阅读说明：本技术 用于抬头显示器系统的非球面镜及其形成方法 (Aspherical mirror for head-up display system and forming method thereof ) 是由 金奉徹 金泰文 柳济春 于 2018-11-21 设计创作，主要内容包括：一种用于抬头显示器(HUD)系统的镜的基于玻璃的预制件,包含基于玻璃的基板,具有第一主表面,相对于所述第一主表面的第二主表面,以及连接所述第一与第二主表面的副表面；第一倒角,位于所述第一主表面的边缘,所述第一倒角具有位在所述第一倒角与所述第一主表面的交会处的第一端,并且具有位在所述第一倒角与所述副表面的交会处的第二端；以及第二倒角,位于所述第二主表面的边缘,所述第二倒角具有位在所述第二倒角与所述第二主表面的交会处的第一端,并且具有位在所述第二倒角与所述副表面的交会处的第二端。所述第一倒角具有与所述第二倒角不同的尺寸或形状。(A glass-based preform for a mirror of a head-up display (HUD) system, comprising a glass-based substrate having a first major surface, a second major surface opposite the first major surface, and a minor surface connecting the first and second major surfaces; a first chamfer at an edge of the first major surface, the first chamfer having a first end at an intersection of the first chamfer with the first major surface and having a second end at an intersection of the first chamfer with the minor surface; and a second chamfer at an edge of the second major surface, the second chamfer having a first end at an intersection of the second chamfer with the second major surface and having a second end at an intersection of the second chamfer with the minor surface. The first chamfer has a different size or shape than the second chamfer.)

1. A glass-based preform for a mirror of a head-up display (HUD) system, comprising:

a glass-based substrate having a first major surface, a second major surface opposite the first major surface, and a minor surface connecting the first and second major surfaces;

a first chamfer at an edge of the first major surface, the first chamfer having a first end at an intersection of the first chamfer with the first major surface and having a second end at an intersection of the first chamfer with the minor surface; and

a second chamfer at an edge of the second major surface, the second chamfer having a first end at an intersection of the second chamfer with the second major surface and having a second end at an intersection of the second chamfer with the minor surface.

Wherein the first chamfer has a different size or shape than the second chamfer.

2. The glass-based preform of claim 1, wherein the first chamfer has a first length, the second chamfer has a second length, and the first length is different than the second length.

3. The glass-based preform of claim 2, wherein the first length is greater than the second length.

4. The glass-based preform of claim 2 or 3, wherein the first length is measured from a direction lying in a plane of the first major surface at the intersection with the first chamfer and is measured from the first end of the first chamfer to a plane coplanar with the minor surface at the second end of the first chamfer, and wherein the second length is measured from a direction lying in a plane of the second major surface and is measured from the first end of the second chamfer to a plane coplanar with the minor surface at the second end of the second chamfer.

5. The glass-based preform of any one of claims 2 to 4, wherein the first length is at least about 1.0 mm.

6. The glass-based preform of any one of claims 2 to 5, wherein the first length is about 1.0mm to about 3.0 mm.

7. The glass-based preform of any one of claims 1-6, wherein the first chamfer comprises a first inclined surface at a first angle measured from the first surface, wherein the first inclined surface meets the first major surface at a first distance from a minor surface that is coplanar with the minor surface at the second end of the first chamfer of from about 0.5mm to about 3mm, and meets the minor surface at a second distance from a first major plane that is coplanar with the first major surface at the first end of the first chamfer of from about 0.2mm to about 0.3 mm.

8. The glass-based preform of any one of claims 1-7, wherein the second chamfer comprises a second inclined surface at a second angle measured relative to the second surface, wherein the second inclined surface intersects the second major surface at a first distance from a secondary surface that is coplanar with the secondary surface at the second end of the second chamfer of from about 0.2mm to about 0.3mm and intersects the secondary surface at a second distance from a second major plane that is coplanar with the second major surface at the first end of the first chamfer of from about 0.2mm to about 0.3 mm.

9. The glass-based preform of claim 8, wherein the first angle is about 3 degrees to about 31 degrees and the second angle is about 33 degrees to about 57 degrees.

10. The glass-based preform of claim 8, wherein the first angle is from about 5 degrees to about 45 degrees and the second angle is from about 5 degrees to about 45 degrees.

11. The glass-based preform of any one of claims 1-7, wherein the first chamfer comprises a first inclined surface measured at a first angle relative to the first surface and the second chamfer comprises a second inclined surface measured at a second angle relative to the second surface, and wherein the first angle is different than the second angle.

12. The glass-based preform of any of claims 8-11, wherein the first angle is less than the second angle.

13. The glass-based preform of any one of claims 7-12, wherein the first inclined surface extends from the first edge to the second edge of the first chamfer, and wherein the second inclined surface extends from the first edge to the second edge of the second chamfer.

14. The glass-based preform of any one of claims 1-13, wherein at least a portion of the first major surface is reflective.

15. The glass-based preform of claim 14, wherein the portion of the first major surface that is reflective comprises a reflective coating on the glass-based substrate.

16. The glass-based preform of claim 15, wherein the reflective coating comprises a metal, a metal oxide, a ceramic oxide, or a cermet alloy.

17. The glass-based preform of claim 15 or 16, wherein the reflective coating comprises aluminum or silver.

18. The glass-based preform of any one of claims 1-17, wherein a length of the first inclined surface measured in a direction parallel to the first major surface is about 0.5mm to 3mm, and a length of the first inclined surface measured in a direction parallel to the secondary surface is about 0.2mm to 0.3 mm.

19. The glass-based preform of any one of claims 1-18, wherein a length of the second inclined surface measured in a direction parallel to the second major surface is about 0.2mm to 0.3mm, and a length of the second inclined surface measured in a direction parallel to the secondary surface is about 0.2mm to 0.3 mm.

20. The glass-based preform of any one of claims 1-19, wherein the glass-based substrate has a thickness of less than or equal to 3.0 mm.

21. The glass-based preform of any one of claim 20, wherein the thickness of the glass-based substrate is from about 0.5mm to about 3.0 mm.

22. The glass-based preform of claim 21, wherein the thickness of the glass-based substrate is from about 0.5mm to about 1.0 mm.

23. The glass-based preform of claim 21, wherein the thickness of the glass-based substrate is from about 1.0mm to about 3.0 mm.

24. The glass-based preform of any one of claims 1-23, wherein the second major surface comprises one or more manufacturing artifacts, and wherein the manufacturing artifacts are confined to a peripheral region of the second major surface that extends from an edge of the second major surface to a distance that is less than the first length.

25. The glass-based preform of claim 24, wherein the manufacturing artifact is a vacuum suction artifact.

26. The glass-based preform of claim 24 or 25, wherein the manufacturing artifact is from a process of bending the mirror.

27. A mirror for a Heads Up Display (HUD) system comprising the web-based preform of any one of claims 1 to 26.

28. The mirror according to claim 27, further comprising a reflective layer on said first major surface of said glass-based preform.

29. A mirror according to claim 27 or 28, wherein the glass-based substrate has a first radius of curvature such that the first major surface has a concave shape and the second major surface has a convex shape, the first radius of curvature being measured with respect to a first axis of curvature.

30. A mirror according to claim 29, wherein said glass-based substrate has a second radius of curvature, said second radius of curvature being measured with respect to a second axis of curvature different from said first axis of curvature.

31. A mirror as claimed in claim 30, wherein said first axis of curvature is perpendicular to said second axis of curvature.

32. A mirror according to any one of claims 27 to 31, wherein the first major surface has an aspherical shape.

33. A method of forming a three-dimensional mirror, the method comprising the steps of:

providing a glass-based mirror preform comprising: a first major surface having an edge with a first chamfer; a second major surface opposite the first major surface and having an edge with a second chamfer; and a minor surface connecting the first and second major surfaces, the second chamfer having a different size or shape than the first chamfer;

disposing the glass-based preform on a molding device having a curved support surface with the second major surface facing the curved support surface; and

the glass-based preform is conformed to the curved support surface to form a curved mirror substrate having a first radius of curvature.

34. The method of claim 33, wherein the step of conforming the glass-based preform to the curved support surface is performed at a temperature below a glass transition temperature of the glass-based preform.

35. The method of claim 33 or 34, wherein the temperature of the glass-based substrate does not rise above the glass transition temperature of the glass-based substrate during or after the conforming.

36. The method of any one of claims 33 to 35, wherein the curved support surface has a concave shape.

37. The method of claim 36, wherein the concave shape is an aspheric shape.

38. The method of any one of claims 33 to 37, wherein the curved support surface also comprises a vacuum chuck having at least one aperture in the curved support surface.

39. The method of claim 38, further comprising providing a vacuum to the at least one opening to conform the curved glass blank to the curved support surface.

40. The method of claim 38 or 39, wherein the at least one opening is a vacuum hole of the trench type.

41. The method according to any one of claims 38 to 40, wherein the first chamfer is formed within the first major surface such that the first chamfer begins at the first major surface at a first distance from the minor surface, wherein the at least one opening is a second distance from the minor surface when the glass-based preform is disposed on the curved support surface, and wherein the first distance is greater than or equal to the second distance.

42. The method of any of claims 38-41, wherein the molding device comprises a raised peripheral surface or wall abutting the curved support surface and defining a space above the curved support surface into which the glass-based preform is to be positioned.

43. The method of claim 42, wherein the first chamfer is formed within the first major surface such that the first chamfer begins at the first major surface at a first distance from the minor surface, wherein the at least one aperture is a second distance from the raised peripheral surface or wall, and wherein the first distance is greater than or equal to the second distance.

44. The method of any one of claims 41 to 43, wherein the first distance is greater than the second distance.

45. The method of any one of claims 33 to 44, further comprising forming a reflective layer on the first major surface.

46. The method of claim 45, wherein the reflective layer is formed by: a reflective layer of material is sputtered, electroplated, or vapor deposited onto the first major surface.

47. The method of claim 45 or 46, wherein the reflective coating comprises a metal, a metal oxide, a ceramic oxide, or a cermet alloy.

48. The method of claim 47, wherein the reflective layer comprises aluminum or silver.

49. A method according to any one of claims 45 to 48, wherein the reflective layer is formed on the first major surface after forming a curved mirror substrate to form an aspherical mirror.

50. The method of any of claims 33-49, wherein the first chamfer includes a first sloped surface at a first angle measured relative to the first surface, the first sloped surface having a first length, wherein the second chamfer includes a second sloped surface at a second angle measured relative to the second surface, the second sloped surface having a second length, and wherein the first length is different than the second length.

51. The method of claim 50, wherein the first length is greater than the second length.

52. A method according to claim 50 or 51, wherein the first length is measured from a direction in the plane of the first major surface and from the intersection of the first inclined surface with the first major surface to a plane coplanar with the secondary surface, and wherein the second length is measured from a direction in the plane of the second major surface and from the intersection of the second inclined surface with the second major surface to a plane coplanar with the secondary surface.

53. The method of any one of claims 50-52, wherein the first length is at least about 1.0 mm.

54. The method of claim 53, wherein the first length is from about 1.0mm to about 3.0 mm.

55. The method of claim 53, wherein the first sloping surface meets the first major surface from about 0.5mm to about 3mm from a first plane coplanar with the secondary surface, and meets the secondary surface from about 0.2mm to about 0.3mm from a second plane coplanar with the first major surface.

56. The method of claim 50 or 55, wherein the second sloping surface meets the second major surface from about 0.2mm to about 0.3mm from a plane coplanar with the secondary surface, and meets the secondary surface from about 0.2mm to about 0.3mm from a plane coplanar with the second major surface.

57. The method of any one of claims 33-49, wherein the first chamfer defines a first sloped surface measured at a first angle relative to the first surface and the second chamfer defines a second sloped surface measured at a second angle relative to the second surface, and wherein the first angle is different than the second angle.

58. The method of claim 57, wherein the first angle is less than the second angle.

59. A Heads Up Display (HUD) projection system, comprising:

a display unit configured to display an image for viewing by a user of the HUD system; and

a mirror configured to reflect the image to a viewing area viewable by the user, the mirror comprising:

a glass-based substrate having a reflective first major surface, a second major surface opposite the first major surface, and a minor surface connecting the first and second major surfaces, a first chamfer at an edge of the first major surface, the first chamfer having a first end at an intersection of the first chamfer and the first major surface and having a second end at an intersection of the first chamfer and the minor surface, and

a second chamfer at an edge of the second major surface, the second chamfer having a first end at an intersection of the second chamfer with the second major surface and having a second end at an intersection of the second chamfer with the minor surface, wherein the first chamfer has a different size or shape than the second chamfer.

60. The HUD projection system of claim 59, wherein the first chamfer has a first length, the second chamfer has a second length, and the first length is different than the second length.

61. The HUD projection system of claim 60, wherein the first length is greater than the second length.

62. The HUD projection system of claim 60 or 61, wherein the first length is measured from a direction lying in a plane of the first major surface at the intersection with the first chamfer and from the first end of the first chamfer to a plane coplanar with the secondary surface at the second end of the first chamfer, and wherein the second length is measured from a direction lying in a plane of the second major surface and from the first end of the second chamfer to a plane coplanar with the secondary surface at the second end of the second chamfer.

63. The HUD projection system of any of claims 60-62, wherein the first length is at least about 1.0 mm.

64. The HUD projection system of claim 63, wherein the first length is from about 1.0mm to about 3.0 mm.

65. The HUD projection system of any one of claims 59-64, wherein the first chamfer includes a first inclined surface at a first angle measured from the first surface, wherein the first inclined surface intersects the first major surface at a first distance from a secondary surface that is coplanar with the secondary surface at the second end of the first chamfer and intersects the secondary surface at a second distance from a first major plane that is coplanar with the first major surface at the first end of the first chamfer of from about 0.5mm to about 3 mm.

66. The HUD projection system of any one of claims 59-65, wherein the second chamfer includes a second inclined surface at a second angle measured relative to the second surface, wherein the second inclined surface intersects the second major surface at a first distance from a secondary surface that is coplanar with the secondary surface at the second end of the second chamfer of from about 0.2mm to about 0.3mm, and intersects the secondary surface at a second distance from a second major plane that is coplanar with the second major surface at the first end of the first chamfer of from about 0.2mm to about 0.3 mm.

67. The HUD projection system of claim 66, wherein the first angle is about 3 degrees to about 31 degrees and the second angle is about 33 degrees to about 57 degrees.

68. The HUD projection system of claim 66, wherein the first angle is from about 5 degrees to about 45 degrees and the second angle is from about 5 degrees to about 45 degrees.

69. The HUD projection system of any one of claims 59-64, wherein the first chamfer includes a first inclined surface measured at a first angle relative to a first surface and the second chamfer includes a second inclined surface measured at a second angle relative to a second surface, and wherein the first angle is different than the second angle.

70. The HUD projection system of claim 69, wherein the first angle is less than the second angle.

71. The HUD projection system of claim 69 or 70, wherein the first inclined surface extends from the first edge to the second edge of the first chamfer, and wherein the second inclined surface extends from the first edge to the second edge of the second chamfer.

72. The HUD projection system of any one of claims 59-71, wherein the first major surface has a first radius of curvature such that the first major surface has a concave shape and the second major surface has a convex shape, the first radius of curvature being measured relative to a first axis of curvature.

73. The HUD projection system of claim 72, wherein the mirror has a second radius of curvature, the second radius of curvature being measured with respect to a second axis of curvature different from the first axis of curvature.

74. The HUD projection system of claim 73, wherein the first axis of curvature is perpendicular to the second axis of curvature.

75. The HUD projection system of any of claims 59-74, wherein the first major surface has an aspheric shape.

76. The HUD projection system of any of claims 59-75, wherein the first major surface that is reflective comprises a reflective coating on the glass-based substrate.

77. The HUD projection system of claim 76, wherein the reflective coating comprises a metal, metal oxide, ceramic oxide, or cermet alloy.

78. The HUD projection system of claim 76 or 77, wherein the reflective coating comprises aluminum or silver.

79. The HUD projection system of any of claims 59-78, wherein the display unit includes an LCD, LED, OLED, or μ LED display panel.

80. The HUD projection system of any of claims 59-79, wherein the display unit includes a projector.

81. The HUD projection system of any of claims 59-80, wherein the glass-based substrate has a thickness of less than or equal to 3.0 mm.

82. The HUD projection system of claim 81, wherein the glass-based substrate has a thickness of from about 0.5mm to about 3.0 mm.

83. The HUD projection system of claim 82, wherein the glass-based substrate has a thickness of from about 0.5mm to about 1.0 mm.

84. The HUD projection system of claim 82, wherein the glass-based substrate has a thickness of from about 1.0mm to about 3.0 mm.

85. The HUD projection system of any of claims 58-84, also comprising a projection surface configured to display a projected image to a user of the HUD system, wherein the mirror is configured to reflect an image generated by a display unit to form the projected image on the projection surface.

86. The HUD projection system of claim 85, wherein the projection surface has a curvature that corresponds to a curvature of the mirror.

87. The HUD projection system of claim 86, wherein the curvature of the projection surface is substantially the same as the curvature of the mirror.

