WO2019108015A2 - Vacuum mold apparatus, systems, and methods for forming curved mirrors - Google Patents

Abstract

A method of forming a curved mirror for a heads-up display includes providing a mirror preform including a first major surface, a second major surface, and a minor surface connecting the first and second major surfaces. The mirror preform has a central portion and a peripheral portion surrounding the central portion. The method includes disposing the mirror preform on a mold having a concave surface facing the second major surface and within a housing that surrounds at least a portion of the minor surface, a space being defined between the concave surface and the second major surface with a perimeter of the space being bounded by the housing, the mold comprising a ditch-type vacuum line along a periphery of the concave surface underneath the peripheral portion. The method also includes providing vacuum pressure to the space via the ditch-type vacuum line to conform the mirror preform to the concave surface.

Description

VACUUM MOLD APPARATUS, SYSTEMS, AND METHODS FOR FORMING CURVED MIRRORS

<Cross-reference to Related Applications>

This application claims the benefit of priority under 35 U.S.C. §119 of U.S. Provisional Application Serial No. 62/592,588 filed on November 30, 2017, the content of which is relied upon and incorporated herein by reference in its entirety.

Head-Up Display or Heads-Up Display (HUD) systems project visual information onto a transparent surface so that users can see the information without diverting their gaze away from their primary view. HUD systems typically use a mirror to reflect and project an image onto the transparent surface. One application for HUD systems is in transportation, such as automobiles, aircraft, marine craft, and other vehicles. For example, HUD systems can be used in vehicles so that an operator or driver of the vehicle can see information relevant to the operation of the vehicle while maintaining a forward gaze and without having to look down or away towards a display screen. Thus, HUD systems are believed to improve safety by minimizing the need for a vehicle operator to look away from a safe operating viewpoint.

However, HUD systems have often suffered from poor optical quality in the projected image, which may result in an undesirable aesthetic quality to the projected image. Poor optical quality may even decrease the safety of HUD systems, because blurry or unclear projected images can make it more difficult for users to read or understand the projected information, resulting in increased user processing time of the information, delayed user reaction time based on the information, and increased user distraction. Reduced optical quality can result from a sub-optimal mirror used in the HUD system, often resulting from improper shaping of the mirror or defects introduced into the mirror during curving of a mirror preform.

Thus, there remains a need for HUD systems, and particularly improved mirrors for HUD system, that have improved optical quality, as well as improved systems, apparatus, and methods of forming such mirrors.

In some embodiments of the present disclosure, a method of forming a curved mirror for a heads-up display (HUD) is provided. The method comprises providing a mirror preform including a first major surface, a second major surface opposite to the first major surface, and a minor surface connecting the first and second major surfaces, where the mirror preform has a central portion and a peripheral portion surrounding the central portion. The method also includes disposing the mirror preform on a mold having a concave surface facing the second major surface and within a housing that surrounds at least a portion of the minor surface, a space being defined between the concave surface and the second major surface with a perimeter of the space being bounded by the housing, where the mold comprises a ditch-type vacuum line along a periphery of the concave surface underneath the peripheral portion. The method further includes providing vacuum pressure to the space via the ditch-type vacuum line to conform the mirror preform to the concave surface. The central portion of the mirror preform can comprise an effective area of the curved mirror configured to reflect an image to be viewed by a user of the HUD. A distance a, as measured between the minor surface and the housing when the mirror preform is in a two-dimensional state before conforming to the curved surface, can be greater than 0 mm and less than 2 mm. In addition, the mirror preform, when conformed to the curved surface, extends outside the ditch-type vacuum line for a distance c, which is at least 0.5 mm, and can be 3 mm or less.

In additional embodiments of this disclosure, a molding apparatus for forming a curved mirror of a heads-up display (HUD) is provided. The apparatus includes a lower mold comprising a curved surface having an aspheric shape for shaping a mirror preform into an aspheric mirror, and a ditch-type vacuum line disposed in a peripheral portion of the curved surface. The ditch-type vacuum line is configured to supply vacuum pressure to area space between the curved surface and the mirror preform. The apparatus further includes a housing disposed on top of the mold to surround the mirror preform during shaping, the housing comprising a substantially vertical surface extending from the curved surface to at least a height of the mirror preform when the mirror preform is disposed on the lower mold, the vertical surface surrounding a periphery of the space. The housing is sized to surround the mirror preform when placed on the lower mold and to surround the ditch-type vacuum line, the ditch-type vacuum line being disposed below a peripheral portion of the mirror preform.

Further embodiments of this disclosure include a method of forming a three-dimensional mirror for a heads-up display (HUD) system, where the method includes providing a mirror preform having a first major surface, a second major surface opposite to the first major surface, and a minor surface connecting the first and second major surfaces. The minor surface includes first and second longitudinal side surfaces opposite to each other and first and second transverse side surfaces connecting the longitudinal side surfaces. The method includes disposing the mirror preform on a mold having a concave surface such that the second major surface faces the concave surface, where the mold includes one or more openings formed in the curved surface along a periphery of the mold, and disposing a housing on the mold such that a substantially vertical wall of a housing surrounds the minor surface of the mirror preform and the housing hangs over the openings on at least one side of the mold such that there is a gap between the curved surface and the bottom of the housing along at least a portion of the openings. The method further includes supplying a vacuum to the openings to conform the mirror preform to the concave surface.

In some additional embodiments of this disclosure, a molding apparatus for forming a curved mirror of a heads-up display (HUD) is provided. The molding apparatus includes a mold comprising a concave surface for shaping a mirror preform into a curved shape; a ditch-type vacuum line disposed in a peripheral portion of the curved surface, the ditch-type vacuum line configured to supply vacuum pressure to area space between the curved surface and the mirror preform; and a housing disposed on top of the mold to surround the mirror preform during shaping, the housing comprising a substantially vertical surface extending from the curved surface to at least a height of the mirror preform when the mirror preform is disposed on the lower mold, the vertical surface surrounding a periphery of the space. The housing hangs over the ditch-type vacuum line on at least one side of the mold such that there is a gap between the curved surface and the bottom of the housing along at least a portion of the openings.

Additional features and advantages of the claimed subject matter 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 claimed subject matter 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 present embodiments of the present disclosure, and are intended to provide an overview or framework for understanding the nature and character of the claimed subject matter. The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated into and constitute a part of this specification. The drawings illustrate various embodiments and together with the description serve to explain the principles and operations of the claimed subject matter.

For the purposes of illustration, there are forms shown in the drawings that are presently preferred, it being understood, however, that the embodiments disclosed and discussed herein are not limited to the precise arrangements and instrumentalities shown.

Figure 1 is an illustration of HUD system in a vehicle according to some embodiments of the present disclosure.

Figure 2 is an illustration of an automobile driver's viewpoint when using the HUD system of Figure 1, according to some embodiments.

Figure 3 is a photograph of a combiner used in some HUD systems according to some embodiments of the present disclosure.

Figure 4 is an illustration of an automobile driver's viewpoint when using a HUD system with a combiner similar to the one shown in Figure 3, according to some embodiments.

Figure 5 is a plan view of a 2D mirror preform and a resulting aspheric mirror formed from the 2D mirror preform according to some embodiments.

Figure 6 is an isometric view of a 2D mirror preform on a bending mold.

Figure 7 is the partial cross-section view of Figure 6 from the perspective of line A-A.

Figure 8 is the partial cross-section view of Figure 6 from the perspective of line B-B.

Figure 9 is a schematic representation of a 2D reference plane corresponding to a 2D preform before undergoing a 3D forming step and a 3D mirror after undergoing the forming step.

Figure 10 is an isometric schematic of an aspheric mirror for a HUD system according to some embodiments.

Figure 11 is an isometric view of a 2D mirror preform on a forming mold showing gaps between the edges of the preform and the mold.

Figure 12 is a cross-section schematic of a gap between a forming mold and an edge of a preform during forming.

Figures 13A and 13B are isometric and plan views, respectively, of a vacuum mold with a ditch-type vacuum hole, according to some embodiments.

Figures 14A and 14B are detailed top and bottom views, respectively, of the vacuum mold of Figures 13A and 13B.

Figures 15A and 15B are isometric views of a housing assembly according to some embodiments.

Figures 16A and 16B are cross-section views of the long-side and short-side edges, respectively, of the rectangular mirror preform of Figure 15B on a forming mold, according to some embodiments.

Figures 17A and 17B show cross-section views of an edge of the mirror preform on a forming mold before and after conforming to the mold, according to some embodiments.

Figures 18A and 18B are photographs of example curved mirrors, with the top mirror formed according to conventional techniques and the resulting edge distortion, and the bottom mirror formed according to embodiments of the present disclosure and with improved edge optics.

Figure 19A is an isometric, partial cross-section view of a formed mirror substrate, forming mold, and housing according to another embodiment of the present disclosure.

Figure 19B is a side view of the partial cross-section of Figure 19A from the perspective shown by line C-C.

