201240926 、發明說明： 相關申請案之交叉引用 本申請案主張根據專利法主張於2〇 n年2月28日提 出申請之美國臨時申請案第61/447146號及於2011年5 月6曰提出申請之美國臨時申請案第61/483〇95號之優 先權權益’本案依據該等申請案之内容且該等申請案之 内容以整體引用之方式併入本文。 【發明所屬之技術領域】 本發明大體而言係關於一種熱重形成二維 (two-dimensional; 2D)玻璃片成為三維 (three-dimensional; 3D)玻璃製品之方法。 【先前技術】 存在對用於諸如膝上型電、平板電腦及智慧型電話 之便攜式電子裝置之3D玻璃蓋之大量需求。尤其合乎 需要之3D玻璃蓋具有2D表面及3D表面之組合，2d表 面用於與顯态互動，3D表面用於包覆在顯示器之邊緣 周圍。3D表面可為不可展表面，亦即，無法在平面上無 失真的展開或鋪開之表面，且3D表面可包括彎曲、轉 角及曲線之任何組合。春也 & ° f曲可為大角度及陡峭的。曲線 可為不規則的。該等3D玻璃蓋為複雜的且難以精確製 得。 熱重形成已用來從2D玻璃片形成3d玻璃製品。熱重 形成涉及加熱至形成溫度及隨後重形成扣玻 201240926 璃片成為3D形狀。在藉由下垂或將2〇玻璃片壓向模且 進行重形成處，保持玻璃之溫度低於玻璃之軟化點以維 持良好玻璃表面品質且避免玻璃與模具之間的反應為合 :需要低於軟化點’玻璃具有高黏度且需要高壓力才 能重形成為諸如彎曲 '轉角及曲線之複雜形狀。在傳統 玻璃熱重形成中，柱塞用來施加所需要之高壓力。柱塞 接觸玻璃且將玻璃壓向模具。 為達成具有均勻厚度之3D玻璃製品，柱塞將玻璃壓 向模具時在柱塞表面與模具表面之間的間隙必須為均勾 的第1A圖圖不在柱塞表面1〇〇與模具表面1〇2之間 的均勻間隙之實例 '然而，由於在模具加卫中之小誤差 及在模具與柱塞之間的料誤差，通常有結塞表面與 模具表面之間的間隙不均勻之情況。第1B圖圖示歸因 於柱塞與模具之未對準之柱塞表1〇〇與模具表面1〇2 之間的非均勻間隙（例如在1〇3處）。第1C圖圖示歸因 於模具表面102中的加工誤差之柱塞表面1〇〇與模具表 面1 〇2之間的非均勻間隙（例如在1 〇5處）。 非均勻間隙產生在玻璃之一些區域中之過按壓及在玻 璃之其他區域中之欠按壓。過按壓將產生玻璃薄化，此 情況將顯示為3D玻璃製品中的顯著光學失真。欠按壓 在3D玻璃製品，尤其在包括彎曲、轉角及曲線之玻璃 製品之複雜區域中將產生皺紋。例如約為丨〇微米之小加 工誤差可產生非均勻間隙’該等非均勻間隙將產生過按 壓及/或欠按壓。在形成中涉及的柱塞表面、模具表面、 201240926 玻璃或其他裝備之不可避免的熱膨脹亦可影響間隙之均 勻性。 在按壓期間，柱塞亦拉伸玻璃以便改變在柱塞表面與 模具表面之間的玻璃厚度。因此，即使在柱塞表面與模 具表面之間的間隙為理想的，但玻璃之拉伸仍將產生具 有非均勻厚度之3D玻璃製品。可設計模具表面或柱塞 表面以補償由於拉伸而帶來的玻璃厚度之預期改變。然 而’此舉將產生柱塞表面與模具表面之間的非均勻間 隙’ s玄非均勻間隙如上所說明將產生在玻璃之一些區域 中之過按壓及在玻璃之其他區域中之欠按壓。 【發明内容】 在本發明之一態樣中，一種由2D玻璃片形成3D玻璃 製品之方法包含以下步驟：置放2D玻璃片於模具上， 該模具之模具表面之3D表面外形對應於3D玻璃製品之 外形；加熱2D玻璃片至在對應於1 〇7泊至1011泊之玻 璃黏度之溫度範圍内之第一溫度；及施加加熱至溫度範 圍内之第二溫度之加壓氣體至2D玻璃片之第一表面以 使2D玻璃片符合模具表面且形成3D玻璃製品。 在一實施例中，該方法進一步包括以下步驟：在施加 加壓氣體步驟之前或與至少一部分施加加壓氣體步驟同 時’施加真空至2D玻璃片之第二表面以使2D玻璃片符 合模具表面。 在一實施例中，該方法進一步包括以下步驟：提供模 201240926 具及施加輪磨校正至模具表面以補償在形成一部分3d 玻璃製品中之潛在誤差。 在一實施例中，在施加加懕n耱半 加加魘軋體步驟中將加壓氣體均 勻地施加至2D玻璃片之第一表面。 在另-實施例中，在施加加壓氣體步驟中將加塵氣體 有差別地施加至2 D玻璃片之第一表面 在-實施例中，該方法進一步包含以下步驟：在施加 加壓氣體步驟期間在大於第一溫度之第三溫度下施加突 發加壓氣體至2D玻璃片之經選擇區域。 在一實施例中，加壓氣體之壓力處於從1〇{^丨至2〇ρ^ 之範圍内。 在-實施例中，在施加加壓氣體步驟中，經由密封壓 力腔室施加加壓氣體且選擇密封壓力腔室之密封壓力為 大於加壓氣體之壓力或經由非密封壓力腔室施加加壓氣 體。 在-實施例中，在加熱2D玻璃片步驟中’較佳地在 模具上加熱2D玻璃片，以使得模具之溫度低於第一溫 度。 在-實施例中，在加熱2D玻璃片步驟中，模具表面 具有2D區域及3D區$ ’且較佳在模具上加熱2d玻璃 片以使得對應於模具之2D區域的2D玻璃片之第一部分 之溫度處於第-溫度，對應於模具之扣區域的犯玻璃 片之第二部分之溫度高於第一溫度’且模具之溫度低於 第一溫度。 7 201240926 在一實施例中’該方法進一步包含以下步驟：在施加 加壓氣體步驟之前施加真空至2D玻璃片之第二表面以 使2D玻璃片部分符合模具表面。 在一實施例中，該方法進一步包括以下步驟：在低於 第二溫度之第四溫度下藉由施加加壓氣體至3d玻璃製 品冷卻3D玻璃製品。 在一實施例中，在冷卻3D玻璃製品步驟期間，調整 第四溫度以匹配模具之溫度。 在另一實施例中，該方法進一步包括以下步驟：冷卻201240926, Invention Description: Cross-Reference to Related Applications This application claims to file an application under US Patent Application No. 61/447146 filed on February 28, 2000 and filed on May 6, 2011. </ RTI> <RTIgt; </ RTI> <RTIgt; </ RTI> <RTIgt; </ RTI> <RTIgt; </ RTI> <RTIgt; </ RTI> <RTIgt; TECHNICAL FIELD OF THE INVENTION The present invention generally relates to a method of forming a two-dimensional (2D) glass sheet into a three-dimensional (3D) glass article by thermogravimetry. [Prior Art] There is a large demand for 3D glass covers for portable electronic devices such as laptops, tablets, and smart phones. A particularly desirable 3D glass cover has a combination of a 2D surface and a 3D surface, the 2d surface is used to interact with the display, and the 3D surface is used to wrap around the edge of the display. The 3D surface can be a non-expandable surface, i.e., a surface that cannot be unfolded or spread out in a plane without distortion, and the 3D surface can include any combination of bends, corners, and curves. Spring also & ° f can be large angle and steep. The curve can be irregular. These 3D glass covers are complex and difficult to manufacture accurately. Thermogravimetric formation has been used to form 3d glass articles from 2D glass sheets. Thermogravimetric formation involves heating to the formation temperature and subsequent reformation of the buckle glass 201240926. The glass sheet becomes a 3D shape. Keeping the temperature of the glass below the softening point of the glass by sagging or pressing the 2 〇 glass sheet toward the mold and re-forming to maintain good glass surface quality and avoid the reaction between the glass and the mold: need to be lower than The softening point 'glass has a high viscosity and requires high pressure to be reformed into complex shapes such as curved 'corners' and curves. In conventional glass thermogravimetric formation, the plunger is used to apply the required high pressure. The plunger contacts the glass and presses the glass against the mold. In order to achieve a 3D glass product having a uniform thickness, the gap between the surface of the plunger and the surface of the mold when the plunger presses the glass toward the mold must be uniformly hooked. FIG. 1A is not on the surface of the plunger 1〇〇 and the surface of the mold 1〇 An example of a uniform gap between 2 'However, due to small errors in mold reinforcement and material errors between the mold and the plunger, there is usually a case where the gap between the plug surface and the mold surface is not uniform. Figure 1B illustrates a non-uniform gap (e.g., at 1〇3) between the plunger table 1〇〇 and the mold surface 1〇2 due to the misalignment of the plunger with the mold. Figure 1C illustrates a non-uniform gap (e.g., at 1 〇 5) between the plunger surface 1 归因 and the mold surface 1 〇 2 due to machining errors in the mold surface 102. Non-uniform gaps result in over-pressing in some areas of the glass and under-pressing in other areas of the glass. Over-pressing will result in thinning of the glass, which will be shown as significant optical distortion in the 3D glass article. Under Pressing Wrinkles are created in 3D glassware, especially in complex areas of glass products including bends, corners and curves. For example, small machining errors of about 丨〇 microns can produce non-uniform gaps. These non-uniform gaps will result in over-pressure and/or under-pressure. The unavoidable thermal expansion of the plunger surface, mold surface, 201240926 glass or other equipment involved in the formation may also affect the uniformity of the gap. During pressing, the plunger also stretches the glass to change the thickness of the glass between the surface of the plunger and the surface of the mold. Therefore, even if the gap between the surface of the plunger and the surface of the mold is ideal, the stretching of the glass will result in a 3D glass