Patent Application
20150274572
This invention relates to a method for manufacturing a display cover glass and an apparatus for manufacturing a display cover glass.
Mobile devices with a display, including cellular phones, smartphones, notebook personal computers, and tablet personal computers, have recently been widely used (hereinafter, a mobile device with a display is referred to as a “mobile display”).
Patent Literature 1 describes a cover glass that can be used for a mobile display. The cover glass described in Patent Literature 1 includes: a front portion located in front of an image display region; and bent portions located at both sides of the image display region in a width direction thereof and bending away from the front portion.
Patent Literature 1 describes a method for manufacturing a cover glass with bent portions by heating a flat glass sheet placed on a die to soften it.
[PTL 1] JP-A-2012-101975
The manufacturing method described in Patent Literature 1 has a problem in that it has difficulty providing a cover glass having high shape accuracy.
A principal object of the present invention is to provide a display cover glass having high shape accuracy.
A first method for manufacturing a display cover glass according to the present invention relates to a method for manufacturing a display cover glass including a flattened portion and a bent portion continued to the flattened portion. In the first method for manufacturing a display cover glass according to the present invention, a flat glass sheet is placed on a first forming die including a flat first forming surface so that a middle portion of the flat glass sheet is located on top of the first forming surface and an end portion of the flat glass sheet is located outside the first forming surface. A forming step is performed of pressing the end portion of the flat glass sheet using a pressing tool with application of heat to at least the end portion of the flat glass sheet to deform the end portion of the flat glass sheet, thus forming a bent portion to obtain the cover glass. The forming step is performed in a state where a portion of the flat glass sheet corresponding to the bent portion of the cover glass is at a viscosity enabling plastic deformation and elastic deformation to occur therein when the end portion of the flat glass sheet is deformed.
In the first method for manufacturing a display cover glass according to the present invention, preferably, in the forming step, the end portion of the flat glass sheet is deformed by pressing the end portion of the flat glass sheet multiple times using the pressing tool.
A second method for manufacturing a display cover glass according to the present invention relates to a method for manufacturing a display cover glass including a flattened portion and a bent portion continued to the flattened portion. In the second method for manufacturing a display cover glass according to the present invention, a flat glass sheet is placed on a first forming die including a flat first forming surface so that a middle portion of the flat glass sheet is located on top of the first forming surface and an end portion of the flat glass sheet is located outside the first forming surface. A forming step is performed of pressing the end portion of the flat glass sheet using a pressing tool with application of heat to at least the end portion of the flat glass sheet to deform the end portion of the flat glass sheet, thus forming a bent portion to obtain the cover glass. In the forming step, the end portion of the flat glass sheet is deformed by pressing the end portion of the flat glass sheet multiple times using the pressing tool.
In each of the first and second methods for manufacturing a display cover glass according to the present invention, preferably, the first forming die further includes a second forming surface continued to the first forming surface and curved to conform to an inside surface of the bent portion and the pressing is performed so that with each pressing using the pressing tool, a portion of the end portion of the flat glass sheet in contact with the second forming surface increases in area. In this case, the forming step preferably includes a plurality of pressing steps different from each other in direction of pressing of the end portion of the flat glass sheet with the pressing tool. The forming step preferably includes the plurality of pressing steps to be performed one followed by the other, the other pressing step of pressing the end portion of the flat glass sheet with the pressing tool so that an angle formed by the direction of pressing of the end portion of the flat glass sheet with the pressing tool and a normal of the first forming surface is greater than that in the one pressing step. At least at the first time of pressing with the pressing tool in the forming step, a tip end of the end portion of the flat glass sheet is preferably pressed by the pressing tool.
In each of the first and second methods for manufacturing a display cover glass according to the present invention, the forming step is preferably performed with a second forming die disposed above the first forming die and the middle portion of the flat glass sheet clamped between the first and second forming dies and the second forming die is preferably disposed so that an end portion of the first forming die extends beyond the second forming die in plan view.
A third method for manufacturing a display cover glass according to the present invention relates to a method for manufacturing a display cover glass including a flattened portion and a bent portion continued to the flattened portion. In the third method for manufacturing a display cover glass according to the present invention, a flat glass sheet is placed on a first forming die including a flat first forming surface so that a middle portion of the flat glass sheet is located on top of the first forming surface and an end portion of the flat glass sheet is located outside the first forming surface. A forming step is performed of pressing the end portion of the flat glass sheet using a pressing tool with application of heat to at least the end portion of the flat glass sheet to deform the end portion of the flat glass sheet, thus forming a bent portion to obtain the cover glass. The forming step is performed with a second forming die disposed above the first forming die and the middle portion of the flat glass sheet clamped between the first and second forming dies. The second forming die is disposed so that an end portion of the first forming die extends beyond the second forming die in plan view.
In the third method for manufacturing a display cover glass according to the present invention, preferably, the first forming die further includes a second forming surface continued to the first forming surface and curved to conform to an inside surface of the bent portion and the second forming die is provided to avoid being disposed directly above the second forming surface.
In each of the first to third methods for manufacturing a display cover glass according to the present invention, the forming step is preferably performed with a cushioning member elastically deformable in a thickness direction disposed between the first forming die and the flat glass sheet.
In each of the first to third methods for manufacturing a display cover glass according to the present invention, the end portion of the flat glass sheet is preferably pressed using the pressing tool with a cushioning member elastically deformable in a thickness direction disposed on a portion of the pressing tool to be in contact with the flat glass sheet. The cushioning member is preferably formed of at least one of woven fabric and non-woven fabric.
