or less, or at <NUM> or less.

The vacuum chuck <NUM> is used to hold the glass sheet <NUM> in the cold-bent configuration while a frame <NUM> is bonded to the glass sheet <NUM>. Upon curing, the frame <NUM> will permanently keep the glass sheet <NUM> in the cold-bent configuration. During manufacturing of various automotive systems, multiple vacuum chucks <NUM> may be needed for each interior system in which the curved glass article <NUM> is incorporated. In particular, because curing of the adhesive <NUM> bonding the frame <NUM> to the glass sheet <NUM> may take several tens of minutes, manufacturers tend to cold-bend several glass sheets <NUM> at the same time, requiring multiple vacuum chucks <NUM> (e.g., twelve to fifteen identical vacuum chucks <NUM>) potentially for each design. The embodiments of the vacuum chuck <NUM> disclosed herein are intended to decreasing the manufacturing cost and complexity of the vacuum chuck <NUM> while also enhancing functionality and increasing flexibility of use.

The vacuum chuck <NUM> includes a forming surface <NUM> having formed therein one or more sets of elongate grooves <NUM>. The forming surface <NUM> has a first longitudinal end <NUM> and a second longitudinal end <NUM> that define a longitudinal axis α. The forming surface <NUM> is curved at the radius of curvature R1 along the longitudinal axis α. Further, in embodiments, the elongate grooves <NUM> extend across the forming surface <NUM> parallel to the longitudinal axis α. In other embodiments, the elongate grooves <NUM> are arranged transversely to the longitudinal axis α. The chuck <NUM> has a length across the curved forming surface <NUM> between the first longitudinal end <NUM> and the second longitudinal end <NUM>, and in embodiments, the elongate grooves <NUM> extend continuously or discontinuously across at least <NUM>% of the length. In other embodiments, the elongate grooves <NUM> extend continuously or discontinuously across at least <NUM>% of the length. In further embodiments, the elongate grooves <NUM> extend continuously or discontinuously across at least <NUM>% of the length. In still further embodiments, the elongate grooves <NUM> extend continuously or discontinuously across at least <NUM>% of the length, and in yet further embodiments, the elongate grooves <NUM> extend continuously or discontinuously across at least <NUM>% of the length. Further, in embodiments, the elongate grooves <NUM> can be located within <NUM> of the edge of the vacuum chuck <NUM>, e.g., the elongate grooves <NUM> have a start or end point that is within <NUM> of the perimeter of the vacuum chuck.

In the embodiment depicted in <FIG>, the elongate grooves <NUM> extend discontinuously along the length so as to define sets of elongate grooves <NUM>. That is, the sets of elongate grooves <NUM> are separated by a gap G. In embodiments, the gap G is as small as <NUM>. As can be seen in <FIG>, the gaps G define three sets of elongate grooves <NUM> with a first set 34a proximal to the first longitudinal end <NUM>, a second set 34b proximal to the second longitudinal end <NUM>, and a third set 34c disposed at an apex of the curvature and centered between the first longitudinal end <NUM> and the second longitudinal end <NUM>. The elongate grooves <NUM> of each set 34a-c are connected by a respective conduit <NUM> through which a vacuum is drawn. Advantageously, having multiple sets 34a-c of elongate grooves <NUM> allows for vacuum to be drawn sequentially in sections of the forming surface <NUM>. Further, different vacuum pressures can be drawn in different sets 34a-c.

<FIG> depicts a cross-sectional view of the vacuum chuck <NUM> taken along a plane perpendicular to the longitudinal axis α. As can be seen, the elongate grooves <NUM> are formed into the forming surface <NUM>. In embodiments, the elongate grooves <NUM> have a depth D below the forming surface of from <NUM> to <NUM>. Further, in embodiments, each elongate groove <NUM> has a width W of from <NUM> to <NUM>, and in embodiments, each elongate groove <NUM> is spaced apart from an adjacent elongate groove by a spacing S of from <NUM> to <NUM>. Further, in embodiments, the elongate grooves <NUM> have a length as described above and is also much longer than the width W. In embodiments, the elongate grooves <NUM> have a length that is at least 10x the width W, and in other embodiments, the length is at least 20x the width W.

The conduit <NUM> is formed transversely (e.g., perpendicularly) to the substantially parallel elongate grooves <NUM>. For example, in an embodiment, the elongate grooves <NUM> extend along the length of the forming surface <NUM> whereas the conduit <NUM> extends across the width of the forming surface <NUM>. As can be seen in <FIG>, each elongate groove <NUM> is in fluid communication with the conduit <NUM>. In particular, at at least one location along each elongate groove <NUM>, a port <NUM> is formed providing fluid communication between the elongate groove <NUM> and the conduit <NUM>. In this way, the conduit <NUM> acts as a plenum for the particular set of elongate grooves <NUM> in which the conduit <NUM> is in fluid communication. Thus, in embodiments, each set of elongate grooves <NUM> is provided with a conduit <NUM> through which vacuum pressure is drawn.