88. The HUD projection system according to claim 86 or 87, wherein the projection surface may be a windshield or a combiner.

89. The HUD projection system of any of claims 86-88, wherein the projection surface has an aspheric shape.

90. The HUD projection system of any one of claims 59-89, wherein the second major surface includes one or more fabrication artifacts, and wherein the fabrication artifacts are confined to a peripheral region of the second major surface that extends from the edge of the second major surface to a distance that is less than the first length.

91. The HUD projection system of claim 90, wherein the manufacturing artifact is a vacuum suction artifact.

92. The HUD projection system of claim 90 or 91, wherein the manufacturing artifact is from the process of bending the mirror.

93. A method of forming a three-dimensional mirror, the method comprising the steps of:

providing a glass-based mirror preform comprising a first major surface, a second major surface opposite the first major surface, and a minor surface connecting the first and second major surfaces, the mirror preform having a flat shape;

forming a first chamfer on an edge of the first major surface;

forming a second chamfer on an edge of the second major surface, the second chamfer having a different size or shape than the first chamfer;

disposing the glass-based preform on a molding device having a curved support surface with the second major surface facing the curved support surface; and

the glass-based preform is conformed to the curved support surface to form a curved mirror substrate having a first radius of curvature.

94. The method of claim 93, wherein the step of conforming the glass-based preform to the curved support surface is performed at a temperature below the glass transition temperature of the glass-based preform.

95. The method of claim 93 or 94, wherein the temperature of the glass-based substrate does not rise above the glass transition temperature of the glass-based substrate during or after the conforming.

96. The method of any one of claims 93 to 95, wherein the curved support surface has a concave shape.

97. The method of claim 96, wherein the concave shape is an aspherical shape.

98. The method according to any one of claims 93 to 97, wherein the curved support surface also comprises a vacuum chuck having at least one aperture in the curved support surface.

99. The method of claim 98, further comprising the step of providing a vacuum to the at least one opening to conform the curved glass blank to the curved support surface.

100. The method of claim 98 or claim 99, wherein the at least one opening is a vacuum hole of the trench type.

101. The method of any of claims 98-100, wherein the first chamfer is formed in the first major surface such that the first chamfer begins at the first major surface at a first distance from the minor surface, wherein the at least one opening is a second distance from the minor surface when the glass-based preform is disposed on the curved support surface, and wherein the first distance is greater than or equal to the second distance.

102. The method of any one of claims 98 to 101, wherein the molding device comprises a raised peripheral surface or wall abutting the curved support surface and defining a space above the curved support surface into which the glass-based preform is to be positioned.

103. The method of claim 102, wherein the first chamfer is formed within the first major surface such that the first chamfer begins at the first major surface at a first distance from the minor surface, wherein the at least one aperture is a second distance from the raised peripheral surface or wall, and wherein the first distance is greater than or equal to the second distance.

104. The method of any one of claims 101-103, wherein the first distance is greater than the second distance.

105. The method of any one of claims 93-104, further comprising forming a reflective layer on the first major surface.

106. The method of claim 105, wherein the reflective layer is formed by: a reflective layer of material is sputtered, electroplated, or vapor deposited onto the first major surface.

107. The method of claim 105 or 106, wherein the reflective coating comprises a metal, a metal oxide, a ceramic oxide, or a cermet alloy.

108. The method of claim 107, wherein the reflective layer comprises aluminum or silver.

109. The method of any one of claims 105 to 108, wherein the reflective layer is formed on the first major surface after forming the curved mirror substrate to form an aspherical mirror.

110. The method of any one of claims 93-109, wherein the first chamfer comprises a first sloped surface at a first angle measured relative to the first surface, the first sloped surface having a first length, wherein the second chamfer comprises a second sloped surface at a second angle measured relative to the second surface, the second sloped surface having a second length, and wherein the first length is different than the second length.

111. The method of claim 110, wherein the first length is greater than the second length.

112. The method of claim 110 or 111, wherein the first length is measured from a direction within the plane of the first major surface and from the intersection of the first sloping surface with the first major surface to a plane coplanar with the secondary surface, and wherein the second length is measured from a direction within the plane of the second major surface and from the intersection of the second sloping surface with the second major surface to a plane coplanar with the secondary surface.

113. The method of any one of claims 110 to 112, wherein the first length is

At least about 1.0 mm.

114. The method of claim 113, wherein the first length is from about 1.0mm to about 3.0 mm.

115. The method of claim 110, wherein the first sloping surface meets the first major surface from about 0.5mm to about 3mm from a first plane coplanar with the secondary surface, and meets the secondary surface from about 0.2mm to about 0.3mm from a second plane coplanar with the first major surface.

116. The method of claim 110 or 115, wherein the second sloping surface meets the second major surface from about 0.2mm to about 0.3mm from a plane coplanar with the secondary surface, and meets the secondary surface from about 0.2mm to about 0.3mm from a plane coplanar with the second major surface.

117. The method of any one of claims 110-116, wherein the first angle is less than the second angle.

118. A Heads Up Display (HUD) system, comprising:

a projection surface for a user of the HUD system to view a projected image;

a display unit configured to generate an image to be viewed by the user on the projection surface; and

a mirror configured to reflect an image to the projection surface to form the projected image, the mirror including:

a glass-based substrate having a reflective first major surface, a second major surface opposite the first major surface, and a minor surface connecting the first and second major surfaces, a first chamfer located at an edge of the first major surface, the first chamfer and a second chamfer located at an edge of the second major surface, wherein the first chamfer has a different size or shape than the second chamfer.

119. The HUD system of claim 118, wherein the first chamfer has a first end at the intersection of the first chamfer and the first major surface and has a second end at the intersection of the first chamfer and the minor surface, and wherein the second chamfer has a first end at the intersection of the second chamfer and the second major surface and has a second end at the intersection of the second chamfer and the minor surface.

120. The HUD system of claim 118 or 119, wherein the first chamfer has a first length, the second chamfer has a second length, and the first length is different than the second length.

121. The HUD system of claim 120, wherein the first length is greater than the second length.

122. The HUD system of claim 119, wherein the first chamfer has a first length, the second chamfer has a second length, and the first length is different than the second length, wherein the first length is measured from a direction that is within a plane of the first major surface at the intersection with the first chamfer and is measured from the first end of the first chamfer to a plane that is co-planar with the secondary surface at the second end of the first chamfer, and wherein the second length is measured from a direction that is within a plane of the second major surface and is measured from the first end of the second chamfer to a plane that is co-planar with the secondary surface at the second end of the second chamfer.

123. The HUD system according to any of claims 120-122, wherein the first length is at least about 1.0 mm.

124. The HUD system according to claim 12, wherein the first length is from about 1.0mm to about 3.0 mm.

125. The HUD system of any one of claims 118-124, wherein the first chamfer includes a first inclined surface at a first angle measured from the first surface, wherein the first inclined surface intersects the first major surface at a first distance from a minor surface that is coplanar with the minor surface at the second end of the first chamfer and intersects the minor surface at a second distance from the first major surface that is from about 0.2mm to about 0.3mm, the first major surface being coplanar with the first major surface at the first end of the first chamfer.

126. The HUD system of claim 125, wherein the second chamfer includes a second inclined surface at a second angle measured relative to the second surface, wherein the second inclined surface intersects the second major surface at a first distance from a secondary surface that is coplanar with the secondary surface at the second end of the second chamfer of from about 0.2mm to about 0.3mm, and intersects the secondary surface at a second distance from a second major plane that is coplanar with the second major surface at the first end of the first chamfer of from about 0.2mm to about 0.3 mm.

127. The HUD system according to claim 126, wherein the first angle is about 3 degrees to about 31 degrees and the second angle is about 33 degrees to about 57 degrees.

128. The HUD system according to claim 126, wherein the first angle is from about 5 degrees to about 45 degrees and the second angle is from about 5 degrees to about 45 degrees.

129. The HUD system of any of claims 118-124, wherein the first chamfer includes a first inclined surface measured at a first angle relative to the first surface, and the second chamfer includes a second inclined surface measured at a second angle relative to the second surface, and wherein the first angle is different than the second angle.

130. The HUD system according to claim 129, wherein the first angle is less than the second angle.

131. The HUD system according to any one of claims 115-127, wherein the first major surface has a first radius of curvature such that the first major surface has a concave shape and the second major surface has a convex shape, the first radius of curvature being measured relative to a first axis of curvature.

132. The HUD system of claim 131, wherein the first major surface has a second radius of curvature, measured relative to a second axis of curvature, the second axis of curvature being different than the first axis of curvature.

133. The HUD system according to claim 132, wherein the first axis of curvature is perpendicular to the second axis of curvature.

134. The HUD system according to any of claims 118-133, wherein the first major surface has an aspherical shape.

135. The HUD system of claim 134, wherein the aspheric shape corresponds to a shape of the projection surface.

136. The HUD system according to any of claims 118-135, wherein the reflective first major surface comprises a reflective coating on the glass-based substrate.

137. The HUD system of claim 136, wherein the reflective coating comprises a metal, metal oxide, ceramic oxide, or cermet alloy.

138. The HUD system according to claim 137, wherein the metal is aluminum or silver.

139. The HUD system according to any one of claims 118-124 and 127-138, wherein the length of the first inclined surface, measured in a direction parallel to the first major surface, is about 0.5 mm-3 mm, and the length of the first inclined surface, measured in a direction parallel to the secondary surface, is about 0.2 mm-0.3 mm.

140. The HUD system according to any one of claims 118-124 and 127-139, wherein the length of the second inclined surface, measured in a direction parallel to the second major surface, is about 0.2-0.3 mm, and the length of the second inclined surface, measured in a direction parallel to the secondary surface, is about 0.2-0.3 mm.

141. The HUD system according to any of claims 118-140, wherein the display unit comprises an LCD, LED, OLED, or μ LED display panel.

142. The HUD system according to any of claims 118-141, wherein the display unit is a projector.

143. The HUD system according to any one of claims 118-142, wherein the glass-based substrate has a thickness of less than or equal to 3.0 mm.

144. The HUD system according to claim 143, wherein the glass-based substrate has a thickness of from about 0.5mm to about 3.0 mm.

145. The HUD system according to claim 144, wherein the glass-based substrate has a thickness of from about 0.5mm to about 1.0 mm.

146. The HUD system according to claim 144, wherein the glass-based substrate has a thickness of from about 1.0mm to about 3.0 mm.

147. The HUD system of any of claims 118-146, wherein the chamfer of the first major surface is configured to reduce edge distortion of the projected image.

148. The HUD system of any of claims 118-146, wherein the chamfer of the first major surface is configured to reduce an amount of unwanted light reflections towards the user.

149. The HUD system according to any of claims 118-148, wherein the projection surface is a windshield of a vehicle.

150. The HUD system of any of claims 118-148, wherein the projection surface is a combiner configured to be mounted inside a vehicle.

151. A Heads Up Display (HUD) projection system, comprising:

a display unit configured to display an image for viewing by a user of the HUD system; and

a mirror configured to reflect the image to a viewing area viewable by the user, the mirror comprising:

a glass-based substrate having a reflective first major surface, a second major surface opposite the first major surface, and a minor surface connecting the first and second major surfaces, and a chamfer at an edge of the first major surface, the chamfer having a first length.

152. The HUD projection system of claim 151, wherein the first length is measured from a direction within the plane of the first major surface and from the intersection of the first inclined surface and the first major surface to a plane coplanar with the secondary surface, and wherein the first length is at least about 1.0 mm.

153. The HUD projection system of claim 151 or 152, wherein the first length is from about 1.0mm to about 3.0 mm.

154. The HUD projection system of any of claims 151-153, wherein the chamfer intersects the first major surface at a distance of about 0.5mm to about 3mm from a first plane coplanar with the secondary surface, and intersects the secondary surface at a distance of about 0.2mm to about 0.3mm from a second plane coplanar with the first major surface.

155. The HUD projection system of any of claims 151-154, wherein the mirror has a first radius of curvature such that the first major surface has a concave shape and the second major surface has a convex shape, the first radius of curvature being relative to a first axis of curvature.

156. The HUD projection system of claim 155, wherein the mirror has a second radius of curvature, the second radius of curvature being relative to a second axis of curvature different from the first axis of curvature.

157. The HUD projection system of claim 156, wherein the first axis of curvature is perpendicular to the second axis of curvature.

158. The HUD projection system of any of claims 151-157, wherein the first major surface has an aspheric shape.

159. The HUD projection system of any of claims 151-158, wherein the first major surface that is reflective comprises a reflective coating on the glass-based substrate.

160. The HUD projection system of claim 159, wherein the reflective coating comprises a metal, metal oxide, ceramic oxide, or cermet alloy.

161. The HUD projection system of claim 159 or 160, wherein the reflective coating comprises aluminum or silver.

162. The HUD projection system of any of claims 151-161, wherein the display unit comprises an LCD, LED, OLED, or μ LED display panel.

163. The HUD projection system of any of claims 151-162, wherein the display unit is a projector.

164. The HUD projection system of any of claims 151-163, wherein the glass-based substrate has a thickness of less than or equal to 3.0 mm.

165. The HUD projection system of claim 164, wherein the glass-based substrate has a thickness of from about 0.5mm to about 3.0 mm.

166. The HUD projection system of claim 165, wherein the glass-based substrate has a thickness of from about 0.5mm to about 1.0 mm.

167. The HUD projection system of claim 165, wherein the glass-based substrate has a thickness of from about 1.0mm to about 3.0 mm.

168. The HUD projection system of any of claims 161-167, further comprising a projection surface for viewing of a projected image by a user of the HUD system, wherein the display unit is configured to generate an image and the mirror is configured to reflect the image to form the projected image on the projection surface.

169. The HUD projection system of claim 168, wherein the projection surface has substantially the same shape as the mirror.

170. The HUD projection system according to claim 168 or 169, wherein the projection surface may be a windshield or a combiner.

171. The HUD projection system of any of claims 168-170, wherein the projection surface has an aspheric shape.

172. The HUD projection system of claim 153, wherein the second major surface includes one or more fabrication artifacts, and wherein the fabrication artifacts are confined to a peripheral region of the second major surface at a distance from the edge of the second major surface that is less than the first length.

173. The HUD projection system of claim 172, wherein the manufacturing artifact is a vacuum suction artifact from the process of bending the mirror.

174. The glass-based preform of any one of claims 1 to 26, wherein the glass-based substrate comprises strengthened glass.

175. The glass-based preform of claim 174, wherein the strengthened glass is chemically strengthened.

176. The method of any one of claims 33-58, wherein the glass-based substrate comprises strengthened glass.

177. The method of claim 176, wherein the strengthened glass is chemically strengthened.

178. The HUD projection system of any of claims 59-92, wherein the glass-based substrate comprises strengthened glass.

179. The HUD projection system of claim 178, wherein the strengthened glass is chemically strengthened.

Technical Field

Cross reference

U.S. provisional patent application serial No. 62/589,172, filed on 2017, 11/21, according to the patent law, is hereby incorporated by reference in its entirety.

The present disclosure relates to aspherical mirrors for head-up display systems and methods of forming the same.

Background

Head-up display (HUD) systems project visual information onto a transparent surface so that a user can view the information without shifting his or her line of sight away from his or her primary line of sight. HUD systems typically use mirrors to reflect and project images onto the transparent surface. One application of HUD systems is in vehicles, such as automobiles, airplanes, watercraft, and other vehicles. For example, the HUD system may be deployed in a vehicle such that an operator or driver of the vehicle may view information related to vehicle operation while maintaining a forward gaze without having to look down or look away from the display screen. Thus, HUD systems are believed to improve safety by reducing the need for the vehicle operator to look away from a safe operating perspective.

However, HUD systems tend to have poor optical quality of the projected image, which can result in undesirable aesthetic quality of the projected image. Poor optical quality may even reduce the safety of the HUD system, as a blurred or unclear projected image may make it more difficult for the user to read or understand the projected information, thereby resulting in increased time for the user to process the information, delaying the user's information-based reaction time, and making the user more distracted. The mirrors used in HUD systems can degrade optical quality.

Accordingly, there remains a need for HUD systems having improved optical characteristics, and in particular for improved mirrors for HUD systems.

Disclosure of Invention

In some embodiments of the present disclosure, a glass-based preform for a mirror of a head-up display (HUD) system is provided. The glass-based preform includes a glass-based substrate having a first major surface, a second major surface opposite the first major surface, and a minor surface connecting the first and second major surfaces. Further, the preform includes a first chamfer at an edge of the first major surface, the first chamfer having a first end at an intersection of the first chamfer with the first major surface and having a second end at an intersection of the first chamfer with the minor surface, and may also include a second chamfer at an edge of the second major surface, the second chamfer having a first end at an intersection of the second chamfer with the second major surface and having a second end at an intersection of the second chamfer with the minor surface. The first chamfer has a different size or shape than the second chamfer.