Figure 20 is a plan view of the mirror preform, housing, and mold of Figures 19A and 19B.

In the following description, like reference characters designate like or corresponding parts throughout the several views shown in the figures. It is also understood that, unless otherwise specified, terms such as “top,” “bottom,” “outward,” “inward,” and the like are words of convenience and are not to be construed as limiting terms. In addition, whenever a group is described as comprising at least one of a group of elements and combinations thereof, it is understood that the group may comprise, consist essentially of, or consist of any number of those elements recited, either individually or in combination with each other.

Similarly, whenever a group is described as consisting of at least one of a group of elements or combinations thereof, it is understood that the group may consist of any number of those elements recited, either individually or in combination with each other. Unless otherwise specified, a range of values, when recited, includes both the upper and lower limits of the range. As used herein, the indefinite articles “a,” and “an,” and the corresponding definite article “the” mean “at least one” or “one or more,” unless otherwise specified.

The following description of the present disclosure is provided as an enabling teaching thereof and its best, currently-known embodiment. Those skilled in the art will recognize that many changes can be made to the embodiment described herein while still obtaining the beneficial results of the present disclosure. It will also be apparent that some of the desired benefits of the present disclosure can be obtained by selecting some of the features of the present disclosure without utilizing other features. Accordingly, those who work in the art will recognize that many modifications and adaptations of the present disclosure are possible and may even be desirable in certain circumstances and are part of the present disclosure. Thus, the following description is provided as illustrative of the principles of the present disclosure and not in limitation thereof.

Those skilled in the art will appreciate that many modifications to the exemplary embodiments described herein are possible without departing from the spirit and scope of the present disclosure. Thus, the description is not intended and should not be construed to be limited to the examples given but should be granted the full breadth of protection afforded by the appended claims and equivalents thereto. In addition, it is possible to use some of the features of the present disclosure without the corresponding use of other features. Accordingly, the following description of exemplary or illustrative embodiments is provided for the purpose of illustrating the principles of the present disclosure and not in limitation thereof and may include modification thereto and permutations thereof.

HUD systems can be used to provide a wide variety of types of information for improved safety and convenience of users. In transportation, for example, information relevant to vehicle operation, such as vehicle gauges or navigation, can be projected to an area in front of a driver. This can include real-time information on vehicle speed, fuel level, climate control settings, entertainment settings, turn-by-turn navigation indicators, estimated time of arrival, and alerts related to speed, traffic, or dangerous conditions. Information can be presented as text, symbols, pictures, videos, animation, and one or more colors. These are examples only, and embodiments of this disclosure are not intended to be limited to these examples.

In some embodiments of the present disclosure, a HUD system can include an image generating device and one or more optical components for directing or projecting an image from the image generating device to an area that is easily visible to a user. The image generating device can include a cathode ray tube (CRT) display, a light-emitting diode (LED) display, a liquid crystal display (LCD) assembly, laser projection system, or other type of display known by those of ordinary skill in the art. The HUD system may also include a computer or processor for generating the images produced by these displays. The optical components may include some combination of lenses, beam splitters, mirrors, and combiner, for example. The combination of components of a HUD system can be configured to produce collimated light, which can be projected onto a combiner that is in a field of view of a user allowing the user can see the projected image and the normal field of view simultaneously. For example, in vehicular applications, the combiner can be a windshield or a separate component that is built into the vehicle, or a portable component that can be mounted in the vehicle in a location where a driver or passenger can see the projected image on a transparent surface of the combiner. The mirror can include a reflective coating on a curved substrate. The curved substrate may be spherical, aspherical, a Fresnel shape, and/or diffractive. In one preferred embodiment, the mirror has a reflective surface or coating on a concave, aspherical surface.

Figure 1 shows an example of a HUD system 100 according to some embodiments of the present disclosure. The HUD system 100 is shown in an automobile, but embodiments can be used in various vehicles or non-vehicular applications. A driver D is shown with hands on the steering wheel W of the vehicle V. The HUD system 100 is incorporated into the dash 110 of the vehicle V, and includes a programmable graphical unit (PGU) 102 connected to an image source 103 configured to produce an image based on a signal from the PGU 102. The PGU 102 may include a processor operably connected to a non-transient, computer-readable storage medium containing instructions that, when executed, generate and/or supply data for generating a image by the image source 103 to be displayed by the HUD system 100. That image is reflected by a flat mirror 104 towards a curved mirror 106. From the curved mirror 106, the image is projected toward the windshield 108 and onto a projection area 112 of the windshield 108. The HUD system 100 can be configured so that the projection area 112 is within the normal line of sight of the driver D while driving the vehicle V. For example, the projection area 112 can be positioned so that the projected image is overlaid on the road as seen from the driver’s perspective. An example of this scenario is shown in the illustration of Figure 2.

While the projection area 112 is located on the windshield 108 in Figures 1 and 2, Figures 3 and 4 show an alternative embodiment in which a combiner 208 is used for the location of the projection area 212. The combiner 208 can be built into the dash 210 of a vehicle or can be a portable or separable component that is positioned on top of the dash 210.

Embodiments of this disclosure are not limited to one or more particular arrangements of the optical components of a HUD system, as persons of ordinary skill in the art will understand the basic arrangement of components in a HUD system. The present disclosure is directed primarily to the curved mirrors used in HUD systems, and to systems and methods for forming such mirrors. In particular, embodiments are directed to system and methods of forming such three-dimensional (3D) mirrors from two-dimensional (2D) mirror preforms. Figure 5 shows an example of a 2D mirror preform 300 that can be used to form a 3D mirror 302 using systems and methods discussed herein.

There are various systems and methods conventionally used for forming 3D mirrors. However, the authors of the present disclosure realized that improvements were needed in the design of and the methods of forming the curved mirrors used in HUD systems. To prevent degradation of image quality as the image is reflected by the curved mirror, the mirror should have a high level of shape accuracy and surface roughness. For example, a shape precision of less than 50 μm and a surface roughness (Ra) of less than 3 nm is desirable. A particular type of optical distortion that occurs in mirrors for HUD systems is referred to as edge distortion, which is optical distortion of light reflected at or near the edge of the mirror. In existing HUD systems, optically impactful imperfections may be introduced into the mirror during manufacturing or shaping of the mirror. These imperfections can include artifacts such as uneven surfaces or impressions created by equipment or heating in the manufacturing of the mirrors, or imperfections in the curvature of the mirror, particularly in the curvature at or near the edges of the mirror.

The most common methods for forming 3D-shaped mirrors or mirror substrates can be divided into two categories: pressing methods and vacuum-forming methods. Both pressing and vacuum-forming methods, however, can have disadvantages. In a pressing method, upper and lower molds are used to press the substrate, such as a glass substrate, by physical force. For example, the upper mold may be pressed into a lower mold with a 2D glass preform disposed between the two molds, and the glass preform is formed according to the shape of a surface on one or both of the molds. As a result, mold imprints may be left on both the concave and convex surfaces of the formed glass substrate, which then requires polishing. In addition, due to deviations in the contours of the upper and lower molds, it can be difficult to precisely match the contours of the upper and lower molds, and thus difficult to achieve a precise shape for the formed glass substrate. For example, the specification for aspheric mirror contours can be less than ± 25 μm, while the mold contour deviation after machining is normally 30-50 μm.

In a vacuum forming method, a single mold (e.g., lower mold) can be used, where vacuum holes are formed in the surface of the mold. For example, as shown in Figure 6, a flat (2D) glass sheet or 2D preform 300 is disposed on or above the forming surface 312 of the mold 310, the preform 300 being aligned to the mold 310 by a number of guide pines 313.Vacuum pressure is supplied via a number of vacuum holes 314 distributed throughout the forming surface 312 to conform the mirror preform to the curved (3D) surface of the mold. The forming surface 312 is shaped to a desired shape of the 3D mirror. Figure 7 shows a view from the perspective shown by line A-A, and Figure 8 shows the view from the perspective of line B-B. However, it is difficult to avoid the formation of vacuum hole marks on the surface of the formed glass substrate. These vacuum hole marks or manufacturing artifacts can impair the optical performance of the substrate or the finished mirror, especially since the vacuum holes 312 are distributed throughout the forming surface 314 and thus the artifacts are present in an effective area of the finished mirror. Also, it is difficult to get constant vacuum pressure across the many vacuum holes 312 in the mold 310, leading to pressure differentials across the forming surface 314 and thus to potential deviations from the desired shape of the finished 3D mirror. In addition, typical vacuum forming methods can require higher forming temperatures compared to pressing methods. Higher forming temperatures can affect surface quality and form defects such as dimples, pits, and imprints. Vacuum forming can be performed on a mirror preform, which is a substrate that is pre-cut to the desired size before forming into a 3D shape with vacuum forming, or on an oversized sheet of glass, which is cut to the desired size after forming into a 3D shape with vacuum forming. Both preform-based and oversized-glass-based vacuum forming have certain advantages and disadvantages.

