PATENT DOCUMENT

Publication Number: US-10494860-B1
Application Number: US-201715655236-A
Country: US
Kind Code: B1

Title: Glazings and processes for producing glazings

Abstract:
A method includes forming a glass structure that has a peripheral edge, wherein an exterior surface of the glass structure includes a compound curvature. The method also includes fractionalizing the glass structure to define a primary portion and one or more panels, wherein the primary portion includes a front window area, a roof area, and a rear window area, and connecting the primary portion and the one or more panels to a body of a vehicle.

Claims:
What is claimed is: 
     
       1. A method, comprising:
 forming a glass structure that has a peripheral edge, wherein an exterior surface of the glass structure includes a compound curvature; 
 fractionalizing the glass structure to define a primary portion, first side panels, and second side panels, wherein the primary portion includes a front window area, a roof area, and a rear window area; and 
 connecting the primary portion, the first side panels, and the second side panels to a body of a vehicle such that the front window area of the primary portion defines a windshield of the vehicle, the roof area of the primary portion defines a roof of the vehicle, the rear window area of the primary portion defines a rear window of the vehicle, the first side panels define first side windows of the vehicle, and the second side panels define second side windows of the vehicle. 
 
     
     
       2. The method of  claim 1 , wherein the glass structure includes a top area, a front area that extends from the top area to the peripheral edge, a rear area that extends from the top area to the peripheral edge, a first side area that extends from the top area to the peripheral edge, and a second side area that extends from the top area to the peripheral edge wherein the front area, the rear area, the first side area, and the second side area all extend upward from the peripheral edge. 
     
     
       3. The method of  claim 2 , wherein a first transition area of the glass structure extends in a front-to-rear direction, a second transition area of the glass structure extends in the front-to-rear direction, and the top area is located between the first transition area and the second transition area. 
     
     
       4. The method of  claim 1 , wherein fractionalizing the glass structure includes removing the first side panels and the second side panels from respective pre-fractionalization positions relative to the primary portion, and the first side panels and the second side panels are positioned relative to the primary portion according to their respective pre-fractionalization positions subsequent to connecting the primary portion the first side panels and the second side panels to the body of the vehicle. 
     
     
       5. The method of  claim 1 , further comprising:
 forming an inner glass layer; and 
 laminating the inner glass layer to the primary portion, the first side panels, and the second side panels subsequent to fractionalizing the glass structure. 
 
     
     
       6. The method of  claim 5 , wherein forming the inner glass layer comprises:
 forming a second glass structure; and 
 fractionalizing the second glass structure. 
 
     
     
       7. The method of  claim 5 , wherein forming the inner glass layer comprises:
 separately forming glass panels for the inner glass layer. 
 
     
     
       8. A method, comprising:
 forming a glass structure that has a top area, a front area that extends from the top area to a front end of the glass structure, a rear area that extends from the top area to a rear end of the glass structure, a first side area that extends downward from the top area, a second side area that extends downward from the top area, a first transition area that extends in a front-to-rear direction between the top area and the first side area and is defined by increased curvature relative to the top area and the first side area, and a second transition area that extends in the front-to-rear direction between the top area and the second side area and is defined by increased curvature relative to the top area and the second side area; 
 dividing the glass structure to define a primary portion that includes the front end and the rear end of the glass structure, first side panels that include at least part of the first side area of the glass structure, and second side panels that include at least part of the second side area of the glass structure; 
 forming inner glass panels corresponding to the primary portion, the first side panels, and the second side panels; 
 subsequent to dividing the glass structure, laminating the inner glass panels to respective ones of the primary portion, the first side panels, and the second side panels; and 
 connecting the primary portion, the first side panels, and the second side panels to a body of a vehicle such that the front area of the primary portion defines a windshield of the vehicle, the top area of the primary portion defines a roof of the vehicle, the rear area of the primary portion defines a rear window of the vehicle, the first side panels define first side windows of the vehicle, and the second side panels define second side windows of the vehicle. 
 
     
     
       9. The method of  claim 8 , wherein the glass structure has a convex exterior. 
     
     
       10. The method of  claim 8 , wherein the glass structure has a front end, a rear end, and a curved side profile that extends from the front end to the rear end. 
     