In further embodiments, a mirror for a HUD system is provided, comprising a glass-based preform having a glass-based substrate with a first major surface, a second major surface opposite the first major surface, and a minor surface connecting the first and second major surfaces. Further, the preform includes a first chamfer at an edge of the first major surface, the first chamfer having a first end at an intersection of the first chamfer with the first major surface and having a second end at an intersection of the first chamfer with the minor surface, and may also include a second chamfer at an edge of the second major surface, the second chamfer having a first end at an intersection of the second chamfer with the second major surface and having a second end at an intersection of the second chamfer with the minor surface. The first chamfer has a different size or shape than the second chamfer. The mirror also includes a reflective layer on the first major surface of the glass-based preform. The glass-based substrate has a first radius of curvature such that the first major surface has a concave shape and the second major surface has a convex shape, the first radius of curvature being measured relative to a first axis of curvature. The glass-based substrate can have a second radius of curvature measured with respect to a second axis of curvature different from the first axis of curvature, wherein the first axis of curvature is perpendicular to the second axis of curvature. In some embodiments, the first major surface has an aspherical shape.

In a further embodiment, a method of forming a three-dimensional mirror is provided, the method comprising the steps of: providing a glass-based mirror preform comprising a first major surface having an edge with a first chamfer; a second major surface opposite the first major surface and having an edge with a second chamfer; and a secondary surface connecting the first and second major surfaces, the second chamfer having a different size or shape than the first chamfer. The method also comprises the steps of: placing the glass-based preform on a molding device having a curved support surface with the second major surface facing the curved support surface; and conforming the glass-based preform to the curved support surface to form a curved mirror substrate having a first radius of curvature.

In another embodiment, a head-up display (HUD) projection system is provided. The HUD system includes a display unit configured to display an image to be viewed by a user of the HUD system; and a mirror configured to reflect an image to a viewing area viewable by a user. The mirror includes a glass-based substrate having a reflective first major surface, a second major surface opposite the first major surface, and a minor surface connecting the first and second major surfaces; a first chamfer at an edge of the first major surface, the first chamfer having a first end at an intersection of the first chamfer with the first major surface and having a second end at an intersection of the first chamfer with the minor surface; and a second chamfer at an edge of the second major surface, the second chamfer having a first end at an intersection of the second chamfer with the second major surface and having a second end at an intersection of the second chamfer with the minor surface. The first chamfer has a different size or shape than the second chamfer.

In another embodiment, a method of forming a three-dimensional mirror is provided. The method comprises the following steps: providing a glass-based mirror preform comprising a first major surface, a second major surface opposite the first major surface, and a minor surface connecting the first and second major surfaces, the glass preform having a flat shape; forming a first chamfer on an edge of the first major surface; forming a second chamfer on an edge of the second major surface, the second chamfer having a different size or shape than the first chamfer; placing the glass-based preform on a molding device having a curved support surface with the second major surface facing the curved support surface; and conforming the glass-based preform to the curved support surface to form a curved mirror substrate having a first radius of curvature. The step of conforming the glass-based preform to the curved support surface is performed at a temperature below a glass transition temperature of the glass-based preform, and the temperature of the glass-based substrate does not rise above the glass transition temperature of the glass-based substrate during or after the conforming.

In another embodiment, a heads-up display (HUD) system is provided, the heads-up display (HUD) system including a projection surface for viewing a projected image by a user of the HUD system; a display unit configured to generate an image on the projection surface to be viewed by the user; and a mirror configured to reflect an image to the projection surface to form the projected image. The mirror includes a glass-based substrate having a reflective first major surface, a second major surface opposite the first major surface, and a minor surface connecting the first and second major surfaces; a first chamfer at an edge of the first major surface, the first chamfer; and a second chamfer at an edge of the second major surface, wherein the first chamfer has a different size or shape than the second chamfer.

In another embodiment, a heads-up display (HUD) projection system is provided, the heads-up display (HUD) projection system comprising a display unit configured to display an image for viewing by a user of the HUD system; and a mirror configured to reflect the image to a viewing area viewable by the user. The mirror includes a glass-based substrate having a reflective first major surface; a second major surface opposite the first major surface; and a secondary surface connecting the first and second major surfaces; and a chamfer at an edge of the first major surface, the chamfer having a first length.

Additional features and advantages of the claimed invention will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the claimed invention as described herein, including the detailed description which follows, the claims, as well as the appended drawings.

It is to be understood that both the foregoing general description and the following detailed description present embodiments of the invention, and are intended to provide an overview or summary for understanding the nature and character of the invention as it is claimed. The accompanying drawings are included to provide a further understanding of the disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate various embodiments and together with the description serve to explain the principles and operations of the claimed invention.

Drawings

For the purposes of illustration, there is shown in the drawings a form that is presently preferred. It should be understood, however, that the embodiments disclosed and discussed herein are not limited to the precise arrangements and instrumentalities shown.

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

FIG. 2 is a graphical depiction of a perspective (viewpoint) of an automobile driver when using the HUD system of FIG. 1, in accordance with some embodiments.

Fig. 3 is a photograph of an example of a combiner used in a HUD system according to some embodiments herein.

Figure 4 is a graphical depiction of a perspective (viewpoint) of a motorist when using a HUD system having a combiner similar to that shown in figure 3, in accordance with some embodiments.

FIG. 5 is a photograph of three exemplary mirrors for a HUD system according to some embodiments.

FIG. 6 is an illustration of an aspherical mirror for use in a HUD system according to some embodiments.

Fig. 7A and 7B are schematic views of symmetrical edges of a 2D pre-substrate and a 3D shaped substrate, respectively, for a HUD system.

Fig. 8A and 8B are schematic views of asymmetric edges of a 2D pre-substrate and a 3D shaped substrate, respectively, for a HUD system according to some embodiments of the present disclosure.

FIG. 9 is a schematic illustration of an asymmetric edge of a 3D shaped substrate for a HUD system according to some embodiments.

Fig. 10 is a graphical depiction of a vacuum-based forming surface according to some embodiments herein.

Fig. 11A and 11B are cross-sectional views of an edge of a substrate on the vacuum-based shaping surface of fig. 10.

Fig. 12 shows a photographic comparison of the optical quality of a generic mirror substrate for a HUD system and a mirror substrate according to some embodiments of the present disclosure.

FIG. 13 illustrates steps in a method of forming a mirror or mirror substrate according to some embodiments of the present disclosure.

Detailed Description

In the description below, like reference numerals designate identical or corresponding components in the several views shown in the figures. It should also be understood that terms such as "top," "bottom," "outward," "inward," and the like are words of convenience and are not to be construed as limiting terms unless otherwise specified. In addition, whenever a group is described as including at least one of a set of elements and combinations thereof, it is understood that the group may include, consist essentially of, or consist of any number of the recited elements, either individually or in combination with each other.

Similarly, whenever a group is described as consisting of at least one of a set of elements or combinations thereof, it is understood that the group may consist of any number of the elements, either individually or in combination with each other. Unless otherwise indicated, numerical ranges include the upper and lower limits of the stated ranges when recited. As used herein, the indefinite articles "a" and "an" and the corresponding definite articles "the" mean "at least one" or "one or more" unless otherwise indicated.

The following description of the present disclosure is provided as an enabling teaching and best mode presently known. Those skilled in the art will recognize that many changes may be made to the embodiments described herein while still obtaining the advantageous results of the present disclosure. It will also be apparent that some of the desired benefits of the present disclosure can be obtained by selecting some of the features of the present disclosure without utilizing other features. Accordingly, those who work in the art will appreciate that many modifications and variations of the present disclosure are possible and may even be contemplated as being a part of the present disclosure in certain circumstances. Accordingly, the following description is provided as illustrative of the principles of the present disclosure and not in limitation thereof.

Those skilled in the art will appreciate that many modifications may be made to the exemplary embodiments described herein without departing from the spirit and scope of the present disclosure. Accordingly, this description is not intended to be, and should not be construed as, limited to the examples provided, but rather should be afforded the full scope of protection afforded by the appended claims, and equivalents thereof. Furthermore, some of the features of the present disclosure could be used without the corresponding use of other features. Thus, the following description of exemplary or illustrative embodiments is provided to illustrate the principles of the disclosure and not to limit it, and may include modifications and substitutions.

The HUD system may be used to provide various types of information to improve user security and convenience. In transit, for example, information related to vehicle operation (e.g., vehicle instrumentation or navigation) may be projected to an area in front of the driver. This may include real-time information about vehicle speed, fuel level, air control settings, entertainment settings, navigational directions for each turn alert, predicted arrival time, and alerts related to speed, traffic, or dangerous conditions. The information may be represented as text, symbols, pictures, video, animation, and one or more colors. These are by way of example only and embodiments of the disclosure are not intended to be limited to these examples.

In some embodiments of the present disclosure, a HUD system may include an image generation apparatus and one or more optical components for directing or projecting an image from the image generation apparatus to an area that is readily viewable by a user. The image-generating device may include a Cathode Ray Tube (CRT) display, a Light Emitting Diode (LED) display, a Liquid Crystal Display (LCD) assembly, a laser projection system, or other types of displays known to those skilled in the art. The HUD system may also include a computer or processor for generating images produced by these displays. For example, the optical components may include some combination of lenses, beam splitters, mirrors, and combiners. The combination of the components of the HUD system may be configured to produce collimated light.

The collimated light is projected onto a combiner located in the user's field of view so that the user can see the projected image simultaneously with the normal field of view. For example, in a vehicle application, the combiner may be a windshield. Alternatively, the combiner may be a separate component built into the vehicle, or a portable component mountable in the vehicle in a position where the driver or passenger can see the projected image on a transparent surface of the combiner. The mirror may include a reflective coating on the curved substrate. The curved substrate may be spherical, aspherical, Fresnel lens (Fresnel) shaped, and/or diffractive shaped. In a preferred embodiment, the mirror has a reflective surface or coating on a concave aspheric surface.

Fig. 1 illustrates an example of a HUD system 100 according to some embodiments of the present disclosure. The HUD system 100 is shown in an automobile, but embodiments may be used in a variety of vehicular and non-vehicular applications. The driver D holds the steering wheel W of the vehicle V with his hands as shown. The HUD system 100 is incorporated into a dashboard 110 of a vehicle V and includes a Programmable Graphics Unit (PGU)102 connected to an image source 103, the image source 103 configured to generate an image based on signals from the PGU 102. This image is reflected by the flat mirror 104 towards the curved mirror 106. The image is projected from the curved mirror 106 toward the windshield 108 and onto a projection area 112 of the windshield 108. The HUD system 100 may be configured such that the projection area 112 will be within the normal line of sight of the driver D while driving the vehicle V. For example, the projection area 112 may be positioned such that the projected image is overlaid on a road as viewed from the perspective of the driver. An example of the scene is shown in the icon of fig. 2.

Although in fig. 1 and 2 the projection area 112 is located on the windshield 108, fig. 3 and 4 show an alternative embodiment in which the combiner 208 is used in the location of the projection area 212. The combiner 208 may be built into the dashboard 210 of the vehicle, or may be a portable or detachable component located on top of the dashboard 210.

Embodiments of the present disclosure are not limited to one or more particular arrangements of optical components of the HUD system, as one of ordinary skill in the art will appreciate the basic configuration of components in a HUD system. The scheme is mainly directed at a curved mirror used in the HUD system. Fig. 5 shows an example of curved mirrors 301, 302 and 303 used in a HUD system. The mirrors in HUD systems generally have an aspheric reflective surface, which may be a reflective coating formed on the aspheric surface of the mirror substrate. Aspheric or aspheric surfaces have multiple radii of curvature. In particular, for example, in the case of a four-mirror as shown in fig. 5, the aspherical surface has a different radius of curvature along each of the four edges. Thus, as shown in FIG. 6, the mirror 400 has a reflective surface 408 with an aspheric shape of the reflective surface 408 having a radius of curvature R1 along a first edge, a radius of curvature R2 along a second edge, a radius of curvature R3 along a third edge, and a radius of curvature R4 along a fourth edge. Since the surface 408 is aspheric, R1 ≠ R2 ≠ R3 ≠ R4. Fig. 6 also shows how different points on curved surface 408 are displaced by varying amounts a-e relative to a two-dimensional plane connecting the four corners of mirror 400. In some embodiments, a ≠ b ≠ c ≠ d.

However, the authors of the present application have recognized that there is a need for improved methods of shaping and designing curved mirrors for HUD systems. For example, to avoid degradation of the image quality after the image is reflected by a curved mirror, the mirror should have a high level of shape accuracy and surface roughness. For example, a shape accuracy of less than 50 μm and a surface roughness (Ra) of less than 3nm are required. A particular type of optical distortion that occurs in mirrors used in HUD systems is referred to as edge distortion, which is the optical distortion of light reflected at or near the edges of the mirror. In prior HUD systems, optically significant defects may be introduced into the mirror during the manufacture or shaping of the mirror. The most common methods of forming 3D mirrors or mirror substrates can be divided into two categories: stamping methods and vacuum forming methods. However, both stamping and vacuum forming methods have disadvantages.

In the pressing method, an upper mold and a lower mold are used to press a substrate, such as a glass substrate, by physical force. For example, an upper mold may be pressed into a lower mold with a 2D glass preform disposed between the two molds and the glass preform shaped according to the shape of the surfaces on one or both molds. Therefore, mold impressions remain on the concave and convex surfaces of the formed glass substrate, which subsequently need to be polished. Further, due to the deviation of the contours of the upper and lower molds, it may be difficult to precisely fit the contours of the upper and lower molds, and thus it is difficult to achieve a precise shape of the formed glass substrate. For example, the profile of an aspherical mirror may be specified to be less than + -25 μm, while the deviation of the mold profile after machining is typically 30-50 μm.

In the vacuum forming method, a single mold (e.g., a lower mold) may be used, in which vacuum holes are formed in a surface of the mold. A flat (2D) glass plate is placed on the surface of the mold and vacuum pressure is supplied through the vacuum holes to enable the glass to conform to the curved (3D) surface of the mold. However, it is difficult to avoid forming vacuum hole marks on the surface of the formed glass substrate. The vacuum hole marks or manufacturing artifacts can compromise the optical performance of the substrate or finished mirror. In addition, typical vacuum forming processes may require higher forming temperatures than stamping processes. Higher forming temperatures can affect surface quality and form defects such as pits, and marks. Vacuum forming may be performed on a mirror preform, which is a substrate cut to a desired size in advance before forming a 3D shape by vacuum forming, or on an oversized glass plate cut to a desired size after forming a 3D shape by vacuum forming. Both vacuum forming based on preforms and vacuum forming based on oversized glass have certain advantages and disadvantages.

For example, forming based on oversized glass has the advantage of obtaining good edge quality due to edge cutting, and has good surface roughness due to lower forming temperatures. However, forming based on oversized glass requires an additional step of cutting the glass after forming; low glass utilization after molding due to trimming glass or waste glass; after cutting, edge polishing and/or chamfer manufacturing are required; and even though the final finished product may be the same size as formed in preform-based molding, larger equipment is still required.

On the other hand, in the preform-based vacuum forming, there is no need to cut the mirror substrate after the vacuum forming, which reduces the generation of waste or cullet. Furthermore, preform-based forming can be a simpler process and more cost-effective. However, in preform-based vacuum forming processes, it is difficult or impossible to apply a relatively uniform vacuum pressure across the entire surface of the glass sheet due to vacuum leakage at one or more edges of the glass preform, at least in part due to vacuum leakage between the preform and the mold. For example, if the glass being formed has a single radius of curvature, the short side edges of the preform may remain in contact with the mold surface until molding is complete, but vacuum will leak along the long side edges of the preform. In the case of more complex curvatures or aspheric mold surfaces (and aspherically shaped substrates), only discrete points of the glass sheet, such as the four corners, contact the mold surface throughout the molding process, which results in vacuum leakage along all edges of the glass substrate. Moreover, to form an aspherical mirror, the corners of the mirror or mirror substrate may chip or crack, which occurs only when the corners of the mirror substrate are in contact with the mold and an external force (e.g., vacuum pressure, mold pressure) is applied, thus concentrating the pressure on the four corners of the substrate. Thus, higher forming temperatures (and lower substrate viscosities) are used to more completely conform the glass to the mold surface and reduce stress near the corners to reduce chipping. However, as described above, higher temperatures may cause the surface of the glass substrate to deteriorate and degrade optical performance. Even at higher temperatures, mirror edge distortion can occur.

Researchers working this case have discovered improvements in the technology of forming mirrors using vacuum-based molding methods. In some preferred embodiments, these techniques may be particularly applicable to preform-based molding processes. However, some embodiments are not limited to mirrors manufactured using preform-based molding methods, nor are they generally limited to vacuum-based methods. One problem addressed by embodiments of the present disclosure is edge distortion. As described above, when the vacuum molding method is used, it may be difficult to achieve uniform vacuum and uniform conformity of the mirror substrate and the mold. Conforming a mirror substrate to a desired shape at or near the edge of the substrate can be particularly difficult, which can result in edge distortion and can reduce the quality of the image reflected by the mirror near the edge. Accordingly, embodiments of the present disclosure provide mirrors and/or mirror substrates having improved optical performance at the edges, and methods of forming the same.