In each of the first to third methods for manufacturing a display cover glass according to the present invention, the flat glass sheet is preferably pressed using the pressing tool with cooling of the pressing tool.
In each of the first to third methods for manufacturing a display cover glass according to the present invention, the pressing tool is preferably made of metal.
In each of the first to third methods for manufacturing a display cover glass according to the present invention, it is preferred that in the forming step a temperature of the first forming die be set so that a portion of the flat glass sheet in direct or indirect contact with the first forming die is made plastically non-deformable whereas a portion of the flat glass sheet out of contact with the first forming die is made plastically and elastically deformable.
In each of the first to third methods for manufacturing a display cover glass according to the present invention, it is preferred that in the forming step the temperature of the first forming die be set so that the portion of the flat glass sheet in contact with the first forming die has a lower temperature than a softening point of the flat glass sheet.
In each of the first to third methods for manufacturing a display cover glass according to the present invention, the flat glass sheet used is preferably a flat glass sheet having a coefficient of linear thermal expansion of 105×10−7/° C. or less at 30° C. to 380° C.
Each of the first to third methods for manufacturing a display cover glass according to the present invention preferably further includes a heat treatment step of, after the forming step, heating the deformed flat glass sheet to a temperature at or above a strain point of the flat glass sheet.
A first apparatus for manufacturing a display cover glass according to the present invention relates to an apparatus for manufacturing a display cover glass including a flattened portion and a bent portion continued to the flattened portion. The first apparatus for manufacturing a display cover glass according to the present invention includes a first forming die, a heating mechanism, a pressing tool, and a drive mechanism. The first forming die includes a flat first forming surface. The first forming die is configured so that a flat glass sheet is placed thereon with a middle portion of the flat glass sheet located on top of the first forming surface and an end portion of the flat glass sheet located outside the first forming surface. The heating mechanism is configured to heat at least the end portion of the flat glass sheet. The pressing tool is configured to press the end portion of the flat glass sheet to deform the end portion of the flat glass sheet, thus forming a bent portion. The drive mechanism is configured to drive the pressing tool. The drive mechanism allows, when a portion of the flat glass sheet corresponding to the bent portion of the cover glass has a viscosity enabling plastic deformation and elastic deformation to occur therein, the pressing tool to press the end portion of the flat glass sheet.
In the first apparatus for manufacturing a display cover glass according to the present invention, the drive mechanism preferably allows the pressing tool to press the end portion of the flat glass sheet multiple times.
A second apparatus for manufacturing a display cover glass according to the present invention relates to an apparatus for manufacturing a display cover glass including a flattened portion and a bent portion continued to the flattened portion. The second apparatus for manufacturing a display cover glass according to the present invention includes a first forming die, a heating mechanism, a pressing tool, and a drive mechanism. The first forming die includes a flat first forming surface. The first forming die is configured so that a flat glass sheet is placed thereon with a middle portion of the flat glass sheet located on top of the first forming surface and an end portion of the flat glass sheet located outside the first forming surface. The heating mechanism is configured to heat at least the end portion of the flat glass sheet. The pressing tool is configured to press the end portion of the flat glass sheet to deform the end portion of the flat glass sheet, thus forming a bent portion. The drive mechanism is configured to drive the pressing tool. The drive mechanism allows the pressing tool to press the end portion of the flat glass sheet multiple times.
In each of the first and second apparatuses for manufacturing a display cover glass according to the present invention, preferably, the first forming die further includes a second forming surface continued to the first forming surface and curved to conform to an inside surface of the bent portion and the drive mechanism is configured to drive the pressing tool so that with each pressing using the pressing tool, a portion of the end portion of the flat glass sheet in contact with the second forming surface increases in area. The drive mechanism is preferably configured to drive the pressing tool so that a plurality of pressing steps different from each other in direction of pressing of the end portion of the flat glass sheet with the pressing tool are performed. The drive mechanism is preferably configured to drive the pressing tool to provide the plurality of pressing steps one followed by the other, the other pressing step of pressing the end portion of the flat glass sheet with the pressing tool so that an angle formed by the direction of pressing of the end portion of the flat glass sheet with the pressing tool and a normal of the first forming surface is greater than that in the one pressing step. The drive mechanism is preferably configured to drive the pressing tool so that at the first time of pressing with the pressing tool, the pressing tool presses a tip end of the end portion of the flat glass sheet.
In each of the first and second apparatuses for manufacturing a display cover glass according to the present invention, the apparatus preferably further includes a second forming die disposed above the first forming die and configured to clamp the middle portion of the flat glass sheet together with the first forming die and an end portion of the first forming die preferably extends beyond the second forming die in plan view.
A third apparatus for manufacturing a display cover glass according to the present invention relates to an apparatus for manufacturing a display cover glass including a flattened portion and a bent portion continued to the flattened portion. The third apparatus for manufacturing a display cover glass according to the present invention includes a first forming die, a heating mechanism, a pressing tool, and a second forming die. The first forming die includes a flat first forming surface. The first forming die is configured so that a flat glass sheet is placed thereon with a middle portion of the flat glass sheet located on top of the first forming surface and an end portion of the flat glass sheet located outside the first forming surface. The heating mechanism is configured to heat at least the end portion of the flat glass sheet. The pressing tool is configured to press the end portion of the flat glass sheet to deform the end portion of the flat glass sheet, thus forming a bent portion. The second forming die is disposed above the first forming die. The second forming die is configured to clamp the middle portion of the flat glass sheet together with the first forming die. An end portion of the first forming die extends beyond the second forming die in plan view.