     
       11. The method of  claim 8 , wherein the primary portion, when connected to the body of the vehicle, defines a front window area, a roof area, and a rear window area of the vehicle. 
     
     
       12. The method of  claim 8 , further comprising:
 strengthening at least one of the primary portion, the first side panels, or the second side panels prior to laminating the inner glass panels to respective ones of the primary portion, the first side panels, and the second side panels. 
 
     
     
       13. A method, comprising:
 forming a one-piece glass structure having a convexly curved exterior shape that extends upward from an outer edge; 
 defining a primary portion and panels from the one-piece glass structure by cutting the primary portion and panels from the one-piece glass structure; 
 connecting the primary portion to a vehicle body of a vehicle such that the primary portion defines a front window, a rear window, and a roof of the vehicle; 
 and connecting the panels to the vehicle body to define at least one side window of the vehicle. 
 
     
     
       14. The method of  claim 13 , wherein defining the primary portion and the panels from the one-piece glass structure further comprises removing the panels from their respective original positions relative to the primary portion, and connecting the primary portion and the panels to the vehicle body includes positioning the panels relative to the primary portion of the one-piece glass structure according to their respective original positions. 
     
     
       15. The method of  claim 13 , wherein the panels define the moveable windows of the vehicle. 
     
     
       16. The method of  claim 13 , wherein a first transition area of the one-piece glass structure extends in a front-to-rear direction, a second transition area of the one-piece glass structure extends in the front-to-rear direction, and a top area of the one-piece glass structure is located between the first transition area and the second transition area. 
     
     
       17. The method of  claim 13 , wherein the one-piece glass structure has a front end, a rear end, and a curved side profile that extends from the front end to the rear end. 
     
     
       18. The method of  claim 13 , the process further comprising:
 forming an inner glass layer; and 
 laminating the inner glass layer to the primary portion and the panels subsequent to defining the primary portion and the panels from the one-piece glass structure. 
 
     
     
       19. The method of  claim 13 , wherein the panels include first side panels and second side panels, the first side panels define first side windows of the vehicle, and the second side panels define second side windows of the vehicle.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Application No. 62/372,445, filed on Aug. 9, 2016 and entitled “Glazings and Processes for Producing Glazings,” which is incorporated herein by reference in its entirety. 
    
    
     TECHNICAL FIELD 
     The application relates generally to automotive glazings, methods for manufacturing automotive glazings, and automotive glazings produced by the methods. 
     BACKGROUND 
     Automobile windows allow vehicle occupants to view the environment outside the vehicle, and also admit light into the interior of the vehicle. In a typical manufacturing process for automobile windows, a flat glass panel is heated and shaped, such as by applying pressure to the glass panel. Individual windows are then installed in the vehicle, typically separated from one another by body panels or trim structures. 
     SUMMARY 
     One aspect of the disclosed embodiments is a method that includes forming a glass structure that has a peripheral edge, wherein an exterior surface of the glass structure includes a compound curvature. The method also includes fractionalizing the glass structure to define a primary portion and one or more panels, wherein the primary portion includes a front window area, a roof area, and a rear window area. The method also includes connecting the primary portion and the one or more panels to a body of a vehicle. 
     Another aspect of the disclosed embodiments is a vehicle having a vehicle body, a front window, a rear window, a roof, and one or more moveable windows that are mounted to the vehicle body. The vehicle is produced by a process that includes forming a one-piece glass structure having a convexly curved exterior shape that extends upward from an outer edge. The process also includes defining a primary portion and the one or more panels from the one-piece glass structure. The process also includes connecting the primary portion to a vehicle body, and connecting the one or more panels to the vehicle body. 
     Another aspect of the disclosed embodiments is a method that includes forming a glass structure that has a top area, a front area that extends from the top area to a front end of the glass structure, a rear area that extends from the top area to a rear end of the glass structure, a first side area that extends downward from the top area, and a second side area that extends downward from the top area. The method also includes dividing the glass structure to define a primary portion that includes the front end and the rear end of the glass structure, one or more first side panels that include at least part of the first side area of the glass structure, and one or more second side panels that include at least part of the second side area of the glass structure. The method also includes forming inner glass panels corresponding to the primary portion, the one or more first side panels, and the one or more second side panels. The method also includes, subsequent to dividing the glass structure, laminating the inner glass panels to respective ones of the primary portion, the one or more first side panels, and the one or more second side panels. The method also includes connecting the primary portion, the one or more first side panels, and the one or more second side panels to a body of a vehicle. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The description herein will be made with reference to the following drawings. 
         FIG. 1  is a side view of a glass structure. 
         FIG. 2  is a cross-section view of the glass structure, taken along line  2 - 2  of  FIG. 1 . 
         FIG. 3  is a side view of a vehicle. 
         FIG. 4  is a cross-section view of the vehicle taken along line  4 - 4  of  FIG. 3 . 
         FIG. 5  is a cross-section view of a glass panel. 
         FIG. 6  is an illustration showing a process. 
     