As shown in fig. 7A and 7B, conventional mirrors for HUD systems have symmetrical, chamfered edges. In particular, fig. 7A illustrates a 2D preform 500, the 2D preform 500 having a first major surface 502 that is the mirror side of the preform; a second major surface 504 opposite the first major surface 502, and a minor surface 503 between the first major surface 502 and the second major surface 504. The edges of first and second major surfaces 502, 504 have symmetrical first and second chamfers 506, 508, respectively. That is, first chamfer 506 at the edge of first major surface 502 is the same size and/or shape as second chamfer 508 at the edge of second major surface 504, resulting in a symmetrical profile when viewed in cross-section, as shown in fig. 7A. Fig. 7B illustrates a three-dimensional (3D) or curved mirror substrate 500' resulting after forming the 2D preform 500 of fig. 7A.

The geometry of first chamfer 506 and second chamfer 508 may be described by the x-component and y-component of the chamfer surface. As used herein, the x component refers to the distance measured in a direction parallel to the first or second major surface of the two-dimensional preform. The y-component refers to the distance measured in a direction perpendicular to the first or second major surface of the two-dimensional preform, or parallel to the minor surface of the two-dimensional preform. In fig. 7A and 7B, the first chamfer 506 has an x-component x1 and a y-component y1, and the second chamfer 508 has an x-component x2 and a y-component y 2. The dimensions of x1, y1, x2, and y2, for example, may be in the range of about 0.2 to about 0.3mm, where x1 is the same as x2 and y1 is the same as y 2. Thus, this conventional form of chamfer can be considered a symmetrical chamfer.

However, researchers in this case have found that asymmetric chamfering of the mirror or mirror preform can reduce edge distortion. In some preferred embodiments, the asymmetric chamfer takes the form of a larger chamfer on the mirror side of the mirror or mirror substrate. A "larger" chamfer is a chamfer having a larger x-component. For example, fig. 8A and 8B illustrate a 2D preform 600 and a 3D or curved mirror substrate 600' with asymmetric chamfers. In particular, fig. 8A illustrates a 2D preform 600 having a first major surface 602 that is the mirror side of the preform; a second major surface 604 opposite the first major surface 602; and a secondary surface 603 between the first and second major surfaces. The edges of the first and second major surfaces 602, 604 have asymmetric first and second chamfers 606, 608, respectively. That is, first chamfer 606 at the edge of first major surface 602 is of a different size and/or shape than second chamfer 608 at the edge of second major surface 604, resulting in an asymmetric profile when viewed in cross-section, as shown in fig. 8A. Due to the chamfering, the minor surface 603 has a reduced thickness t2, which is less than the thickness t3 between the first and second major surfaces 602, 604 in the non-chamfered portion of the substrate 600. In some preferred embodiments, the thickness t3 may be about 1.0mm to about 3.0 mm; about 2.0 mm; less than about 1.0 mm; or about 0.3mm to about 1.0 mm. Fig. 8B illustrates the resulting 3D or curved mirror substrate 600' after forming the 2D preform 600 of fig. 8A.

Similar to fig. 7A and 7B, the geometry of the first chamfer 606 and the second chamfer 608 may be described by the x-component and y-component of the chamfer surface. In fig. 8A and 8B, the first chamfer 606 has an x-component x1 'and a y-component y1', while the second chamfer 608 has an x-component x2 'and a y-component y 2'. However, x1 'and x2' are not equal, resulting in an asymmetric profile. In particular, the mirror-side x-component x1 'is greater than the back or non-mirror-side x-component x 2'. In some embodiments, the x1' dimension may be, for example, about 0.5 to about 3.0 mm. If x1' is too large (e.g., in some embodiments, exceeding 3.0mm), the effective area of the mirror may become too small, which is undesirable. The dimensions of y1', x2', and y2' may be, for example, about 0.2 to about 0.3 mm. If the second chamfer 608 on the side of the second major surface 604 is too large (e.g., greater than about 0.2mm to about 0.3mm in some embodiments), its formability may be degraded and the accuracy of the corner may be reduced. However, embodiments are not limited to these dimensions. This method therefore results in an asymmetric profile at the edge of the mirror or mirror substrate.

Although the length of the chamfer, or the x-and y-components of the chamfer as described above, may be used to measure the chamfer, the geometry of the chamfer may also be described with reference to the angle of inclination of the chamfer surface relative to the substrate surface. For example, in fig. 8A and 8B, the first chamfer 606 comprises an inclined surface having a first end that meets the first major surface 602 and a second end that meets the minor surface 603. The inclined surface is angled with respect to the first major surface 602. Similarly, second chamfer 608 comprises a sloped surface that is angled relative to second major surface 604. In some embodiments, the angle of the chamfer may be, for example, about 5 degrees to about 45 degrees. In some embodiments, the angle of the first chamfer 606 may be, for example, about 3 degrees to about 31 degrees; the angle of the second chamfer 608 may be about 33 degrees to about 57 degrees.

Asymmetric chamfering of the substrate edges results in improved formability and reduces visibility of distorted images reflected by the edges of the mirrors. In the case of edge distortion, the reflection angle of the display image changes due to the inclination of the chamfered surface, which can prevent the user from seeing the distorted image. This results in a projected image with no perceptible edge distortion. The edge formability is considered to be improved because the edge area is thinned due to the large chamfer, which makes the edge area easier to form. For example, when the same vacuum pressure is used, the edge profile deviation with respect to a computer-aided design (CAD) model may be reduced and the profile accuracy of the asymmetric edge may be increased compared to the non-asymmetric edge. This improvement in contour accuracy reduces image distortion. In addition, the asymmetric chamfer can help prevent unwanted or dangerous light from entering the glass edge and being directed toward the eye of the user of the HUD system. Such unwanted light may include, for example, sunlight, which may distract the driver or interfere with their vision.

Although the embodiments in fig. 8A and 8B illustrate the first chamfer 606 and the second chamfer 608, some embodiments of the present disclosure may include a chamfer on only the reflective side of the mirror substrate (i.e., the first chamfer 606). Thus, the advantages of the asymmetric chamfer described herein may be achieved without the second chamfer 608, or without a specific design or geometry for the second chamfer. However, it is still beneficial to have a second chamfer 608 on the back side of the substrate to remove the sharp edge from the edge and improve edge formability.

Fig. 9 illustrates an example of how the improved edge performance described above is achieved by an asymmetric chamfer. In particular, fig. 9 illustrates a cross-sectional view of an edge region of a 3D shaped mirror 650, the edge region having a reflective and concave first major surface 652. Mirror 650 also has a second major surface 654 opposite the first major surface 652, and a minor surface 653 between the first and second major surfaces 652, 654. The edge of the mirror 650 has an asymmetric chamfer with a larger chamfer surface 656 on the side of the first major surface 652 and a smaller chamfer surface 658 on the rear side. In the effective area of the mirror 650Incident light L of upper incidence_isL reflected towards the user_rsSo that the reflected light is visible to the user. However, the incident light L incident on the chamfered surface 656_ieIs reflected as L in one direction_reSaid reflection being such that L_reInvisible to the user of the HUD system.

As described above, embodiments of the present disclosure include using a vacuum forming process to form a curved or 3D mirror substrate. In one aspect, the vacuum forming method uses a mold 700 as shown in fig. 10. The mold 700 has a shaping surface 702, the shaping surface 702 being shaped into the desired shape of the 3D mirror or mirror substrate. Mold 700 may optionally include a shell 706, the shell 706 surrounding the perimeter of the shaped surface 702 and defining a space for a mirror preform to be placed therein for shaping. To conform the mirror substrate (not shown) to the shaping surface 702, vacuum pressure is provided through one or more vacuum holes. However, as described above, the vacuum holes may leave fabrication artifacts in the form of defects in the substrate shrinkage vacuum holes. Thus, mold 700 does not include vacuum holes in the area that will contact the active area of the lens substrate. Rather, mold 700 has a vacuum hole 704 of the channel type at the periphery of forming surface 702. When the mirror preform is placed on mold 700, the vacuum holes 704 are positioned under the larger chamfer on the reflective surface side of the mirror. In addition, the vacuum holes 704 are positioned to remain under the larger chamfer on the reflective surface side of the mirror during the formation of the mirror preform on the mold 700 for the 3D mirror substrate. Due to the location of the vacuum holes 704 relative to the larger chamfer, any imperfections or artifacts created by the vacuum holes 704 will not be apparent to a user of the HUD system, as such imperfections will not be located in the active area of the mirror. The active area as used herein is the portion of the mirror or mirror substrate that will reflect the image to be projected and viewed by the user and is located within the chamfered edge region of the mirror or mirror substrate.

Fig. 11A and 11B illustrate a detailed view of the shaping surface 802 near the edge of the mirror preform 800. The resulting shaped mirror substrate 800' is also illustrated in fig. 11A and 11B. Preform 800 is placed on forming surface 802 such that first major surface 801 (the reflective side of the mirror) faces upward and away from forming surface 802, and second major surface 804 faces forming surface 802. Thus, first major surface 801 faces upward, and larger chamfer 810 will also face upward and away from forming surface 802. After shaping, second major surface 804 conforms to shaping surface 802. When the preform 800 is placed in the mold, there is a gap d1 between the minor surface 803 of the preform 800 and the vertical wall 807 of the housing 806 of the mold. The gap d1 is large enough to allow the mirror substrate to be easily placed and removed before and after formation. Alternatively, the gap d1 may not be present prior to formation. After shaping, due to the curvature of the shaped mirror substrate 800', the secondary surface 803 will move to a distance of d2 from the vertical wall 807, where d2 is greater than d 1. The mold is designed so that d3 will be less than the distance from vertical wall 807 to the gutter-type vacuum holes 808. In other words, even after forming is complete, the gutter-type vacuum holes 808 will still be covered by the formed mirror substrate 800' so that no draft is lost and the mirror substrate remains conformed to the forming surface 802. Thus, after forming, there is a non-zero distance d3 between the opening of the trench-type vacuum holes 808 in the forming surface 802 and the minor surface 803 'of the curved mirror substrate 800'. Distance d3 is less than the length l1 of first chamfer 810, where l1 is defined as the direct light distance from minor surface 803' of the formed mirror substrate 800' to the intersection of the chamfer with the first major surface 801 '. In some embodiments, l1 may be about 1.0 to about 3.0mm, and d3 may be about 0.5mm to about 3.0 mm. Because d3 is less than l1, any trench line artifacts left in the mirror substrate from the trench vacuum holes will be covered by the chamfer on the reflective surface side of the shaped mirror, making the defect invisible to the user.

Fig. 12 illustrates a comparison between a 3D mirror substrate 900 using a normal chamfer (left) and a 3D mirror substrate 910 using an asymmetric chamfer (right). The example of asymmetric chamfering shows excellent optical performance at the edge 912, while the example of ordinary chamfering shows no distortion at the edge 902.

Fig. 13 illustrates a method of forming a mirror or mirror substrate according to one or more embodiments of the present disclosure. The method includes step S1 of creating a pre-manufactured mirror substrate by cutting a glass sheet into the shape of a desired pre-manufactured piece. After cutting, a washing step S2 may be performed to clean the preform, followed by a step S3 of vacuum forming the preform into a 3D formed substrate. Finally, one or more post-processing steps S4 may be performed, including edge or surface finishing or coating, or mounting the curved mirror in some portion of the HUD system.

The reflective surface may be formed by: sputtering, evaporation (e.g., CVD, PVD), electroplating, or other coating methods, or providing a reflective surface known to those of ordinary skill in the art. The reflective surface may, for example, comprise one or more metal/ceramic oxides, metal/ceramic alloys. The reflective surface is formed on the 3D molded substrate after the substrate is formed into a curved or aspherical shape. However, embodiments are not limited to this order, and it is contemplated that the 3D mirror may be formed from a 2D preform having a reflective surface.

In some embodiments, a glass-based preform for a mirror of a head-up display (HUD) system is provided. The glass-based preform includes a glass-based substrate having a first major surface, a second major surface opposite the first major surface, and a minor surface connecting the first and second major surfaces. Further, the preform includes a first chamfer at an edge of the first major surface, the first chamfer having a first end at an intersection of the first chamfer with the first major surface and having a second end at an intersection of the first chamfer with the minor surface; and may also include a second chamfer at an edge of the second major surface, the second chamfer having a first end at an intersection of the second chamfer with the second major surface and having a second end at an intersection of the second chamfer with the minor surface. The first chamfer has a different size or shape than the second chamfer.

In one aspect, the first chamfer has a first length, the second chamfer has a second length, and the first length is different than the second length. The first length may be greater than the second length. The first length is measured in a direction within a plane of the first major surface at an intersection with the first chamfer and is measured from the first end of the first chamfer to a plane coplanar with the minor surface at the second end of the first chamfer. Similarly, the second length is measured from a direction within the plane of the second major surface and from the first end of the second chamfer to a plane coplanar with the minor surface at the second end of the second chamfer. In some embodiments, the first length is at least about 1.0 mm; from about 1.0mm to about 3.0 mm; or about 2.0 mm.

The first chamfer can include a first sloped surface at a first angle measured from the first surface, wherein the first sloped surface meets the first major surface at a first distance from a minor surface that is coplanar with the minor surface at the second end of the first chamfer of from about 0.5mm to about 3mm, and meets the minor surface at a second distance from a first major plane that is coplanar with the first major surface at the first end of the first chamfer of from about 0.2mm to about 0.3 mm. The second chamfer can include a second sloped surface at a second angle measured relative to the second surface, wherein the second sloped surface intersects the second major surface at a first distance from a minor surface that is coplanar with the minor surface at the second end of the second chamfer of from about 0.2mm to about 0.3mm, and intersects the minor surface at a second distance from a second major plane that is coplanar with the second major surface at the first end of the first chamfer of from about 0.2mm to about 0.3 mm. The first angle is from about 3 degrees to about 31 degrees and the second angle is from about 33 degrees to about 57 degrees. In some embodiments, the first angle may be from about 5 degrees to about 45 degrees, and the second angle may be from about 5 degrees to about 45 degrees.

In another aspect of some embodiments, the first chamfer includes a first sloped surface at a first angle measured relative to the first surface, and the second chamfer includes a second sloped surface at a second angle measured relative to the second surface, the first angle being different than the second angle. The first angle is less than the second angle. The first sloped surface extends from a first edge to a second edge of the first chamfer and the second sloped surface extends from the first edge to the second edge of the second chamfer.

In an aspect of some embodiments, at least a portion of the first major surface is reflective. The portion of the first major surface that is reflective can have a reflective coating on the glass-based substrate, and the reflective coating can comprise a metal, a metal oxide, a ceramic oxide, or a cermet alloy. In some aspects, the reflective coating comprises aluminum or silver.

The length of the first inclined surface measured in a direction parallel to the first major surface may be about 0.5mm to 3mm, and the length of the first inclined surface measured in a direction parallel to the minor surface may be about 0.2mm to 0.3 mm. The length of the second inclined surface measured in a direction parallel to the second major surface may be about 0.2mm to 0.3mm, and the length of the second inclined surface measured in a direction parallel to the minor surface may be about 0.2mm to 0.3 mm. As an aspect of some embodiments, the glass-based substrate has a thickness less than or equal to 3.0 mm; from about 0.5mm to about 3.0 mm; from about 0.5mm to about 1.0 mm; or from about 1.0mm to about 3.0 mm.

In another embodiment, a mirror for a HUD system is provided comprising the glass-based preform of any of the above embodiments. The mirror also includes a reflective layer on the first major surface of the glass-based preform. The glass-based substrate has a first radius of curvature such that the first major surface has a concave shape and the second major surface has a convex shape, the first radius of curvature being measured relative to a first axis of curvature. The glass-based substrate has a second radius of curvature measured with respect to a second axis of curvature different from the first axis of curvature, wherein the first axis of curvature is perpendicular to the second axis of curvature. In some embodiments, the first major surface has an aspherical shape.

In another embodiment, a method of forming a three-dimensional mirror is provided, the method comprising the steps of: providing a glass-based mirror preform comprising: a first major surface having an edge with a first chamfer; a second major surface opposite the first major surface and having an edge with a second chamfer; and a secondary surface connecting the first and second major surfaces, the second chamfer having a different size or shape than the first chamfer. The method also comprises the steps of: placing the glass-based preform on a molding device having a curved support surface with the second major surface facing the curved support surface; and conforming the glass-based preform to the curved support surface to form a curved mirror substrate having a first radius of curvature.

In some aspects of some embodiments, the step of conforming the glass-based preform to the curved support surface is performed at a temperature below the glass transition temperature of the glass-based preform. The temperature of the glass-based substrate does not rise above the glass transition temperature of the glass-based substrate during or after the attaching.

In further aspects of some embodiments, the curved support surface has a concave shape, and the concave shape may be an aspheric shape. The curved support surface also includes a vacuum chuck having at least one aperture in the curved support surface. The method may further include the step of providing a vacuum to the at least one opening to conform the curved glass blank to the curved support surface. The at least one opening may be a vacuum hole of a trench type.