article having a non-uniform thickness. The mold surface or plunger surface can be designed to compensate for the expected change in glass thickness due to stretching. However, this will result in a non-uniform gap between the surface of the plunger and the surface of the mold. The non-uniform gap will produce over-pressing in some areas of the glass and under-pressure in other areas of the glass as explained above. SUMMARY OF THE INVENTION In one aspect of the present invention, a method for forming a 3D glass article from a 2D glass sheet includes the steps of: placing a 2D glass sheet on a mold, the 3D surface profile of the mold surface corresponding to the 3D glass Forming the product; heating the 2D glass sheet to a first temperature within a temperature range corresponding to a glass viscosity of 1 〇 7 poise to 1011 poise; and applying a pressurized gas heated to a second temperature within the temperature range to the 2D glass sheet The first surface is such that the 2D glass sheet conforms to the mold surface and forms a 3D glass article. In one embodiment, the method further includes the step of applying a vacuum to the second surface of the 2D glass sheet prior to the step of applying the pressurized gas or simultaneously with the step of applying at least a portion of the pressurized gas to conform the 2D glass sheet to the mold surface. In one embodiment, the method further includes the steps of providing a mold 201240926 and applying a wheel grinding correction to the mold surface to compensate for potential errors in forming a portion of the 3d glass article. In one embodiment, the pressurized gas is uniformly applied to the first surface of the 2D glass sheet during the step of applying the twisted n 耱 half plus nip. In another embodiment, the dusting gas is differentially applied to the first surface of the 2D glass sheet in the step of applying a pressurized gas. In an embodiment, the method further comprises the step of: applying a pressurized gas step A burst of pressurized gas is applied to the selected region of the 2D glass sheet at a third temperature greater than the first temperature. In one embodiment, the pressure of the pressurized gas is in the range from 1 〇{^丨 to 2〇ρ^. In an embodiment, in the step of applying a pressurized gas, the pressurized gas is applied via the sealed pressure chamber and the sealing pressure of the sealed pressure chamber is selected to be greater than the pressure of the pressurized gas or the pressurized gas is applied via the unsealed pressure chamber . In an embodiment, the 2D glass piece is preferably heated on the mold in the step of heating the 2D glass sheet such that the temperature of the mold is lower than the first temperature. In an embodiment, in the step of heating the 2D glass sheet, the mold surface has a 2D region and a 3D region $' and preferably the 2d glass sheet is heated on the mold such that the first portion of the 2D glass sheet corresponding to the 2D region of the mold The temperature is at the first temperature, the temperature of the second portion of the glass sheet corresponding to the buckle region of the mold is higher than the first temperature ' and the temperature of the mold is lower than the first temperature. 7 201240926 In an embodiment the method further comprises the step of applying a vacuum to the second surface of the 2D glass sheet prior to the step of applying the pressurized gas to conform the 2D glass sheet portion to the mold surface. In one embodiment, the method further includes the step of cooling the 3D glass article by applying a pressurized gas to the 3d glass article at a fourth temperature below the second temperature. In one embodiment, during the step of cooling the 3D glass article, the fourth temperature is adjusted to match the temperature of the mold. In another embodiment, the method further comprises the steps of: cooling
玻璃製品及加工3D玻璃製品至最終尺寸、退火3D 玻璃製品及藉由離子交換強化3D玻璃製品中之至少一 者。 在本發明之另一態樣中’用於從2D玻璃片形成3〇玻 璃製品之設備包含：能夠支撐2D玻璃片之模具、導引 加壓氣體朝向模具表面之構件及在鄰近模具處提供熱量 之構件，該模具之模具表面之3D表面外形對應於3〇玻 璃製品之外形。 在一實施例中，模具表面界定模具穴且模具包括施加 真空至模具穴或從模具穴排放氣體之一或更多琿。 在一實施例中，導引加壓氣體之構件包含具有充氣部 之罩知。充氣部具有充氣腔室及氣體格柵，充氣腔室用 於接收加壓氣體，氣體格栅經安裝鄰接於充氣腔室以用 於導5丨充氣腔室中之加壓氣體朝向模具表面。 在一實施例中，配置且定位氣體格柵以跨越模具表面 8 201240926 均勻地分佈加壓氣體。 在實轭例中，配置且定位氣體格柵以跨越模具表面 有差別地分佈加壓氣體。 在一實施例中，導引加壓氣體之構件進一步包括在罩 帽與模具之間的可密封壓力腔室。 應理解，以上-般描述及以下詳細描述兩者皆為本發 明之實例且意欲提供概述或框架以用於理解如本發明所 主張的本發明之本質及特性4包括隨附圖式以提供本 發明之進一步理解，且將該等隨附圖式併入本說明書且 構成本說明書之一部分。圖式圖示本發明之各種實施例 且連同描述一起用作說明本發明之原理及操作。 【實施方式】 在隨後之詳細描述中將闡述本發明之額外特徵結構及 優點，且對於熟習此項技術者而言，該等額外特徵結構 及優點從彼描述中將部分地為顯而易見或藉由實踐本文 所述之本發明來認識到。At least one of glassware and processed 3D glassware to final size, annealed 3D glassware, and enhanced 3D glassware by ion exchange. In another aspect of the invention, an apparatus for forming a 3D glass article from a 2D glass sheet comprises: a mold capable of supporting a 2D glass sheet, a member directing pressurized gas toward the surface of the mold, and providing heat adjacent the mold The member has a 3D surface profile of the mold surface corresponding to the shape of the 3 〇 glass article. In an embodiment, the mold surface defines a mold cavity and the mold includes applying a vacuum to the mold cavity or discharging one or more gases from the mold cavity. In one embodiment, the means for directing the pressurized gas comprises a cover having an inflator. The inflator has a plenum chamber for receiving pressurized gas, and a gas grid mounted adjacent to the plenum chamber for directing pressurized gas in the plenum chamber toward the mold surface. In one embodiment, the gas grid is configured and positioned to evenly distribute the pressurized gas across the mold surface 8 201240926. In the solid yoke example, the gas grid is configured and positioned to differentially distribute the pressurized gas across the surface of the mold. In an embodiment, the means for directing the pressurized gas further comprises a sealable pressure chamber between the cap and the mold. It is to be understood that both the foregoing description of the invention, The invention is further understood, and is incorporated in the specification and constitute a part of the specification. The drawings illustrate various embodiments of the invention and, together, The additional features and advantages of the present invention are set forth in the Detailed Description of the Detailed Description, It is recognized that the invention described herein is practiced.