Oversized-glass-based forming, for example, has advantages of achieving good edge quality due to edge cutting, and good surface roughness due to lower forming temperatures. However, oversized-glass-based forming requires the added steps of cutting the glass after forming; has low glass utilization due to trim glass or waste glass after forming; requires edge polishing and/or chamfering after cutting; and requires larger equipment even though the eventual finished product may be the same size as that formed in preform-based forming.

On the other hand, in preform-based vacuum forming, there is no need to cut the mirror substrate after vacuum forming, which reduces the production of waste or cullet glass. In addition, preform-based forming can be a more simple process and more cost effective. However, in a preform-based vacuum forming method, it has been difficult or impossible to apply a relatively uniform vacuum pressure over the entire surface of the glass sheet due to vacuum leaks at one or more edges of the glass preform, due at least in part to vacuum leakage between the preform and the mold. For example, if the formed glass is to have a single radius of curvature, the short-side edge of the preform may maintain contact with the mold surface until forming is complete, but the vacuum will leak along the long-side edge of the preform. In the case of more complex curvature or an aspheric mold surface (and aspheric formed substrate), only discrete points of the glass sheet, such as the four corners, may contact the mold surface throughout forming, which results in vacuum leakage along all edges of the glass substrate. Also, for forming an aspheric mirror, it is possible for the corner of the mirror or mirror substrate to chip or break, which occurs when only the corners of the mirror substrate are in contact with the mold and an external force (e.g., vacuum pressure, mold pressing force) is applied, thus concentrating pressure at the four corners of the substrate. In some cases, such as when the forming surface is not aspheric but has a single radius of curvature, the short-side edge of a preform may maintain better contact with the forming surface until forming is completed, but a vacuum leak can occur along the long-side edge of the preform. These gaps or leaks in vacuum pressure make it difficult or impossible to provide relatively uniform vacuum pressure to the entire surface of the mirror or preform. As such, higher forming temperature (lower viscosity of the substrate) is used to conform the glass onto the mold surface more completely, and to reduce the stress near the corners to reduce chipping. However, as discussed above, higher temperatures cause surface degradation of the glass substrate and decreased optical performance. Even with higher temperatures, edge distortion of the mirror occurs.

Investigators behind the present disclosure have discovered systems, apparatus, and methods to improve the mirrors formed using vacuum-based forming methods. In some preferred embodiments, these techniques may be particularly well-suited for the preform-based forming methods. However, some embodiments are not limited to mirrors made using the preform-based forming methods, nor even to vacuum-based methods, generally. Some of the problems addressed by the embodiments of the present disclosure is that of edge distortion and manufacturing artifacts left in the effective area of the formed mirror. As mentioned above, when using vacuum forming methods, it can be difficult to achieve a uniform vacuum and uniform conformation of the mirror substrate to the mold. It can be particularly difficult to conform the mirror substrate to the desired shape at or near the edges of the substrate, which causes edge distortion and degrades the quality of the image reflected by the mirror near the edge. In addition, typical strategies for achieving better conformity (e.g., stronger vacuum pressure and higher temperatures during forming) lead to undesired artifacts and imperfections in the finished product. Therefore, embodiments of the present disclosure provide mirrors and/or mirror substrates with improved optical performance, including at the edge and the effective area, and include forming apparatus and methods of forming the mirrors.

The mirrors in HUD systems generally have an aspheric reflective surface, which can include a reflective coating formed on an aspheric surface of a mirror substrate. As discussed above and shown in Figure 9, a 3D mirror 400 may be formed from a 2D mirror preform 420. As a rectangular preform, the mirror preform 420 has long-side edges 402 and short-side edges 404. In forming the 3D mirror, the long-side edge 402 and the short-side edge 404 bend to conform to the forming mold. Based on the shape of the forming mold, as determined by the desired shape of the resulting 3D mirror, the linear distance between opposite short-side edges 404 decreases, and the magnitude of the decrease between the short-side edges may differ from that of the long-side edges. An aspheric or aspherically shaped surface has multiple radii of curvature. In the case of a four-sided mirror as shown in Figures 9 and 10, for example, an aspheric surface has a different radius of curvature along each of the four edges. Thus, as shown in Figure 10, a mirror 400 has a reflective surface 408 that is aspherically shaped with a radius of curvature Ra along a first edge, a radius of curvature Rb along a second edge, a radius of curvature Rc along a third edge, and a radius of curvature Rd along a fourth edge. Because the surface 408 is aspherically shaped, Ra ≠ Rb ≠ Rc ≠ Rd. In addition, Rb and Rd may be less than Ra and Rc. Due to the differences in curvature of the long-side edges as compared to the short-side edges, a change in the distance between the short-side edges 404 due to forming may be greater than any decrease of the distance between opposite long-side edges 402 due to the smaller radii of curvature Rb, Rd on the long-side edges and the larger radii of curvature Ra, Rc on the short-side edges. This can make it more difficult to prevent leaking of the vacuum pressure along the short-side edge, as discussed below. Figure 10 also shows how different points on the curved surface 408 have been displaced by varying amounts j-n with respect to a two-dimensional plane 406 connecting the four corners of the mirror 400. In some embodiments, j ≠ k ≠ l ≠ m. In one example, displacements j-n may be equal to the following: j = 7.73, k = 6.32, l = 6.52, m = 1.31, and n = 1.31, where the displacements are given in unitless, relative magnitudes, but the units of displacements a-e may be in millimeters, depending on the size of the mirror and application. The two-dimensional plane 406 comprises a minor axis 408 between opposite long-side edges of the 2D preform and a major axis 410 between opposite short-side edges of the 2D preform.

As shown in Figure 11, when a 2D mirror preform 420 is disposed on a forming mold 430, only the corners of the mirror preform 420 may contact the forming mold 430 prior to a conforming the preform 420 to forming surface 432. As such, a gap remains between the mirror preform 420 and the forming surface 432. In particular, a gap 434 remains between a short-side edge 422 of the mirror preform 420 and a gap 436 remains between a long-side edge 424 of the mirror preform 420. To the extent gaps 434 and 436 remain open during a conforming step of the preform 420 to the forming surface 432, some of the vacuum suction from the vacuum holes in the forming surface 432 is lost. This can lead to sub-optimal conforming of the mirror preform 420 to the forming surface 432, and thus to a failure to achieve the desired shape of the 3D mirror.

Figure 12 shows a cross-section view of an edge of a 3D mirror 420′ during or after a step of conforming the 2D mirror preform 420 of Figure 11 to the forming mold 430. While there may be good conformity between the forming surface 432 and an interior portion of the 3D mirror 420′ near one or more interior vacuum holes 438, a gap 434′ can remain near an edge of the 3D mirror 420′. As shown in Figure 10, gap 434′ can remain even when a vacuum hole 439 is located near the edge, because vacuum suction may be lost as a result of the gap 434′ due to the geometry of the bend and other forming factors. As a result, the desired curvature of the 3D mirror 420′ is not achieved near the edge. Due to the above-discussed challenges in maintaining precise control over the shape of a 3D mirror formed by vacuum forming while preventing other unwanted manufacturing-induced defects, the investigators of the present disclosure developed systems, apparatus, and methods capable of achieving improved 3D mirrors. In particular, these systems, apparatus, and methods allow for improved suction and forming at or near the edge of a 3D mirror using vacuum forming of a 2D preform without creating manufacturing defects such as vacuum-hole impressions in the effective area of the finished mirror.

Figures 13A and 13B show an improved forming mold 450, according to some embodiments of this disclosure. The mold 450 includes a concave forming surface 452 with a ditch-type vacuum line 454 formed along a perimeter of the forming surface 452. To better understand the ditch-type vacuum line, Figures 14A and 14B show detailed top and bottom views, respectively, of one corner of mold 450 encircled by D in Figures 13A and 13B. The ditch-type vacuum line 454 is machined along the entire periphery of the forming (upper) surface 452. In some embodiments, vacuum holes 455, 456 are drilled on the backside of the mold 450, as shown in Figure 14B. However, these holes 455, 456 do not penetrate the mold up to the forming surface 452, but instead end below the forming surface 452 after meeting the ditch-type vacuum line 454 machined into the forming surface 452. Because the ditch-type vacuum line 454 is only on the perimeter of the forming surface 452 and not in an area of the forming surface 452 that will make contact with the effective area of the formed mirror, there will be no vacuum-hole based manufacturing artifacts introduced into the effective area of the finished mirror.

In some embodiments, as shown in Figure 15A, a housing 500 can be used during a step of conforming a 2D preform to a 3D forming surface. The housing 500 forms a ring-like shape with side walls or sealing surfaces configured to be positioned at or near one or more edges of a mirror preform during the step of conforming to the vacuum mold. In Figure 15A, the mold 500 includes short-side walls 502 and long-side walls 504, which in combination form a ring-like shape with a space in the middle that is sized and shaped to contain a preform.