The first chamfer is formed in the first major surface such that the first chamfer begins at the first major surface at a first distance from the minor surface, wherein the at least one opening is a second distance from the minor surface when the glass-based preform is disposed on the curved support surface, and wherein the first distance is greater than or equal to the second distance. The molding device may include a raised peripheral surface or wall abutting the curved support surface and defining a space above the curved support surface in which the glass-based preform is disposed. The first chamfer is formed within the first major surface such that the first chamfer begins at the first major surface at a first distance from the minor surface, wherein the at least one aperture is a second distance from the raised peripheral surface or wall, and the first distance is greater than or equal to the second distance; or the first distance is greater than the second distance.

The method further includes the step of forming a reflective layer on the first major surface. The reflective layer is formed in the following manner: a reflective layer material is sputtered, electroplated, or vapor deposited onto the first major surface. The reflective layer comprises a metal, metal oxide, ceramic oxide, or cermet alloy; and may comprise aluminum or silver. The reflective layer is formed on the first major surface after forming the curved mirror substrate to form the aspherical mirror.

As an aspect of some embodiments, the first chamfer includes a first inclined surface at a first angle measured relative to the first surface, the first inclined surface having a first length, wherein the second chamfer includes a second inclined surface at a second angle measured relative to the second surface, the second inclined surface having a second length, and wherein the first length is different than the second length or may be greater than the second length. The first length is measured in a direction within the plane of the first major surface and from the intersection of the first inclined surface with the first major surface to a plane coplanar with the minor surface, and the second length is measured in a direction within the plane of the second major surface and from the intersection of the second inclined surface with the second major surface to a plane coplanar with the minor surface. The first length may be at least about 1.0 mm; from about 1.0mm to about 3.0 mm; or about 2.0 mm. The first sloping surface meets the first major surface from about 0.5mm to about 3mm from a first plane coplanar with the secondary surface, and meets the secondary surface from about 0.2mm to about 0.3mm from a second plane coplanar with the first major surface. The second inclined surface meets the second major surface from about 0.2mm to about 0.3mm from a plane coplanar with the secondary surface, and meets the secondary surface from about 0.2mm to about 0.3mm from a plane coplanar with the second major surface.

In another aspect of some embodiments of the method, the first chamfer defines a first angled surface measured at a first angle relative to the first surface, and the second chamfer defines a second angled surface measured at a second angle relative to the second surface, the first angle being different than the second angle. The first angle may be less than the second angle.

In an additional embodiment, a head-up display (HUD) projection system is provided. The HUD system includes a display unit configured to display an image to be viewed by a user of the HUD system; and a mirror configured to reflect the image to a viewing area viewable by a user. The mirror includes a glass-based substrate having a first major surface, a second major surface opposite the first major surface, and a minor surface connecting the first and second major surfaces, a first chamfer located at an edge of the first major surface, the first chamfer having a first end located at an intersection of the first chamfer and the first major surface and having a second end located at an intersection of the first chamfer and the minor surface, and a second chamfer located at an edge of the second major surface, the second chamfer having a first end located at an intersection of the second chamfer and the second major surface and having a second end located at an intersection of the second chamfer and the minor surface. The first chamfer has a different size or shape than the second chamfer.

The first chamfer has a first length, the second chamfer has a second length, and the first length is different from the second length, and the first length is greater than the second length. The first length is measured in a direction lying in a plane of the first major surface at an intersection with a first chamfer and is measured from a first end of the first chamfer to a plane coplanar with the minor surface at a second end of the first chamfer, and the second length is measured in a direction lying in a plane of the second major surface and is measured from a first end of the second chamfer to a plane coplanar with the minor surface at a second end of the second chamfer. The first length may be at least about 1.0 mm; from about 1.0mm to about 3.0 mm; or about 2.0 mm.

The first chamfer can include a first sloped surface at a first angle measured from the first surface, wherein the first sloped surface meets the first major surface at a first distance from a minor surface that is coplanar with the minor surface at the second end of the first chamfer of from about 0.5mm to about 3mm, and meets the minor surface at a second distance from a first major plane that is coplanar with the first major surface at the first end of the first chamfer of from about 0.2mm to about 0.3 mm. The second chamfer can include a second sloped surface at a second angle measured relative to the second surface, wherein the second sloped surface meets the second major surface at a first distance from a minor surface that is coplanar with the minor surface at the second end of the second chamfer of from about 0.2mm to about 0.3mm and meets the minor surface at a second distance from a second major plane that is coplanar with the second major surface at the first end of the first chamfer of from about 0.2mm to about 0.3 mm. The first angle is from about 3 degrees to about 31 degrees and the second angle is from about 33 degrees to about 57 degrees. In some embodiments, the first angle may be from about 5 degrees to about 45 degrees, and the second angle may be from about 5 degrees to about 45 degrees.

In additional aspects of some embodiments, the first chamfer includes a first angled surface at a first angle measured relative to the first surface, and the second chamfer includes a second angled surface at a second angle measured relative to the second surface, the first angle being different than the second angle. The first angle is less than the second angle. The first sloped surface extends from a first edge to a second edge of the first chamfer and the second sloped surface extends from the first edge to the second edge of the second chamfer.

As an aspect of some embodiments, the first major surface has a first radius of curvature such that the first major surface has a concave shape and the second major surface has a convex shape, the first radius of curvature being measured relative to the first axis of curvature. The mirror has a second radius of curvature measured with respect to a second axis of curvature different from the first axis of curvature, wherein the first axis of curvature may be perpendicular to the second axis of curvature. The first major surface may have an aspherical shape. The reflective first major surface may include a reflective coating on the glass-based substrate, and the reflective coating may include a metal, metal oxide, ceramic oxide, or cermet alloy, and may include aluminum or silver.

In some embodiments, the display unit comprises an LCD, LED, OLED, or μ LED display panel, or comprises a projector. The HUD system may also include a projection surface configured to display a projected image to a user of the HUD system, wherein the mirror is configured to reflect an image generated by the display unit to form the projected image on the projection surface. The projection surface has a curvature corresponding to a curvature of the mirror, and the curvature of the projection surface is substantially the same as the curvature of the mirror. The projection surface may be a windshield or a combiner. Also, the projection surface may have an aspherical shape.

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

In an aspect of some embodiments of the HUD projection system, the second major surface includes one or more fabrication artifacts, wherein the fabrication artifacts are confined to a perimeter region of the second major surface that extends from an edge of the second major surface to a distance that is less than the first length. The manufacturing artifact may be a vacuum suction artifact from the process of bending the mirror.

In some additional embodiments, a method of forming a three-dimensional mirror is provided. The method comprises the following steps: providing a glass-based mirror preform comprising a first major surface, a second major surface opposite the first major surface, and a minor surface connecting the first and second major surfaces, the glass preform having a flat shape; forming a first chamfer on an edge of the first major surface; forming a second chamfer on an edge of the second major surface, the second chamfer having a different size or shape than the first chamfer; disposing the glass-based preform on a molding device having a curved support surface with the second major surface facing the curved support surface; and conforming the glass-based preform to the curved support surface to form a curved mirror substrate having a first radius of curvature. The step of conforming the glass-based preform to the curved support surface is performed at a temperature below a glass transition temperature of the glass-based preform, and the temperature of the glass-based substrate does not rise above the glass transition temperature of the glass-based substrate during or after the conforming.

In further aspects of some embodiments, the curved support surface has a concave shape, and the concave shape may be an aspheric shape. The curved support surface may include a vacuum chuck having at least one aperture within the curved support surface, and the method further includes supplying a vacuum to the at least one aperture to conform the curved glass blank to the curved support surface. The at least one opening is a vacuum hole of a trench type. The first chamfer is formed within the first major surface such that the first chamfer begins at a first distance from the minor surface. The at least one opening is a second distance from the secondary surface when the glass-based preform is positioned on the curved support surface, wherein the first distance is greater than or equal to the second distance. In an aspect of some embodiments, the molding device includes a raised peripheral surface or wall abutting the curved support surface and defining a space above the curved support surface into which the glass-based preform is to be positioned. The first chamfer is formed in the first major surface such that the first chamfer begins at a first distance from the minor surface, the at least one aperture is a second distance from the raised surrounding surface or wall, and the first distance is greater than or equal to the second distance, or the first distance is greater than the second distance.

The method further includes the step of forming a reflective layer on the first major surface. The reflective layer is formed in the following manner: a reflective layer of material is sputtered, electroplated, or vapor deposited onto the first major surface, and the reflective layer comprises a metal, metal oxide, ceramic oxide, or cermet alloy, and may comprise aluminum or silver. The reflective layer is formed on the first major surface after forming the curved mirror substrate to form the aspherical mirror.

As an aspect of some embodiments, the first chamfer includes a first inclined surface at a first angle measured relative to the first surface, the first inclined surface having a first length, the second chamfer includes a second inclined surface at a second angle measured relative to the second surface, wherein the second inclined surface has a second length, and the first length is different than the second length or may be greater than the second length. The first length is measured in a direction within the plane of the first major surface and from the intersection of the first inclined surface with the first major surface to a plane coplanar with the minor surface, and the second length is measured in a direction within the plane of the second major surface and from the intersection of the second inclined surface with the second major surface to a plane coplanar with the minor surface. The first length may be at least about 1.0 mm; from about 1.0mm to about 3.0 mm; or about 2.0 mm. The first sloping surface meets the first major surface from about 0.5mm to about 3mm from a first plane coplanar with the secondary surface, and meets the secondary surface from about 0.2mm to about 0.3mm from a second plane coplanar with the first major surface. The second inclined surface meets the second major surface from about 0.2mm to about 0.3mm from a plane coplanar with the secondary surface, and meets the secondary surface from about 0.2mm to about 0.3mm from a plane coplanar with the second major surface. The first angle is less than the second angle.

In another embodiment, a heads-up display (HUD) system is provided, comprising a projection surface for a user of the HUD system to view a projected image; a display unit configured to generate an image to be viewed by the user on the projection surface; and a mirror configured to reflect an image to the projection surface to form the projected image. The mirror includes a glass-based substrate having a reflective first major surface, a second major surface opposite the first major surface, and a minor surface connecting the first and second major surfaces; a first chamfer at an edge of the first major surface, the first chamfer; and a second chamfer at an edge of the second major surface, wherein the first chamfer has a different size or shape than the second chamfer. A first chamfer has a first end at the intersection of the first chamfer and the first major surface and has a second end at the intersection of the first chamfer and the minor surface, and a second chamfer has a first end at the intersection of the second chamfer and the second major surface and has a second end at the intersection of the second chamfer and the minor surface. The first chamfer has a first length, the second chamfer has a second length, and the first length is different from the second length, or the first length is greater than the second length.

As an aspect of some embodiments, the first chamfer has a first length, the second chamfer has a second length, and the first length is different than the second length, wherein the first length is measured in a direction that is within a plane of the first major surface at the intersection with the first chamfer and is measured from a first end of the first chamfer to a plane that is coplanar with the minor surface at the second end of the first chamfer, and the second length is measured in a direction that is within a plane of the second major surface and is measured from a first end of the second chamfer to a plane that is coplanar with the minor surface at the second end of the second chamfer. The first length may be at least about 1.0 mm; from about 1.0mm to about 3.0 mm; or about 2.0 mm.

As another aspect of some embodiments, a first chamfer includes a first sloped surface at a first angle measured from the first surface, wherein the first sloped surface intersects the second major surface at a first distance from a minor surface that is coplanar with the minor surface at the second end of the first chamfer of from about 0.5mm to about 3mm, and intersects the minor surface at a second distance from a first major plane that is coplanar with the first major surface at the first end of the first chamfer of from about 0.2mm to about 0.3 mm. The second chamfer includes a second sloped surface at a second angle measured relative to the second surface, wherein the second sloped surface meets the second major surface at a first distance from a minor surface that is coplanar with the minor surface at the second end of the second chamfer of from about 0.2mm to about 0.3mm and meets the minor surface at a second distance from a second major plane that is coplanar with the second major surface at the first end of the first chamfer of from about 0.2mm to about 0.3 mm. The first angle is from about 3 degrees to about 31 degrees and the second angle is from about 33 degrees to about 57 degrees; alternatively, the first angle is from about 5 degrees to about 45 degrees and the second angle is from about 5 degrees to about 45 degrees. The first angle may be different from the second angle, and the first angle may be smaller than the second angle. The length of the first inclined surface measured in a direction parallel to the first major surface is about 0.5mm to 3mm, and the length of the first inclined surface measured in a direction parallel to the minor surface is about 0.2mm to 0.3 mm. The length of the second inclined surface measured in a direction parallel to the second major surface is about 0.2mm to 0.3mm, and the length of the second inclined surface measured in a direction parallel to the minor surface is about 0.2mm to 0.3 mm.

In some aspects of some embodiments, the first major surface has a first radius of curvature such that the first major surface has a concave shape and the second major surface has a convex shape, the first radius of curvature being measured relative to the first axis of curvature. The first major surface may also have a second radius of curvature, measured relative to a second axis of curvature, different from the first axis of curvature. The first axis of curvature is perpendicular to the second axis of curvature. The first major surface may have an aspherical shape, and the aspherical shape corresponds to a shape of the projection surface. The reflective first major surface comprises a reflective coating on the glass-based substrate. The reflective coating comprises a metal, metal oxide, ceramic oxide, or cermet alloy, and the metal can be aluminum or silver.

In aspects of embodiments of the HUD system, the display unit comprises an LCD, LED, OLED, or μ LED display panel, and may include a projector.

The glass-based substrate has a thickness of less than or equal to 3.0 mm; from about 0.5mm to about 3.0 mm; from about 0.5mm to about 1.0 mm; from about 1.0mm to about 3.0 mm; or about 2.0 mm.

As an aspect of some embodiments, the chamfer of the first major surface is configured to reduce edge distortion of the projected image. The chamfer of the first major surface may be configured to reduce the amount of unwanted light reflection towards the user. The projection surface may be a windshield of a vehicle, or a combiner configured to be mounted inside a vehicle.

In some other embodiments, a head-up display (HUD) projection system is provided, comprising a display unit configured to display an image for viewing by a user of the HUD system; and a mirror configured to reflect the image to a viewing area viewable by the user. The mirror includes a glass-based substrate having a reflective first major surface, a second major surface opposite the first major surface, and a minor surface connecting the first and second major surfaces, and a chamfer at an edge of the first major surface, the chamfer having a first length.

As an aspect of some embodiments, the first length is measured from a direction within the plane of the first major surface and is measured from where the first angled surface meets the first major surface to a plane coplanar with the minor surface, and the first length is at least about 1.0 mm; from about 1.0mm to about 3.0 mm; or about 2.0 mm. The chamfer intersects the first major surface from about 0.5mm to about 3mm from a first plane coplanar with the minor surface and intersects the minor surface from about 0.2mm to about 0.3mm from a second plane coplanar with the first major surface.

The mirror has a first radius of curvature such that the first major surface has a concave shape and the second major surface has a convex shape, the first radius of curvature being measured relative to a first axis of curvature. The mirror can also have a second radius of curvature, the second radius of curvature being relative to a second axis of curvature different from the first axis of curvature, wherein the first axis of curvature is perpendicular to the second axis of curvature. In some preferred embodiments, the first major surface has an aspherical shape.

The reflective first major surface comprises a reflective coating on the glass-based substrate, wherein the reflective coating comprises a metal, metal oxide, ceramic oxide, or cermet alloy, and may comprise aluminum or silver. The display unit may include an LCD, LED, OLED, or μ LED display panel, and/or a projector. The HUD system may also include a projection surface for viewing a projected image by a user of the HUD system, wherein the display unit is configured to generate an image and the mirror is configured to reflect the image to form the projected image on the projection surface. The projection surface has substantially the same shape as the shape of the mirror, wherein the projection surface is a windshield or a combiner, and the projection surface may have an aspherical shape.

In some embodiments, the second major surface includes one or more manufacturing artifacts, and these manufacturing artifacts are confined to a peripheral region of the second major surface at a distance from an edge of the second major surface that is less than the first length. The manufacturing artifact may be a vacuum suction artifact from the process of bending the mirror.

The glass-based substrate has a thickness of less than or equal to 3.0 mm; from about 0.5mm to about 3.0 mm; from about 0.5mm to about 1.0 mm; from about 1.0mm to about 3.0 mm; or about 2.0 mm.

Glass substrates suitable for use in mirrors in HUD systems may be non-strengthened glass plates, or may also be strengthened glass plates. These glass sheets (whether strengthened or non-strengthened) may include soda lime glass, aluminosilicate, boroaluminosilicate, or alkali aluminosilicate glass. Alternatively, the glass sheet may be heat strengthened.

Suitable glass substrates may be chemically strengthened by ion exchange processes. In such processes, ions at or near the surface of the glass sheet are exchanged with larger metal ions in the salt bath, typically by immersing the glass sheet in a molten salt bath for a predetermined period of time. In one embodiment, the temperature of the molten salt bath is about 430 ℃ and the predetermined period of time is about 8 hours. Incorporating larger ions into the glass strengthens the sheet by creating compressive stresses in the adjacent surface regions. A corresponding tensile stress is induced in the central region of the glass to balance the compressive stress.