本發明涉及使用熱加壓氣體從2D玻璃片形成3D玻璃 製品。熱加壓氣體用來施加壓力至2D玻璃片以使2D玻 璃片完全符合模具之3D表面’從而形成3D玻璃製品。 可均勻地施加熱加壓氣體至玻璃或可有差別地施加，例 如僅施加或以較大濃度施加至需要高形成壓力之玻璃區 域，諸如將包括彎曲、轉角及曲線之玻璃區域。一般而 言’形成3D玻璃製品之製程包括以下步步驟：置放2D 9 201240926 片於模具上、預熱2D玻璃片及模具至玻璃黏度在 1 0，白與1 0 S白之間的溫度、施加真空以部分地形成扣 形狀且密封玻璃至模具、施加熱加壓氣體以完成31)形 狀形成’及冷卻玻璃’同時控制玻璃中之熱梯度以最小 化玻璃中之失真。 第2A圖圖示根據如上所述之製程從2][)玻璃片2料形 成3D玻璃製品之設備2〇〇β設備2〇〇包括具有模具表面 2〇6之模具2〇2。模具表面2〇6具有表面外形該3D 表面外形對應於欲形成之3D玻璃製品之3D形狀。模具 表面2〇6為凹形且界定模具穴207。將2D玻璃片2〇4 置放於模具2G2上能夠下垂進人模具穴2()7或與模具表 面206相抵之位置。在模具2〇2中提供埠或孔卜埠 則從模具2〇2之外部行進至模具表面咖。在—實施例 中埠208位於模具表面206之轉角處。在替代實施例 中皁208可位於模具表面206之轉角及底部處或恰好 處於模具表面206之底部。隨後將描述珲208僅位於模 具：面206之轉角的優點。埠2〇8可充當真空埠以施加 真空至模具穴2〇7,或充當排放埠以抽取截留在模具穴 207中之氣體。可於模具2〇2上提供對準銷21〇以辅助 將2D玻璃片204與模具穴2〇7對準。 ，模202由可耐尚溫材料製得，諸如當從破璃片 形成3D玻螭製品時將遇到之高溫。模具材料可為在形 成條件下不會與玻璃起反應（或不黏住玻璃）之一種材 料’或可用在形成條件不會與玻璃起反應（或不黏住玻 201240926 璃）之塗覆材料塗覆模具表面206。在一實施例中，模 具202由諸如石墨之非反應性碳材料製得，且當模具表 面206與玻璃接觸時，高度磨光模具表面2〇6以避免引 起玻璃中之缺陷。在另一實施例中，模具2〇2由諸如碳 化矽、碳化鎢及氮化矽之緻密陶瓷材料製得，且以諸如 石墨之非反應性碳材料塗覆模具表面2 〇 6。在另一實施 例中，模具202由諸如英高鎳合金718 ( Inc〇nei 718 )、 鎳鉻合金之超合金製得，且以諸如氮化鈦鋁之硬陶瓷材 料塗覆模具表面206。在一實施例中，有或無塗覆材料 之模具表面206具有Ra< 1〇 nm之表面粗糙度。將碳材 料用於模具202或將碳塗覆材料用於模具表面2〇6將要 求在惰性氣體環境中執行3D玻璃製品之形成。 將罩帽212安裝於模具2〇2之頂部。罩帽212具有充 氣部216 ^當將罩帽212安裝於如圖示模具2〇2之頂部 時在板具202與充氣部216之間形成壓力腔室218。 充氣部216包括充氣腔室220，該充氣腔室22〇經由導 管222連接至熱加壓氣體221之源（未圖示該源）。氣體 較佳地為諸如氮之惰性氣體。充氣部2丨6包括氣體格拇 224’將該氣體格柵224安裝在充氣腔室22〇下麵且定位 在模具202之上。氣體格柵224為多孔板且包括孔，經 由該等孔可將充氣腔室220中之氣體導引入壓力腔室 218且朝向模具表面2〇6。罩帽212及氣體格栅224的製 成材料應在將2D玻璃片204重形成為3D玻璃製品之條 件下不會產生污染物。罩帽212及氣體格栅224可由與 201240926 模具202相同之材料製得，不同之處在於由於在玻璃月 之重形成期間玻璃片將不與罩帽212及氣體格柵224之 表面接觸，故欲高度磨光之罩帽212及氣體格柵224之 表面不必要為該相同材料。 在一個實施例中，在經由充氣部216遞送熱加壓氣體 221至壓力腔室218中之前，密封在罩帽212與模具 之間的壓力腔室218。可藉由施加力F至罩帽212來密 封壓力腔室218 ’以使得罩帽212對模具2〇2之頂部施 壓。撞鎚或能夠施加力之其他裝置可用於此目的。為將 壓力腔室2 1 8维持於密封條件下，歸因於應用力F之施 加之密封壓力應大於遞送入壓力腔室218之熱加壓氣體 221之壓力。 在第2A圖中，氣體格柵224佔用充氣腔室22〇之整 個底部且導引熱加壓氣體跨越模具2〇2上之2D玻璃片 204之整個頂部表面234。若在氣體格栅224中孔之分佈 及大小為均勻的’則將實質上均勻地導引熱加壓氣體 221跨越2D玻璃片204之整個表面。第2B圖圖示替代 佈置’其中氣體格柵228位於充氣腔室230之邊緣且允 許有差別地施加熱加壓氣體221至2D玻璃片204之頂 部表面234❶氣體格柵228可為環形形狀。或者，可使 用沿著充氣腔室230之邊緣佈置之複數個氣體格柵。在 第2B圖圖示之佈置中’氣體格柵228將導引熱加壓氣 體至2D玻璃片204之周邊。此周邊為需要高形成壓力 之處’例如將形成彎曲、轉角或曲線之處。一般而言， 12 201240926The present invention relates to the formation of 3D glass articles from 2D glass sheets using hot pressurized gas. The hot pressurized gas is used to apply pressure to the 2D glass sheet so that the 2D glass sheet fully conforms to the 3D surface of the mold to form a 3D glass article. The hot pressurized gas may be applied uniformly to the glass or may be applied differentially, e.g., applied only or at a greater concentration to a glass region where high pressure formation is desired, such as a glass region that will include bends, corners, and curves. In general, the process of forming a 3D glass article includes the following steps: placing 2D 9 201240926 on the mold, preheating the 2D glass sheet and the mold to a glass viscosity of 10, the temperature between white and 10 S white, A vacuum is applied to partially form the buckle shape and seal the glass to the mold, applying a hot pressurized gas to complete 31) shape forming 'and cooling the glass' while controlling the thermal gradient in the glass to minimize distortion in the glass. Fig. 2A is a view showing an apparatus 2 for forming a 3D glass article from 2] [) glass sheet 2 according to the above-described process. The apparatus 2 2 includes a mold 2 2 having a mold surface 2〇6. The mold surface 2〇6 has a surface profile which corresponds to the 3D shape of the 3D glass article to be formed. The mold surface 2〇6 is concave and defines a mold cavity 207. Placement of the 2D glass sheet 2〇4 on the mold 2G2 can sag into the mold hole 2 () 7 or at a position against the mold surface 206. Providing a crucible or a hole in the mold 2〇2 travels from the outside of the mold 2〇2 to the mold surface. In the embodiment, the crucible 208 is located at the corner of the mold surface 206. In an alternate embodiment, soap 208 may be located at or near the corners and bottom of mold surface 206 or just at the bottom of mold surface 206. The advantage that the crucible 208 is only located at the corner of the mold: face 206 will be described later.埠2〇8 may act as a vacuum crucible to apply vacuum to the mold cavity 2〇7, or act as a discharge enthalpy to extract gas trapped in the mold cavity 207. An alignment pin 21〇 can be provided on the mold 2〇2 to assist in aligning the 2D glass sheet 204 with the mold cavity 2〇7. The mold 202 is made of a material that is resistant to temperature, such as the high temperatures that would be encountered when forming a 3D glass substrate from a glass sheet. The mold material may be a material that does not react with the glass under the forming conditions (or does not stick to the glass) or may be coated with a coating material that does not react with the glass under the forming conditions (or does not adhere to the glass 201240926 glass). The mold surface 206 is covered. In one embodiment, the mold 202 is made of a non-reactive carbon material such as graphite, and when the mold surface 206 is in contact with the glass, the mold surface 2 is highly polished to avoid causing defects in the glass. In another embodiment, the mold 2 2 is made of a dense ceramic material such as tantalum carbide, tungsten carbide, and tantalum nitride, and the mold surface 2 〇 6 is coated with a non-reactive carbon material such as graphite. In another embodiment, the mold 202 is made of a superalloy such as Inco-Nickel 718 (Indene 718), a nickel-chromium alloy, and the mold surface 206 is coated with a hard ceramic material such as titanium aluminum nitride. In one embodiment, the mold surface 206 with or without coating material has a surface roughness of Ra < 1 〇 nm. The use of a carbon material for the mold 202 or the use of a carbon coating material for the mold surface 2〇6 would require the formation of a 3D glass article in an inert gas environment. The cap 212 is mounted on top of the mold 2〇2. The cap 212 has an inflating portion 216. A pressure chamber 218 is formed between the panel 202 and the inflator 216 when the cap 212 is mounted on top of the mold 2〇2 as shown. The inflator 216 includes an inflating