In each of the first to third apparatuses for manufacturing a display cover glass according to the present invention, preferably, the first forming die further includes a second forming surface continued to the first forming surface and curved to conform to an inside surface of the bent portion and the second forming die is provided to avoid being located directly above the second forming surface.
In each of the first to third apparatuses for manufacturing a display cover glass according to the present invention, the apparatus preferably further includes a cushioning member disposed on at least the first forming surface of the first forming die and elastically deformable in a thickness direction.
In each of the first to third apparatuses for manufacturing a display cover glass according to the present invention, the apparatus preferably further includes a cushioning member disposed on a portion of the pressing tool to be in contact with the flat glass sheet, the cushioning member being elastically deformable in a thickness direction. The cushioning member is preferably formed of at least one of woven fabric and non-woven fabric.
In each of the first to third apparatuses for manufacturing a display cover glass according to the present invention, the pressing tool preferably includes a through hole to which a coolant is supplied.
In each of the first to third apparatuses for manufacturing a display cover glass according to the present invention, the pressing tool is preferably made of metal.
In each of the first to third apparatuses for manufacturing a display cover glass according to the present invention, the first forming die preferably includes a through hole to which a coolant is supplied.
The present invention can provide a display cover glass having high shape accuracy.
Hereinafter, a description will be given of an exemplary preferred embodiment for working of the present invention. However, the following embodiment is merely illustrative. The present invention is not at all limited to the following embodiment.
Throughout the drawings to which the embodiment and the like refer, elements having substantially the same functions will be referred to by the same reference signs. The drawings to which the embodiment and the like refer are schematically illustrated. The dimensional ratios and the like of objects illustrated in the drawings may be different from those of the actual objects. Different drawings may have different dimensional ratios and the like of the objects. Dimensional ratios and the like of specific objects should be determined in consideration of the following descriptions.
In this embodiment, a description will be given of an example where a display cover glass 1 shown in
(Display Cover Glass 1)
The display cover glass 1 shown in
The display cover glass 1 is preferably made of, for example, a tempered glass such as a chemically tempered glass, a crystallized glass or the like.
The thickness of the display cover glass 1 is not particularly limited but is preferably 0.2 mm to 1.5 mm, more preferably 0.25 mm to 1.1 mm, and still more preferably 0.3 mm to 1.0 mm.
The display cover glass 1 includes a flattened portion 11. The flattened portion 11 is a portion to be disposed in front of the display region of the display. The term “in front of” herein refers to a direction (a z1 side) of extension of the normal of the display region and the side (a z2 side) opposite to the direction (the z1 side) of extension of the normal is referred to as backward.
The flattened portion 11 has a flat sheet-like shape. The flattened portion 11 has a rectangular shape. The dimension of the flattened portion 11 along the x-axis direction may be, for example, about 40 mm to about 200 mm. The dimension of the flattened portion 11 along the y-axis direction may be, for example, about 80 mm to about 300 mm. The term “flat sheet-like shape” includes a substantially flat sheet-like shape. For example, the term “flat sheet” includes a sheet having one surface and the other surface inclined at 5° or less to the one surface.
An x1-side end of the flattened portion 11 in the x-axis direction is connected to a first side portion 12. This first side portion 12 is a portion to be disposed lateral to the display. Specifically, the first side portion 12 is disposed on an x1 side of the display in the x-axis direction.
The ratio of the dimension of the first side portion 12 along the z-axis direction to the dimension of the flattened portion 11 along the x-axis direction ((dimension of the first side portion 12 along the z-axis direction):(dimension of the flattened portion 11 along the x-axis direction)) can be, for example, 1:1000 to 1:5. If the display is for a mobile device, the ratio ((dimension of the first side portion 12 along the z-axis direction):(dimension of the flattened portion 11 along the x-axis direction)) is, for example, preferably about 1:300 to about 1:5. If the display is of stationary type, the ratio ((dimension of the first side portion 12 along the z-axis direction):(dimension of the flattened portion 11 along the x-axis direction)) is, for example, preferably about 1:1000 to about 1:10.
The first side portion 12 includes a first bent portion 12a. The first bent portion 12a is continued to the flattened portion 11. The first bent portion 12a bends backward (toward the z2 side) from the x1-side end of the flattened portion 11 in the x-axis direction. A bending angle, which is the angle formed by the tangent line of the inside wall surface of the x1-side end of the flattened portion 11 and the tangent line of the inside wall surface of the distal end of the first side portion 12, is preferably 90° to 170° and more preferably 90° to 150°.
Particularly in this embodiment, the first side portion 12 includes the first bent portion 12a and a first flat portion 12b connected to an end of the first bent portion 12a. However, the present invention is not limited to this configuration. The first side portion 12 may be composed of the first bent portion 12a alone.
The first bent portion 12a, the first flat portion 12b, and the flattened portion 11 preferably have substantially equal thicknesses. Each of the first bent portion 12a and the first flat portion 12b more preferably has a thickness 0.9 to 1.1 times that of the flattened portion 11.
An x2-side end of the flattened portion 11 in the x-axis direction is connected to a second side portion 13. This second side portion 13, the flattened portion 11, and the first side portion 12 are formed of a single glass sheet. This second side portion 13 is a portion to be disposed lateral to the display. Specifically, the second side portion 13 is disposed on an x2 side of the display in the x-axis direction.