Exemplary ion-exchange glasses suitable for forming the glass substrate are soda lime glass, alkali aluminosilicate glass, or alkali aluminoborosilicate glass, although other glass compositions may be included. As used herein, "ion-exchangeable" means that the glass is capable of exchanging a larger or smaller volume of cations having the same valence with cations located at or near the surface of the glass. Exemplary glass compositions include SiO₂、B₂O₃And Na₂O, wherein (SiO)₂+B₂O₃) Not less than 66 mol% and Na₂O is more than or equal to 9 mol percent. In one embodiment, the glass sheet comprises at least 6% by weight alumina. In another embodiment, the glass sheet comprises one or more alkaline earth metal oxides such that the content of alkaline earth metal oxides is at least 5 wt.%. In some embodiments, suitable glass compositions also include K₂O, MgO and CaO. In a particular embodiment, the glass can comprise 61-75 mol% SiO₂(ii) a 7-15 mol% Al₂O₃(ii) a 0-12 mol% of B₂O₃(ii) a 9-21 mol% of Na₂O; 0-4 mol% of K₂O; 0-7 mol% MgO; and 0-3 mol% CaO.

Another exemplary glass composition suitable for forming a glass substrate comprises: 60-70 mol% SiO₂(ii) a 6-14 mol% Al₂O₃(ii) a 0-15 mol% ofB₂O₃(ii) a 0-15 mol% Li₂O; 0-20 mol% Na₂O; 0-10 mol% of K₂O; 0-8 mol% MgO; 0-10 mol% CaO; 0-5 mol% of ZrO₂(ii) a 0-1 mol% of SnO₂(ii) a 0-1 mol% of CeO₂(ii) a Less than 50ppm of As₂O₃(ii) a And less than 50ppm Sb₂O₃(ii) a Wherein 12 mol percent is less than or equal to (Li)₂O+Na₂O+K₂O) is less than or equal to 20 mol percent, and 0 mol percent is less than or equal to (MgO + CaO) is less than or equal to 10 mol percent.

Still another exemplary glass composition comprises: 63.5-66.5 mol% SiO₂(ii) a 8-12 mol% Al₂O₃(ii) a 0-3 mol% of B₂O₃(ii) a 0-5 mol% Li₂O; 8-18 mol% Na₂O; 0-5 mol% of K₂O; 1-7 mol% MgO; 0-2.5 mol% CaO; 0-3 mol% of ZrO₂(ii) a 0.05-0.25 mol% SnO₂(ii) a 0.05-0.5 mol% of CeO₂(ii) a Less than 50ppm of As₂O₃(ii) a And less than 50ppm Sb₂O₃(ii) a Wherein 14 mol percent is less than or equal to (Li)₂O+Na₂O+K₂O) is less than or equal to 18 mol percent, and 2 mol percent is less than or equal to (MgO + CaO) is less than or equal to 7 mol percent.

In certain embodiments, the alkali aluminosilicate glass comprises alumina, at least one alkali metal, and in some embodiments greater than 50 mole% SiO₂And in other embodiments at least 58 mole% SiO₂And additionally in other embodiments at least 60 mole% SiO₂Wherein the ratio ofWherein in said ratio these compositions are expressed in mole% and the modifier is an alkali metal oxide. In particular embodiments, the glass comprises, consists essentially of, or consists of: 58-72 mol% SiO₂(ii) a 9-17 mol% Al₂O₃(ii) a 2-12 mol% of B₂O₃(ii) a 8-16 mol% Na₂O; and 0-4 mol% of K₂O, wherein the ratio

In another embodiment, the alkali aluminosilicate glass comprises, consists essentially of, or consists of: 61-75 mol% SiO₂(ii) a 7-15 mol% Al₂O₃(ii) a 0-12 mol% of B₂O₃(ii) a 9-21 mol% of Na₂O; 0-4 mol% of K₂O; 0-7 mol% MgO; and 0-3 mol% CaO.

In yet another embodiment, the alkali aluminosilicate glass substrate comprises, consists essentially of, or consists of: 60-70 mol% SiO₂(ii) a 6-14 mol% Al₂O₃(ii) a 0-15 mol% of B₂O₃(ii) a 0-15 mol% Li₂O; 0-20 mol% Na₂O; 0-10 mol% of K₂O; 0-8 mol% MgO; 0-10 mol% CaO; 0-5 mol% of ZrO₂(ii) a 0-1 mol% of SnO₂(ii) a 0-1 mol% of CeO₂(ii) a Less than 50ppm of As₂O₃(ii) a And less than 50ppm of Sb₂O₃(ii) a Wherein Li is more than or equal to 12 mol percent₂O+Na₂O+K₂O is less than or equal to 20 mol percent, and MgO plus CaO is less than or equal to 0 mol percent and less than or equal to 10 mol percent.

In yet another embodiment, the alkali aluminosilicate glass comprises, consists essentially of, or consists of: 64-68 mol% SiO₂(ii) a 12-16 mol% Na₂O; 8-12 mol% Al₂O₃(ii) a 0-3 mol% of B₂O₃(ii) a 2-5 mol% of K₂O; 4-6 mol% MgO; and 0-5 mol% CaO, wherein: SiO is not more than 66 mol percent₂+B₂O₃CaO is less than or equal to 69 mol%; na (Na)₂O+K₂O+B₂O₃+MgO+CaO+SrO>10 mol%; MgO, CaO and SrO are more than or equal to 5 mol% and less than or equal to 8 mol%; (Na)₂O+B₂O₃)-Al₂O₃Less than or equal to 2 mol percent; na is not more than 2 mol percent₂O-Al₂O₃Less than or equal to 6 mol percent; and 4 mol% is less than or equal to (Na)₂O+K₂O)-Al₂O₃Less than or equal to 10 mol percent.

In some embodiments, chemically strengthened and non-chemically strengthened glass may be formulated with 0-2 mole% of at least one fining agent selected from the group consisting of Na₂SO₄、NaCl、NaF、NaBr、K₂SO₄KCl, KF, KBr, and SnO₂The group of (1).

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

At temperatures below which the glass network can relax, replacing smaller ions with larger ions creates an ion distribution at the glass surface, thereby creating a stress distribution. The larger volume of incident ions creates a Compressive Stress (CS) on the surface and a tension (central tension, or CT) in the center of the glass. The compressive stress has the following relationship with the central tension:

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

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

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

Exemplary methods of forming glass sheets include fusion draw and slot draw processes, which are each examples of a down-draw process, and a float process. These methods can be used to form strengthened and non-strengthened glass sheets. The fusion draw process uses a draw tank having a channel for receiving molten glass feedstock. The channel has weirs that open at the top along the length of the channel on both sides of the channel. When the channel is filled with molten material, the molten glass flows over these weirs. The molten glass flows down the outer surface of the draw tank due to gravity. These outer surfaces extend downwardly and inwardly so that they join at the edges below the draw tank. The two flowing glass surfaces are joined at the edge to fuse and form a single flow sheet. An advantage of the fusion draw process is that because the two glass films flowing through the channel fuse together, the outer surface of the resulting glass sheet does not contact any part of the apparatus. Thus, the surface properties of the fusion drawn glass sheet are not affected by such contact.

The slit draw process is different from the fusion draw process. Here, molten glass raw materials are supplied to the drawing tank. The bottom of the draw tank has an open slot with a nozzle extending the length of the slot. The molten glass flows through the slot/nozzle and is drawn down as a continuous sheet and into the annealing zone. The slot draw process may provide a thinner sheet than the fusion draw process because only a single sheet is drawn through the slot, rather than fusing two sheets together.

The downdraw process produces a glass sheet having a uniform thickness with a relatively pristine surface. Because the strength of the glass surface is controlled by the number and size of surface defects, the pristine surface with minimal contact has a higher initial strength. When such high strength glass is then chemically strengthened, the resulting strength may be higher than that of the ground and polished surface. The downdraw glass may be drawn to a thickness of less than about 2 mm. In addition, the drawn glass has a very flat, smooth surface that can be used in its final application without expensive grinding and polishing.

In the float glass process, a glass sheet characterized by a smooth surface and uniform thickness is made by floating molten glass on a bed of molten metal, usually tin. In one exemplary method, molten glass fed onto the surface of a molten tin bed forms a float zone. As the ribbon flows along the tin bath, the temperature gradually decreases until the solid glass sheet can be lifted from the tin onto the rollers. Once exiting the trough, the glass sheet may be further cooled and annealed to reduce internal stresses.

As described in the preceding paragraph, exemplary glass substrates can include glass sheets of chemically strengthened glass, e.g., glass sheets of chemically strengthened glassAnd (3) glass. The glass sheet may be heat treated, ion exchanged, and/or annealed. In a laminated construction, the strengthened glass sheet can be an inner layer and the outer layer can be a non-chemically strengthened glass sheet, such as conventional soda lime glass, annealed glass, and the like. The laminate structure may also include a polymer interlayer intermediate the outer glass layer and the inner glass layer. The strengthened glass sheet can have a thickness of less than or equal to 1.0mm and a residual surface CS level between about 250MPa and about 350MPa with a DOL greater than 60 microns. In another embodiment, the CS level of the strengthened glass sheet is preferably about 300 MPa. Exemplary thicknesses of the glass sheet can range from about 0.3mm to about 1.5mm, from 0.5mm to 1.5mm to 2.0mm or greater.

In a preferred embodiment, the thin chemically strengthened glass sheet can have a surface stress of about 250MPa and 900MPa, and can range in thickness from about 0.3mm to about 1.0 mm. In embodiments where the strengthened glass sheets are included in a laminate structure, the outer layer can be annealed (non-chemically strengthened) glass having a thickness of about 1.5mm to about 3.0mm or greater. Of course, the thickness of the outer and inner layers may be different in the respective laminated structures. Another preferred embodiment of the illustrated laminated structure may include an inner layer of 0.7mm of chemically strengthened glass, a layer of polyvinyl butyral having a thickness of about 0.76mm and an outer layer of annealed glass of 2.1 mm.

In some embodiments, exemplary glass substrates of the embodiments described herein may be used in vehicles (automobiles, aircraft, etc.) having heads-up displays or head-up display (HUD) systems. The clarity of the fusion formed according to some embodiments may be superior to glass formed by a float process, providing a better driving experience and improved safety as the information may be easier to read and less distracting. A non-limiting HUD system may include a projection unit, a combiner, and a video generation computer. The projection unit in the illustrated HUD may be, but is not limited to, having a convex lens or a concave mirror with a display (e.g., light guide, scanning laser, LED, CRT, video image, etc.) at its focal point. The projection unit may be used to generate the desired image. In some embodiments, the HUD system may also include a combiner or beam splitter to redirect the projected image from the projection unit to change or alter the field of view and the projected image. Some combiners may include special coatings to reflect monochromatic light projected thereon, while allowing other wavelengths of light to pass through. In further embodiments, the combiner may also be curved to refocus the image from the projection unit. Any of the illustrated HUD systems may also include a processing system to provide an interface between the projection unit and applicable vehicle systems from which data may be received, manipulated, monitored, and/or displayed. Some processing systems may also be used to generate images and symbols to be displayed by the projection unit.

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

According to some embodiments of the exemplified glass substrate, a thin, pristine surface mirror may thus be provided for the mirror. In some embodiments, fusion drawn Gorilla glass may be used as the glass substrate. Such glass does not contain any typical float of conventional glass (e.g., soda lime glass) made in a float process.

HUDs according to embodiments of the present disclosure may be used in automobiles, airplanes, composite vision systems, and/or mask displays (e.g., head-mounted displays such as goggles, masks, helmets, etc.) that utilize the exemplary glass substrates described herein. Such HUD systems can project critical information (speed, fuel, temperature, turn signals, navigation, warning information, etc.) in front of the driver through the glass laminate structure.

According to some embodiments, the HUD system described herein may use nominal HUD system parameters of radius of curvature, refractive index, and angle of incidence (e.g., radius of curvature Rc 8301mm, distance to source Ri 1000mm, refractive index n 1.52, and angle of incidence θ 62.08 degrees).

The applicant has demonstrated that the glass substrate and the laminated structure disclosed in the present application have excellent durability, impact resistance, toughness and scratch resistance. It is well known to the skilled artisan that the strength and mechanical impact properties of a glass sheet or laminate are limited by defects in the glass, including surface and internal defects. When a glass sheet or laminate structure is impacted, the point of impact is compressed while a ring or "hoop" around the point of impact and the opposing face of the impacted sheet are placed in tension. In general, the cause of breakage will be at the defect at or near the point of highest tension, typically on the glass surface. This may occur on the opposite face, but may occur within the loop. If a defect in the glass is in tension during an impact event, the defect may propagate and the glass typically breaks. Therefore, high magnitude and depth (depth of layer) compressive stresses are preferred.

Because of the strengthening relationship, one or both of the surfaces of the strengthened glass sheets disclosed herein are in a compressed state. The introduction of compressive stress in the near-surface region of the glass can inhibit crack propagation and glass sheet failure. In order for the defect to propagate and crack, the tensile stress generated by the impact must exceed the surface compressive stress at the tip of the defect. In embodiments, the high compressive stress and high depth of layer of the strengthened glass sheet can allow for the use of thinner glass than non-chemically strengthened glass.

Aspect (1) of the present disclosure relates to a glass-based preform for a mirror of a head-up display (HUD) system, comprising a glass-based substrate having a first major surface, a second major surface opposite the first major surface, and a minor surface connecting the first and second major surfaces; a first chamfer at an edge of the first major surface, the first chamfer having a first end at an intersection of the first chamfer with the first major surface and having a second end at an intersection of the first chamfer with the minor surface; and a second chamfer at an edge of the second major surface, the second chamfer having a first end at an intersection of the second chamfer with the second major surface and having a second end at an intersection of the second chamfer with the minor surface, wherein the first chamfer is different in size and shape from the second chamfer.

Aspect (2) of the present disclosure relates to the glass-based preform of aspect (1), wherein the first chamfer has a first length, the second chamfer has a second length, and the first length is different than the second length.

Aspect (3) of the present disclosure relates to the glass-based preform of aspect (2), wherein the first length is greater than the second length.

Aspect (4) of the present disclosure relates to the glass-based preform of aspect (2) or aspect (3), wherein the first length is measured in a direction lying in a plane of the first major surface at an intersection with a first chamfer and is measured from a first end of the first chamfer to a plane coplanar with the minor surface at a second end of the first chamfer, and wherein the second length is measured in a direction lying in a plane of the second major surface and is measured from a first end of the second chamfer to a plane coplanar with the minor surface at a second end of the second chamfer.

Aspect (5) of the present disclosure relates to the glass-based preform of any one of aspects (2) - (4), wherein the first length is at least about 1.0 mm.

Aspect (6) of the present disclosure relates to the glass-based preform of any one of aspects (2) - (5), wherein the first length is from about 1.0mm to about 3.0 mm.

Aspect (7) of the present disclosure relates to the glass-based preform of any one of aspects (1) - (6), wherein the first chamfer comprises a first inclined surface at a first angle measured from relative to the first surface, wherein the first inclined surface meets the first major surface at a first distance from a minor surface that is coplanar with the minor surface at the second end of the first chamfer and meets the minor surface at a second distance from a first major plane that is coplanar with the first major surface at the first end of the first chamfer of about 0.2mm to about 0.3 mm.

Aspect (8) of the present disclosure relates to the glass-based preform of any one of aspects (1) - (7), wherein the second chamfer comprises a second inclined surface at a second angle measured relative to the second surface, wherein the second inclined surface meets the second major surface at a first distance from a minor surface that is coplanar with the minor surface at the second end of the second chamfer and meets the minor surface at a second distance from a second major surface that is coplanar with the second major surface at the first end of the first chamfer of from about 0.2mm to about 0.3 mm.

Aspect (9) of the present disclosure relates to the glass-based preform of aspect (8), wherein the first angle is about 3 degrees to about 31 degrees and the second angle is about 33 degrees to about 57 degrees.

Aspect (10) of the present disclosure relates to the glass-based preform of aspect (8), wherein the first angle is from about 5 degrees to about 45 degrees and the second angle is from about 5 degrees to about 45 degrees.

Aspect (11) of the present disclosure relates to the glass-based preform of any one of aspects (1) - (7), wherein the first chamfer includes a first inclined surface measured at a first angle relative to the first surface and the second chamfer includes a second inclined surface measured at a second angle relative to the second surface, and wherein the first angle is different than the second angle.

Aspect (12) of the present disclosure relates to the glass-based preform of any one of aspects (8) - (11), wherein the first angle is less than the second angle.

Aspect (13) of the present disclosure relates to the glass-based preform of any one of aspects (7) - (12), wherein the first inclined surface extends from a first edge to a second edge of the first chamfer, and wherein the second inclined surface extends from the first edge to the second edge of the second chamfer.

Aspect (14) of the present disclosure relates to the glass-based preform of any one of aspects (1) - (13), wherein at least a portion of the first major surface is reflective.

Aspects (15) of the present disclosure relate to the glass-based preform of aspect (14), wherein the portion of the first major surface that is reflective comprises a reflective coating on the glass-based substrate.