<FIG> depicts another cross-sectional view taken along a plane parallel to the longitudinal axis α. As can be seen, the vacuum chuck <NUM> has a glass sheet <NUM> bent over the forming surface <NUM>. After bending the glass sheet <NUM> over the forming surface, a vacuum is drawn through the elongate grooves <NUM> and each conduit <NUM> in order to hold the glass sheet <NUM> in the cold-bent configuration. Once held in the cold-bent configuration, the frame <NUM> and/or any displays can be adhered to the exposed surface of the glass sheet <NUM>.

Conventionally, vacuum chucks contained holes drilled in the forming surface, and the interior of the chuck was hollowed out to form a plenum connecting the holes. As compared to the formation of elongate grooves <NUM> and the conduit <NUM>, fabrication of the vacuum holes and hollowing out of the chuck requires greater manufacturing time. Further, the vacuum pulling force is proportional to the area under the glass sheet through which the vacuum can be drawn. In the conventional vacuum chuck, the vacuum holes cover less than <NUM>% of the area through which vacuum can be drawn. By comparison, the elongate channels <NUM> allow for vacuum to be drawn over at least <NUM>% of the area under the glass sheet. In other embodiments, the elongate channels <NUM> allow for vacuum to be drawn over at least <NUM>% of the area under the glass sheet. In embodiments, the elongate channels <NUM> allow for vacuum to be drawn over up to <NUM>% of the area under the glass sheet. Accordingly, the greater vacuum area provides proportionally greater vacuum pulling force, and less energy is required is required to hold the glass sheet in the cold-bent configuration, especially at tight bend radii.

In embodiments, the vacuum chuck <NUM> is formed of a metal material. For example, the vacuum chuck <NUM> can be formed of an aluminum alloy, a steel alloy, a stainless steel alloy, or a magnesium alloy, among others. Conventionally, vacuum chucks made of metal materials took a long time to manufacture because the interior of the vacuum chuck had to be hollowed out, which required removal of a significant amount of material, and several vacuum holes had to be drilled. In contrast, the elongate grooves <NUM> and conduits <NUM> can be routed or drilled out in less time than drilling the vacuum holes and hollowing out the plenum of a conventional chuck. Therefore, the presently disclosed vacuum chuck <NUM> both provides greater vacuum force to hold the glass sheet <NUM> against the forming surface <NUM> and is more efficient to manufacture.

In another embodiment, the manufacturing efficiency is further improved by forming the vacuum chuck <NUM>, or at least the forming surface of the vacuum chuck, from a resin material. Exemplary resin materials that can be used to make the vacuum chuck <NUM> include polyurethanes, epoxies, phenolic resins, polyesters, polyamides, acetal, and engineering plastics (such as polyetherimide, polyetheretherketone, and polyphenylene sulfide), among others. A commercially available resin that can be used for the vacuum chuck <NUM> is RenShape® (<NUM> or <NUM> grade; available from Huntsman International LLC, The Woodlands, TX). As compared to conventional materials for forming the vacuum chuck <NUM> (such as the metals described above), the resin material is quicker to mold and machine, and the resin material is less expensive. Further, the resin material of the vacuum chuck <NUM> has the additional advantage that it will not damage the glass sheet <NUM>, e.g., by accidentally scratching the glass sheet <NUM>.

In still another embodiment, the vacuum chuck <NUM> is made to accommodate a variety of differently sized glass articles <NUM> that all have the same curvature. In the embodiment depicted in <FIG>, the vacuum chuck <NUM> has a larger forming surface <NUM> than the glass sheet <NUM> that is cold-bent on the forming surface <NUM>. In this embodiment, the elongate grooves <NUM> are not cut into the forming surface <NUM>. Instead, as shown in <FIG>, the forming surface includes a plurality of vacuum ports <NUM> in fluid communication with underlying conduits <NUM>. The forming surface <NUM> is then covered with one or more layers of a film <NUM>. Elongate grooves <NUM> are cut into the thickness of the film <NUM> over the plurality of vacuum ports <NUM>. Each elongate groove <NUM> is cut over at least one vacuum port <NUM>. In this way, the shape, length, and number of elongate grooves <NUM> can be customized for providing a desired vacuum pressure for individual glass sheets <NUM>.

In embodiments, the film <NUM> comprises a non-stick tape. Exemplary embodiments of non-stick tape include polyimide tape (e.g., Kapton® Tapes), polyethylene tape, vinyl tape, foam, tape, polyester tape, or PTFE tape, among others. In embodiments, the film <NUM> may be a polymer film (e.g.. , an acrylic, polyester, urethane, or vinyl film) that is screen printed or brushed over the forming surface <NUM>. Further, in embodiments, the film <NUM> has a thickness of at least <NUM>. In embodiments, the film <NUM> has a thickness of up to <NUM>. Because the elongate grooves <NUM> are cut into the film <NUM>, the thickness of the layer or layers of film <NUM> defines the depth of the elongate grooves <NUM>.

As shown in <FIG>, the glass sheet <NUM> has a trapezoidal shape whereas the forming surface <NUM> of the vacuum chuck <NUM> has a rectangular perimeter. The length and width of the forming surface are both greater than the length and width of the glass sheet <NUM>. However, the forming surface <NUM> is adapted for cold-bending of the dissimilarly shaped glass sheet <NUM> by cutting a plurality of elongate grooves <NUM> parallel to the length of the forming surface <NUM> and of the glass sheet <NUM>. As can be seen in <FIG>, the elongate grooves <NUM> taper in length to match the shape of the glass sheet <NUM>.