chamber 220 that is coupled via a conduit 222 to a source of hot pressurized gas 221 (the source is not shown). The gas is preferably an inert gas such as nitrogen. The plenum 2丨6 includes a gas grid 224' that mounts the gas grid 224 below the plenum chamber 22 and is positioned over the mold 202. The gas grid 224 is a perforated plate and includes apertures through which gas in the plenum chamber 220 can be directed into the pressure chamber 218 and toward the mold surface 2〇6. The material of the cap 212 and the gas grid 224 should be such that no contaminants are produced under the condition that the 2D glass sheet 204 is reformed into a 3D glass article. The cap 212 and the gas grid 224 may be made of the same material as the 201240926 mold 202, except that the glass sheet will not contact the surface of the cap 212 and the gas grid 224 during the formation of the glass moon. The surfaces of the highly polished cap 212 and gas grid 224 need not be the same material. In one embodiment, the pressure chamber 218 between the cap 212 and the mold is sealed prior to delivery of the hot pressurized gas 221 to the pressure chamber 218 via the plenum 216. The pressure chamber 218' can be sealed by applying a force F to the cap 212 such that the cap 212 applies pressure to the top of the mold 2〇2. A ram or other device capable of applying a force can be used for this purpose. In order to maintain the pressure chamber 2 18 under sealed conditions, the applied seal pressure due to the applied force F should be greater than the pressure of the hot pressurized gas 221 delivered into the pressure chamber 218. In Figure 2A, the gas grid 224 occupies the entire bottom of the plenum chamber 22 and directs the hot pressurized gas across the entire top surface 234 of the 2D glass sheet 204 on the mold 2〇2. If the distribution and size of the holes in the gas grid 224 are uniform, then the hot pressurized gas 221 will be substantially uniformly directed across the entire surface of the 2D glass sheet 204. Figure 2B illustrates an alternative arrangement 'where the gas grid 228 is located at the edge of the plenum chamber 230 and allows differential application of the hot pressurized gas 221 to the top surface 234 of the 2D glass sheet 204. The gas grid 228 may be annular in shape. Alternatively, a plurality of gas grids disposed along the edges of the plenum chamber 230 can be used. In the arrangement illustrated in Figure 2B, the gas grid 228 will direct the hot pressurized gas to the periphery of the 2D glass sheet 204. This periphery is where high pressure is required to be formed, for example, where a bend, a corner or a curve will be formed. In general, 12 201240926
氣體格柵位於充氣部的位置將決定經由氣體格柵遞送之 熱加壓氣體之聚集’且氣體格柵之位置以及氣體格柵中 孔之大小及間隔可經調整適合於使用模具表面206欲形 成之3D形狀。可將諸如第2B圖圖示之氣體格栅稱為定 向氣體格柵，該氣體格柵導引熱加壓氣體至模具上之2D 玻璃片之經選擇區域或導引熱加壓氣體有差別地跨越模 具上之2D玻璃片。 在一貫施例中’在遞送熱加壓氣體221進入壓力腔室 218之前不密封壓力腔室218。將諸如第2B圖中之氣體 格栅208之定向氣體格柵定位在離2Γ)玻璃片2〇4之小 距離内。此小距離較佳地為小於5 nim。該小距離允許將 經由定向氣體格柵施加之定向喷射約束至2d玻璃片 2〇4要求尚壓形成之所要區域。高速定向喷射用來在2d 玻璃片之所要區域產生點壓力或線壓力。因為在此情況 下不密封壓力腔室218,故在壓力腔室218中不形成平 衡壓力。因此，僅2D玻璃片2〇4之所要區域將接收高 速氣體喷射壓力。 在一實施例中將模具202置放於真空吸盤2〇3上，如 第2A圖圖示。在真空吸盤203下面佈置一或更多加熱 器240以加熱模具202及置放於模具2〇2上之2d玻璃 片204。若不使用真空吸盤203,則可在模具2〇2下面簡 單地佈置一或更多加熱器240。在另一實施例中’可在 壓力腔室218中佈置一或更多加熱器以加熱模具2〇2及 2D玻璃片204。壓力腔室218中之加熱器可為除佈置在The location of the gas grid at the plenum will determine the accumulation of hot pressurized gas delivered via the gas grid and the location of the gas grid and the size and spacing of the holes in the gas grid can be adjusted to suit the use of the mold surface 206. 3D shape. A gas grid such as illustrated in FIG. 2B may be referred to as an oriented gas grid that directs hot pressurized gas to selected regions of the 2D glass sheet on the mold or directs hot pressurized gas to differentially Cross the 2D glass piece on the mold. In a consistent embodiment, the pressure chamber 218 is not sealed until the hot pressurized gas 221 is delivered into the pressure chamber 218. The directional gas grid, such as gas grid 208 in Figure 2B, is positioned within a small distance from the 2 Γ glass sheet 2〇4. This small distance is preferably less than 5 nim. This small distance allows the directed jet applied via the directional gas grid to be constrained to the desired area where the 2d glass sheet 2〇4 is still pressed. High speed directional jets are used to create point or line pressure in the desired area of the 2d glass. Since the pressure chamber 218 is not sealed in this case, no equilibrium pressure is formed in the pressure chamber 218. Therefore, only the desired area of the 2D glass sheet 2〇4 will receive the high velocity gas injection pressure. In one embodiment, the mold 202 is placed on the vacuum chuck 2〇3 as illustrated in Figure 2A. One or more heaters 240 are disposed under the vacuum chuck 203 to heat the mold 202 and the 2d glass sheet 204 placed on the mold 2〇2. If the vacuum chuck 203 is not used, one or more heaters 240 can be simply disposed under the mold 2〇2. In another embodiment, one or more heaters may be disposed in the pressure chamber 218 to heat the mold 2〇2 and the 2D glass sheet 204. The heater in the pressure chamber 218 can be arranged in addition to
S 13 201240926 模具202或真空吸盤203下麵之加熱器24〇之外的加熱 器或代替加熱器240。加熱器可為中紅外（mid__infrared; mid-IR)加熱器，諸如Hereaus Noblelight中紅外加熱 器。Mid-IR加熱器可用來較佳地加熱模具202上之2D 玻璃片204，以使得在重形成2D玻璃片204成為3D玻 璃製品之前及在重形成的同時’模具202與玻璃相比處 於較低溫度，例如低100。〇至20(TC。亦可使用除mid_IR 加熱器以外之其他類型加熱器’諸如電阻式加熱器。 在一實施例中’ 2D玻璃片204為薄的，例如具有從 0.3 mm至1.5 mm範圍内之厚度。在一實施例中，2d玻 璃片204為可離子交換玻璃。可離子交換玻璃為具有小 驗離子之含鹼玻璃，該等小鹼離子為諸如u+、Na+或以 上兩者。在離子交換製程期間，該等小鹼離子可交換為 諸如K之較大驗離子。適當可離子交換含驗玻璃之實例 為驗銘矽酸鹽玻璃。在美國專利第7,666,51 1號（Euis〇n 等人；2010年2月23曰）及美國專利申請案公開案第 US 2009/0142568 A1 號（Dejneka 等人；2009 年 6 月 4 曰）、第 US 2009/0215607 號（Dejneka 等人；2009 年 8 月 27 日）、第 US 2009/0220761 號（Dejneka 等人；2009 年 9 月 3 曰）及第 US 2010/0035038 A1 號（Barefoot 等 人’2010年2月11日）中描述該等玻璃之實例。可以 相對低溫離子交換該等鹼鋁矽酸鹽玻璃且可離子交換該 等鹼鋁矽酸玻璃至至少30微米之深度。適當可離子交換 玻璃之適當實例為GORILLA玻璃，該GORILLA玻璃可 14 201240926 根據代碼2317購自紐約c〇rning 。在例如 美國專利第5,674,790號（Araujo ; 1997年10月7日） 中描述藉由離子交換強化玻璃之製程。 為形成3D玻璃製品，將2D玻璃片2〇4置放於如第 2A圖圖不之模具2〇2上。對準銷可用來精確定置 2D玻璃片204於模具202上。在將2D玻璃片2〇4置放 於模具202之後，加熱2D玻璃# 2〇4及模具2〇2。在— 實^例中’至少加熱2D玻璃ϋ 204至對應於1 〇7泊至 【〇丨丨泊範圍内之玻璃黏度之溫度範圍内之形成溫度。在 一實施例中，加熱2D玻璃片204及模具202,以使得在 玻璃片204開始形成為3D玻璃製品時，2D玻璃片 204及模具202兩者皆處於相同溫度。