    
    
     DETAILED DESCRIPTION 
     Typical methods of forming a multi-part glass structure may lead to variations or distortions at the edges of the individual panels. If the panels are assembled with respect to one another such that edges of the individual glazings are adjacent to one another, the panels may not align properly and/or may not present consistent reflections due to the variations and/or distortions. The following disclosure relates to forming automotive glazings by first forming a glass structure such as a dome-shaped glass structure, and then fractionalizing the glass structure into individual glazings. The glazings are assembled with respect to the vehicle according to the relative positions that they were in prior to fractionalization. Since formation of the glass structure is a single process, variations and distortions may be avoided. 
       FIG. 1  is a side view that shows a side profile of a glass structure  100 . The glass structure  100  is an intermediate product formed during a process for forming automotive glazings, as will be described herein. 
     The glass structure  100  is a one-piece glass structure, and may be formed entirely from glass. The external shape of the glass structure  100  may be convex. In some implementations, the glass structure  100  has a dome-like shape that includes or is defined by simple curvatures and/or compound curvatures in the front-to-rear and side-to-side directions. A simple curvature can include circular or spiral arcs that are joined by tangent sections. A compound curvature is defined by two or more arcs of differing radii, which are joined tangentially without reversal. Glass structure  100  need not be dome-like and can include any structure that covers at least a portion of a vehicle, including structures that have conical, semispherical, planar or other shapes. 
     The external shape of the glass structure  100  may be defined in part by a curvature that extends between a front end  102 , which may be referred to as the front of the glass structure  100 , and a rear end  104 , which may be referred to as the rear of the glass structure  100 . The front end  102  and the rear end  104  may be spaced from one another in a longitudinal direction of the glass structure  100 . 
     In some embodiments, the curvature between the front end  102  and the rear end  104  may be substantially continuous, without abrupt transitions. As examples, the front-to-rear curvature of the glass structure may be a curve of constant radius, a compound curve including segments of different radii that meet at tangents, or a curve of constantly changing radius (i.e., a spiral curve). 
     When assembled with respect to a vehicle, the glazings resulting from the glass structure  100  may be oriented such that the longitudinal direction of the glass structure  100  extends in the front-to-rear direction of the vehicle. Thus the front end  102  of the glass structure  100  may be installed adjacent to the front end of the vehicle, and the rear end  104  of the glass structure  100  may be installed adjacent to the rear end of the vehicle, with the front-to-rear direction of the vehicle being defined, for example, relative to an intended primary direction of travel for the vehicle. 
     The front end  102  and the rear end  104  may be located along portions of an outer edge or a peripheral edge  106  of the glass structure  100 . The peripheral edge  106  of the glass structure  100  has a substantially closed shape. The closed shape of the peripheral edge  106  may be regular (e.g., circular, elliptical, or polygonal) or irregular. 
     In some embodiments, the glass structure  100  may have a generally constant thickness between an exterior surface  108  of the glass structure  100  and an interior surface  110  of the glass structure  100 . As used herein, “generally constant thickness” indicates that the thickness of the glass structure deviates from a constant thickness as a result of inconsistencies introduced by manufacturing processes, and/or deviates from a constant thickness according to typical manufacturing tolerances. 
     In some embodiments, at least a portion of the exterior surface  108  of the glass structure  100  is convex, and at least a portion of an interior surface  110  of the glass structure  100  is concave. In some embodiments, all of the exterior surface  108  of the glass structure  100  is convex, and all of the interior surface  110  of the glass structure  100  is concave. 
     The glass structure  100  has a top area  112  located between the front end  102  and the rear end  104 . The top area  112  is a portion of the glass structure  100  that is spaced from the peripheral edge. In some embodiments, the top area  112  is a portion of the glass structure  100  that is located furthest outward from the peripheral edge. Upon completion of the processes described herein, the top area  112  of the glass structure  100  may define a roof of the vehicle. 
     A front area  114  of the glass structure  100  is located between the top area  112  and the front end  102 . Upon completion of the processes described herein, the front area  114  of the glass structure  100  may define a windshield of the vehicle. A rear area  116  of the glass structure  100  is located between the top area  112  and the rear end  104 . Upon completion of the processes described herein, the rear area  116  of the glass structure  100  may define a rear window of the vehicle. 
       FIG. 2  is a cross-section view of the glass structure  100  of  FIG. 1 , taken along line  2 - 2  of  FIG. 1 , looking toward the rear of the glass structure  100  in the front-to-rear direction. In the illustrated example, the glass structure  100  has a convex exterior shape in the side-to-side direction. 