The ratio of the dimension of the second side portion 13 along the z-axis direction to the dimension of the flattened portion 11 along the x-axis direction ((dimension of the second side portion 13 along the z-axis direction):(dimension of the flattened portion 11 along the x-axis direction)) can be, for example, 1:1000 to 1:5. If the display is for a mobile device, the ratio ((dimension of the second side portion 13 along the z-axis direction):(dimension of the flattened portion 11 along the x-axis direction)) is, for example, preferably about 1:300 to about 1:5. If the display is of stationary type, the ratio ((dimension of the second side portion 13 along the z-axis direction):(dimension of the flattened portion 11 along the x-axis direction)) is, for example, preferably about 1:1000 to about 1:10.
The second side portion 13 includes a second bent portion 13a. The second bent portion 13a is continued to the flattened portion 11. The second bent portion 13a bends backward (toward the z2 side) from the x2-side end of the flattened portion 11 in the x-axis direction. The bending angle between the flattened portion 11 and the second side portion 13 is preferably 90° to 170° and more preferably 90° to 150°.
Particularly in this embodiment, the second side portion 13 includes the second bent portion 13a and a second flat portion 13b connected to an end of the second bent portion 13a. However, the present invention is not limited to this configuration. The second side portion 13 may be composed of the second bent portion 13a alone.
The second bent portion 13a, the second flat portion 13b, and the flattened portion 11 preferably have substantially equal thicknesses. Each of the second bent portion 13a and the second flat portion 13b more preferably has a thickness 0.9 to 1.1 times that of the flattened portion 11.
At least one of a pair of side surfaces of the display may form a display region where an image can be displayed. In other words, each of the side portions 12, 13 may be located over the side surface forming a display region.
(Manufacturing Apparatus 2 for Display Cover Glass 1)
Next, a description will be given of the structure of a manufacturing apparatus 2 for the display cover glass 1 with reference to
As shown in
The preheating chamber 21 is a chamber for use in preheating a flat glass sheet 50 to be described hereinafter. Arranged in the preheating chamber 21 are: a preheating table 24 on which the flat glass sheet 50 is to be placed; and a heater 25 capable of controlling the atmospheric temperature inside the preheating chamber 21. The preheating table 24 is provided with a plunger 24a. This plunger 24a enables upward movement of the flat glass sheet 50 placed on the preheating table 24.
The forming chamber 22 is a chamber for use in heating the flat glass sheet 50 to a temperature suitable for forming and forming the flat glass sheet 50 into a display cover glass 1. Arranged in the forming chamber 22 are: a first forming die 26 on which the flat glass sheet 50 is to be placed; a second forming die 27 configured to clamp the flat glass sheet 50 together with the first forming die 26; a heater (heating mechanism) 28 capable controlling the atmospheric temperature inside the forming chamber 22; and pressing tools 29a, 29b configured to press x-axis end portions of the flat glass sheet 50. Each of the lengths of the first and second forming dies 26, 27 in the depth direction (the lengths thereof in the vertical direction of the plane of
As shown in
The first forming die 26 is made of a hard material, such as ceramic or metal. The second forming die 27 is also made of a hard material, such as ceramic or metal. The first and second forming dies 26, 27 may be made of a heat insulating material consisting of a porous body or so on. As shown in
The cushioning member 30 is a member elastically deformable in the thickness direction. The cushioning member 30 is preferably formed of at least one of woven fabric and non-woven fabric made of, for example, alumina fibers, glass fibers or carbon fibers. The cushioning member 30 preferably has a thickness of, for example, about 0.1 mm to about 2 mm. Illustration of the cushioning member 30 is omitted in
The first forming die 26 includes through holes 26a formed therein to which a coolant, such as air, is supplied. The supply of the coolant to these through holes 26a causes the first forming die 26 to be cooled. The through holes 26a are preferably provided near the corners defining the second forming surfaces 26B of the first forming die 26. Likewise, the second forming die 27 includes through holes 27a formed therein to which a coolant, such as air, is supplied. The supply of the coolant to these through holes 27a causes the second forming die 27 to be cooled.
Like the preheating table 24, the first forming die 26 is provided with a plunger 26b configured to lift the flat glass sheet 50 or the display cover glass 1 located on top of the first forming die 26.
The length of the second forming die 27 in the width direction is smaller than the length of the first forming die 26 in the width direction. Therefore, as shown in
The pressing tools 29a, 29b are members for use in pressing widthwise end portions of the flat glass sheet 50. The pressing tools 29a, 29b can be driven by a pressing tool drive mechanism 29c shown in
As shown in
The pressing tools 29a, 29b may be made of, for example, ceramic or glass but, in this embodiment, is made of metal which is an elastic material. A cushioning member 30 is provided on a portion of each pressing tool 29a, 29b to be in contact with the flat glass sheet 50. Specifically, in this embodiment, the pressing tools 29a, 29b are covered with respective cushioning members 30.
As shown in
The manufacturing apparatus 2 is provided with transfer devices 32a, 32b configured to be driven by a transfer device drive mechanism 33. These transfer devices 32a, 32b enable the transfer of the flat glass sheet 50 or the display cover glass 1 among the preheating chamber 21, the forming chamber 22, and the slow cooling chamber 23.
(Method for Manufacturing Display Cover Glass 1)
Next, a detailed description will be given of a method for manufacturing a display cover glass 1 with reference to FIGS. 1 to 26.