The housing 500 positioned on a forming mold 530 is shown in Figure 15B. The housing 500 surrounds the perimeter of the forming surface of mold 530 and defines a space in which the mirror preform 520 is placed for forming. The housing 500 includes opposite short- side walls 502, 503, and opposite long- side walls 504, 505. The housing 500 operates to minimize vacuum leaking at the edges of the mirror preform 520 where there is a ditch-type vacuum line 534. The housing 500 does not necessarily need to touch the mirror preform 520 to improve vacuum performance. Indeed, it may be advantageous in some embodiments for there to not be physical contact between the housing 500 and the preform 520 so that the preform 520 can move without friction forces from the housing 500 that could negatively impact the finished product. The clearance between the inside walls of the housing 500 may be, for example, 0.5 mm or less, in some embodiments. However, this clearance can be adjusted based on the coefficient of thermal expansion of the glass-based preform 520 and the housing 500.

Figures 16A and 16B show cross-section views of the long-side edge and short-side edge, respectively, of the preform 520, mold 520, and housing 500 of Figure 15B. Specifically, Figure 16A shows a cross-section view of from the perspective shown by line C-C in Figure 15B, and Figure 16B shows a cross-section view of from the perspective shown by line D-D in Figure 15B. For the long-side edge in Figure 16A, the direction of sagging (shown by the arrow) during forming is substantially vertical, so that the long-side edge does not move significantly away from the wall 505 of the housing 500. As such, there is low risk of the vacuum hole 534 in forming surface 552 being exposed or losing vacuum pressure.

On the other hand, the direction of sagging (shown by the arrow in Figure 16B) of the short-side edge can have vertical and horizontal components. The horizontal movement or shrinkage pulls the short-side edge away from the wall 503 of the housing 530 and threatens to reduce vacuum pressure near the short-side edge. The distance x′ is the distance between the wall 503 and the vacuum hole 534 on the short-side edge of the preform 520. The distance x′ should be large enough to ensure that the vacuum hole 534 is not uncovered by the preform 520 during forming so that vacuum pressure is maintained near the edge.

Figure 17A shows the preform 520 before forming and the formed shape 520′ after forming. The mold 530, housing 500, and location of the ditch-type vacuum line 534 should be designed so that the formed shape 520′ overlaps the ditch-type vacuum line 534 by a distance c. The distance c can be, in some preferred embodiments, at least 0.5 mm, or greater than 0 mm but less than 3.0 mm, or from 0.5 mm to 3 mm. In particular, as shown in Figure 17B, the mold 530, housing 500, and location of the ditch-type vacuum line 534 can be designed with a distance a between the wall of the housing 500 an edge of the preform 520, and a distance b between the edge of the 2D preform 520 and the edge of the formed shape 520′. The distance b is the result of glass edge-to-edge “shrinkage” due to forming, and depends on the glass composition and forming conditions, for example. Thus, the distance x′ of Figure 16B can be expressed by the sum of a, b, and c, or x = a + b + c.

Figures 18A and 18B are photographs of two example mirrors. In Figure 18A, a mirror was formed according to traditional vacuum forming techniques, which resulted in noticeable edge distortion. In contrast, the mirror in Figure 18B was formed according to the above-described systems and methods and showed noticeable improvement in edge distortion.

In some further embodiments, the location and form of the ditch-type vacuum line can be altered relative to the position of the housing. As discussed above, vacuum holes can result in manufacturing artifacts or defects in the finished product. Generally, vacuum holes are machined on the top of the mold surface in a perpendicular direction to the glass. Therefore, hole marks are generated on the surface of the glass after forming. The above-discussed embodiments are an improvement because vacuum holes are not formed in areas of the forming surface that correspond to an effective area of the finished mirror. However, some embodiments of this disclosure allow for further reducing the change of unwanted artifacts even when using the ditch-type vacuum line. Figures 19A and 19B show one such embodiment.

Figure 19A shows a partial cross-section view of a formed product 620′, housing 600, and a mold 630, similar to that shown in Figure 15B. However, while the mold 630 has a ditch-type vacuum line 634 along the short-side edge in a similar location as the embodiment discussed above, the ditch-type vacuum line 635 along the long-side edge of mold 630 is shifted with respect to the inner wall of the housing 600. In particular, as shown in Figure 19B, the interior wall of the housing 600 along the long-side edge of the preform 620 overhangs the ditch-type vacuum line 635, and the bottom of the interior wall of the housing 600 along this long-side edge does not touch the forming surface 652. Thus, when a vacuum is applied, air flow or suction is directed underneath the overhanding wall of the housing 600 and then down through the ditch-type vacuum line 635 along the long-side edge. The height of the gap between the bottom of the interior wall of the housing 600 and the forming surface 652 is smaller than the thickness of the preform so that suction is not lost upon conforming the preform to the forming surface 652. Through this housing structure, the direction of vacuum flow acting on the glass is changed from a vertical direction to a parallel direction (i.e., parallel to the surface of the glass or forming surface). Thus, it is possible to form curved surface without worrying about vacuum hole marks on glass surface.

In preferred embodiments, the overhanging interior wall of the housing 600 shown in Figures 19A and 19B is used on the long-side of the mold 630, but not on the short-side. This is because the preform is more likely to move away from the housing during the conforming step, as discussed above. Therefore, if the overhanding housing is used on the short-side edge, then suction may be lost during the conforming step because a gap will open between the short-side edge of the formed shape and the housing. Therefore, in the plan view of Figure 20, a ditch-type vacuum line 634 in the mold 602 can be seen spaced apart from the housing 608, but the vacuum line cannot be seen along the long-side edge because the housing 608 overhangs the vacuum line. The vacuum line 634 may be, for example, 1-2 mm from the housing, or between 0.5 mm and 3 mm. Nonetheless, any vacuum artifacts formed by line 634 on the finished product is unlikely to impact the effective area of the mirror.

According to the embodiments of this disclosure, it is possible to achieve the required shape accuracy and good surface quality, and to carry out vacuum forming with the same or better performance as that of the oversized-glass forming without the additional waste and expense of oversized-glass forming methods. In terms of the forming quality, when using a 2D-preform in accordance with the embodiments of this disclosure, it is possible to secure the required forming quality through vacuum forming without vacuum hole imprints in the effective glass area due to there being no vacuum holes on the area of the forming surface corresponding to the effective glass area. In addition, it is possible to obtain edge quality similar to oversized-glass vacuum forming even using a 2D-preform. These advantages are possible without the problems encountered in oversized-based forming, such as unnecessarily increasing the size of the equipment and mold, or cutting the substrate after forming, which generates waste and can introduce new defects.

The reflective surface can be formed on the formed product via sputtering, evaporation (e.g., CVD, PVD), plating, or other methods of coating or supplying a reflective surface known to those of ordinary skill in the art. The reflective surface can include one or more metals, metallic/ceramic oxides, metallic/ceramic alloys, for example. The reflective coating can include aluminum or silver. The reflective surface is formed on the 3D formed substrate after forming the substrate to a curved or aspheric shape. However, embodiments are not limited to this order, and it is contemplated that a 3D mirror can be formed from a 2D preform having a reflective surface.

The glass-based substrate has a thickness that is less than or equal to 3.0 mm; from about 0.5 mm to about 3.0 mm; from about 0.5 mm to about 1.0 mm; or from about 1.0 mm to about 3.0 mm.

Suitable glass substrates for mirrors in HUD systems can be non-strengthened glass sheets or can also be strengthened glass sheets. The glass sheets (whether strengthened or non-strengthened) may include soda-lime glass, aluminosilicate, boroaluminosilicate or alkali aluminosilicate glass. Optionally, the glass sheets may be thermally strengthened. In embodiments where soda-lime glass is used as the non -strengthened glass sheet, conventional decorating materials and methods (e.g., glass frit enamels and screen printing) can be used

Suitable glass substrates may be chemically strengthened by an ion exchange process. In this process, typically by immersion of the glass sheet into a molten salt bath for a predetermined period of time, ions at or near the surface of the glass sheet are exchanged for larger metal ions from the salt bath. In one embodiment, the temperature of the molten salt bath is about 430ºC and the predetermined time period is about eight hours. The incorporation of the larger ions into the glass strengthens the sheet by creating a compressive stress in a near surface region. A corresponding tensile stress is induced within a central region of the glass to balance the compressive stress.