     In the side-to-side direction, the glass structure  100  has a first side edge  218  and a second side edge  220 , which may be portions of the peripheral edge  106 . A first side area  222  is positioned between the first side edge  218  and the top area  112  such that the first side area  222  extends downward from the top area  112  to the first side edge  218 . A second side area  224  may be positioned between the second side edge  220  and the top area  112  such that the second side area extends downward from the top area  112  to the second side edge  220 . 
     In some embodiments, the glass structure  100  includes a first transition area  226  and a second transition area  228 . The first transition area  226  and the second transition area  228  are portions of the glass structure  100  where the curvature increases and defines a visible boundary between adjacent areas. In the illustrated example, the first transition area  226  extends in a generally front-to-rear direction and defines a boundary between the first side area  222  and the top area  112 , and the second transition area  228  extends in a generally front-to-rear direction and defines a boundary between the second side area  224  and the top area  112 . The first transition area  226  is configured such that the top area  112  is located on a first side of the first transition area  226 , and the first side area  222  is located on a second side of the first transition area  226 . The second transition area  228  is configured such that the top area  112  is located on a first side of the second transition area  228 , and the second side area  224  is located on a second side of the second transition area  228 . 
       FIG. 3  is a side view that shows a vehicle  340 . The vehicle  340  includes a body  342 , which may include any or all of exterior panels, interior panels, a frame, a subframe, a unibody, or a monocoque. The vehicle  340  includes glazings that are formed from the glass structure  100  of  FIG. 1 , such as by fractionalizing the glass structure  100 . As used herein, “fractionalizing” refers to dividing a single glass panel into multiple parts by any process, such as by cutting or breaking. 
     The glazings include a primary portion  344  and one or more panels  346  that have an exterior surface  308  and an interior surface  310 . The primary portion  344  is mounted to the body  342 . In some embodiments, the primary portion  344  is rigidly and immovably attached to the body  342  using structures such as fasteners and/or adhesives. 
     The primary portion  344  of the glazings includes a roof area  312  that corresponds to the top area  112  of the glass structure  100  of  FIG. 1 . The primary portion  344  also includes a front window area  314  (i.e., a windshield area) that corresponds to the front area  114  of the glass structure  100  of  FIG. 1 , and a rear window area  316  that corresponds to the rear area  116  of the glass structure  100  of  FIG. 1 . 
     The panels  346  may be, for example, windows. In the illustrated example in  FIG. 3 , the panels  346  are configured as side windows for the vehicle  340 , and may be movably mounted to the vehicle  340 , such as by conventional window mounting structures that allow lowering of windows into portions of the body  342 , such as doors that are included as part of the body  342 . The panels  346  may be separated from the primary portion  344  by a primary gap  348 , and the panels  346  may be separated from one another by secondary gaps  350 . The sizes of the primary gap  348  and the secondary gaps  350  may correspond to the kerf width of a tool or process used to fractionalize the glass structure  100  of  FIG. 1 , as will be described herein. 
     In some embodiments, the glazings include panels other than windows. As one example, the glazings may include a sunroof panel. As another example, the glazings may include a rear door (e.g., a tailgate or a liftgate) panel. 
       FIG. 4  is a cross-section view of the vehicle  340  taken along line  4 - 4  of  FIG. 3 , looking toward the rear of the vehicle  340  in the front-to-rear direction, and shows a side-to-side profile of the primary portion  344  and the panels  346 . 
     The primary portion  344  may include a first side area  422 , a second side area  424 , a first transition area  426 , and a second transition area  428 . The first transition area  426  separates the first side area  422  from the roof area  312 , and the second transition area  428  separates the second side area  424  from the roof area  312 . In the illustrated example, the panels  346  are disposed adjacent to the first side area  422  and the second side area  424  of the primary portion  344 . 
     The primary portion  344  may be supported by internal structures  452  that are connected to or form a part of the body  342 , and engage or are otherwise connected to the interior surface  310  of the primary portion  344 . In the illustrated example, the internal structures are beams, such as cant rails, that extend in the longitudinal direction of the vehicle  340  and support the roof area  312  of the primary portion  344 . The internal structures  452  may be positioned, in some embodiments, along or adjacent to the first transition area  426  and the second transition area  428 . 
       FIG. 5  is a cross-section view that shows a glazing portion  554 . The glazing portion  554  is representative of a laminated cross-sectional structure that may be utilized for the primary portion  344  and the panels  346  of  FIG. 3 . 
     The glazing portion  554  includes an outer layer  556 , an inner layer  558 , and an interlayer  560  that is located between the outer layer  556  and the inner layer  558 . The outer layer  556  may define an exterior surface for the glazing portion  554 , facing away from the interlayer  560 . The inner layer  558  may define an interior surface of the glazing portion  554 , facing away from the interlayer  560 . 