First, a flat glass sheet 50 (see
Next, as shown in
Next, the flat glass sheet 50 preheated in the preheating chamber 21 is conveyed to the forming chamber 22. Specifically, first, as shown in
Note that it is preferred that after the flat glass sheet 50 is placed on top of the first forming die 26, an unshown centering mechanism be driven to align the widthwise midpoint of the flat glass sheet 50 with the widthwise midpoint of the first forming die 26.
Next, as shown in
During the time, the coolant is supplied to the through holes 26a and 27a provided in the first and second forming dies 26 and 27, respectively, to prevent the first and second forming dies 26 and 27 from increasing in temperature. Thus, the flat glass sheet 50 has the lowest temperature at the portion of the flat glass sheet 50 clamped between the first and second forming dies 26, 27, the highest temperature at the portions of the flat glass sheet 50 out of contact with both the first and second forming dies 26, 27, and an intermediate temperature at the portions of the flat glass sheet 50 in contact only with the first forming die 26.
The heating in the forming chamber 22 is performed until the widthwise end portions of the flat glass sheet 50 reach a viscosity enabling both of plastic deformation and elastic deformation to occur therein. Normally, when the flat glass sheet 50 has a viscosity of less than 108 dPa·s, the flat glass sheet 50 does not elastically deform but plastically deforms. On the other hand, when the flat glass sheet 50 has a viscosity of more than 1011 dPa·s, the flat glass sheet 50 does not plastically deform but elastically deforms. When the flat glass sheet 50 has a viscosity of about 108 dPa·s to about 1011 dPa·s, the flat glass sheet 50 plastically and elastically deforms. Therefore, the heating in the forming chamber 22 is preferably performed so that the flat glass sheet 50 has a viscosity of about 108.5 dPa·s to about 1010.5 dPa·s and more preferably performed so that the flat glass sheet 50 has a viscosity of about 109 dPa·s to about 1010 dPa·s. The temperature at which the flat glass sheet 50 has a viscosity of about 108 dPa·s to about 1011 dPa·s varies depending upon the composition of the flat glass sheet 50.
Furthermore, in heating the flat glass sheet 50, it is preferred to supply the coolant to the through holes 26a, 27a to cool the first and second forming dies 26, 27 so that the portion of the flat glass sheet 50 in contact with the first forming die 26 has a viscosity range making it plastically non-deformable. In other words, the temperature of the first forming die 26 is preferably set so that the portion of the flat glass sheet 50 in contact with the first forming die 26 is made plastically non-deformable whereas the portion thereof out of contact with the first forming die 26 is made plastically and elastically deformable. In the forming step, the portion of the flat glass sheet 50 in contact with the first forming die 26 preferably has a temperature lower than the softening point of the flat glass sheet 50, more preferably a temperature not higher than the glass transition point of the flat glass sheet 50 plus 100° C., still more preferably a temperature not higher than the glass transition point, yet still more preferably a temperature 10° C. or more lower than the glass transition point, and most preferably a temperature of the strain point of the flat glass sheet 50 to the glass transition point minus 30° C. When the portion of the flat glass sheet 50 in contact with the first forming die 26 has a temperature lower than the softening point thereof, the deformation of the portion in contact with the first forming die 26 can be reduced, resulting in a display cover glass 1 having a highly smooth flattened portion 11. In the forming step, on the other hand, the portion of the flat glass sheet 50 out of contact with the first forming die 26 preferably has a temperature of the glass transition point of the flat glass sheet 50 to not higher than the glass softening point, more preferably a temperature of the glass transition point to the glass softening point minus 40° C., and still more preferably a temperature of the glass transition point to the glass softening point minus 130° C.
When in the above manner a temperature difference is created between the portion of the flat glass sheet 50 in contact with the first forming die 26 and the portion thereof out of contact with the first forming die 26, the portions of the flat glass sheet 50 in and out of contact with the first forming die 26 have different amounts of thermal expansion. Specifically, the relatively high-temperature portion of the flat glass sheet 50 out of contact with the first forming die 26 has a greater amount of thermal expansion than the relatively low-temperature portion of the flat glass sheet 50 in contact with the first forming die 26. Owing to this difference in amount of thermal expansion, the flat glass sheet 50 may cause distortion, such as warpage or waviness. Therefore, from the viewpoint of reducing the distortion of the flat glass sheet 50 in the forming step to obtain a display cover glass 1 having high shape accuracy, the flat glass sheet 50 preferably has a small coefficient of thermal expansion. Specifically, the coefficient of linear thermal expansion of the flat glass sheet 50 at 30° C. to 380° C. is preferably 105×10−7/° C. or less, more preferably 100×10−7/° C. or less, still more preferably 90×10−7/° C. or less, even more preferably 85×10−7/° C., and particularly preferably 80×10−7/° C.
Next, as shown in
Thereafter, as shown in
As described previously, in the present invention, the forming is performed in a state where the widthwise end portions of the flat glass sheet 50 are at a viscosity enabling both of plastic deformation and elastic deformation to occur therein. Therefore, unlike the case where a glass sheet is formed into shape by the application of heat to a high temperature providing a viscosity at which elastic deformation does not substantially occur and only plastic deformation substantially occurs, the first bent portion 12a, the first flat portion 12b, and the flattened portion 11 can have substantially equal thicknesses. Also, the second bent portion 13a, the second flat portion 13b, and the flattened portion 11 can have substantially equal thicknesses. Thus, a display cover glass 1 having high dimensional accuracy can be obtained.
