WO2019241013A1

WO2019241013A1 - Deadfront for displays having a metal layer with a network of cracks formed throughout

Info

Publication number: WO2019241013A1
Application number: PCT/US2019/035711
Authority: WO
Inventors: Antoine D. LESUFFLEUR; Xu Ouyang; Yawei Sun
Original assignee: Corning Inc
Current assignee: Corning Inc
Priority date: 2018-06-12
Filing date: 2019-06-06
Publication date: 2019-12-19
Anticipated expiration: 2020-12-12
Also published as: TW202012335A

Abstract

Embodiments of a deadfront article are provided. The deadfront article includes a substrate having a first major surface and a second major surface in which the second major surface is opposite the first major surface. A polymer layer is disposed on the second major surface of the transparent substrate, and the polymer layer has a first coefficient of thermal expansion (CTE). A metal layer is disposed on the polymer layer such that the polymer layer is between the transparent substrate and the metal layer. Further, the metal layer has a surface area and a network of cracks that extend through a thickness of the metal layer and that are disposed across at least a portion of the surface area. The metal layer has a second CTE, and the first CTE is greater than the second CTE. The deadfront article may also include a touch panel and/or a light source.

Description

DEADFRONT FOR DISPLAYS HAVING A METAL LAYER WITH A NETWORK

OF CRACKS FORMED THROUGHOUT

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of priority under 35 U.S.C. § 119 of U.S.

Provisional Application Serial No. 62/683,919 filed on June 12, 2018 the content of which is relied upon and incorporated herein by reference in its entirety.

BACKGROUND

[0002] The disclosure relates to a deadfront for a display, and more particularly to touch- enabled displays and methods for forming the same.

SUMMARY

[0003] In one aspect, embodiments of the disclosure relates to a deadfront article are provided. The deadfront article includes a substrate having a first major surface and a second major surface in which the second major surface is opposite the first major surface. A polymer layer is disposed on the second major surface of the transparent substrate, and the polymer layer has a first coefficient of thermal expansion (CTE). A metal layer is disposed on the polymer layer such that the polymer layer is between the transparent substrate and the metal layer. Further, the metal layer has a surface area and a network of cracks that extend through a thickness of the metal layer and that are disposed across at least a portion of the surface area. The metal layer has a second CTE, and the first CTE is greater than the second CTE.

[0004] In another aspect, embodiments of the disclosure relates to a method of manufacturing a deadfront. In the method, a polymer layer is applied to a first major surface of a transparent substrate. The polymer layer has a first coefficient of thermal expansion (CTE) and a glass transition temperature of less than 200 °C. A metal layer is deposited onto the polymer layer, the metal layer having a second CTE that is less than the first CTE. Further, the transparent substrate, polymer layer, and metal layer are annealed at a temperature of from 50 °C to 300 °C so as to create a network of cracks through the thickness of the metal-containing layer and across surface area of the metal layer.

[0005] In still another aspect, embodiments of the disclosure relates to a deadfront article.

The deadfront article has a transparent substrate having a first major surface and a second major surface in which the second major surface is opposite the first major surface. A polymer layer is disposed on the second major surface of the transparent substrate. Further, a metal layer is disposed on the polymer layer such that the polymer layer is between the transparent substrate and the metal-containing layer. A touch panel is disposed on the metal- containing layer, and the metal layer includes a network of cracks through a thickness of the metal layer and across a surface area of the metal containing layer.

[0006] In yet another aspect, embodiments of the disclosure relates to a deadfront article.

The deadfront article includes a substrate having a first major surface and a second major surface in which the second major surface is opposite the first major surface. A polymer layer is disposed on the second major surface of the transparent substrate, and the polymer layer has a first coefficient of thermal expansion (CTE). A metal-containing layer is disposed on the polymer layer such that the polymer layer is between the transparent substrate and the metal-containing layer. When the deadfront article is disposed over a light source, the deadfront article exhibits a transmittance of 15% or greater when the light source emits a light.