<FIG> depicts still another embodiment of a vacuum chuck <NUM> in which a peripheral gasket <NUM> is provided around the elongate grooves <NUM>. In particular, a peripheral channel <NUM> is formed into the forming surface <NUM>, and the gasket <NUM> is seated into the peripheral channel <NUM>. When a glass sheet <NUM> is bent over the forming surface <NUM>, the glass sheet <NUM> compresses the gasket <NUM> until it is flush with the forming surface <NUM>, which creates a peripheral seal between the glass sheet <NUM> and the forming surface <NUM>. In an embodiment, the gasket <NUM> is a vacuum gasket cord, such as SmartVac II vacuum gasket (available from Pierson Workholding, Simi Valley, CA).

<FIG> depicts a 3D scan of a glass sheet <NUM> formed on a vacuum chuck <NUM> having elongate grooves <NUM> as described herein. The 3D scan demonstrates the liftoff of the glass sheet <NUM> from the forming surface <NUM> during cold-forming. As can be seen, the liftoff is minimal over most of the glass sheet <NUM> with the highest degree of liftoff occurring at the longitudinal ends <NUM>, <NUM>. Notwithstanding, the disclosed vacuum chuck <NUM> including elongate grooves <NUM> connected by a conduit <NUM> prevents liftoff that deviates from the desired curvature of the forming surface <NUM> by more than <NUM>.

In various embodiments, glass sheet <NUM> 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 sheet <NUM> is formed from a strengthened glass material, first major surface <NUM> and second major surface <NUM> are under compressive stress, and thus second major surface <NUM> can experience greater tensile stress during bending to the convex shape without risking fracture. This allows for strengthened glass sheet <NUM> to conform to more tightly curved surfaces.

A feature of a cold-formed glass sheet <NUM> is an asymmetric surface compressive between the first major surface <NUM> and the second major surface <NUM> once the glass sheet <NUM> 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 <NUM> and the second major surface <NUM> of glass sheet <NUM> are substantially equal. After cold-forming, the compressive stress on concave first major surface <NUM> increases such that the compressive stress on the first major surface <NUM> is greater after cold-forming than before cold-forming. In contrast, convex second major surface <NUM> experiences tensile stresses during bending causing a net decrease in surface compressive stress on the second major surface <NUM>, such that the compressive stress in the second major surface <NUM> following bending is less than the compressive stress in the second major surface <NUM> when the glass sheet is flat.

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 curved 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 sheets formed utilizing the cold-bending processes/systems discussed herein provide for both curved glass shapes along with improved optical qualities not believed achievable with hot-bending processes.

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 <NUM> and/or to the second major surface <NUM> of glass sheet <NUM> prior to cold-bending, and the glass sheet <NUM> including the surface treatment is bent to a curved shape as discussed herein. Thus, Applicant believes that the 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.

In various embodiments, a cold-formed glass sheet <NUM> may have a compound curve including a major radius and a cross curvature. A complexly curved cold-formed glass sheet <NUM> may have a distinct radius of curvature in two independent directions. According to one or more embodiments, a complexly curved cold-formed glass sheet <NUM> may thus be characterized as having "cross curvature," where the cold-formed glass sheet <NUM> 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 cold-formed glass sheet and the curved display 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, glass sheet <NUM> can have more than two curved regions with the same or differing curved shapes. In some embodiments, glass sheet <NUM> can have one or more region having a curved shape with a variable radius of curvature.

Referring to <FIG>, additional structural details of glass sheet <NUM> are shown and described. As noted above, glass sheet <NUM> has a thickness T1 that is substantially constant and is defined as a distance between the first major surface <NUM> and the second major surface <NUM>. In various embodiments, T1 may refer to an average thickness or a maximum thickness of the glass sheet. In addition, glass sheet <NUM> includes a width W1 defined as a first maximum dimension of one of the first or second major surfaces <NUM>, <NUM> orthogonal to the thickness T1, and a length L1 defined as a second maximum dimension of one of the first or second major surfaces <NUM>, <NUM> orthogonal to both the thickness and the width. In other embodiments, W1 and L1 may be the average width and the average length of glass sheet <NUM>, respectively.

In various embodiments, thickness T1 is <NUM> or less and specifically is <NUM> to <NUM>. For example, thickness T1 may be in a range from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, or from about <NUM> to about <NUM>. In other embodiments, the T1 falls within any one of the exact numerical ranges set forth in this paragraph.

In various embodiments, width W1 is in a range from <NUM> to <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, or from about <NUM> to about <NUM>. In other embodiments, W1 falls within any one of the exact numerical ranges set forth in this paragraph.

In various embodiments, length L1 is in a range from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, or from about <NUM> to about <NUM>. In other embodiments, L1 falls within any one of the exact numerical ranges set forth in this paragraph.