Exemplary ion-exchangeable glasses that are suitable for forming glass substrates are soda lime glasses, alkali aluminosilicate glasses or alkali aluminoborosilicate glasses, though other glass compositions are contemplated. As used herein, “ion exchangeable” means that a glass is capable of exchanging cations located at or near the surface of the glass with cations of the same valence that are either larger or smaller in size. One exemplary glass composition comprises SiO ₂, B ₂O ₃ and Na ₂O, where (SiO ₂ + B ₂O ₃) ≥ 66 mol.%, and Na ₂O ≥ 9 mol.%. In an embodiment, the glass sheets include at least 6 wt.% aluminum oxide. In a further embodiment, a glass sheet includes one or more alkaline earth oxides, such that a content of alkaline earth oxides is at least 5 wt.%. Suitable glass compositions, in some embodiments, further comprise at least one of K ₂O, MgO, and CaO. In a particular embodiment, the glass can comprise 61-75 mol.% SiO ₂; 7-15 mol.% Al ₂O ₃; 0-12 mol.% B ₂O ₃; 9-21 mol.% Na ₂O; 0-4 mol.% K ₂O; 0-7 mol.% MgO; and 0-3 mol.% CaO.

A further exemplary glass composition suitable for forming glass substrates comprises: 60-70 mol.% SiO ₂; 6-14 mol.% Al ₂O ₃; 0-15 mol.% B ₂O ₃; 0-15 mol.% Li ₂O; 0-20 mol.% Na ₂O; 0-10 mol.% K ₂O; 0-8 mol.% MgO; 0-10 mol.% CaO; 0-5 mol.% ZrO ₂; 0-1 mol.% SnO ₂; 0-1 mol.% CeO ₂; less than 50 ppm As ₂O ₃; and less than 50 ppm Sb ₂O ₃; where 12 mol.% ≤ (Li ₂O + Na ₂O + K ₂O) ≤ 20 mol.% and 0 mol.% ≤ (MgO + CaO) ≤ 10 mol.%.

A still further exemplary glass composition comprises: 63.5-66.5 mol.% SiO ₂; 8-12 mol.% Al ₂O ₃; 0-3 mol.% B ₂O ₃; 0-5 mol.% Li ₂O; 8-18 mol.% Na ₂O; 0-5 mol.% K ₂O; 1-7 mol.% MgO; 0-2.5 mol.% CaO; 0-3 mol.% ZrO ₂; 0.05-0.25 mol.% SnO ₂; 0.05-0.5 mol.% CeO ₂; less than 50 ppm As ₂O ₃; and less than 50 ppm Sb ₂O ₃; where 14 mol.% ≤ (Li ₂O + Na ₂O + K ₂O) ≤ 18 mol.% and 2 mol.% ≤ (MgO + CaO) ≤ 7 mol.%.

In a particular embodiment, an alkali aluminosilicate glass comprises alumina, at least one alkali metal and, in some embodiments, greater than 50 mol.% SiO ₂, in other embodiments at least 58 mol.% SiO ₂, and in still other embodiments at least 60 mol.% SiO ₂, wherein the ratio

, where in the ratio the components are expressed in mol.% and the modifiers are alkali metal oxides. This glass, in particular embodiments, comprises, consists essentially of, or consists of: 58-72 mol.% SiO ₂; 9-17 mol.% Al ₂O ₃; 2-12 mol.% B ₂O ₃; 8-16 mol.% Na ₂O; and 0-4 mol.% K ₂O, wherein the ratio

.

In another embodiment, an alkali aluminosilicate glass comprises, consists essentially of, or consists of: 61-75 mol.% SiO ₂; 7-15 mol.% Al ₂O ₃; 0-12 mol.% B ₂O ₃; 9-21 mol.% Na ₂O; 0-4 mol.% K ₂O; 0-7 mol.% MgO; and 0-3 mol.% CaO.

In yet another embodiment, an alkali aluminosilicate glass substrate comprises, consists essentially of, or consists of: 60-70 mol.% SiO ₂; 6-14 mol.% Al ₂O ₃; 0-15 mol.% B ₂O ₃; 0-15 mol.% Li ₂O; 0-20 mol.% Na ₂O; 0-10 mol.% K ₂O; 0-8 mol.% MgO; 0-10 mol.% CaO; 0-5 mol.% ZrO ₂; 0-1 mol.% SnO ₂; 0-1 mol.% CeO ₂; less than 50 ppm As ₂O ₃; and less than 50 ppm Sb ₂O ₃; wherein 12 mol.% ≤ Li ₂O + Na ₂O + K ₂O ≤ 20 mol.% and 0 mol.% ≤ MgO + CaO ≤ 10 mol.%.

In still another embodiment, an alkali aluminosilicate glass comprises, consists essentially of, or consists of: 64-68 mol.% SiO ₂; 12-16 mol.% Na ₂O; 8-12 mol.% Al ₂O ₃; 0-3 mol.% B ₂O ₃; 2-5 mol.% K ₂O; 4-6 mol.% MgO; and 0-5 mol.% CaO, wherein: 66 mol.% ≤ SiO ₂ + B ₂O ₃ + CaO ≤ 69 mol.%; Na ₂O + K ₂O + B ₂O ₃ + MgO + CaO + SrO > 10 mol.%; 5 mol.% ≤ MgO + CaO + SrO ≤ 8 mol.%; (Na ₂O + B ₂O ₃) - Al ₂O ₃ ≤ 2 mol.%; 2 mol.% ≤ Na ₂O - Al ₂O ₃ ≤ 6 mol.%; and 4 mol.% ≤ (Na ₂O + K ₂O) - Al ₂O ₃ ≤ 10 mol.%.

The chemically-strengthened as well as the non-chemically-strengthened glass, in some embodiments, can be batched with 0-2 mol.% of at least one fining agent selected from a group that includes Na ₂SO ₄, NaCl, NaF, NaBr, K ₂SO ₄, KCl, KF, KBr, and SnO ₂.

In one exemplary embodiment, sodium ions in the chemically-strengthened glass can be replaced by potassium ions from the molten bath, though other alkali metal ions having a larger atomic radii, such as rubidium or cesium, can replace smaller alkali metal ions in the glass. According to particular embodiments, smaller alkali metal ions in the glass can be replaced by Ag ⁺ ions. Similarly, other alkali metal salts such as, but not limited to, sulfates, halides, and the like may be used in the ion exchange process.

The replacement of smaller ions by larger ions at a temperature below that at which the glass network can relax produces a distribution of ions across the surface of the glass that results in a stress profile. The larger volume of the incoming ion produces a compressive stress (CS) on the surface and tension (central tension, or CT) in the center of the glass. The compressive stress is related to the central tension by the following relationship:

where t is the total thickness of the glass sheet and DOL is the depth of exchange, also referred to as depth of layer.

According to various embodiments, glass substrates comprising ion-exchanged glass can possess an array of desired properties, including low weight, high impact resistance, and improved sound attenuation. In one embodiment, a chemically-strengthened glass sheet can have a surface compressive stress of at least 300 MPa, e.g., at least 400, 450, 500, 550, 600, 650, 700, 750 or 800 MPa, a depth of layer at least about 20 μm (e.g., at least about 20, 25, 30, 35, 40, 45, or 50 μm) and/or a central tension greater than 40 MPa (e.g., greater than 40, 45, or 50 MPa) but less than 100 MPa (e.g., less than 100, 95, 90, 85, 80, 75, 70, 65, 60, or 55 MPa).

A modulus of elasticity of a chemically-strengthened glass sheet can range from about 60 GPa to 85 GPa (e.g., 60, 65, 70, 75, 80 or 85 GPa). If used in a glass-based laminate with a polymer interlayer, the modulus of elasticity of the glass sheet(s) and the polymer interlayer can affect both the mechanical properties (e.g., deflection and strength) and the acoustic performance (e.g., transmission loss) of the resulting glass laminate structure.

Suitable glass substrates may be thermally strengthened by a thermal tempering process or an annealing process. The thickness of the thermally-strengthened glass sheets may be less than about 2 mm or less than about 1mm.

Exemplary glass sheet forming methods include fusion draw and slot draw processes, which are each examples of a down-draw process, as well as float processes. These methods can be used to form both strengthened and non- strengthened glass sheets. The fusion draw process uses a drawing tank that has a channel for accepting molten glass raw material. The channel has weirs that are open at the top along the length of the channel on both sides of the channel. When the channel fills with molten material, the molten glass overflows the weirs. Due to gravity, the molten glass flows down the outside surfaces of the drawing tank. These outside surfaces extend down and inwardly so that they join at an edge below the drawing tank. The two flowing glass surfaces join at this edge to fuse and form a single flowing sheet. The fusion draw method offers the advantage that, because the two glass films flowing over the channel fuse together, neither outside surface of the resulting glass sheet comes in contact with any part of the apparatus. Thus, the surface properties of the fusion drawn glass sheet are not affected by such contact.

The slot draw method is distinct from the fusion draw method. Here the molten raw material glass is provided to a drawing tank. The bottom of the drawing tank has an open slot with a nozzle that extends the length of the slot. The molten glass flows through the slot/nozzle and is drawn downward as a continuous sheet and into an annealing region. The slot draw process can provide a thinner sheet than the fusion draw process because only a single sheet is drawn through the slot, rather than two sheets being fused together.