[0007] Additional features and advantages 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 embodiments as described herein, including the detailed description which follows, the claims, as well as the appended drawings.

[0008] It is to be understood that both the foregoing general description and the following detailed description are merely exemplary, and are intended to provide an overview or framework to understanding the nature and character of the claims. The accompanying drawings are included to provide a further understanding, and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiment s), and together with the description serve to explain principles and operation of the various embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] FIG. 1 depicts a partial cross-sectional view of an electronic device, according to an exemplary embodiment.

[0010] FIG. 2 depicts a cross-sectional view of the layers of a deadfront, according to an exemplary embodiment.

[0011] FIG. 3 depicts a network of cracks in a metal layer of a deadfront, according to an exemplary embodiment. [0012] FIG. 4 is a graph depicting the transmittance properties of deadfronts having metal layers of different thicknesses.

[0013] FIG. 5 is a photograph of two experimentally-produced deadfronts having metal layers of different thicknesses.

[0014] FIG. 6 is a photograph of the two deadfronts of FIG. 5 placed in front of a display unit.

[0015] FIG. 7 depicts another cross-sectional view of a deadfront, according to an exemplary embodiment.

[0016] FIG. 8 depicts an ink layer placed in front of one the deadfronts shown in FIG. 5.

[0017] FIG. 9 is a side view of a curved deadfront for use with a display, according to an exemplary embodiment.

[0018] FIG. 10 is a front perspective view of a glass substrate for the deadfront of FIG. 2 prior to curve formation, according to an exemplary embodiment.

[0019] FIG. 11 shows a curved glass deadfront shaped to conform with a curved display frame, according to an exemplary embodiment.

[0020] FIG. 12 shows a process for cold forming a glass deadfront to a curved shape, according to an exemplary embodiment.

[0021] FIG. 13 shows a process for forming a curved glass deadfront utilizing a curved glass layer, according to an exemplary embodiment.

DETAILED DESCRIPTION

[0022] Referring generally to the figures, embodiments of a deadfront for touch-enabled electronic devices are provided. In general, a deadfront is a structure used in a display that blocks visibility of display components, icons, graphics, etc. when the display is off, but allows display components to be easily viewed when the display is on. Additionally, in embodiments of an electronic device incorporated into a larger structure, such as a vehicle or an appliance, a deadfront layer on the electronic device, such as a control panel, can be used to match the color or pattern of the glass component to adjacent non-glass components to eliminate the visibility of transitions from the glass article to the non-glass article. For example, a display with a glass deadfront having a wood grain pattern or a leather pattern can be used to match the appearance of the display with surrounding wood or leather

components, e.g., of a vehicle interior system having a wood or leather dashboard in which the display is mounted. [0023] As will be discussed in greater detail herein, the deadfront includes a polymer layer and a metal layer that have different coefficients of thermal expansion, such that, upon annealing, the polymer layer will cause the metal layer to form a network of cracks throughout its surface area. In this way, the metal layer becomes discontinuous such that the metal layer is non-conducting. Accordingly, the metal layer will not shunt the touch functionality of the electronic device while still providing an enhanced deadfront aesthetic. That is, normally, the conductivity of a metal layer would cause the localization of a capacitance to be confused during detection. By creating a network of cracks, the metal layer is divided up into islands between which there is no electrical conductivity. Thus, the capacitance change in response to a touch remains much more localized for the purposes of detection.

[0024] FIG. 1 is a partial cross-sectional view of an electronic device 100 including a touch interface 102. In embodiments, the electronic device 100 is a standalone device, such as a laptop computer, a tablet computer, a smart-phone, a digital music player, portable gaming station, a television, etc. That is, a standalone electronic device 100 is primarily a display screen or interactive panel not incorporated into another structure, device, or apparatus. In other embodiments, the electronic device 100 is incorporated into another structure, device, or apparatus, such the electronic device 100 is a control panel, e.g., in a vehicle, on an appliance, for an elevator, etc., that allows for interaction with the structure, device, or apparatus.