In various embodiments, one or more radius of curvature (e.g., R1 shown in <FIG>) of glass sheet <NUM> is about <NUM> or greater. For example, R1 may be in a range from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, or from about <NUM> to about <NUM>. In other embodiments, R1 falls within any one of the exact numerical ranges set forth in this paragraph.

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).

As noted above, glass sheet <NUM> may be strengthened. In one or more embodiments, glass sheet <NUM> 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.

In various embodiments, glass sheet <NUM> 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 sheet may be strengthened thermally by heating the glass to a temperature above the glass transition point and then rapidly quenching.

In various embodiments, glass sheet <NUM> may be chemically strengthened by ion exchange. In the ion exchange process, ions at or near the surface of the glass sheet are replaced by - or exchanged with - larger ions having the same valence or oxidation state. In those embodiments in which the glass sheet 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 sheet generate a stress.

Ion exchange processes are typically carried out by immersing a glass sheet 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 sheet. 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 sheet 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 sheet (including the structure of the article and any crystalline phases present) and the desired DOC and CS of the glass sheet that results from strengthening. Exemplary molten bath compositions may include nitrates, sulfates, and chlorides of the larger alkali metal ion. Typical nitrates include KNO<NUM>, NaNO<NUM>, LiNO<NUM>, NaSO<NUM> and combinations thereof. The temperature of the molten salt bath typically is in a range from about <NUM> up to about <NUM>, while immersion times range from about <NUM> minutes up to about <NUM> hours depending on glass sheet thickness, bath temperature and glass (or monovalent ion) diffusivity. However, temperatures and immersion times different from those described above may also be used.

In one or more embodiments, the glass sheet 12io may be immersed in a molten salt bath of <NUM>% NaNO<NUM>, <NUM>% KNO<NUM>, or a combination of NaNO<NUM> and KNO<NUM> having a temperature from about <NUM> to about <NUM>. In some embodiments, the glass sheet may be immersed in a molten mixed salt bath including from about <NUM>% to about <NUM>% KNO<NUM> and from about <NUM>% to about <NUM>% NaNO<NUM>. In one or more embodiments, the glass sheet 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.

In one or more embodiments, the glass sheet may be immersed in a molten, mixed salt bath including NaNO<NUM> and KNO<NUM> (e.g., <NUM>%/<NUM>%, <NUM>%/<NUM>%, <NUM>%/<NUM>%) having a temperature less than about <NUM> (e.g., about <NUM> or about <NUM>). for less than about <NUM> hours, or even about <NUM> hours or less.

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 sheet. 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 sheets described herein.

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

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-<NUM>, manufactured by Orihara Industrial Co. 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-<NUM> (<NUM>), entitled "Standard Test Method for Measurement of Glass Stress-Optical Coefficient", 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 sheet. 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.

DOC may be measured by FSM or by a scattered light polariscope (SCALP) (such as the SCALP-<NUM> scattered light polariscope available from Glasstress Ltd. , located in Tallinn Estonia), depending on the strengthening method and conditions. When the glass sheet is chemically strengthened by an ion exchange treatment, FSM or SCALP may be used depending on which ion is exchanged into the glass sheet. Where the stress in the glass sheet is generated by exchanging potassium ions into the glass sheet, FSM is used to measure DOC. Where the stress is generated by exchanging sodium ions into the glass sheet, SCALP is used to measure DOC. Where the stress in the glass sheet 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 sheets is measured by FSM. Central tension or CT is the maximum tensile stress and is measured by SCALP.

In one or more embodiments, the glass sheet may be strengthened to exhibit a DOC that is described as a fraction of the thickness T1 of the glass sheet (as described herein). For example, in one or more embodiments, the DOC may be equal to or greater than about <NUM>. 05T1, equal to or greater than about <NUM>. 1T1, equal to or greater than about <NUM>. 11T1, equal to or greater than about <NUM>. 12T1, equal to or greater than about <NUM>. 13T1, equal to or greater than about <NUM>. 14T1, equal to or greater than about <NUM>. 15T1, equal to or greater than about <NUM>. 16T1, equal to or greater than about <NUM>. 17T1, equal to or greater than about <NUM>. 18T1, equal to or greater than about <NUM>. 19T1, equal to or greater than about <NUM>. 2T1, equal to or greater than about <NUM>. In some embodiments, the DOC may be in a range from about <NUM>. 08T1 to about <NUM>. 25T1, from about <NUM>. 09T1 to about <NUM>. 25T1, from about <NUM>. 18T1 to about <NUM>. 25T1, from about <NUM>. 11T1 to about <NUM>. 25T1, from about <NUM>. 12T1 to about <NUM>. 25T1, from about <NUM>. 13T1 to about <NUM>. 25T1, from about <NUM>. 14T1 to about <NUM>. 25T1, from about <NUM>. 15T1 to about <NUM>. 25T1, from about <NUM>. 08T1 to about <NUM>. 24T1, from about <NUM>. 08T1 to about <NUM>. 23T1, from about <NUM>. 08T1 to about <NUM>. 22T1, from about <NUM>. 08T1 to about <NUM>. 21T1, from about <NUM>. 08T1 to about <NUM>. 2T1, from about <NUM>. 08T1 to about <NUM>. 19T1, from about <NUM>. 08T1 to about <NUM>. 18T1, from about <NUM>. 08T1 to about <NUM>. 17T1, from about <NUM>. 08T1 to about <NUM>. 16T1, or from about <NUM>. 08T1 to about <NUM>. In some instances, the DOC may be about <NUM> or less. In one or more embodiments, the DOC may be about <NUM> or greater (e.g., from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, or from about <NUM> to about <NUM>. In other embodiments, DOC falls within any one of the exact numerical ranges set forth in this paragraph.