Down-draw processes produce glass sheets having a uniform thickness that possess surfaces that are relatively pristine. Because the strength of the glass surface is controlled by the amount and size of surface flaws, a pristine surface that has had minimal contact has a higher initial strength. When this high strength glass is then chemically strengthened, the resultant strength can be higher than that of a surface that has been a lapped and polished. Down-drawn glass may be drawn to a thickness of less than about 2 mm. In addition, down drawn glass has a very flat, smooth surface that can be used in its final application without costly grinding and polishing.

In the float glass method, a sheet of glass that may be characterized by smooth surfaces and uniform thickness is made by floating molten glass on a bed of molten metal, typically tin. In an exemplary process, molten glass that is fed onto the surface of the molten tin bed forms a floating ribbon. As the glass ribbon flows along the tin bath, the temperature is gradually decreased until a solid glass sheet can be lifted from the tin onto rollers. Once off the bath, the glass sheet can be cooled further and annealed to reduce internal stress.

In some embodiments, exemplary glass substrates of embodiments discussed herein can be employed in vehicles (automobile, aircraft, and the like) having a Head-up or Heads-up Display (HUD) system. The clarity of fusion formed according to some embodiments can be superior to glass formed by a float process to thereby provide a better driving experience as well as improve safety since information can be easier to read and less of a distraction. A non-limiting HUD system can include a projector unit, a combiner, and a video generation computer. The projection unit in an exemplary HUD can be, but is not limited to, an optical collimator having a convex lens or concave mirror with a display (e.g., optical waveguide, scanning lasers, LED, CRT, video imagery, or the like) at its focus. The projection unit can be employed to produce a desired image. In some embodiments, the HUD system can also include a combiner or beam splitter to redirect the projected image from the projection unit to vary or alter the field of view and the projected image. Some combiners can include special coatings to reflect monochromatic light projected thereon while allowing other wavelengths of light to pass through. In additional embodiments, the combiner can also be curved to refocus an image from the projection unit. Any exemplary HUD system can also include a processing system to provide an interface between the projection unit and applicable vehicle systems from which data can be received, manipulated, monitored and/or displayed. Some processing systems can also be utilized to generate the imagery and symbology to be displayed by the projection unit.

Using such an exemplary HUD system, a display of information (e.g., numbers, images, directions, wording, or otherwise) can be created by projecting an image from the HUD system onto an interior facing surface of a glass-based mirror substrate. The mirror can then redirect the image so that it is in the field of view of a driver.

Exemplary glass substrates according to some embodiments can thus provide a thin, pristine surface for the mirror. In some embodiments, fusion drawn Gorilla Glass can be used as the glass substrate. Such glass does not contain any float lines typical of conventional glass manufactured with the float process (e.g., soda lime glass).

HUDs according to embodiments of the present disclosure can be employed in automotive vehicles, aircraft, synthetic vision systems, and/or mask displays (e.g., head mounted displays such as goggles, masks, helmets, and the like) utilizing exemplary glass substrates described herein. Such HUD systems can project critical information (speed, fuel, temperature, turn signal, navigation, warning messages, etc.) in front of the driver through the glass laminate structure.

According to some embodiments, the HUD systems described herein can use nominal HUD system parameters for radius of curvature, refractive index, and angle of incidence(e.g., radius of curvature R _c = 8301 mm, distance to source: R _i = 1000 mm, refractive index n=1.52, and angle of incidence θ=62.08°).

Aspect 1 of this disclosure pertains to a method of forming a curved mirror for a heads-up display (HUD), the method comprising: providing a mirror preform comprising a first major surface, a second major surface opposite to the first major surface, and a minor surface connecting the first and second major surfaces, the mirror preform having a central portion and a peripheral portion surrounding the central portion; disposing the mirror preform on a mold having a concave surface facing the second major surface and within a housing that surrounds at least a portion of the minor surface, a space being defined between the concave surface and the second major surface with a perimeter of the space being bounded by the housing, the mold comprising a ditch-type vacuum line along a periphery of the concave surface underneath the peripheral portion; providing vacuum pressure to the space via the ditch-type vacuum line to conform the mirror preform to the concave surface.

Aspect 2 of this disclosure pertains to the method of Aspect 1, wherein disposing the mirror preform within the housing comprises first disposing the mirror preform on the mold and then positioning the housing over the mold and around the mirror preform.

Aspect 3 of this disclosure pertains to the method of Aspect 1 or Aspect 2, wherein the minor surface comprises first and second longitudinal side surfaces, and first and second transverse side surfaces, and wherein the housing comprises first and second longitudinal side surfaces in close conformity with the first and second longitudinal side surfaces of the mirror preform, and also comprises first and second transverse side surfaces in close conformity with the first and second transverse side surfaces of the mirror preform.

Aspect 4 of this disclosure pertains to the method of any one of the preceding Aspects, wherein the central portion of the mirror preform comprises an effective area of the curved mirror configured to reflect an image to be viewed by a user of the HUD.

Aspect 5 of this disclosure pertains to the method of any one of the preceding Aspects, wherein the central portion of the mirror preform comprises a reflective surface.

Aspect 6 of this disclosure pertains to the method of any one of the preceding Aspects, wherein the concave surface is an aspheric surface.

Aspect 7 of this disclosure pertains to the method of any one of the preceding Aspects, wherein a distance a, as measured between the minor surface and the housing when the mirror preform is in a two-dimensional state before conforming to the curved surface, is greater than 0 mm and less than 2 mm.

Aspect 8 of this disclosure pertains to the method of any one of the preceding Aspects, wherein a face of the minor surface moves from a first position before conforming to a second position after conforming in a direction away from the housing, the face moving a distance b from the first position to the second position.

Aspect 9 of this disclosure pertains to the method of any one of the preceding Aspects, wherein the mirror preform, when conformed to the curved surface, extends outside the ditch-type vacuum line for a distance c, which is at least 0.5 mm.

Aspect 10 of this disclosure pertains to the method of any one of the preceding Aspects, wherein the mirror preform, when conformed to the curved surface, extends outside the ditch-type vacuum line for a distance c, which is not more than 3 mm.

Aspect 22 of this disclosure pertains to the method of Aspect 9 or Aspect 10, wherein the ditch-type vacuum line is a distance x from the housing, where x = a + b + c.

Aspect 12 of this disclosure pertains to the method of any one of the preceding Aspects, wherein a width of the ditch-type vacuum line is less than or equal to 1.0 mm.

Aspect 13 of this disclosure pertains to the method of any one of the preceding Aspects, wherein a width of the ditch-type vacuum line is greater than or equal to 0.3 mm.

Aspect 14 of this disclosure pertains to the method of any one of the preceding Aspects, wherein a depth of the ditch-type vacuum line is less than or equal to half the thickness of the mold at the curved surface.

Aspect 15 of this disclosure pertains to the method of any one of the preceding Aspects, further comprising forming the curved mirror without leaving any vacuum suction artifacts in the effective area of the curved mirror.

Aspect 16 of this disclosure pertains to the method of any one of the preceding Aspects, further comprising, after conforming the mirror preform, providing a reflective surface on the first major surface.

Aspect 17 of this disclosure pertains to a curved mirror formed according to the method of any one of Aspects 1-16.

Aspect 18 of this disclosure pertains to a molding apparatus for forming a curved mirror of a heads-up display (HUD), comprising: a lower mold comprising a curved surface having an aspheric shape for shaping a mirror preform into an aspheric mirror; a ditch-type vacuum line disposed in a peripheral portion of the curved surface, the ditch-type vacuum line configured to supply vacuum pressure to area space between the curved surface and the mirror preform; and a housing disposed on top of the mold to surround the mirror preform during shaping, the housing comprising a substantially vertical surface extending from the curved surface to at least a height of the mirror preform when the mirror preform is disposed on the lower mold, the vertical surface surrounding a periphery of the space; wherein the housing is sized to surround the mirror preform when placed on the lower mold and to surround the ditch-type vacuum line, the ditch-type vacuum line being disposed below a peripheral portion of the mirror preform.

Aspect 19 of this disclosure pertains to the molding apparatus of Aspect 18, further comprising a pressure regulation system configured to supply a vacuum to the ditch-type vacuum line.

Aspect 20 of this disclosure pertains to the molding apparatus of Aspect 18 or Aspect19, wherein a distance from the substantially vertical wall to the ditch-type vacuum line is greater than a distance from the substantially vertical wall to the mirror preform when the mirror preform is shaped to conform to the curved surface.

Aspect 21 of this disclosure pertains to the molding apparatus of any one of Aspects 18-20, wherein the mirror preform, when conformed to the curved surface, extends outside the ditch-type vacuum line for a distance c of at least 0.5 mm.

Aspect 22 of this disclosure pertains to the molding apparatus of any one of Aspects 18-21, wherein the mirror preform, when conformed to the curved surface, extends outside the ditch-type vacuum line for a distance c of not more than 3 mm.