     The outer layer  556  and the inner layer  558  may both be formed from glass, as will be described herein, and the interlayer  560  may be any material suitable for laminating layers of glass together. As an example, the interlayer  560  may be formed from transparent polyvinyl butyral (PVB). As will be described, the outer layer  556  may be formed from the glass structure  100  of  FIG. 1 . In some embodiments, the inner layer  558  is formed from a second glass structure that is similar to the glass structure  100  of  FIG. 1 . In other embodiments, the inner layer  558  is formed by a different process, and may be defined by multiple panels that are formed separately. 
       FIG. 6  shows a process  660  for producing the glazings such as a primary portion  644  and panels  646 , and for producing a vehicle  640  that includes the glazings. 
     Operation  662  includes forming a glass structure  600 . Forming the glass structure  600  includes making a glass structure that is shaped according to a predetermined contour. The glass structure  600  may be formed to have geometrical features similar to those described with respect to the glass structure  100  of  FIG. 1 . In some embodiments, operation  662  includes forming a one-piece glass structure having a convexly curved exterior shape that extends upward from an outer edge to a top area, and the outer edge may be a peripheral edge that has a closed shape. 
     The glass structure  600  may be formed by any process suitable for the geometry of the glass structure  600 . Suitable processes for forming the glass structure  600  may include press molding, blow forming, mold forming, sheet forming, glass casting, vapor growth, 3D printing, and injection molding. 
     Operation  664  includes fractionalizing the glass structure  600  to define a primary portion and one or more panels. Fractionalizing the glass structure  600  may be performed using a tool  666 . As examples, the tool  666  may be an abrasive water jet cutter, a laser, a diamond wire cutter, a thin flexible blade, or a score-and-break cutting operation. Operation  664  results in a fractionalized glass structure  668  that includes portions that correspond to and will be used to form the primary portion  644  and panels  646  of the vehicle  640 . The positions that the panels  646  are located in relative to the primary portion  644  prior to fractionalization may be referred to as original positions or pre-fractionalization positions. 
     The fractionalized glass structure  668  is strengthened in operation  670 . Operation  670  may include strengthening at least part of the primary portion  644  or the panels  646  of the fractionalized glass structure  668  prior to laminating. Strengthening the fractionalized glass structure  668 , such as the parts corresponding to the primary portion  644  and the panels  646  of the glazings of the vehicle  640 , is optional and may be omitted some applications. Conventional methods (e.g., tempering) may be used to strengthen the fractionalized glass structure  668 . 
     Operation  672  includes forming an inner glass layer  658  that will subsequently be laminated to the glazings of the fractionalized glass structure  668  and will define an interior of the primary portion  644 . Operation  672  may include separately forming glass panels for the inner glass layer  658  with each of the glass panels corresponding to a portion of the fractionalized glass structure  668 . The inner glass layer  658 , when laminated to the fractionalized glass structure  668 , will be the interior of the laminated structure, and when incorporated in the vehicle will be positioned adjacent to the interior of the vehicle. The inner glass layer  658  is shaped according to the predetermined contour as described with respect to forming the glass structure  600  in operation  662 . 
     In some embodiments, operation  672  includes forming and fractionalizing a second glass structure in the manner described with respect to operations  662  and  664 . 
     Operation  674  includes laminating the fractionalized glass structure  668  to the inner glass layer  658 . Operation  674  results in glazings, such as the primary portion  644  and the panels  646 . 
     In operation  676 , the glazings, including the primary portion  644  and the panels  646 , are assembled to the body  642 . Assembling the primary portion  644  and one or more panels  646  to the body  642  of the vehicle  640  includes positioning the panels  646  relative to the primary portion  644  of the fractionalized glass structure  668  according to their respective pre-fractionalization positions and connecting the primary portion  644  and one or more panels  646  to the body  642 . Operation  676  results in the vehicle  640 . As a result of the positioning included in operation  676 , the one or more panels  646  are positioned relative to the primary portion  644  according to their respective pre-fractionalization positions subsequent to connecting the primary portion  644  and the one or more panels  646  to the body  642  of the vehicle  640 . 
     As an example, the primary portion  644  may be fixed to the body  642  in operation  676  by conventional methods such as by adhesives or fasteners, and the panels  646  may be secured to the body  642  using hardware that allows them to move relative to the primary portion  644 , such as by raising and lowering. When the panels  646  are moveable with respect to the primary portion  644 , the panels  646  may move between positions that include their respective pre-fractionalization positions. 
     As a result of the process  660 , variations and distortions may be avoided between the glazings of the vehicle  640 . Thus, the glazings of the vehicle  640  may be assembled in a close relationship with respect to one another and, in some embodiments, without intervening trim elements or body structures.