In one or more embodiments, the strengthened glass sheet may have a CS (which may be found at the surface or a depth within the glass sheet) of about <NUM> MPa or greater, <NUM> MPa or greater, <NUM> MPa or greater, about <NUM> MPa or greater, about <NUM> MPa or greater, about <NUM> MPa or greater, about <NUM> MPa or greater, about <NUM> MPa or greater, about <NUM> MPa or greater, about <NUM> MPa or greater, or about <NUM> MPa or greater.

In one or more embodiments, the strengthened glass sheet may have a maximum tensile stress or central tension (CT) of about <NUM> MPa or greater, about <NUM> MPa or greater, about <NUM> MPa or greater, about <NUM> MPa or greater, about <NUM> MPa or greater, about <NUM> MPa or greater, about <NUM> MPa or greater, about <NUM> MPa or greater, about <NUM> MPa or greater, or about <NUM> MPa or greater. In some embodiments, the maximum tensile stress or central tension (CT) may be in a range from about <NUM> MPa to about <NUM> MPa. In other embodiments, CS falls within the exact numerical ranges set forth in this paragraph.

Suitable glass compositions for use in glass sheet <NUM> include soda lime glass, aluminosilicate glass, borosilicate glass, boroaluminosilicate glass, alkali-containing aluminosilicate glass, alkali-containing borosilicate glass, and alkali-containing boroaluminosilicate glass.

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

In one or more embodiments, the glass composition may include SiO<NUM> in an amount in a range from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, or from about <NUM> mol% to about <NUM> mol%, and all ranges and sub-ranges therebetween.

In one or more embodiments, the glass composition includes Al<NUM>O<NUM> in an amount greater than about <NUM> mol%, or greater than about <NUM> mol%. In one or more embodiments, the glass composition includes Al<NUM>O<NUM> in a range from greater than about <NUM> mol% to about <NUM> mol%, from greater than about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, or from about <NUM> mol% to about <NUM> mol%, and all ranges and sub-ranges therebetween. In one or more embodiments, the upper limit of Al<NUM>O<NUM> may be about <NUM> mol%, <NUM> mol%, <NUM> mol%, <NUM> mol%, or <NUM> mol%.

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 SiO<NUM> and Al<NUM>O<NUM> and is not a soda lime silicate glass. In this regard, the glass composition or article formed therefrom includes Al<NUM>O<NUM> in an amount of about <NUM> mol% or greater, <NUM> mol% or greater, <NUM> mol% or greater, about <NUM> mol% or greater, about <NUM> mol% or greater.

In one or more embodiments, the glass composition comprises B<NUM>O<NUM> (e.g., about <NUM> mol% or greater). In one or more embodiments, the glass composition comprises B<NUM>O<NUM> in an amount in a range from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, and all ranges and sub-rangs therebetween. In one or more embodiments, the glass composition is substantially free of B<NUM>O<NUM>.

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 <NUM> mol%.

In one or more embodiments, the glass composition optionally comprises P<NUM>O<NUM> (e.g., about <NUM> mol% or greater). In one or more embodiments, the glass composition comprises a non-zero amount of P<NUM>O<NUM> up to and including <NUM> mol%, <NUM> mol%, <NUM> mol%, or <NUM> mol%. In one or more embodiments, the glass composition is substantially free of P<NUM>O<NUM>.

In one or more embodiments, the glass composition may include a total amount of R<NUM>O (which is the total amount of alkali metal oxide such as Li<NUM>O, Na<NUM>O, K<NUM>O, Rb<NUM>O, and Cs<NUM>O) that is greater than or equal to about <NUM> mol%, greater than or equal to about <NUM> mol%, or greater than or equal to about <NUM> mol%. In some embodiments, the glass composition includes a total amount of R<NUM>O in a range from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, or from <NUM> mol% to about <NUM> mol%, and all ranges and sub-ranges therebetween. In one or more embodiments, the glass composition may be substantially free of Rb<NUM>O, Cs<NUM>O or both Rb<NUM>O and Cs<NUM>O. In one or more embodiments, the R<NUM>O may include the total amount of Li<NUM>O, Na<NUM>O and K<NUM>O only. In one or more embodiments, the glass composition may comprise at least one alkali metal oxide selected from Li<NUM>O, Na<NUM>O and K<NUM>O, wherein the alkali metal oxide is present in an amount greater than about <NUM> mol% or greater.

In one or more embodiments, the glass composition comprises Na<NUM>O in an amount greater than or equal to about <NUM> mol%, greater than or equal to about <NUM> mol%, or greater than or equal to about <NUM> mol%. In one or more embodiments, the composition includes Na<NUM>O in a range from about from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, or from <NUM> mol% to about <NUM> mol%, and all ranges and sub-ranges therebetween.