Aspect 23 of this disclosure pertains to the molding apparatus of any one of Aspects 18-22, wherein a distance a between an edge of the mirror preform and the housing is 2 mm or less.

Aspect 24 of this disclosure pertains to the molding apparatus of any one of Aspects 18-23, wherein a distance a between an edge of the mirror preform and the housing is greater than 0 mm and less than 2 mm.

Aspect 25 of this disclosure pertains to the molding apparatus of any one of Aspects 18-24, wherein a width of the ditch-type vacuum line is between about 0.3 mm and 1.0 mm.

Aspect 26 of this disclosure pertains to the molding apparatus of any one of Aspects 18-25, wherein a depth of the ditch-type line is less than half the thickness of the lower mold.

Aspect 27 of this disclosure pertains to a method of forming a three-dimensional mirror for a heads-up display (HUD) system, the method comprising: providing a mirror preform having a first major surface, a second major surface opposite to the first major surface, and a minor surface connecting the first and second major surfaces, the minor surface comprising first and second longitudinal side surfaces opposite to each other and first and second transverse side surfaces connecting the longitudinal side surfaces; disposing the mirror preform on a mold having a concave surface such that the second major surface faces the concave surface, the mold having one or more openings formed in the curved surface along a periphery of the mold; disposing a housing on the mold such that a substantially vertical wall of a housing surrounds the minor surface of the mirror preform, the housing hanging over the openings on at least one side of the mold such that there is a gap between the curved surface and the bottom of the housing along at least a portion of the openings; and supplying a vacuum to the openings to conform the mirror preform to the concave surface.

Aspect 28 of this disclosure pertains to the method of Aspect 27, wherein the gap is smaller than a thickness of the mirror preform.

Aspect 29 of this disclosure pertains to the method of Aspect 27 or Aspect 28, wherein the longitudinal wall of the housing prevents leakage of the vacuum at a portion of a space between the first and second longitudinal side surfaces and the concave surface, and between the first and second transverse side surfaces and the concave surface.

Aspect 30 of this disclosure pertains to the method of any one of Aspects 27-29, wherein the concave surface of the mold comprises a first radius of curvature for a first curvature running in a longitudinal direction of the mold, and a second radius of curvature for a second curvature running in a transverse direction of the mold, the second radius of curvature being larger than the first radius of curvature.

Aspect 31 of this disclosure pertains to the method of any one of Aspects 27-30, wherein the concave surface is shaped such that, during conforming, a distance between the first and second longitudinal side surfaces of the mirror preform decreases less than a distance between the first and second transverse side surfaces of the mirror preform.

Aspect 32 of this disclosure pertains to the method of any one of Aspects 27-31, wherein a transverse wall of the housing prevents leakage of the vacuum at a portion of the gap between the first transverse side surface and the concave surface, and between the second transverse side surface and the concave surface.

Aspect 33 of this disclosure pertains to the method of any one of Aspects 27-32, wherein clearance between the housing and the minor surface is less than about 0.5 mm.

Aspect 34 of this disclosure pertains to the method of any one of Aspects 27-33, wherein the curved shape of at least one of the first and second transverse side surfaces comprises a single radius of curvature.

Aspect 35 of this disclosure pertains to the method of any one of Aspects 27-34, wherein the curved shape of at least one of the first and second transverse side surfaces comprises a spline curve.

Aspect 36 of this disclosure pertains to the method of any one of Aspects 27-35, wherein the three-dimensional mirror is not cut after conforming the second major surface such that the three-dimensional mirror for the HUD system has a first major surface that is concavely shaped, a second major surface opposite to the first major surface, and a minor surface connecting the first and second major surfaces, the minor surface corresponding to the minor surface of the glass preform.

Aspect 37 of this disclosure pertains to the method of any one of Aspects 27-36, wherein at least a portion of the first major surface is a reflective surface.

Aspect 38 of this disclosure pertains to the method of Aspect 37, wherein the reflective surface comprises a metallic layer disposed on the first major surface.

Aspect 39 of this disclosure pertains to the method of Aspect 38, wherein the metallic layer comprises aluminum.

Aspect 40 of this disclosure pertains to the method of any one of Aspects 27-39, wherein the conforming of the second major surface to the concave surface of the mold is performed at a temperature below the glass transition temperature of the mirror preform.

Aspect 41 of this disclosure pertains to the method of Aspect 40, wherein the temperature is about 5ºC to 30ºC below the glass transition temperature of the mirror preform.

Aspect 42 of this disclosure pertains to the method of Aspect 41, wherein the temperature is about 10ºC to 20ºC below the glass transition temperature of the mirror preform.

Aspect 43 of this disclosure pertains to the method of any one of Aspects 27-42, further comprising forming a reflective surface on the first major surface after the conforming of the second major surface to the concave surface.

Aspect 44 of this disclosure pertains to a molding apparatus for forming a curved mirror of a heads-up display (HUD), comprising: a mold comprising a concave surface for shaping a mirror preform into a curved shape; a ditch-type vacuum line disposed in a peripheral portion of the curved surface, the ditch-type vacuum line configured to supply vacuum pressure to area space between the curved surface and the mirror preform; and a housing disposed on top of the mold to surround the mirror preform during shaping, the housing comprising a substantially vertical surface extending from the curved surface to at least a height of the mirror preform when the mirror preform is disposed on the lower mold, the vertical surface surrounding a periphery of the space, wherein the housing hangs over the ditch-type vacuum line on at least one side of the mold such that there is a gap between the curved surface and the bottom of the housing along at least a portion of the openings.

Aspect 45 of this disclosure pertains to the molding apparatus of Aspect 44, wherein the gap is smaller than a thickness of the mirror preform.

Aspect 46 of this disclosure pertains to the molding apparatus of Aspect 44 or Aspect 45, wherein the longitudinal wall of the housing prevents leakage of the vacuum at a portion of a space between the first and second longitudinal side surfaces and the concave surface, and between the first and second transverse side surfaces and the concave surface.

Aspect 47 of this disclosure pertains to the molding apparatus of any one of Aspects 44-46, wherein the concave surface of the mold comprises a first radius of curvature for a first curvature running in a longitudinal direction of the mold, and a second radius of curvature for a second curvature running in a transverse direction of the mold, the second radius of curvature being larger than the first radius of curvature.

Aspect 48 of this disclosure pertains to the molding apparatus of any one of Aspects 44-47, wherein clearance between the housing and the minor surface is less than about 0.5 mm.

While this description may include many specifics, these should not be construed as limitations on the scope thereof, but rather as descriptions of features that may be specific to particular embodiments. Certain features that have been heretofore described in the context of separate embodiments may also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment may also be implemented in multiple embodiments separately or in any suitable sub-combination. Moreover, although features may be described above as acting in certain combinations and may even be initially claimed as such, one or more features from a claimed combination may in some cases be excised from the combination, and the claimed combination may be directed to a sub-combination or variation of a sub-combination.

Similarly, while operations are depicted in the drawings or figures in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. In certain circumstances, multitasking and parallel processing may be advantageous

Ranges can be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, examples include from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

It is also noted that recitations herein refer to a component of the present disclosure being “configured” or “adapted to” function in a particular way. In this respect, such a component is “configured” or “adapted to” embody a particular property, or function in a particular manner, where such recitations are structural recitations as opposed to recitations of intended use. More specifically, the references herein to the manner in which a component is “configured” or “adapted to” denotes an existing physical condition of the component and, as such, is to be taken as a definite recitation of the structural characteristics of the component.

As shown by the various configurations and embodiments illustrated in the figures, various glass-based structures for head-up displays have been described.

While preferred embodiments of the present disclosure have been described, it is to be understood that the embodiments described are illustrative only and that the scope of the invention is to be defined solely by the appended claims when accorded a full range of equivalence, many variations and modifications naturally occurring to those of skill in the art from a perusal hereof.