對於此類型加熱， 模具202 T由諸如石.¾之非反應性碳材料製得或由塗有 碳塗覆材料之敏密Μ材料製得。該加熱需要在惰性氣 體％境中發生。在另一實施例中，較佳地在該2D玻璃 片204在杈具202上時加熱2D玻璃片2〇4,以使得模具 2〇2之溫度低於2D玻璃片2〇4之溫度，例如模具2〇2 之溫度可為比2D玻璃片2〇4之溫度低1〇〇<€至2〇〇ec。 mid-IR加熱器可用於此較佳加熱。對於此較佳加熱，模 八202可由具有硬陶瓷塗層之超合金製得。利用此材 料，較佳加熱可發生在非惰性氣體環境中。 在加熱2D玻璃片204及模具202之後，施加真空至 模具穴207以抽拉與模具表面2〇6相抵的2D玻璃片之 底部表面232且密封玻璃至模具表面2〇6。在施加真空 15 201240926 之前，由於重力，2D玻璃片204可能已開始與模具表面 206相抵下垂。在—實施例中’可在2 in Hg至1〇 之範圍内施加真空。經由充氣部216及壓力腔室218施 加熱加壓氣體221至部分成型之2D玻璃片204之頂部 表面234。熱加壓氣體221提供需要之壓力以使2d玻璃 片204完全符合模具表面2〇6，從而完整地形成3D玻璃 製品。熱加壓氣體之溫度處於先前提及之對應於1 〇7泊 至1〇11泊之玻璃黏度範圍之溫度範圍内。熱加壓氣體之 溫度可與2D玻璃片之溫度相同或不同。在一實施例中， 熱加壓氣體之溫度處於8〇〇C之21)玻璃片之溫度 加壓氣體之溫度可與2D玻璃片之溫度相同，或高於或 低於2D玻璃片之溫度。可在高於2D玻璃片溫度之溫度 下有選擇地施加突發熱加壓氣體至2D玻璃片，如下文 將進步說明。可没什氣體格栅2 2 4以便定向施加突發 熱加壓氣體，亦即，僅對需要突發加壓氣體之2D玻璃 片區域處施加突發熱加壓氣體。第2C圖圖示藉由熱加 壓氣體之壓力由2D玻璃片204形成之3D玻璃製品 205。形成3D形狀所要求之典型氣體壓力可與在接觸形 成中所使用之柱塞壓力相當。取決於形成之3D形狀及 玻璃黏度，此壓力可在1〇1)8丨至2〇psii範圍内。舉例 而言，由玻璃黏度為大約109泊之1〇mm厚度玻璃形成 具有半徑小於5 mm之彎曲的碟形將要求約2〇 。 已如上所述，在施加熱加壓氣體221至21)玻璃片 之前，可密封壓力腔室218。若藉由自模具2〇2之傳導 16 201240926 及辕射加熱2D玻璃片204，則在加熱2D玻璃片204之 前、加熱期間或加熱之後可密封壓力腔室218 ◊或者， 若欲密封壓力腔室218,則若使用輻射加熱器在模具2〇2 上直接加熱2D玻璃片204，則在加熱2D玻璃片204之 後應密封壓力腔室218❶在施加熱加壓氣體221至玻璃 片之前幾秒鐘，可施加真空至模具穴2〇7。可在施加熱 加壓氣體22i至玻璃片之整個持續時間之部分或貫穿整 個持續時間維持真空，在此情況下，真空可幫助維持玻 璃片在模具表面206上之位置，以使得正施加熱加壓氣 體221時，玻璃片不移動。若開始之2D玻璃片大 於模具穴207以使得該開始之2D玻璃片2〇4覆蓋模具 穴207，則可將2D玻璃片形成為3D玻璃製品而不使用 真空。當使用真空或不使用真空而形成3D玻璃製品時， 模具202中之埠208用來排放截留在模具穴207中之氣 體。 在形成3D玻璃製品2〇5之後，熱加壓氣體221至壓 力腔室218之流動停止或替換為較冷加壓氣體之流動。 隨後，使用或不使用較冷加壓氣體冷卻3d玻璃製品2〇5 至低於玻璃之應變點。較冷加壓氣體可輔助於更快速冷 卻3D玻璃2G5。在-實施例中，當在冷卻3D玻璃 製品205中使用較冷加壓氣體時，較冷加壓氣體之溫度 係選自對應於玻璃轉移溫度加或減 1 o°c之溫度範圍。在 另一實施例中’當在冷卻3D玻璃製〇口〇 2〇5中使用較冷 加壓氣n # &冷卻m調整較冷加壓氣體之溫度以匹 17 201240926 配模具202之溫度。可藉由以諸如熱電偶之感測器監控 模具202之溫度及使用感測器之輸出調整較冷加壓氣體 之溫度達成此效果。較冷加壓氣體之壓力可小於熱加壓 氣體之壓力或與熱加壓氣體之壓力相同。3D玻璃製品之 冷卻使得最小化跨越玻璃製品之厚度、沿著玻璃製品之 長度及沿著玻璃製品之寬度的溫度差（ΔΤ)。較佳地，跨 越玻璃製品之厚度及沿著玻璃製品之長度及寬度的δτ 小於10 C。在冷卻期間ΔΤ愈低，玻璃製品中之應力愈 低。若冷卻期間在玻璃製品中產生高應力，則玻璃製品 將回應於該應力而產生翹曲。因此，在冷卻期間避免在 玻璃製品中產生高應力為合乎需要的。藉由在3D玻璃 製品205兩側施加溫度受控之氣流可以對流方式冷卻 3D玻璃製品205。如上所述，經由充氣部216及壓力腔 室218可施加較冷加壓氣體至3D玻璃製品2〇5之頂部 表面236，且經由模具2〇2中之埠2〇8可施加溫度受控 之氣流至3D玻璃製品205之底部表面238，溫度受控之 氣流可具有類似於較冷加壓氣體之特性。經由埠2〇8供 應之氣體麗力可使得淨力產生而在冷卻期間從模具2〇2 舉升3D玻璃製品205。由於模具202具有比玻璃更大熱 201240926 量，模具202以比玻璃更緩慢之速率冷卻，模具2〇2之 此缓慢冷卻可跨越玻璃之厚度產生大ΔΤ。冷卻期間從模 具202舉升玻璃幫助避免此大么丁。 冷卻後可退火3D玻璃製品205，且退火3]〇玻璃製品 205後可為涉及3D玻璃製品205之離子交換製程。在形 成3D玻璃製品中使用之2D玻璃片204可為過大的片， 在形成為3D玻璃製品205之後將該過大的片加工至最 終尺寸《在此情況下，在離子交換製程之前可執行加工❶ 第3A圖圖示由過大的玻璃片3〇2形成之3〇玻璃製品 3〇〇之實例。將需要從過大的玻璃片中擷取之3D玻璃製 品300且隨後藉由適當加工製程修整3D玻璃製品 的邊緣。或者，2D玻璃片204可為加工之2D預製件， 該預製件需要精確對準在模具202上且在形成為3D玻 璃製品之後將不加工該預製件。加工預製件將已邊緣輪 靡化且邊緣修整成形成3D玻璃製品所需要之精確形狀 及大小。第3B圖圖示由加工之預製件形成的3D玻璃製 。。304之實例。3D玻璃製品3〇4不要求額外邊緣修整。 以例如1〇9泊至1〇π泊之高玻璃黏度可形成平緩輪 廓，同時大角度彎曲（tight bend )及尖銳轉角要求例如 在1 〇泊與1 〇8.2泊之間的更低黏度。更低黏度允許玻璃 201240926 更好地符合模具。然而，以低黏度達成良好玻璃表面漂 亮外觀是有挑戰性的，因為此操作更易於在玻璃表面上 印記缺陷。於低黏度之形成可引起玻璃再沸，此舉產生 橘皮狀表面。以較低玻璃黏度在玻璃上容易印上模具表 面上之真空或排放埠。另一方面，則更易於以高破璃黏 度達成良好表面漂亮外觀。因此，為在3D玻璃製品中 達成良好破璃表面漂亮外觀及緊密尺寸公差兩者，將必 須最佳化藉由熱加壓氣體施加至玻璃之壓力、玻璃黏度 及施加熱加壓氣體之壓力至玻璃之位置。對於獲得緊密 尺寸公差同時維持良好玻璃表面漂亮外觀存在若干選 擇。 遇擇马在模具中使用輪廓校 成具有大角度彎曲之3D形狀，可設計模具之壁具有比 最終开/狀更大角度彎曲半徑及更陡峭之側壁切線角。舉 例而言，若欲形成之碟形之側壁切線角為6〇。，且若維持 良好玻璃表面漂亮外觀要求以9 5 p之對數黏度形成碟 形’則形成製程可產生具有46。側壁切線角之碟形，亦 即，右不校正模具輪廓，則比所要角度小14。。為增加 側壁切線角，不降低玻璃黏度，可補償模具輪廓以藉由 在理想形狀與形成製品上量測角度之間的差異增加側壁 切線角。上述實例令，經補償之模具將具有74。之側壁 :線角。做此輪廊校正且達成具有均勾厚度之玻璃製品 -有可能的’因為由於藉由熱加職體正提供形成形狀 要之壓力&在柱塞與模具之間不存在需擔心之間 20 201240926 隙。 另選擇為在模具上使用高磨光度，該高磨光度將允 許降低玻璃黏度而不在玻璃表面上產生缺陷。可使模具 表面具有Ra< 1〇 nm之表面粗糙度且可使模具表面為非 黏性或非反應性的。舉例而言’在模具表面上可使用玻 璃狀石墨塗層。同樣，可將真空或排放埠（第2A圖中 之218)僅置放於模具之轉角，亦即，在壓力形成期間 玻璃將持續接觸模具的位置。 $ 一選擇為使用諸如第2B圖圖示之定向充氣部，在 〇疋向充氣。卩導引熱氣體之壓力朝向玻璃之複雜區域， 例如L括彎曲或轉角之區域。在比玻璃溫度大。〇至 C之溫度下可施加加壓氣體突發作為定向喷氣以在複雜 區域中較佳地升高玻璃溫度且降低玻璃黏度。 另一選擇為使用冷模具/熱玻璃佈置，此時模具溫度比 正形成之玻璃低100-C至2〇〇。〇。S 13 201240926 A mold 202 or a heater other than the heater 24 下面 under the vacuum chuck 203 or in place of the heater 240. The heater can be a mid-infrared (mid-IR) heater such as a Hereaus Noblelight mid-infrared heater. The Mid-IR heater can be used to preferably heat the 2D glass sheet 204 on the mold 202 such that the mold 202 is lower than the glass prior to reforming the 2D glass sheet 204 into a 3D glass article and while reforming. The temperature is, for example, lower by 100. 〇 to 20 (TC. Other types of heaters other than mid_IR heaters may be used, such as resistive heaters. In one embodiment '2D glass sheets 204 are thin, for example having a range from 0.3 mm to 1.5 mm In one embodiment, the 2d glass sheet 204 is an ion exchangeable glass. The ion exchangeable glass is an alkali-containing glass having a small ion, such as u+, Na+, or both. During the exchange process, the small alkali ions can be exchanged for larger ions such as K. An example of a suitable ion exchangeable glass is the silicate glass. In US Patent No. 7,666, 51 1 (Euis〇n) Et al.; February 23, 2010) and U.S. Patent Application Publication No. US 2009/0142568 A1 (Dejneka et al.; June 4, 2009), US 2009/0215607 (Dejneka et al.; 2009) The glass is described in August 27th), US 2009/0220761 (Dejneka et al.; September 3, 2009) and US 2010/0035038 A1 (Barefoot et al. 'February 11, 2010'). An example. The base can be ion exchanged at a relatively low temperature. The bismuth silicate glass can be ion exchanged to a depth of at least 30 microns. A suitable example of a suitable ion exchangeable glass is GORILLA glass, which can be purchased from New York c〇rning according to code 2317. The process of strengthening glass by ion exchange is described in, for example, U.S. Patent No. 5,674,790 (Araujo; October 7, 1997). To form a 3D glass article, 2D glass sheets 2〇4 are placed as shown in Fig. 2A. The mold pin 2 can be used to precisely determine the 2D glass piece 204 on the mold 202. After placing the 2D glass piece 2〇4 in the mold 202, the 2D glass #2〇4 and the mold 2〇2 are heated. In the example, 'at least 2D glass crucible 204 is heated to a temperature corresponding to a temperature range of 1 〇 7 to [the glass viscosity within the anchorage range. In one embodiment, the 2D glass piece is heated. 204 and mold 202 such that both the 2D glass sheet 204 and the mold 202 are at the same temperature as the glass sheet 204 begins to form into a 3D glass article. For this type of heating, the mold 202 T is non-reactive, such as stone. Made of carbon material or coated with The sensitive material of the carbon coating material is prepared. The heating needs to occur in the inert gas%. In another embodiment, the 2D glass sheet 2 is preferably heated while the 2D glass sheet 204 is on the cookware 202. 