In one or more embodiments, the glass composition includes less than about <NUM> mol% K<NUM>O, less than about <NUM> mol% K<NUM>O, or less than about <NUM> mol% K<NUM>O. In some instances, the glass composition may include K<NUM>O in an amount in a range from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, or from about <NUM> mol% to about <NUM> mol%, and all ranges and sub-ranges therebetween. In one or more embodiments, the glass composition may be substantially free of K<NUM>O.

In one or more embodiments, the glass composition is substantially free of Li<NUM>O.

In one or more embodiments, the amount of Na<NUM>O in the composition may be greater than the amount of Li<NUM>O. In some instances, the amount of Na<NUM>O may be greater than the combined amount of Li<NUM>O and K<NUM>O. In one or more alternative embodiments, the amount of Li<NUM>O in the composition may be greater than the amount of Na<NUM>O or the combined amount of Na<NUM>O and K<NUM>O.

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 <NUM> mol% to about <NUM> mol%. In some embodiments, the glass composition includes a non-zero amount of RO up to about <NUM> mol%. In one or more embodiments, the glass composition comprises RO in an amount from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, and all ranges and sub-ranges therebetween.

In one or more embodiments, the glass composition includes CaO in an amount less than about <NUM> mol%, less than about <NUM> mol%, or less than about <NUM> mol%. In one or more embodiments, the glass composition is substantially free of CaO.

In some embodiments, the glass composition comprises MgO in an amount from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, or from about <NUM> mol% to about <NUM> mol%, and all ranges and sub-ranges therebetween.

In one or more embodiments, the glass composition comprises ZrO<NUM> in an amount equal to or less than about <NUM> mol%, less than about <NUM> mol%, less than about <NUM> mol%, less than about <NUM> mol%, less than about <NUM> mol%, less than about <NUM> mol%. In one or more embodiments, the glass composition comprises ZrO<NUM> in a range from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, or from about <NUM> mol% to about <NUM> mol%, and all ranges and sub-ranges therebetween.

In one or more embodiments, the glass composition comprises SnO<NUM> in an amount equal to or less than about <NUM> mol%, less than about <NUM> mol%, less than about <NUM> mol%, less than about <NUM> mol%, less than about <NUM> mol%, less than about <NUM> mol%. In one or more embodiments, the glass composition comprises SnO2 in a range from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, or from about <NUM> mol% to about <NUM> mol%, and all ranges and sub-ranges therebetween.

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.

In one or more embodiments, the glass composition includes Fe expressed as Fe<NUM>O<NUM>, wherein Fe is present in an amount up to (and including) about <NUM> mol%. In some embodiments, the glass composition is substantially free of Fe. In one or more embodiments, the glass composition comprises Fe<NUM>O<NUM> in an amount equal to or less than about <NUM> mol%, less than about <NUM> mol%, less than about <NUM> mol%, less than about <NUM> mol%, less than about <NUM> mol%, less than about <NUM> mol%. In one or more embodiments, the glass composition comprises Fe<NUM>O<NUM> in a range from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, from about <NUM> mol% to about <NUM> mol%, or from about <NUM> mol% to about <NUM> mol%, and all ranges and sub-ranges therebetween.

Where the glass composition includes TiO<NUM>, TiO<NUM> may be present in an amount of about <NUM> mol% or less, about <NUM> mol% or less, about <NUM> mol% or less or about <NUM> mol% or less. In one or more embodiments, the glass composition may be substantially free of TiO<NUM>.

An exemplary glass composition includes SiO<NUM> in an amount in a range from about <NUM> mol% to about <NUM> mol%, Al<NUM>O<NUM> in an amount in a range from about <NUM> mol% to about <NUM> mol%, Na<NUM>O in an amount in a range from about <NUM> mol% to about <NUM> mol%, K<NUM>O in an amount in a range of about <NUM> mol% to about <NUM> mol%, and MgO in an amount in a range from about <NUM> mol% to about <NUM> mol%. Optionally, SnO<NUM> 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 sheet <NUM> may be made from any glass composition falling with any one of the exact numerical ranges discussed above.

Aspect (<NUM>) of this disclosure pertains to a vacuum chuck, comprising: a forming surface comprising a first longitudinal end, a second longitudinal end, and a curved region, wherein the first longitudinal end and the second longitudinal end define a longitudinal axis, and wherein the curved region defines a radius of curvature along the longitudinal axis; a plurality of elongate grooves formed into the forming surface in the curved region, each elongate groove of the plurality of elongate grooves having a length, a width, and a depth extending into the forming surface, wherein the length of each elongate groove is greater than the width; and at least one conduit configured for connection to a vacuum source, the at least one conduit disposed beneath the forming surface and the at least one conduit extending transversely across the plurality of elongate grooves, wherein the at least one conduit is in fluid communication with the plurality of elongate grooves.

Aspect (<NUM>) of this disclosure pertains to the vacuum chuck of Aspect (<NUM>), wherein the width of each elongate groove of the plurality of elongate grooves is from <NUM> to <NUM>.