When the forming is performed in a state where the widthwise end portions of the flat glass sheet 50 are at a viscosity enabling both of plastic deformation and elastic deformation to occur therein, strain occurs, during the forming of the flat glass sheet 50, for example, at a portion thereof constituting the flattened portion 11, which is likely to cause distortion, such as waviness or warpage. When the forming is performed in a state where the temperature of the flat glass sheet 50 is not higher than the softening point of the flat glass sheet 50, strain, waviness, and warpage are particularly likely to occur. Therefore, it is preferred that after the forming step, the formed flat glass sheet 50 be subjected to a heat treatment by heating it to a temperature of not less than the stain point (the heat treatment step). Through this heat treatment step, the residual stress of the formed flat glass sheet 50 can be reduced to reduce distortion, such as waviness or warpage. As a result, a display cover glass 1 having higher shape accuracy can be obtained. From the viewpoint of obtaining a display cover glass 1 having higher shape accuracy, the heating temperature of the formed flat glass sheet 50 in the heat treatment step is preferably 50° C. or more higher than the strain point of the flat glass sheet 50 and more preferably 80° C. or more higher than the strain point. However, if the heating temperature of the formed flat glass sheet 50 in the heat treatment step is too high, the formed flat glass sheet 10 may have an excessively small viscosity, which may, on the contrary, decrease the shape accuracy. Therefore, the heating temperature of the formed flat glass sheet 50 in the heat treatment step is preferably equal to or below the temperature 150° C. higher than the strain point of the flat glass sheet 50 and more preferably equal to or below the temperature 140° C. higher than the strain point.
Prior to or after the forming step, the step of fire-polishing the end surfaces of the display cover glass 1 may be further performed. Thus, a display cover glass 1 whose end surfaces have less microcracks can be obtained.
In this embodiment, after the forming step, the step of polishing the surfaces of the formed flat glass sheet 50 other than the end surfaces is not performed.
Next, a description will be given of the details of the forming step in this embodiment.
In this embodiment, in the forming step, the end portions of the flat glass sheet 50 are gradually deformed by pressing them multiple times using the pressing tools 29a, 29b, thus forming bent portions 12a, 13a. In other words, the pressing tools 29a, 29b are driven by the pressing tool drive mechanism 29c to press the end portions of the flat glass sheet 50 multiple times.
Specifically, first, as shown in
Next, as shown in
Next, as shown in
In the above manner, in this embodiment, a plurality of pressing steps are performed which are different from each other in direction of pressing of the end portions of the flat glass sheet 50 with the pressing tools 29a, 29b. The plurality of pressing steps include those to be performed one followed by the other, the other pressing step of pressing the end portions of the flat glass sheet 50 with the pressing tools 29a, 29b so that the angle formed by the direction of pressing of each end portion of the flat glass sheet 50 with the relevant pressing tool 29a, 29b and the first forming surface 26A is greater than that in the one pressing step. Specifically, the plurality of pressing steps are performed by changing the direction of pressing so that the direction of pressing of each end portion of the flat glass sheet 50 with the relevant pressing tool 29a, 29b gradually approaches from the vertical (z-axis) to horizontal (x-axis) direction. For example, the direction of pressing of each end portion of the flat glass sheet 50 with the relevant pressing tool 29a, 29b is changed so that the angle formed by the direction of pressing and the first forming surface 26A is 90° in the first pressing step and 180° in the last pressing step. The plurality of pressing steps are performed so that with each pressing using the pressing tools 29a and 29b, the portions of the end portions of the flat glass sheet 50 in contact with the second forming surfaces 26B increase in area.
At least at the first time of pressing with the pressing tools 29a, 29b (in the first pressing step) in the forming step, the tip ends of the end portions of the flat glass sheet 50 are pressed by the pressing tools 29a, 29b. In all the pressing steps, the tip ends of the end portions of the flat glass sheet 50 can be pressed by the pressing tools 29a, 29b. In this embodiment, however, at the times of pressing with the pressing tools 29a, 29b along the x-axis direction shown in
As described previously, in this embodiment, the forming step is performed with the cushioning member 30 elastically deformable in the thickness direction disposed between the first forming die 26 and the flat glass sheet 50. Therefore, the hard first forming die 26 and the flat glass sheet 50 are free from direct contact. Hence, it can be prevented that in the forming step and so on, scratches and like damages are formed on the surface of the display cover glass 1 owing to the contact of the first forming die 26 with the flat glass sheet 50. As a result, a display cover glass 1 having less surface defects can be obtained.
In this embodiment, the cushioning member 30 is also disposed between the second forming die 27 and the flat glass sheet 50. Thus, it can be prevented that scratches and like damages are formed on the surface of the display cover glass 1 owing to the contact of the second forming die 27 with the flat glass sheet 50. Furthermore, the cushioning members 30 are also disposed on the portions of the pressing tools 29a, 29b to be in contact with the flat glass sheet 50. Thus, it can be prevented that scratches and like damages are formed on the surface of the display cover glass 1 owing to the contact of the pressing tools 29a, 29b with the flat glass sheet 50. Therefore, a display cover glass 1 having lesser surface defects can be obtained.