〇4, so that the temperature of the mold 2〇2 is lower than the temperature of the 2D glass sheet 2〇4, for example, the temperature of the mold 2〇2 may be lower than the temperature of the 2D glass sheet 2〇4<€ to 2〇 〇ec. The mid-IR heater can be used for this preferred heating. For this preferred heating, the mold 88 can be made from a superalloy having a hard ceramic coating. With this material, preferred heating can occur in a non-inert gas environment. After heating the 2D glass sheet 204 and the mold 202, a vacuum is applied to the mold cavity 207 to draw the bottom surface 232 of the 2D glass sheet against the mold surface 2〇6 and seal the glass to the mold surface 2〇6. Prior to the application of vacuum 15 201240926, the 2D glass sheet 204 may have begun to sag against the mold surface 206 due to gravity. In the embodiment, a vacuum may be applied in the range of 2 in Hg to 1 Torr. The pressurized gas 221 is heated via the plenum 216 and the pressure chamber 218 to the top surface 234 of the partially formed 2D glass sheet 204. The hot pressurized gas 221 provides the pressure required to cause the 2d glass sheet 204 to fully conform to the mold surface 2〇6 to completely form the 3D glass article. The temperature of the hot pressurized gas is within the previously mentioned temperature range corresponding to the glass viscosity range of 1 〇 7 poise to 1 〇 11 poise. The temperature of the hot pressurized gas may be the same as or different from the temperature of the 2D glass sheet. In one embodiment, the temperature of the hot pressurized gas is at 8 〇〇C. 21) The temperature of the glass sheet The temperature of the pressurized gas may be the same as the temperature of the 2D glass sheet, or higher or lower than the temperature of the 2D glass sheet. The burst hot pressurized gas can be selectively applied to the 2D glass sheet at a temperature above the 2D glass sheet temperature, as will be explained below. The gas grid 2 2 4 may be absent for the purpose of applying a burst of hot pressurized gas, i.e., applying a burst of hot pressurized gas only to the area of the 2D glass sheet where a burst of pressurized gas is required. Figure 2C illustrates a 3D glass article 205 formed from a 2D glass sheet 204 by the pressure of a hot pressurized gas. The typical gas pressure required to form a 3D shape can be comparable to the plunger pressure used in contact formation. Depending on the 3D shape formed and the glass viscosity, this pressure can range from 1 〇 1) 8 丨 to 2 〇 psi. For example, forming a dish having a thickness of about 10 poise with a glass viscosity of about 109 poises having a curvature of less than 5 mm will require about 2 〇. As described above, the pressure chamber 218 can be sealed prior to application of the hot pressurized gases 221 to 21) of the glass sheet. If the 2D glass piece 204 is heated by the conduction 16 201240926 from the mold 2 2, and the 2D glass piece 204 is heated, the pressure chamber 218 can be sealed before, during or after heating the 2D glass piece 204, or if the pressure chamber is to be sealed. 218, if the 2D glass piece 204 is directly heated on the mold 2〇2 using a radiant heater, the pressure chamber 218 should be sealed after heating the 2D glass piece 204 for a few seconds before the hot pressurized gas 221 is applied to the glass piece. A vacuum can be applied to the mold cavity 2〇7. The vacuum may be maintained throughout the duration of application of the hot pressurized gas 22i to the glass sheet or throughout the duration, in which case the vacuum may help maintain the position of the glass sheet on the mold surface 206 such that heat is being applied When the gas 221 is pressed, the glass piece does not move. If the starting 2D glass sheet is larger than the mold cavity 207 such that the starting 2D glass sheet 2〇4 covers the mold cavity 207, the 2D glass sheet can be formed into a 3D glass article without using a vacuum. When a 3D glass article is formed using a vacuum or without using a vacuum, the crucible 208 in the mold 202 is used to discharge the gas trapped in the mold cavity 207. After the formation of the 3D glass article 2〇5, the flow of the hot pressurized gas 221 to the pressure chamber 218 is stopped or replaced with the flow of the cooler pressurized gas. Subsequently, the 3d glass article 2〇5 is cooled to a strain point below the glass with or without a cold pressurized gas. The cooler pressurized gas assists in cooling the 3D glass 2G5 more quickly. In an embodiment, when a cooler pressurized gas is used in cooling the 3D glass article 205, the temperature of the cooler pressurized gas is selected from a temperature range corresponding to a glass transition temperature plus or minus 1 °C. In another embodiment, when the cold pressurized gas n # & This effect can be achieved by monitoring the temperature of the mold 202 with a sensor such as a thermocouple and adjusting the temperature of the colder pressurized gas using the output of the sensor. The pressure of the colder pressurized gas may be less than the pressure of the hot pressurized gas or the same as the pressure of the hot pressurized gas. Cooling of the 3D glass article minimizes the temperature difference (ΔΤ) across the thickness of the glass article, along the length of the glass article, and along the width of the glass article. Preferably, the thickness of the glazing and the δτ along the length and width of the glazing are less than 10 C. The lower the Δ Τ during cooling, the lower the stress in the glass article. If high stress is generated in the glass article during cooling, the glass article will warp in response to the stress. Therefore, it is desirable to avoid creating high stresses in the glazing during cooling. The 3D glass article 205 can be convectively cooled by applying a temperature controlled gas flow across the 3D glass article 205. As described above, the colder pressurized gas can be applied to the top surface 236 of the 3D glass article 2〇5 via the plenum 216 and the pressure chamber 218, and the temperature controlled by the 埠2〇8 in the mold 2〇2 can be applied. The gas stream is directed to the bottom surface 238 of