Claims (48)

1. A method of forming a curved mirror for a heads-up display (HUD), the method comprising:

   providing a mirror preform comprising a first major surface, a second major surface opposite to the first major surface, and a minor surface connecting the first and second major surfaces, the mirror preform having a central portion and a peripheral portion surrounding the central portion;

   disposing the mirror preform on a mold having a concave surface facing the second major surface and within a housing that surrounds at least a portion of the minor surface, a space being defined between the concave surface and the second major surface with a perimeter of the space being bounded by the housing, the mold comprising a ditch-type vacuum line along a periphery of the concave surface underneath the peripheral portion;

   providing vacuum pressure to the space via the ditch-type vacuum line to conform the mirror preform to the concave surface.
2. The method of claim 1, wherein disposing the mirror preform within the housing comprises first disposing the mirror preform on the mold and then positioning the housing over the mold and around the mirror preform.
3. The method of claim 1 or claim 2, wherein the minor surface comprises first and second longitudinal side surfaces, and first and second transverse side surfaces,

   and wherein the housing comprises first and second longitudinal side surfaces in close conformity with the first and second longitudinal side surfaces of the mirror preform, and also comprises first and second transverse side surfaces in close conformity with the first and second transverse side surfaces of the mirror preform.
4. The method of any one of the preceding claims, wherein the central portion of the mirror preform comprises an effective area of the curved mirror configured to reflect an image to be viewed by a user of the HUD.
5. The method of any one of the preceding claims, wherein the central portion of the mirror preform comprises a reflective surface.
6. The method of any one of the preceding claims, wherein the concave surface is an aspheric surface.
7. The method of any one of the preceding claims, wherein a distance a, as measured between the minor surface and the housing when the mirror preform is in a two-dimensional state before conforming to the curved surface, is greater than 0 mm and less than 2 mm.
8. The method of any one of the preceding claims, wherein a face of the minor surface moves from a first position before conforming to a second position after conforming in a direction away from the housing, the face moving a distance b from the first position to the second position.
9. The method of any one of the preceding claims, wherein the mirror preform, when conformed to the curved surface, extends outside the ditch-type vacuum line for a distance c, which is at least 0.5 mm.
10. The method of any one of the preceding claims, wherein the mirror preform, when conformed to the curved surface, extends outside the ditch-type vacuum line for a distance c, which is not more than 3 mm.
11. The method of claim 9 or claim 10, wherein the ditch-type vacuum line is a distance x from the housing, where x = a + b + c.
12. The method of any one of the preceding claims, wherein a width of the ditch-type vacuum line is less than or equal to 1.0 mm.
13. The method of any one of the preceding claims, wherein a width of the ditch-type vacuum line is greater than or equal to 0.3 mm.
14. The method of any one of the preceding claims, wherein a depth of the ditch-type vacuum line is less than or equal to half the thickness of the mold at the curved surface.
15. The method of any one of the preceding claims, further comprising forming the curved mirror without leaving any vacuum suction artifacts in the effective area of the curved mirror.
16. The method of any one of the preceding claims, further comprising, after conforming the mirror preform, providing a reflective surface on the first major surface.
17. A curved mirror formed according to the method of any one of claims 1-16.
18. A molding apparatus for forming a curved mirror of a heads-up display (HUD), comprising:

    a lower mold comprising a curved surface having an aspheric shape for shaping a mirror preform into an aspheric mirror;

    a ditch-type vacuum line disposed in a peripheral portion of the curved surface, the ditch-type vacuum line configured to supply vacuum pressure to area space between the curved surface and the mirror preform; and

    a housing disposed on top of the mold to surround the mirror preform during shaping, the housing comprising a substantially vertical surface extending from the curved surface to at least a height of the mirror preform when the mirror preform is disposed on the lower mold, the vertical surface surrounding a periphery of the space;

    wherein the housing is sized to surround the mirror preform when placed on the lower mold and to surround the ditch-type vacuum line, the ditch-type vacuum line being disposed below a peripheral portion of the mirror preform.
19. The molding apparatus of claim 18, further comprising a pressure regulation system configured to supply a vacuum to the ditch-type vacuum line.
20. The molding apparatus of claim 18 or claim 19, wherein a distance from the substantially vertical wall to the ditch-type vacuum line is greater than a distance from the substantially vertical wall to the mirror preform when the mirror preform is shaped to conform to the curved surface.
21. The molding apparatus of any one of claims 18-20, wherein the mirror preform, when conformed to the curved surface, extends outside the ditch-type vacuum line for a distance c of at least 0.5 mm.
22. The molding apparatus of any one of claims 18-21, wherein the mirror preform, when conformed to the curved surface, extends outside the ditch-type vacuum line for a distance c of not more than 3 mm.
23. The molding apparatus of any one of claims 18-22, wherein a distance a between an edge of the mirror preform and the housing is 2 mm or less.
24. The molding apparatus of any one of claims 18-23, wherein a distance a between an edge of the mirror preform and the housing is greater than 0 mm and less than 2 mm.
25. The molding apparatus of any one of claims 18-24, wherein a width of the ditch-type vacuum line is between about 0.3 mm and 1.0 mm.
26. The molding apparatus of any one of claims 18-25, wherein a depth of the ditch-type line is less than half the thickness of the lower mold.
27. A method of forming a three-dimensional mirror for a heads-up display (HUD) system, the method comprising:

    providing a mirror preform having a first major surface, a second major surface opposite to the first major surface, and a minor surface connecting the first and second major surfaces, the minor surface comprising first and second longitudinal side surfaces opposite to each other and first and second transverse side surfaces connecting the longitudinal side surfaces;

    disposing the mirror preform on a mold having a concave surface such that the second major surface faces the concave surface, the mold having one or more openings formed in the curved surface along a periphery of the mold;

    disposing a housing on the mold such that a substantially vertical wall of a housing surrounds the minor surface of the mirror preform, the housing hanging over the openings on at least one side of the mold such that there is a gap between the curved surface and the bottom of the housing along at least a portion of the openings; and

    supplying a vacuum to the openings to conform the mirror preform to the concave surface.
28. The method of claim 27, wherein the gap is smaller than a thickness of the mirror preform.
29. The method of claim 27 or claim 28, wherein the longitudinal wall of the housing prevents leakage of the vacuum at a portion of a space between the first and second longitudinal side surfaces and the concave surface, and between the first and second transverse side surfaces and the concave surface.
30. The method of any one of claims 27-29, wherein the concave surface of the mold comprises a first radius of curvature for a first curvature running in a longitudinal direction of the mold, and a second radius of curvature for a second curvature running in a transverse direction of the mold, the second radius of curvature being larger than the first radius of curvature.
31. The method of any one of claims 27-30, wherein the concave surface is shaped such that, during conforming, a distance between the first and second longitudinal side surfaces of the mirror preform decreases less than a distance between the first and second transverse side surfaces of the mirror preform.
32. The method of any one of claims 27-31, wherein a transverse wall of the housing prevents leakage of the vacuum at a portion of the gap between the first transverse side surface and the concave surface, and between the second transverse side surface and the concave surface.
33. The method of any one of claims 27-32, wherein clearance between the housing and the minor surface is less than about 0.5 mm.
34. The method of any one of claims 27-33, wherein the curved shape of at least one of the first and second transverse side surfaces comprises a single radius of curvature.
35. The method of any one of claims 27-34, wherein the curved shape of at least one of the first and second transverse side surfaces comprises a spline curve.
36. The method of any one of claims 27-35, wherein the three-dimensional mirror is not cut after conforming the second major surface such that the three-dimensional mirror for the HUD system has a first major surface that is concavely shaped, a second major surface opposite to the first major surface, and a minor surface connecting the first and second major surfaces, the minor surface corresponding to the minor surface of the glass preform.
37. The method of any one of claims 27-36, wherein at least a portion of the first major surface is a reflective surface.
38. The method of claim 37, wherein the reflective surface comprises a metallic layer disposed on the first major surface.
39. The method of claim 38, wherein the metallic layer comprises aluminum.
40. The method of any one of claims 27-39, wherein the conforming of the second major surface to the concave surface of the mold is performed at a temperature below the glass transition temperature of the mirror preform.
41. The method of claim 40, wherein the temperature is about 5ºC to 30ºC below the glass transition temperature of the mirror preform.
42. The method of claim 41, wherein the temperature is about 10ºC to 20ºC below the glass transition temperature of the mirror preform.
43. The method of any one of claims 27-42, further comprising forming a reflective surface on the first major surface after the conforming of the second major surface to the concave surface.
44. A molding apparatus for forming a curved mirror of a heads-up display (HUD), comprising:

    a mold comprising a concave surface for shaping a mirror preform into a curved shape;

    a ditch-type vacuum line disposed in a peripheral portion of the curved surface, the ditch-type vacuum line configured to supply vacuum pressure to area space between the curved surface and the mirror preform; and

    a housing disposed on top of the mold to surround the mirror preform during shaping, the housing comprising a substantially vertical surface extending from the curved surface to at least a height of the mirror preform when the mirror preform is disposed on the lower mold, the vertical surface surrounding a periphery of the space,

    wherein the housing hangs over the ditch-type vacuum line on at least one side of the mold such that there is a gap between the curved surface and the bottom of the housing along at least a portion of the openings.
45. The molding apparatus of claim 44, wherein the gap is smaller than a thickness of the mirror preform.
46. The molding apparatus of claim 44 or claim 45, wherein the longitudinal wall of the housing prevents leakage of the vacuum at a portion of a space between the first and second longitudinal side surfaces and the concave surface, and between the first and second transverse side surfaces and the concave surface.
47. The molding apparatus of any one of claims 44-46, wherein the concave surface of the mold comprises a first radius of curvature for a first curvature running in a longitudinal direction of the mold, and a second radius of curvature for a second curvature running in a transverse direction of the mold, the second radius of curvature being larger than the first radius of curvature.
48. The molding apparatus of any one of claims 44-47, wherein clearance between the housing and the minor surface is less than about 0.5 mm.

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