When the cushioning member 30 is formed of woven fabric or non-woven fabric, the surface roughness of the surface of the cushioning member 30 close to the flat glass sheet 50 is greater than that of the surfaces of the forming dies 26, 27. In this embodiment, however, the through holes 26a, 27a, 29a1, 29b1 to which the coolant is supplied are formed in the forming dies 26, 27 and/or the pressing tools 29a, 29b and, in the forming step, the forming dies 26, 27 and/or the pressing tools 29a, 29b are cooled. Therefore, the surface shapes of the forming dies 26, 27 and/or the pressing tools 29a, 29b are less likely to be transferred.
From the viewpoint of reducing the temperature rise of the portion of the flat glass sheet 50 clamped between the first forming die 26 and the second forming die 27, the forming dies 26, 27 are each preferably made of a heat insulating material. Specifically, the forming dies 26, 27 are preferably made of, for example, a ceramic material containing as a major ingredient alumina, silicon carbide or diatomite.
The term “heat insulating material” used in the present invention refers to a material having a lower thermal conductivity than the flat glass sheet 50, specifically, a material having a thermal conductivity of 5 W/(m·K) or less.
In the forming step, the portion of the flat glass sheet 50 in direct or indirect contact with the first forming die 26 is at a viscosity making it plastically non-deformable. Therefore, the surface shape of the first forming die 26 is less likely to be transferred to the portion of the flat glass sheet 50 in direct or indirect contact with the first forming die 26. Likewise, the portion of the flat glass sheet 50 in direct or indirect contact with the second forming die 27 is at a viscosity making it plastically non-deformable. Therefore, the surface shape of the second forming die 27 is less likely to be transferred to the portion of the flat glass sheet 50 in direct or indirect contact with the second forming die 27. Hence, a display cover glass 1 having still lesser surface defects can be obtained.
The forming step is performed in a state where the portions of the flat glass sheet 50 corresponding to the bent portions 12a, 13a of the display cover glass 1 are at a high viscosity enabling plastic deformation and elastic deformation to occur therein. Thus, in the forming step, the end portions of the flat glass sheet 50 also have a high viscosity. Therefore, the surface shapes of the pressing tools 29a, 29b are less likely to be transferred to the end portions of the flat glass sheet 50. From the viewpoint of making the surface shapes of the pressing tools 29a, 29b still less likely to be transferred, the forming step is preferably performed in a state where the end portions of the flat glass sheet 50 are at a viscosity of 1010 dPa·s or more.
In addition, since the forming step is performed in a state where the portions of the flat glass sheet 50 corresponding to the bent portions 12a, 13a of the display cover glass 1 are at a viscosity enabling plastic deformation and elastic deformation to occur therein, the first bent portion 12a, the first flat portion 12b, and the flattened portion 11 can have substantially equal thicknesses. The second bent portion 13a, the second flat portion 13b, and the flattened portion 11 can have substantially equal thicknesses.
In this embodiment, in the forming step, the end portions of the flat glass sheet 50 are pressed multiple times using the pressing tools 29a, 29b. In other words, the flat glass sheet 50 is gradually deformed in multiple times. Therefore, the time for contact of the pressing tools 29a, 29b with the flat glass sheet 50 can be reduced. Hence, the surface shapes of the pressing tools 29a, 29b are still less likely to be transferred to the end portions of the flat glass sheet 50.
Furthermore, since the pressing tools 29a, 29b are made of metal exhibiting elastic deformation, excessive stress is less likely to be applied between the pressing tools 29a, 29b and the flat glass sheet 50 in the forming step. Therefore, the surface shapes of the pressing tools 29a, 29b are still less likely to be transferred to the end portions of the flat glass sheet 50.
In this embodiment, pressing is performed so that with each pressing using the pressing tools 29a and 29b, the portions of the end portions of the flat glass sheet 50 in contact with the second forming surfaces 26B increase in area. The portions of the end portions of the flat glass sheet 50 in contact with the second forming surfaces 26B are cooled by the first forming die 26 to the temperature providing a viscosity making the end portions plastically non-deformable. When, as in this embodiment, pressing is performed so that with each pressing using the pressing tools 29a and 29b, the portions of the end portions of the flat glass sheet 50 in contact with the second forming surfaces 26B increase in area, the portions of the end portions of the flat glass sheet 50 being in a temperature range making them plastically and elastically deformable are gradually cooled after being deformed. Thus, it can be prevented that the portions of the flat glass sheet 50 being in a temperature range making them plastically and elastically deformable come into contact the first forming die 26 over a long period of time. Therefore, the surface shape of the first forming die 26 is still less likely to be transferred to the end portions of the flat glass sheet 50.
When the end portions of the flat glass sheet 50 come into contact with the cooled pressing tools 29a, 29b, the temperature of the end portions of the flat glass sheet 50 decreases. Therefore, the temperature of the end portions of the flat glass sheet 50 is highest immediately before the start of the forming step and decreases with each pressing step. In this embodiment, at least in the first pressing step in which the temperature of the end portions of the flat glass sheet 50 is highest, the tip ends of the end portions of the flat glass sheet 50 are pressed by the pressing tools 29a, 29b. Thus, in the first pressing step, the contact of the pressing tools 29a, 29b with the principal surfaces of the end portions of the flat glass sheet 50 is reduced. Therefore, the resultant display cover glass 1 is less likely to cause surface defects.