Aspect (<NUM>) of this disclosure pertains to the vacuum chuck of Aspect (<NUM>) or Aspect (<NUM>), wherein the depth of each elongate groove is from <NUM> to <NUM>.

Aspect (<NUM>) of this disclosure pertains to the vacuum chuck of any one of Aspects (<NUM>) through (<NUM>), wherein each elongate groove of the plurality of elongate grooves is spaced apart from an adjacent elongate groove by <NUM> to <NUM>.

Aspect (<NUM>) of this disclosure pertains to the vacuum chuck of any one of Aspects (<NUM>) through (<NUM>), wherein the plurality of elongate grooves cover from <NUM>% to <NUM>% of the forming surface.

Aspect (<NUM>) of this disclosure pertains to the vacuum chuck of any one of Aspects (<NUM>) through (<NUM>), wherein the forming surface comprises a resin material.

Aspect (<NUM>) of this disclosure pertains to the vacuum chuck of Aspect (<NUM>), wherein the resin material comprises at least one of a polyurethane, an epoxy, a phenolic resin, a polyester, a polyamide, an acetal, a polyetherimide, a polyetheretherketone, or a polyphenylene sulfide.

Aspect (<NUM>) of this disclosure pertains to the vacuum chuck of any one of Aspects (<NUM>) through (<NUM>), wherein the vacuum chuck comprises a resin material.

Aspect (<NUM>) of this disclosure pertains to the vacuum chuck of any one of Aspects (<NUM>) through (<NUM>), wherein the forming surface comprises a steel alloy, a stainless steel alloy, an aluminum alloy, or a magnesium alloy.

Aspect (<NUM>) of this disclosure pertains to the vacuum chuck of any one of Aspects (<NUM>) through (<NUM>), wherein the forming surface comprises a film layer, wherein the plurality of elongate grooves are cut into the film layer, and wherein the vacuum chuck comprises a plurality of ports providing fluid communication between the plurality of elongate grooves and the at least one conduit.

Aspect (<NUM>) of this disclosure pertains to the vacuum chuck of Aspect (<NUM>), wherein the film layer has a thickness of <NUM> to <NUM>.

Aspect (<NUM>) of this disclosure pertains to the vacuum chuck of Aspect (<NUM>) or Aspect (<NUM>), wherein the film layer comprises a polyimide tape, a polyethylene tape, a vinyl tape, a foam tape, a polyester tape, or a PTFE tape.

Aspect (<NUM>) of this disclosure pertains to the vacuum chuck of Aspect (<NUM>) or Aspect (<NUM>), wherein the film layer comprises an acrylic film, a polyester film, a urethane film, or a vinyl film.

Aspect (<NUM>) of this disclosure pertains to the vacuum chuck of any one of Aspects (<NUM>) through (<NUM>), further comprising a channel extending around a perimeter of the forming surface and a gasket disposed within the channel.

Aspect (<NUM>) of this disclosure pertains to the vacuum chuck of any one of Aspects (<NUM>) through (<NUM>), wherein the first set of elongate grooves extends across at least <NUM>% of the curved region.

Aspect (<NUM>) of this disclosure pertains to the vacuum chuck of any one of Aspects (<NUM>) through (<NUM>), wherein the plurality of elongate grooves comprises a first set of elongate grooves and a second set of elongate grooves, wherein the at least one conduit comprises a first conduit in fluid communication with the first set of elongate grooves and a second conduit in fluid communication with the second set of elongate grooves, and wherein a different level of vacuum can be drawn through the first set of elongate grooves than through the second set of elongate grooves.

Aspect (<NUM>) of this disclosure pertains to the vacuum chuck of any one of Aspects (<NUM>) through (<NUM>), wherein the length of each elongate groove extends parallel to the longitudinal axis.

Aspect (<NUM>) of this disclosure pertains to a method, comprising bending a glass sheet over a forming surface; wherein the glass sheet comprises a first major surface and a second major surface, wherein the second major surface opposes the first major surface, and wherein the first major surface and the second major surface define a thickness of the glass sheet; wherein the forming surface comprises a curved region and a plurality of elongate grooves, wherein the curved region defines a first radius of curvature; and wherein the second major surface of the glass sheet conforms to the curved region of the forming surface; and drawing a vacuum through the plurality of elongate grooves to hold the glass sheet against the forming surface.

Aspect (<NUM>) of this disclosure pertains to the method of Aspect (<NUM>), wherein each elongate groove comprises a width of from <NUM> to <NUM>.

Aspect (<NUM>) of this disclosure pertains to the method of Aspect (<NUM>) or Aspect (<NUM>), wherein each elongate groove comprises a depth of from <NUM> to <NUM>.

Aspect (<NUM>) of this disclosure pertains to the method of any one of Aspects (<NUM>) through (<NUM>), wherein each elongate groove within the plurality of elongate grooves is spaced apart from an adjacent elongate groove by <NUM> to <NUM>.

Aspect (<NUM>) of this disclosure pertains to the method of any one of Aspects (<NUM>) through (<NUM>), wherein the forming surface comprises a resin material.

Aspect (<NUM>) of this disclosure pertains to the method of Aspect (<NUM>), wherein the resin material comprises at least one of a polyurethane, an epoxy, a phenolic resin, a polyester, a polyamide, an acetal, a polyetherimide, a polyetheretherketone, or a polyphenylene sulfide.