the 3D glass article 205, and the temperature controlled gas stream can have characteristics similar to the colder pressurized gas. The gas force supplied via 埠2〇8 allows the net force to be generated while lifting the 3D glass article 205 from the mold 2〇2 during cooling. Since the mold 202 has a greater heat than the glass 201240926, the mold 202 is cooled at a slower rate than the glass, and the slow cooling of the mold 2〇2 produces a large ΔΤ across the thickness of the glass. Lifting the glass from the mold 202 during cooling helps to avoid this problem. The 3D glass article 205 can be annealed after cooling, and the annealed glass article 205 can be an ion exchange process involving the 3D glass article 205. The 2D glass sheet 204 used in forming the 3D glass article may be an oversized sheet which is processed to a final size after being formed into the 3D glass article 205. In this case, the processing may be performed prior to the ion exchange process. Fig. 3A illustrates an example of a 3-inch glass article 3〇〇 formed of an oversized glass sheet 3〇2. The 3D glass article 300 will need to be taken from an oversized glass sheet and the edges of the 3D glass article will then be trimmed by a suitable processing process. Alternatively, the 2D glass sheet 204 can be a machined 2D preform that needs to be precisely aligned on the mold 202 and will not be processed after being formed into a 3D glass article. The machined preforms have been edged and the edges are trimmed to the exact shape and size required to form a 3D glass article. Figure 3B illustrates a 3D glass formed from a machined preform. . An example of 304. 3D glassware 3〇4 does not require extra edge trimming. A high glass viscosity of, for example, 1 〇 9 to 1 〇 泊 poise can form a gentle profile, while a tight bend and a sharp corner require, for example, a lower viscosity between 1 Torr and 1 〇 8.2 Torr. The lower viscosity allows the glass 201240926 to better conform to the mold. However, achieving a good glass surface bleaching appearance with low viscosity is challenging because it makes it easier to imprint defects on the glass surface. The formation of a low viscosity causes the glass to be reboiled, which results in an orange peel surface. It is easy to print the vacuum or discharge enthalpy on the surface of the mold with a lower glass viscosity on the glass. On the other hand, it is easier to achieve a good surface appearance with a high glass viscosity. Therefore, in order to achieve both a good appearance and a tight dimensional tolerance of a good glass surface in a 3D glass article, it is necessary to optimize the pressure applied to the glass by the hot pressurized gas, the viscosity of the glass, and the pressure of the hot pressurized gas to The location of the glass. There are several options for obtaining tight dimensional tolerances while maintaining a good appearance on a good glass surface. In the case of a horse, the contour is used in the mold to form a 3D shape with a large angle of curvature. The wall of the mold can be designed to have a larger angular curvature radius than the final opening/shape and a steeper sidewall tangential angle. For example, if the side of the dish to be formed has a tangential angle of 6 〇. And if a good appearance of a good glass surface is required to form a dish with a logarithmic viscosity of 9 5 p, then the formation process can be produced with 46. The dish shape of the tangential angle of the side wall, that is, the right side does not correct the contour of the mold, which is 14 smaller than the desired angle. . To increase the sidewall tangential angle without reducing the glass viscosity, the mold profile can be compensated to increase the sidewall tangential angle by the difference between the ideal shape and the angle at which the article is formed. The above example gives the compensated mold a 74. Side wall: line angle. Doing this porch correction and achieving a glass product with a uniform thickness - it is possible 'because the pressure required to form the shape is provided by the hot plus body & there is no need to worry between the plunger and the mold 20 201240926 gap. Alternatively, high polish is used on the mold, which will allow the glass to be reduced without creating defects on the glass surface. The surface of the mold can have a surface roughness of Ra < 1 〇 nm and the surface of the mold can be made non-viscous or non-reactive. For example, a glassy graphite coating can be used on the surface of the mold. Similarly, the vacuum or bleed enthalpy (218 in Figure 2A) can be placed only at the corners of the mold, i.e., where the glass will continue to contact the mold during pressure formation. $ One is selected to be inflated in the direction of the orientation using an directional plenum such as illustrated in Figure 2B. The pressure of the hot gas is directed toward a complex area of the glass, such as an area of curved or cornered corners. It is larger than the glass temperature. A burst of pressurized gas can be applied as a directional jet at a temperature of 〇C to preferably raise the glass temperature and reduce the glass viscosity in complex areas. Another option is to use a cold mold/hot glass arrangement where the mold temperature is 100-C to 2 Torr lower than the glass being formed. Hey.
又選擇為在玻璃片之3D區域（亦即，欲形成為3D 形狀之區域，該區域包括彎曲、轉角及曲線之任何組合） 上使用小加熱器。舉例而言，可加熱3D區域中之玻璃 至^玻璃片之2D區域（亦即，不會形成為31)形狀之餘 留區域）中之玻璃高1(rc至3〇υ。此操作可與如上所述 之定向喷射組合使用。 另一選擇為在模具中具有加熱器以加熱模具之3D區 域（亦即，欲在形成玻璃片之3D區域中使用之區域） 至尚於模具之2D區域之溫度的溫度。可加熱模具之3d 21 201240926 區域至超過模具之2D區域（或平坦區域）之溫度ι〇丨 至30 (：的；盈度。&操作可與如上所述之定向喷射組合使 用。 另選擇為在玻璃片之3D區域之上及附近具有輻射 加熱器以施加輻射加熱至玻璃片之3D區域，因此較佳 地軟化需要製《3D形狀之玻璃片之小區域，同時維持 玻璃片之2D區域溫度相對較低。保持2D區域比區 域溫度較低允許維肖2D區域十之初始表面光潔度。 第:圖圖示從2D玻璃片形成3D玻璃製品之連續系統 系統400包括形成台402。形成台402包括設備200 (在第2A圖至帛2C圖中）。系統4〇〇包括形成台術 之上游的預熱台4〇4。在預熱台4〇4上預熱運送2D玻璃 片2〇4之模具202。在傳送帶406上沿著預熱台404傳 輸模具2〇2至形成台402。預熱台404包括用於加熱由 模具202運送之2D玻璃片2〇4之加熱器4〇8。如上所 述，加熱器408可為mid_IR加熱器或能夠遞送熱量至 扣玻璃片及模具2〇2之其他類型加熱器。系统包括 形成台402之下游的冷卻台41〇。將在形成台術處形 成之3D玻璃製品205運送至冷卻台41〇且允許將扣玻 璃製品205冷卻至可從模具中移除該等3d玻璃製品而 無形狀失真（亦即，玻璃溫度低於玻璃之轉移溫度）之 溫度。在冷卻台41G中可施加主動冷卻至模具^藉由 熱傳遞流體或氣體從底部冷卻模具，此舉允許模具π 匹配在玻璃之上的空氣溫度以最小化跨越玻璃厚 22 201240926 △ TOD玻璃製品205之初始冷卻亦可發生在形成台4〇2 處。在傳送帶412上沿著冷卻台410傳輸模具202。系 統400亦可包括冷卻台410之下游的退火台414。退火 台414可包括熱空氣抽承416’且藉由在熱空氣轴承416 上之浮動可退火3D玻璃製品。