Metadata:
Filing Date: 20170720
Publication Date: 20191203
Grant Date: 20191203
Priority Date: 20160809
Inventors: JONES, CHRISTOPHER D.
Kamei, Ibuki
LYNCH, STEPHEN B.
MEMERING, DALE N.
Assignee: APPLE INC
CPC Classifications: [{"code": "B62D29/043", "inventive": true, "first": false, "tree": "[]"}, {"code": "B62D25/06", "inventive": true, "first": false, "tree": "[]"}, {"code": "B60J1/008", "inventive": true, "first": true, "tree": "[]"}, {"code": "E06B3/66309", "inventive": true, "first": false, "tree": "[]"}, {"code": "B60J10/21", "inventive": true, "first": false, "tree": "[]"}, {"code": "B60J10/70", "inventive": true, "first": false, "tree": "[]"}, {"code": "E06B3/67308", "inventive": true, "first": true, "tree": "[]"}, {"code": "B60J1/008", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29L2031/7782", "inventive": false, "first": false, "tree": "[]"}, {"code": "B60J1/008", "inventive": true, "first": false, "tree": "[]"}, {"code": "E06B3/66309", "inventive": true, "first": false, "tree": "[]"}, {"code": "E06B3/67308", "inventive": true, "first": true, "tree": "[]"}, {"code": "B60J10/70", "inventive": true, "first": false, "tree": "[]"}, {"code": "B60J10/21", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29L2031/7782", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 68695867