In this embodiment, the second forming die 27 has a smaller widthwise dimension than the first forming die 26 and is disposed so that both widthwise end portions of the first forming die 26 extend beyond the second forming die 27 when viewed in plan (when viewed in the z-axis direction). Therefore, it can be prevented that the end portions and near-end portions of the flat glass sheet 50 to be deformed have an undesirably high viscosity (undesirably low temperature). Thus, the portions of the flat glass sheet 50 corresponding to the bent portions 12a, 13a of the display cover glass 1 can have a viscosity enabling plastic deformation and elastic deformation to occur therein upon deformation of the end portions of the flat glass sheet 50. From the viewpoint of effectively deforming these portions within a viscosity range enabling plastic deformation and elastic deformation, the second forming die 27 is preferably provided to avoid being disposed directly above (on the z1 side of) the second forming surfaces 26B. In addition, avoiding the second forming die 27 being disposed directly above the second forming surfaces 26B is preferred because it can be prevented that the impression of the first forming die 26 is made on the surface of the flat glass sheet 50 having come into contact with the first forming die 26.
In this embodiment, a plurality of pressing steps are performed differently from each other in direction of pressing of the flat glass sheet 50 with the pressing tools 29a, 29b. Specifically, the next pressing step is performed so that the angle formed by the direction of pressing of each end portion of the flat glass sheet 50 with the relevant pressing tool 29a, 29b and the first forming surface 26A is greater than that in the previous pressing step. By doing so, the directions of pressing of the pressing tools 29a, 29b gradually approach parallel to the directions of the normals of the surfaces of the end portions of the flat glass sheet 50. Thus, during pressing with the pressing tools 29a, 29b, the pressing tools 29a, 29b can be prevented from sliding on the surfaces of the end portions of the flat glass sheet 50. Therefore, the formation of scratches can be more effectively prevented.
Since the forming step is performed in a state where the end portions of the flat glass sheet 50 are in a viscosity range enabling plastic deformation and elastic deformation to occur therein when deformed, the end portions of the flat glass sheet 50 are less likely to undesirably deform. Thus, a display cover glass 1 having high shape accuracy can be obtained. Therefore, it is not necessarily needed to perform the step of polishing the surfaces of the formed flat glass sheet 50 other than the end surfaces after the forming step. Hence, a display cover glass 1 can be easily manufactured in a small number of steps for manufacturing it. In addition, a display cover glass 1 having less microcracks can be obtained.
From the viewpoint of increasing the shape accuracy of the flattened portion 11, the forming step is preferably performed while cooling the middle portion of the flat glass sheet 50 with the first forming die 26 so that the portion of the flat glass sheet 50 in contact with the first forming die 26 has a viscosity making it plastically non-deformable. In this case, even if the cushioning member 30 elastically deformable in the thickness direction is provided, the surface shape of the cushioning member 30 is less likely to be transferred to the middle portion of the flat glass sheet 50 since the middle portion of the flat glass sheet 50 is not plastically deformable.
From the viewpoint of further increasing the shape accuracy of the display cover glass 1, it is preferred, without deforming the end portions of the flat glass sheet 50 at once, to gradually deform them by pressing them multiple times using the pressing tools 29a, 29b. During this process, the portions deformed in the previous pressing step come into contact with the first forming die 26 and are thus cooled to reach a viscosity making them plastically non-deformable. Thus, the portions deformed in the previous pressing step can be prevented from undesirably deforming in the subsequent pressing steps. Therefore, the shape accuracy can be further increased.
Furthermore, in this embodiment, the plurality of pressing steps include those to be performed one followed by the other, the other pressing step of pressing the end portions of the flat glass sheet 50 with the pressing tools 29a, 29b so that the angle formed by the direction of pressing of each end portion of the flat glass sheet 50 with the relevant pressing tool 29a, 29b and the first forming surface 26A is greater than that in the one pressing step. Specifically, the plurality of pressing steps are performed by changing the direction of pressing so that the direction of pressing of each end portion of the flat glass sheet 50 with the relevant pressing tool 29a, 29b gradually approaches from the vertical (z-axis) to horizontal (x-axis) direction. Thus, in each pressing step, the end portions of the flat glass sheet 50 can be pressed at a near right angle. Therefore, the pressing forces of the pressing tools 29a, 29b can be suitably applied to the flat glass sheet 50. Hence, higher shape accuracy can be achieved.
Moreover, in this embodiment, the forming step is performed with cooling of the pressing tools 29a, 29b. Thus, the portions of the flat glass sheet 50 in direct or indirect contact with the pressing tools 29a, 29b are decreased in temperature, increased in viscosity, and thus can be prevented from undesirably deforming. Therefore, still higher shape accuracy can be achieved.
In addition, since the second forming die 27 has a smaller widthwise dimension than the first forming die 26 and the widthwise end portions of the first forming die 26 extend beyond the second forming die 27 in plan view, the end portions of the flat glass sheet 50 are made more bendable in the forming step. Therefore, yet still higher shape accuracy can be achieved. From the viewpoint of achieving even still higher shape accuracy, it is preferred to avoid locating the second forming die 27 directly above the second forming surfaces 26B.
In this embodiment, the direction of extension of the pressing tools 29a, 29b is parallel to the edges of the flat glass sheet 50 extending in the depth direction. However, the present invention is not limited to this configuration. The direction of extension of the pressing tools 29a, 29b may not be parallel to the edges of the flat glass sheet 50 extending in the depth direction.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2012-245754 | Nov 2012 | JP | national |
| 2012-277820 | Dec 2012 | JP | national |
| 2013-213647 | Oct 2013 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2013/077980 | 10/15/2013 | WO | 00 |