Aspects (16) of the present disclosure relate to the glass-based preform of aspect (15), wherein the reflective coating comprises a metal, a metal oxide, a ceramic oxide, or a cermet alloy.

Aspect (17) of the present case relates to the glass-based preform of aspect (15) or aspect (16), wherein the reflective coating comprises aluminum or silver.

Aspect (18) of the present disclosure relates to the glass-based preform of any one of aspects (1) to (17), wherein a length of the first inclined surface measured in a direction parallel to the first major surface is about 0.5mm to 3mm, and a length of the first inclined surface measured in a direction parallel to the secondary surface is about 0.2mm to 0.3 mm.

Aspect (19) of the present disclosure relates to the glass-based preform of any one of aspects (1) to (18), wherein a length of the second inclined surface measured in a direction parallel to the second major surface is about 0.2mm to 0.3mm, and a length of the second inclined surface measured in a direction parallel to the secondary surface is about 0.2mm to 0.3 mm.

Aspect (20) of the present disclosure relates to the glass-based preform of any one of aspects (1) - (19), wherein the glass-based substrate has a thickness of less than or equal to 3.0 mm.

Aspect (21) of the present disclosure relates to the glass-based preform of aspect (20), wherein the glass-based substrate has a thickness of from about 0.5mm to about 3.0 mm.

Aspects (22) of the present disclosure relate to the glass-based preform of aspect (21), wherein the glass-based substrate has a thickness from about 0.5mm to about 1.0 mm.

Aspect (23) of the present disclosure relates to the glass-based preform of aspect (21), wherein the glass-based substrate has a thickness of from about 1.0mm to about 3.0 mm.

Aspect (24) of the present disclosure relates to the glass-based preform of any one of aspects (1) - (23), wherein the second major surface includes one or more manufacturing artifacts, and wherein these manufacturing artifacts are confined to a peripheral region of the second major surface that extends from an edge of the second major surface to a distance that is less than the first length.

Aspects (25) of the present disclosure relate to the glass-based preform of aspect (24), wherein the manufacturing artifacts are vacuum suction artifacts.

Aspect (26) of the present disclosure relates to the glass-based preform of aspect (24) or aspect (25), wherein the manufacturing artifacts are from a process of bending the mirror.

Aspects (27) of the present application relate to a mirror for a head-up display (HUD) system comprising a glass-based preform according to any of claims 1-26.

Aspects (28) of the present disclosure relate to the mirror of aspect (27), further comprising a reflective layer on the first major surface of the glass-based preform.

Aspect (29) of the present disclosure relates to the mirror of aspect (27) or aspect (28), wherein the glass-based substrate has a first radius of curvature such that the first major surface has a concave shape and the second major surface has a convex shape, the first radius of curvature being measured with respect to a first axis of curvature.

Aspects (30) of the present disclosure relate to the mirror of aspect (29), wherein the glass-based substrate has a second radius of curvature measured with respect to a second axis of curvature different from the first axis of curvature.

Aspects (31) of the present disclosure relate to the mirror of aspect (30), wherein the first axis of curvature is perpendicular to the second axis of curvature.

Aspect (32) of the present disclosure relates to the mirror of any one of aspects (27) - (31), wherein the first major surface has an aspherical shape.

Aspects (33) of the present disclosure relate to a method of forming a three-dimensional mirror, the method comprising the steps of: providing a glass-based mirror preform comprising a first major surface having an edge with a first chamfer, a second major surface opposite the first major surface and having an edge with a second chamfer, and a minor surface connecting the first and second major surfaces, the second chamfer having a size or shape different from the first chamfer; positioning the glass-based preform on a molding device having a curved support surface with the second major surface facing the curved support surface; and attaching the glass-based preform to the curved support surface to form a curved mirror substrate having a first radius of curvature.

Aspects (34) of the present disclosure relate to the method of aspect (33), wherein the step of conforming the glass-based preform to the curved support surface is performed at a temperature below a glass transition temperature of the glass-based preform.

Aspect (35) of the present disclosure relates to the method of aspect (33) or aspect (34), wherein a temperature of the glass-based substrate does not rise above the glass transition temperature of the glass-based substrate during or after the attaching.

Aspect (36) of the present disclosure relates to the method of any one of aspects (33) - (35), wherein the curved support surface has a concave shape.

Aspect (37) of the present disclosure relates to the method of aspect (36), wherein the concave shape is an aspherical shape.

Aspect (38) of the present disclosure relates to the method of any one of aspects (33) - (37), wherein the curved support surface also includes a vacuum chuck having at least one aperture within the curved support surface.

Aspects (39) of the present disclosure relate to the method of aspect (38), further comprising the step of providing a vacuum to the at least one opening to conform the curved glass blank to the curved support surface.

Aspects (40) of the present disclosure relate to the method of aspects (38) or (39), wherein the at least one opening is a vacuum hole of a trench type.

Aspect (41) of the present disclosure relates to the method of any one of aspects (38) - (40), wherein the first chamfer is formed within the first major surface such that the first chamfer begins at the first major surface at a first distance from the minor surface, wherein the at least one opening is a second distance from the minor surface when the glass-based preform is disposed on the curved support surface, and wherein the first distance is greater than or equal to the second distance.

Aspect (42) of the present disclosure relates to the method of any one of aspects (38) - (41), wherein the molding device includes a raised peripheral surface or wall abutting the curved support surface and defining a space on the curved support surface into which the glass-based preform is to be positioned.

Aspects (43) of the present disclosure relate to the method of aspect (42), wherein the first chamfer is formed within the first major surface such that the first chamfer begins at the first major surface at a first distance from the minor surface, wherein the at least one aperture is a second distance from the raised peripheral surface or wall, and the first distance is greater than or equal to the second distance.

Aspect (44) of the present disclosure relates to the method of any one of aspects (41) - (43), wherein the first distance is greater than the second distance.

Aspect (45) of the present disclosure relates to the method of any one of aspects (33) - (44), further comprising forming a reflective layer on the first major surface.

Aspects (46) of the present disclosure relate to the method of aspect (45), wherein the reflective layer is formed in the following manner: a reflective layer of material is sputtered, electroplated, or vapor deposited onto the first major surface.

Aspect (47) of the present disclosure relates to the method of aspect (45) or aspect (46), wherein the reflective coating comprises a metal, a metal oxide, a ceramic oxide, or a cermet alloy.

Aspects (48) of the present disclosure relate to the method of aspect (45), wherein the reflective layer comprises aluminum or silver.

Aspect (49) of the present disclosure relates to the method of any one of aspects (45) to (48), wherein the reflective layer is formed on the first major surface after forming the curved mirror substrate to form the aspherical mirror.

Aspects (50) of the present disclosure relate to the method of any one of aspects (33) - (49), wherein the first chamfer includes a first angled surface at a first angle measured relative to a first surface, the first angled surface having a first length, wherein the second chamfer includes a second angled surface at a second angle measured relative to a second surface, the second angled surface having a second length, and wherein the first length is different than the second length.

Aspects (51) of the present disclosure relate to the method of aspect (50), wherein the first length is greater than the second length.

An aspect (52) of the present disclosure relates to the method of aspect (50) or aspect (51), wherein the first length is measured from a direction within the plane of the first major surface and from an intersection of the first angled surface with the first major surface to a plane coplanar with the secondary surface, and wherein the second length is measured from a direction within the plane of the second major surface and from an intersection of the second angled surface with the second major surface to a plane coplanar with the secondary surface.

Aspect (53) of the present disclosure relates to the method of any one of aspects (50) - (52), wherein the first length is at least about 1.0 mm.

Aspects (54) of the present disclosure relate to the method of aspect (53), wherein the first length is from about 1.0mm to about 3.0 mm.

Aspects (55) of the present disclosure relate to the method of aspect (53), wherein the first sloping surface meets the first major surface at a distance of about 0.5mm to about 3mm from a first plane coplanar with the minor surface, and meets the minor surface at a distance of about 0.2mm to about 0.3mm from a second plane coplanar with the first major surface.

An aspect (55) of the present disclosure relates to the method of aspect (50) or aspect (53), wherein the second sloping surface meets the second major surface from about 0.2mm to about 0.3mm from a plane coplanar with the secondary surface, and meets the secondary surface from about 0.2mm to about 0.3mm from a plane coplanar with the second major surface.

Aspect (57) of the present disclosure relates to the method of any one of aspects (33) - (49), wherein the first chamfer defines a first inclined surface measured at a first angle relative to the first surface, and the second chamfer defines a second inclined surface measured at a second angle relative to the second surface, and wherein the first angle is different than the second angle.

Aspects (58) of the present disclosure relate to the method of aspect (57), wherein the first angle is less than the second angle.

Aspects (59) of the present disclosure relate to a head-up display (HUD) projection system, comprising: a display unit configured to display an image for viewing by a user of the HUD system; and a mirror configured to reflect the image to a viewing area viewable by the user, the mirror comprising: a glass-based substrate having a reflective first major surface, a second major surface opposite the first major surface, and a minor surface connecting the first and second major surfaces, a first chamfer at an edge of the first major surface, the first chamfer having a first end at an intersection of the first chamfer and the first major surface and having a second end at an intersection of the first chamfer and the minor surface, and a second chamfer at an edge of the second major surface, the second chamfer having a first end at an intersection of the second chamfer and the second major surface and having a second end at an intersection of the second chamfer and the minor surface, wherein the first chamfer has a different size or shape than the second chamfer.

Aspects (60) of the present disclosure relate to the HUD projection system of aspect (59), wherein the first chamfer has a first length, the second chamfer has a second length, and the first length is different from the second length.

Aspects (61) of the present disclosure relate to the HUD projection system of aspect (60), wherein the first length is greater than the second length.

An aspect (62) of the present disclosure relates to the HUD projection system of aspect (60) or aspect (61), wherein the first length is measured from a direction lying in a plane of the first major surface at the intersection with the first chamfer and from the first end of the first chamfer to a plane coplanar with the minor surface at the second end of the first chamfer, and wherein the second length is measured from a direction lying in a plane of the second major surface and from the first end of the second chamfer to a plane coplanar with the minor surface at the second end of the second chamfer.

Aspect (63) of the present case relates to the HUD projection system of any one of aspects (60) - (62), wherein the first length is at least about 1.0 mm.

Aspects (64) of the present disclosure relate to the HUD projection system of aspect (63), wherein the first length is from about 1.0mm to about 3.0 mm.

An aspect (65) of the present disclosure is directed to the HUD projection system of any one of aspects (59) - (64), wherein the first chamfer includes a first sloped surface at a first angle measured from the first surface, wherein the first sloped surface intersects the first major surface at a first distance from a minor surface that is coplanar with the minor surface at the second end of the first chamfer and intersects the minor surface at a second distance from the first major surface that is coplanar with the first major surface at the first end of the first chamfer of about 0.5mm to about 3 mm.

An aspect (66) of the present disclosure relates to the HUD projection system of any one of aspects (59) - (65), wherein the second chamfer includes a second inclined surface at a second angle measured relative to the second surface, wherein the second inclined surface intersects the second major surface at a first distance from a minor surface that is coplanar with the minor surface at the second end of the second chamfer and at a second distance from a second major plane that is coplanar with the second major surface at the first end of the first chamfer of about 0.2mm to about 0.3mm from the minor surface.

Aspects (67) of the present disclosure relate to the HUD projection system of aspect (66), wherein the first angle is about 3 degrees to about 31 degrees and the second angle is about 33 degrees to about 57 degrees.

Aspects (68) of the present disclosure relate to the HUD projection system of aspect (66), wherein the first angle is from about 5 degrees to about 45 degrees and the second angle is from about 5 degrees to about 45 degrees.

An aspect (69) of the present disclosure relates to the HUD projection system of any one of aspects (59) - (64), wherein the first chamfer includes a first inclined surface measured at a first angle relative to the first surface, and the second chamfer includes a second inclined surface measured at a second angle relative to the second surface, and wherein the first angle is different from the second angle.

An aspect (70) of the present case relates to the HUD projection system of aspect (69), wherein the first angle is smaller than the second angle.

An aspect (71) of the present application relates to the HUD projection system of the aspect (69) or the aspect (70), wherein the first inclined surface extends from a first edge to a second edge of the first chamfer, and wherein the second inclined surface extends from the first edge to the second edge of the second chamfer.

Aspects (72) of the present disclosure relate to the HUD projection system of any one of (59) - (71), wherein the first major surface has a first radius of curvature such that the first major surface has a concave shape and the second major surface has a convex shape, the first radius of curvature being measured with respect to a first axis of curvature.

An aspect (73) of the present application relates to the HUD projection system of aspect (72), wherein the mirror has a second radius of curvature measured with respect to a second axis of curvature different from the first axis of curvature.

Aspects (74) of the present disclosure relate to the HUD projection system of aspect (73), wherein the first axis of curvature is perpendicular to the second axis of curvature.

An aspect (75) of the present application relates to the HUD projection system of any one of (59) to (74), wherein the first main surface has an aspherical shape.

Aspects (76) of the present disclosure relate to the HUD projection system of any one of (59) - (75), wherein the first major surface that is reflective comprises a reflective coating on the glass-based substrate.

An aspect (77) of the present case relates to the HUD projection system of aspect (76), wherein the reflective coating comprises a metal, a metal oxide, a ceramic oxide, or a cermet alloy.

Aspects (78) of the present disclosure relate to the HUD projection system of aspect (76) or aspect (77), wherein the reflective coating comprises aluminum or silver.

Aspects (79) of the present disclosure relate to the HUD projection system of any one of (59) - (78), wherein the display unit includes an LCD, LED, OLED, or μ LED display panel.

An aspect (80) of the present case relates to the HUD projection system of any one of (59) to (79), wherein the display unit includes a projector.

Aspect (81) of the present disclosure relates to the HUD projection system of any one of (59) to (80), wherein the glass-based substrate has a thickness of less than or equal to 3.0 mm.

Aspects (82) of the present disclosure relate to the HUD projection system of aspect (81), wherein the glass-based substrate has a thickness of from about 0.5mm to about 3.0 mm.

Aspects (83) of the present disclosure relate to the HUD projection system of aspect (82), wherein the glass-based substrate has a thickness of from about 0.5mm to about 1.0 mm.

Aspects (84) of the present disclosure relate to the HUD projection system of aspect (82), wherein the glass-based substrate has a thickness of from about 1.0mm to about 3.0 mm.

Aspects (85) of this disclosure relate to the HUD projection system of any of (58) - (84), also including a projection surface configured to display a projected image to a user of the HUD system, wherein the mirror is configured to reflect an image generated by the display unit to form the projected image on the projection surface.

An aspect (86) of the present application relates to the HUD projection system of aspect (85), wherein the projection surface has a curvature corresponding to a curvature of the mirror.

An aspect (87) of the present application relates to the HUD projection system of aspect (86), wherein the curvature of the projection surface is substantially the same as the curvature of the mirror.

An aspect (88) of the present disclosure relates to the HUD projection system of aspect (86) or aspect (87), wherein the projection surface may be a windshield or a combiner.

An aspect (89) of the present application relates to the HUD projection system of any one of (86) to (88), wherein the projection surface has an aspherical shape.

Aspects (90) of this disclosure relate to the HUD projection system of any of (59) - (89), wherein the second major surface includes one or more manufacturing artifacts, and wherein these manufacturing artifacts are confined to a peripheral region of the second major surface that extends from the edge of the second major surface to a distance that is less than the first length.

Aspects (91) of the present disclosure relate to the HUD projection system of aspect (90), wherein the manufacturing artifacts are vacuum suction artifacts.

An aspect (92) of the present application relates to the HUD projection system of aspect (90) or aspect (91), wherein the manufacturing artifacts are from a process of bending the mirror.

Aspects (93) of the present disclosure relate to a method of forming a three-dimensional mirror, the method comprising the steps of: providing a glass-based mirror preform comprising a first major surface, a second major surface opposite the first major surface, and a minor surface connecting the first and second major surfaces, the mirror preform having a flat shape; forming a first chamfer on an edge of the first major surface; forming a second chamfer on an edge of the second major surface, the second chamfer having a different size or shape than the first chamfer; disposing the glass-based preform on a molding device having a curved support surface with the second major surface facing the curved support surface; and conforming the glass-based preform to the curved support surface to form a curved mirror substrate having a first radius of curvature.

Aspects (94) of the present disclosure relate to the method of aspect (33), wherein the step of conforming the glass-based preform to the curved support surface is performed at a temperature below a glass transition temperature of the glass-based preform.

Aspect (95) of the present disclosure relates to the method of aspect (93) or aspect (94), wherein the temperature of the glass-based substrate does not rise above the glass transition temperature of the glass-based substrate during or after the attaching.

Aspect (96) of the present disclosure relates to the method of any one of aspects (93) - (95), wherein the curved support surface has a concave shape.

Aspects (97) of the present disclosure relate to the method of aspect (96), wherein the concave shape is an aspherical shape.

Aspect (98) of the present disclosure relates to the method of any one of aspects (93) - (97), wherein the curved support surface also includes a vacuum chuck having at least one aperture within the curved support surface.