Aspect (<NUM>) of this disclosure pertains to the method of any one of Aspects (<NUM>) through (<NUM>), wherein the forming surface comprises a steel alloy, a stainless alloy, an aluminum alloy, or a magnesium alloy.

Aspect (<NUM>) of this disclosure pertains to the method of any one of Aspects (<NUM>) through (<NUM>), wherein the forming surface comprises a polymer film or tape and wherein regions of the polymer film or tape are removed to define the plurality of elongate grooves.

Aspect (<NUM>) of this disclosure pertains to the method of Aspect (<NUM>), wherein the layer of tape has a thickness of <NUM> to <NUM>.

Aspect (<NUM>) of this disclosure pertains to the method of Aspect (<NUM>) or Aspect (<NUM>), wherein the tape comprises a polyimide tape, a polyethylene tape, a vinyl tape, a foam tape, a polyester tape, or a PTFE tape.

Aspect (<NUM>) of this disclosure pertains to the method of Aspect (<NUM>) or Aspect (<NUM>), wherein the polymer film comprises an acrylic film, a polyester film, a urethane film, or a vinyl film.

Aspect (<NUM>) of this disclosure pertains to the method of any one of Aspects (<NUM>) through (<NUM>), wherein the forming surface further comprises a perimeter channel and wherein the method further comprises seating a gasket in the channel.

Aspect (<NUM>) of this disclosure pertains to the method of any one of Aspects (<NUM>) through (<NUM>), wherein the method further comprises applying an adhesive to the first major surface of the glass sheet after the step of drawing the vacuum.

Aspect (<NUM>) of this disclosure pertains to the method of Aspect (<NUM>), further comprising the step of attaching a display to the adhesive.

Aspect (<NUM>) of this disclosure pertains to the method of Aspect (<NUM>) or Aspect (<NUM>), further comprising the step of attaching a frame to the adhesive to form a curved glass article.

Aspect (<NUM>) of this disclosure pertains to the method of Aspect (<NUM>), further comprising the steps of curing the adhesive and removing the curved glass article from the forming surface.

Aspect (<NUM>) of this disclosure pertains to a vacuum chuck, comprising: a resin body comprising a forming surface, wherein the forming surface defines a curvature having a first radius of curvature; a plurality of elongate grooves formed into the forming surface; at least one conduit formed in the resin body, wherein the plurality of elongate grooves are in fluid communication with the at least one conduit and wherein the at least one conduit is configured for connection to a vacuum source; and a gasket extending around a periphery of the forming surface, wherein the gasket is seated within a channel formed into the forming surface.

Aspect (<NUM>) of this disclosure pertains to the vacuum chuck of Aspect (<NUM>), wherein the resin body comprises at least one of a polyurethane, an epoxy, a phenolic resin, a polyester, a polyamide, an acetal, a polyetherimide, a polyetheretherketone, or a polyphenylene sulfide.

Aspect (<NUM>) of this disclosure pertains to the vacuum chuck of Aspect (<NUM>) or Aspect (<NUM>), wherein each elongate groove comprises a width of from <NUM> to <NUM>.

Aspect (<NUM>) of this disclosure pertains to the vacuum chuck of any one of Aspects (<NUM>) through (<NUM>), wherein each elongate groove comprises a depth of from <NUM> to <NUM>.

Aspect (<NUM>) of this disclosure pertains to the vacuum chuck of any one of Aspect (<NUM>) through (<NUM>), wherein each elongate groove within the plurality of elongate grooves is spaced apart from an adjacent elongate groove by <NUM> to <NUM>.

Aspect (<NUM>) of this disclosure pertains to the vacuum chuck of any one of Aspects (<NUM>) through (<NUM>), wherein the plurality of elongate grooves arranged substantially parallel to a longitudinal axis of the resin body.

Claim 1:
A vacuum chuck (<NUM>), comprising:
a forming surface (<NUM>) comprising a first longitudinal end (<NUM>), a second longitudinal end (<NUM>) , and a curved region, wherein the first longitudinal end (<NUM>) and the second longitudinal end (<NUM>) define a longitudinal axis (α), and wherein the curved region defines a radius of curvature (R1) along the longitudinal axis (α);
a plurality of elongate grooves (<NUM>) formed into the forming surface (<NUM>) in the curved region, each elongate groove (<NUM>) of the plurality of elongate grooves (<NUM>) having a length, a width (W), and a depth (D) extending into the forming surface (<NUM>), wherein the length of each elongate groove (<NUM>) is greater than the width (W), and wherein the plurality of elongate grooves (<NUM>) extend parallel to one another and are spaced apart from one another by a spacing of <NUM> to <NUM> in a direction perpendicular to the length; and
at least one conduit (<NUM>) configured for connection to a vacuum source, the at least one conduit (<NUM>) disposed beneath the forming surface (<NUM>) and the at least one conduit (<NUM>) extending transversely across the plurality of elongate grooves (<NUM>), wherein the at least one conduit (<NUM>) is in fluid communication with the plurality of elongate grooves (<NUM>).