拾取裝置用來從模具2〇2 中拾取3D玻璃製品205且置放30玻璃製品205於熱空 氣轴承416上。 儘管已相對於有限數目之實施例描述本發明，但從本 揭示案獲益之熟習此項技術者將瞭解，可設計其他實施 例而不脫離本文所揭示之本發明之範疇。因此，本發明 之範疇將僅由隨附申請專利範圍限制。 【圖式簡單說明】 以下是隨附圖式中圖式之描述。該等圖式不必要按比 例製得，且為了清晰度及簡潔性，可按比例或在示意圖 中放大圖示某些特徵結構及圖式之某些視圖。 第1A圖為在柱塞與模具之間的均勻間隙之示意圖。 第1B圖為在柱塞與模具之間的非均勻間隙之示意圖。 第1C圖為在柱塞與模具之間的非均勻間隙之示意圖。 第2A圖為從2D玻璃片形成3D玻璃製品的設備之橫 截面。 第2B圖為從2D玻璃片形成3D玻璃製品的設備之橫 截面。 23 201240926 第2C圖為從2D玻璃片形成3D玻璃製品的設備之 截面。 汽 第3A圖為由過大2D玻璃片形成之3d玻璃製品之透 視圖。 第3B圖為由加工之2D預製件形成之3D玻璃製品之 透視圖。 第4圖為從2D玻璃片形成3D玻璃製品之連續系統之 示意圖。 【主要元件符號說明】 100 柱塞表面 102 模具表面 103 非均勻間隙 105 非均勻間隙 200 設備 202 模具 203 真空吸盤 204 2D玻璃片 205 3D玻璃製品 206 模具表面 207 模具穴 208 埠或孔 210 對準銷 212 罩帽 216 充氣部 218 壓力腔室 220 充氣腔室 221 熱加壓氣體 222 導管 224 氣體格栅 228 氣體格柵 230 充氣腔室 232 底部表面 234 項部表面 236 頂部表面 238 底部表面 240 加熱器 300 3D玻璃製品 24 201240926 302 玻璃片 304 3D玻璃製品 400 連續系統 402 形成台 404 預熱台 406 傳送帶 408 加熱器 410 冷卻台 412 傳送帶 414 退火台 416 熱空氣軸承 25It is also selected to use a small heater on the 3D region of the glass sheet (i.e., the region that is to be formed into a 3D shape that includes any combination of bends, corners, and curves). For example, the glass in the 3D region can be heated to a glass height of 1 in the 2D region of the glass sheet (ie, not formed into the shape of 31) (rc to 3 〇υ. This operation can be The directional spray as described above is used in combination. Another option is to have a heater in the mold to heat the 3D region of the mold (i.e., the area to be used in forming the 3D region of the glass sheet) to the 2D region of the mold. The temperature of the temperature. The temperature of the mold can be heated to 3d 21 201240926 area to the temperature of the 2D area (or flat area) of the mold ι〇丨 to 30 (:; the degree of & operation can be combined with the directional spray as described above Alternatively, there is a radiant heater on and near the 3D region of the glass sheet to apply radiation to the 3D region of the glass sheet, thus preferably softening the small area of the 3D shaped glass sheet while maintaining the glass sheet The 2D region temperature is relatively low. Maintaining the 2D region lower than the region temperature allows the initial surface finish of the Visa 2D region to be tenth. Figure: illustrates a continuous system system 400 that forms a 3D glass article from a 2D glass sheet including formation Stage 402. Forming station 402 includes apparatus 200 (in Figures 2A through 2C). System 4A includes a preheating station 4〇4 that forms upstream of the stage. Preheated transport on preheating station 4〇4 2D glass sheet 2〇4 mold 202. The mold 2〇2 is transported along the preheating station 404 on the conveyor belt 406 to the forming station 402. The preheating station 404 includes a 2D glass sheet 2〇4 for heating the mold 202. Heater 4〇8. As noted above, heater 408 can be a mid_IR heater or other type of heater capable of delivering heat to the buckle glass and mold 2〇 2. The system includes a cooling stage 41〇 downstream of forming station 402. The 3D glass article 205 formed at the forming stage is transported to the cooling station 41 and allows the glazing unit 205 to be cooled to remove the 3d glass articles from the mold without shape distortion (ie, the glass temperature is lower than The temperature at which the glass is transferred to the temperature. Active cooling can be applied to the mold in the cooling stage 41G. The mold is cooled from the bottom by heat transfer fluid or gas, which allows the mold π to match the temperature of the air above the glass to minimize the spanning of the glass. Thick 22 201240926 △ TOD glass products 205 Initial cooling may also occur at the forming station 4〇 2. The mold 202 is transported along the cooling station 410 on the conveyor belt 412. The system 400 may also include an annealing station 414 downstream of the cooling station 410. The annealing station 414 may include hot air pumping 416' and annealed the 3D glass article by floating on the hot air bearing 416. The pick-up device is used to pick up the 3D glass article 205 from the mold 2〇2 and place 30 the glass article 205 on the hot air bearing 416. The invention is described with respect to a limited number of embodiments, but those skilled in the art will appreciate that other embodiments can be devised without departing from the scope of the invention disclosed herein. Therefore, the scope of the invention is limited only by the scope of the accompanying claims. [Simple description of the drawings] The following is a description of the drawings in the accompanying drawings. The drawings are not necessarily to scale, and some of the features and drawings may be shown in a scale or in a schematic representation for clarity and simplicity. Figure 1A is a schematic illustration of the uniform gap between the plunger and the mold. Figure 1B is a schematic illustration of the non-uniform gap between the plunger and the mold. Figure 1C is a schematic illustration of the non-uniform gap between the plunger and the mold. Figure 2A is a cross section of an apparatus for forming a 3D glass article from a 2D glass sheet. Figure 2B is a cross section of an apparatus for forming a 3D glass article from a 2D glass sheet. 23 201240926 Figure 2C is a cross section of a device for forming 3D glass products from 2D glass sheets. Steam Figure 3A is a perspective view of a 3d glass article formed from an oversized 2D glass sheet. Figure 3B is a perspective view of a 3D glass article formed from a machined 2D preform. Figure 4 is a schematic illustration of a continuous system for forming 3D glass articles from 2D glass sheets. [Main component symbol description] 100 Plunger surface 102 Mold surface 103 Non-uniform gap 105 Non-uniform gap 200 Equipment 202 Mold 203 Vacuum chuck 204 2D glass sheet 205 3D glassware 206 Mold surface 207 Mold hole 208 埠 or hole 210 Alignment pin 212 Cap 216 Inflator 218 Pressure Chamber 220 Inflation Chamber 221 Hot Pressurized Gas 222 Catheter 224 Gas Grille 228 Gas Grill 230 Inflation Chamber 232 Bottom Surface 234 Item Surface 236 Top Surface 238 Bottom Surface 240 Heater 300 3D glassware 24 201240926 302 Glass sheet 304 3D glassware 400 Continuous system 402 Forming station 404 Preheating station 406 Conveyor belt 408 Heater 410 Cooling station 412 Conveyor belt 414 Annealing station 416 Hot air bearing 25