Aspect (99) of the present disclosure relates to the method of aspect (98), further comprising the step of providing a vacuum to the at least one opening to conform the curved glass blank to the curved support surface.

Aspect (100) of the present disclosure relates to the method of aspect (98) or aspect (99), wherein the at least one opening is a vacuum hole of a trench type.

Aspect (101) of the present disclosure relates to the method of any one of aspects (98) - (100), wherein the first chamfer is formed within the first major surface such that the first chamfer begins at the first major surface at a first distance from the minor surface, wherein the at least one opening is a second distance from the minor surface when the glass-based preform is disposed on the curved support surface, and the first distance is greater than or equal to the second distance.

Aspect (102) of the present disclosure relates to the method of any one of aspects (98) - (101), wherein the molding device includes a raised peripheral surface or wall abutting the curved support surface and defining a space above the curved support surface into which the glass-based preform is to be positioned.

Aspects (103) of the present disclosure relate to the method of aspect (102), wherein the first chamfer is formed within the first major surface such that the first chamfer begins at the first major surface at a first distance from the minor surface, wherein the at least one aperture is a second distance from the raised surrounding surface or wall, and the first distance is greater than or equal to the second distance.

Aspect (104) of the present disclosure relates to the method of any one of aspects (101) - (103), wherein the first distance is greater than the second distance.

Aspect (105) of the present disclosure relates to the method of any one of aspects (93) - (104), further comprising forming a reflective layer on the first major surface.

Aspects (106) of the present disclosure relate to the method of aspect (105), wherein the reflective layer is formed in the following manner: a reflective layer of material is sputtered, electroplated, or vapor deposited onto the first major surface.

Aspects (107) of the present disclosure relate to the method of aspect (105) or aspect (106), wherein the reflective coating comprises a metal, a metal oxide, a ceramic oxide, or a cermet alloy.

Aspects (108) of the present disclosure relate to the method of aspect (107), wherein the reflective layer comprises aluminum or silver.

Aspect (109) of the present disclosure relates to the method of any one of aspects (105) - (108), wherein the reflective layer is formed on the first major surface after forming the curved mirror substrate to form an aspherical mirror.

Aspects (110) of the present disclosure relate to the method of any one of aspects (93) - (109), wherein the first chamfer includes a first angled surface at a first angle measured relative to a first surface, the first angled surface having a first length, wherein the second chamfer includes a second angled surface at a second angle measured relative to a second surface, the second angled surface having a second length, and wherein the first length is different than the second length.

Aspects (111) of the present disclosure relate to the method of aspect (110), wherein the first length is greater than the second length.

Aspects (112) of the present disclosure relate to the method of aspect (110) or aspect (111), wherein the first length is measured from a direction within the plane of the first major surface and from an intersection of the first angled surface with the first major surface to a plane coplanar with the minor surface, and wherein the second length is measured from a direction within the plane of the second major surface and from an intersection of the second angled surface with the second major surface to a plane coplanar with the minor surface.

Aspect (113) of the present disclosure relates to the method of any one of aspects (110) - (112), wherein the first length is at least about 1.0 mm.

Aspects (114) of the present disclosure relate to the method of aspect (113), wherein the first length is from about 1.0mm to about 3.0 mm.

Aspects (115) of the present disclosure relate to the method of aspect (110), wherein the first sloping surface meets the first major surface from about 0.5mm to about 3mm from a first plane that is coplanar with the secondary surface, and meets the secondary surface from about 0.2mm to about 0.3mm from a second plane that is coplanar with the first major surface.

Aspects (116) of the present disclosure relate to the method of aspect (110) or aspect (115), wherein the second sloping surface meets the second major surface from about 0.2mm to about 0.3mm from a plane coplanar with the secondary surface, and meets the secondary surface from about 0.2mm to about 0.3mm from a plane coplanar with the second major surface.

Aspect (117) of the present disclosure relates to the method of any one of aspects (110) - (116), wherein the first angle is less than the second angle.

Aspects (118) relate to a head-up display (HUD) system, comprising: a projection surface for a user of the HUD system to view a projected image; a display unit configured to generate an image to be viewed by the user on the projection surface; and a mirror configured to reflect an image to the projection surface to form the projected image, the mirror including: a glass-based substrate having a reflective first major surface, a second major surface opposite the first major surface, and a minor surface connecting the first and second major surfaces, a first chamfer at an edge of the first major surface, the first chamfer, and a second chamfer at an edge of the second major surface, wherein the first chamfer has a different size or shape than the second chamfer.

Aspects (119) of the present disclosure relate to the HUD system of aspect (118), wherein the first chamfer has a first end at an intersection of the first chamfer and the first major surface and has a second end at an intersection of the first chamfer and the minor surface, and the second chamfer has a first end at an intersection of the second chamfer and the second major surface and has a second end at an intersection of the second chamfer and the minor surface.

Aspects (120) of the present disclosure relate to the HUD system of aspect (118) or aspect (119), wherein the first chamfer has a first length, the second chamfer has a second length, and the first length is different than the second length.

An aspect (121) of the present case relates to the HUD system of aspect (120), wherein the first length is greater than the second length.

Aspects (122) of the present disclosure relate to the HUD system of aspect (119), wherein the first chamfer has a first length, the second chamfer has a second length, and the first length is different than the second length, wherein the first length is measured from a direction lying in a plane of the first major surface at the intersection with the first chamfer and is measured from the first end of the first chamfer to a plane coplanar with the minor surface at the second end of the first chamfer, and wherein the second length is measured from a direction lying in a plane of the second major surface and is measured from the first end of the second chamfer to a plane coplanar with the minor surface at the second end of the second chamfer.

Aspect (123) of the present disclosure relates to the HUD system of any one of aspects (120) - (122), wherein the first length is at least about 1.0 mm.

Aspects (124) of the present case relate to the HUD system of aspect (120), wherein the first length is from about 1.0mm to about 3.0 mm.

An aspect (125) of the present disclosure is directed to the HUD system of any one of aspects (118) - (124), wherein the first chamfer includes a first inclined surface at a first angle measured from relative to the first surface, wherein the first inclined surface meets the first major surface at a first distance of about 0.5mm to about 3mm from a minor surface that is coplanar with the minor surface at the second end of the first chamfer and meets the minor surface at a second distance of about 0.2mm to about 0.3mm from a first major plane that is coplanar with the first major surface at the first end of the first chamfer.

Aspects (126) of the present disclosure relate to the HUD system of aspect (125), wherein the second chamfer includes a second inclined surface at a second angle measured relative to the second surface, wherein the second inclined surface intersects the second major surface at a first distance from a minor surface that is coplanar with the minor surface at the second end of the second chamfer of from about 0.2mm to about 0.3mm, and intersects the minor surface at a second distance from a second major plane that is coplanar with the second major surface at the first end of the first chamfer of from about 0.2mm to about 0.3 mm.

Aspects (127) of the present disclosure relate to the HUD system of aspect (126), wherein the first angle is about 3 degrees to about 31 degrees and the second angle is about 33 degrees to about 57 degrees.

Aspects (128) of the present disclosure relate to the HUD system of aspect (126), wherein the first angle is from about 5 degrees to about 45 degrees and the second angle is from about 5 degrees to about 45 degrees.

Aspect (129) of the present disclosure relates to the HUD system of any one of aspects (118) - (124), wherein the first chamfer includes a first inclined surface measured at a first angle relative to a first surface, and the second chamfer includes a second inclined surface measured at a second angle relative to a second surface, and wherein the first angle is different than the second angle.

Aspects (130) of the present disclosure relate to the HUD system of aspect (129), wherein the first angle is less than the second angle.

Aspect (131) of the present disclosure relates to the HUD system of any one of (115) to (127), wherein the first major surface has a first radius of curvature such that the first major surface has a concave shape and the second major surface has a convex shape, the first radius of curvature being measured with respect to a first axis of curvature.

Aspects (132) of the present disclosure relate to the HUD system of aspect (131), wherein the first major surface has a second radius of curvature measured relative to a second axis of curvature, the second axis of curvature being different than the first axis of curvature.

Aspects (133) of the present disclosure relate to the HUD system of aspect (132), wherein the first axis of curvature is perpendicular to the second axis of curvature.

Aspects (134) of the present disclosure relate to the HUD system of any one of (118) - (133), wherein the first major surface has an aspherical shape.

Aspects (135) of the present disclosure relate to the HUD system of aspect (134), wherein the aspheric shape corresponds to a shape of the projection surface.

Aspects (136) of the present disclosure relate to the HUD system of any one of (118) - (135), wherein the first major surface that is reflective comprises a reflective coating on the glass-based substrate.

Aspects (137) of the present disclosure relate to the HUD system of aspect (136), wherein the reflective coating comprises a metal, a metal oxide, a ceramic oxide, or a cermet alloy.

Aspects (138) of the present disclosure relate to the HUD system of aspect (137), wherein the metal is aluminum or silver.

Aspect (139) of the present case relates to the HUD system of any one of aspects (118) to (124) and aspects (127) to (138), wherein a length of the first inclined surface measured in a direction parallel to the first main surface is about 0.5mm to 3mm, and a length of the first inclined surface measured in a direction parallel to the secondary surface is about 0.2mm to 0.3 mm.

An aspect (140) of the present case relates to the HUD system of any one of aspects (118) to (124) and aspects (127) to (139), wherein a length of the second inclined surface measured in a direction parallel to the second main surface is about 0.2mm to 0.3mm, and a length of the second inclined surface measured in a direction parallel to the secondary surface is about 0.2mm to 0.3 mm.

An aspect (141) of the present disclosure relates to the HUD system of any one of (118) to (140), wherein the display unit includes an LCD, LED, OLED, or μ LED display panel.

An aspect (142) of the present application relates to the HUD system of any one of (118) to (141), wherein the display unit is a projector.

Aspects (143) of the present disclosure relate to the HUD system of any one of (118) - (142), wherein the glass-based substrate has a thickness of less than or equal to 3.0 mm.

Aspects (144) of the present disclosure relate to the HUD system of aspect (143), wherein the glass-based substrate has a thickness of from about 0.5mm to about 3.0 mm.

Aspects (145) of the present disclosure relate to the HUD system of aspect (144), wherein the glass-based substrate has a thickness of from about 0.5mm to about 1.0 mm.

Aspects (146) of the present disclosure relate to the HUD system of aspect (144), wherein the glass-based substrate has a thickness of from about 1.0mm to about 3.0 mm.

Aspects (147) of this disclosure relate to the HUD system of any one of (118) - (146), wherein the chamfer of the first major surface is configured to reduce edge distortion of a projected image.

Aspects (148) of the present disclosure relate to the HUD system of any one of (118) - (146), wherein the chamfer of the first major surface is configured to reduce an amount of unwanted light reflections towards the user.

Aspects (149) of the present disclosure relate to the HUD system of any one of (118) - (148), wherein the projection surface is a windshield of a vehicle.

Aspects (150) of this disclosure relate to the HUD system of any one of (118) - (148), wherein the projection surface is a combiner configured to be mounted inside a vehicle.

Aspects (151) relate to a head-up display (HUD) projection system, including a display unit configured to display an image for viewing by a user of the HUD system; and a mirror configured to reflect the image to a viewing area viewable by the user providing a Heads Up Display (HUD) projection system, the mirror comprising: a glass-based substrate having a reflective first major surface, a second major surface opposite the first major surface, and a minor surface connecting the first and second major surfaces, and a chamfer at an edge of the first major surface, the chamfer having a first length.

Aspects (152) of the present disclosure relate to the HUD projection system of aspect (151), wherein the first length is measured from a direction in the plane of the first major surface and from the intersection of the first inclined surface and the first major surface to a plane coplanar with the secondary surface, and wherein the first length is at least about 1.0 mm.

Aspects (153) of the present disclosure relate to the HUD projection system of aspects (151) or (152), wherein the first length is from about 1.0mm to about 3.0 mm.

Aspect (154) of the present disclosure relates to the HUD projection system of any one of aspects (151) - (153), wherein the chamfer intersects the first major surface at a distance of about 0.5mm to about 3mm from a first plane coplanar with the minor surface, and intersects the minor surface at a distance of about 0.2mm to about 0.3mm from a second plane coplanar with the first major surface.

Aspect (155) of the present disclosure relates to the HUD projection system of any one of aspects (151) - (154), wherein the mirror has a first radius of curvature such that the first major surface has a concave shape and the second major surface has a convex shape, the first radius of curvature being relative to a first axis of curvature.

An aspect (156) of the present disclosure relates to the HUD projection system of aspect (155), wherein the mirror has a second radius of curvature, the second radius of curvature being relative to a second axis of curvature different from the first axis of curvature.

Aspects (157) of the present disclosure relate to the HUD projection system of aspect (156), wherein the first axis of curvature is perpendicular to the second axis of curvature.

Aspects (158) of the present disclosure relate to the HUD projection system of any one of (151) to (157), wherein the first major surface has an aspherical shape.

An aspect (159) of the present case relates to the HUD projection system of any one of (151) - (158), wherein the first major surface that is reflective comprises a reflective coating on the glass-based substrate.

Aspects (160) of the present disclosure relate to the HUD projection system of aspect (159), wherein the reflective coating comprises a metal, a metal oxide, a ceramic oxide, or a cermet alloy.

Aspect (161) of the present disclosure relates to the HUD projection system of aspect (159) or aspect (160), wherein the reflective coating comprises aluminum or silver.

Aspect (162) of the present application relates to the HUD projection system of any one of (151) to (161), wherein the display unit includes an LCD, LED, OLED, or μ LED display panel.

An aspect (163) of the present application relates to the HUD projection system of any one of (151) to (162), wherein the display unit is a projector.

Aspects (164) of the present disclosure relate to the HUD projection system of any one of (151) - (163), wherein the glass-based substrate has a thickness of less than or equal to 3.0 mm.

Aspects (165) of the present disclosure relate to the HUD projection system of aspect (164), wherein the glass-based substrate has a thickness of from about 0.5mm to about 3.0 mm.

Aspects (166) of the present disclosure relate to the HUD projection system of aspect (165), wherein the glass-based substrate has a thickness of from about 0.5mm to about 1.0 mm.

Aspects (167) of the present disclosure relate to the HUD projection system of aspect (165), wherein the glass-based substrate has a thickness of from about 1.0mm to about 3.0 mm.

An aspect (168) of the present case relates to the HUD projection system of any one of (161) - (167), further comprising a projection surface for a user of the HUD system to view a projected image, wherein the display unit is configured to generate an image, and the mirror is configured to reflect the image to form the projected image on the projection surface.

Aspects (169) of the present disclosure relate to the HUD projection system of aspect (168), wherein the projection surface has a shape substantially identical to the mirror.

Aspects (170) of the present disclosure relate to the HUD projection system of aspect (168) or aspect (169), wherein the projection surface may be a windshield or a combiner.

An aspect (171) of the present disclosure relates to the HUD projection system of any one of (168) to (170), wherein the projection surface has an aspherical shape.

Aspects (172) of the present disclosure relate to the HUD projection system of aspect (153), wherein the second major surface includes one or more manufacturing artifacts, and wherein the manufacturing artifacts are confined to a peripheral region of the second major surface at a distance from the edge of the second major surface that is less than the first length.

Aspects (173) of the present disclosure relate to the HUD projection system of aspect (172), wherein the manufacturing artifacts are vacuum suction artifacts from the process of bending the mirror.

Aspects (174) of the present disclosure relate to the glass-based preform of any one of aspects (1) - (26), wherein the glass-based substrate comprises strengthened glass.

Aspects (175) of the present disclosure relate to the glass-based preform of aspect (174), wherein the strengthened glass is chemically strengthened.

Aspects (176) of the present disclosure relate to the method of any one of (33) - (58), wherein the glass-based substrate comprises strengthened glass.

Aspects (177) of the present disclosure relate to the method of aspect (176), wherein the strengthened glass is chemically strengthened.

Aspects (178) of this disclosure relate to the HUD projection system of any one of (59) - (92), wherein the glass-based substrate comprises strengthened glass.

Aspects (179) of the present disclosure relate to the HUD projection system of aspect (178), wherein the strengthened glass is chemically strengthened.

Although this specification may include many specifics, these should not be construed as limitations on the scope thereof, but rather as descriptions of features that may be specific to particular embodiments. Certain features that are, for brevity, described in the context of a single embodiment, may also be provided in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable subcombination. Furthermore, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination, or a variation of a subcombination.

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

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

It should also be noted that reference to a component as "configured" or "for" is made herein as a function of the particular manner in which the component is configured. In this regard, such a component is "configured" or "used" to embody a particular property or function in a particular manner, wherein such recitation is meant to be structural and not meant to be a recitation of intended use. More specifically, recitation of a component herein as "configured" or "to" is meant to denote an existing physical condition of the component, and as such, is to be taken as a definite recitation of the structural characteristics of the component.

Various configurations and embodiments have been shown and described for various glass-based structures for heads-up displays.

Although the preferred embodiments of the present invention have been described above, it is to be understood that the embodiments described are illustrative only and that the scope of the invention is to be defined by the broadest equivalent of the appended claims and that numerous changes and modifications will naturally occur to those skilled in the art upon reading.