[0025] In the embodiment depicted in FIG. 1, the electronic device 100 includes the touch interface 102, a housing 104, a deadfront 106, a display unit 108, and a circuit board 110.

The housing 104 at least partially surrounds the touch interface 102, and in the embodiment depicted, provides a seating surface 112 for the deadfront 106. Further, in a standalone device, the housing 104 may provide the boundaries of the electronic device 100, whereas when the electronic device 100 is incorporated into another structure, device, or apparatus, the housing 104 may just provide a mount for the electronic device 100 within the larger overall structure, device, or apparatus. In either configuration, the deadfront 106 covers at least a portion of the touch interface 102 and may be seated into the housing 104 to as to provide a substantially planar viewing surface 114. The circuit board 110 supplies power to the touch interface 102 and to the display unit 108 and processes inputs from the touch interface 102 to produce a corresponding response on the display unit 108.

[0026] The touch interface 102 may include one or more touch sensors in order to detect one or more touch or capacitive inputs, such as due to the placement of a user's finger, stylus, or other interaction device close to or on the deadfront 106. The touch interface 102 may generally be any type of interface configured to detect changes in capacitance or other electrical parameters that may be correlated to a user input. The touch interface 102 may be operably connected to and/or in communication the circuit board 110. The touch interface 102 is configured to receive inputs from an object (e.g., location information based on a user's finger or data from the input device). The display unit 108 is configured to display one or more output images, graphics, icons, and/or videos for the electronic device 100. The display unit 108 may be substantially any type of display mechanism, such as an light emitting diode (LED) display, an organic LED (OLED) display, a liquid crystal display (LCD), plasma display, or the like.

[0027] As mentioned above, the deadfront 106 provides a decorative surface that hides any graphics, icons, displays, etc. until a backlight of the display unit 108 is activated. Further, in embodiments, the deadfront 106 provides a protective surface for the touch interface 102. As will be discussed more fully below, the deadfront 106 is constructed so as to allow for a user's interaction to be transmitted through the thickness of the deadfront 106 for detection by the touch interface 102.

[0028] Having described the general structure of the electronic device 100, the structure of the deadfront article 106 is now described. As can be seen in FIG. 2, the deadfront article 106 includes a substrate 120, a polymer layer 122, and a metal layer 124. While FIG. 2 depicts a single polymer layer 122 and a single metal layer 124, in embodiments, the deadfront article 106 has multiple, alternating polymer layers 122 and metal layers 124. In such embodiments, up to ten alternating layers of each of a polymer layer 122 and a metal layer 124 can be provided over the substrate 120.

[0029] In embodiments, the substrate 120 is a glass, glass-ceramic, or a plastic. Suitable glass substrates 120 may include at least one of silicates, borosilicates, aluminosilicates, aluminoborosilicates, alkali aluminosilicates, and alkaline earth aluminosilicates, among others. Such glasses may be chemically or thermally strengthened, and embodiments of such glasses are provided below. Exemplary glass-ceramics suitable for use with the deadfront 106 include at least one of the LEO x AI2O3 x «SiCh system (LAS system), the MgO x AI2O3 x //S1O2 system (the MAS system), and the ZnO x AI2O3 x //S1O2 system (the ZAS system), among others. Exemplary plastic substrates suitable for use with the deadfront 106 include at least one of polymethylmethacrylate (PMMA), polyethylene terephthalate (PET), and cellulose triacetate (TAC), among others. In embodiments, the substrate 120 has a thickness (i.e., distance between a first major surface 126 and a second major surface 128) of about 2 mm or less, about 1.8 mm or less, about 1.6 mm or less, about 1.5 m or less, about 1.4 mm or less, about 1.2 mm or less, about 1.1 mm or less, about 1 mm or less, about 0.8 mm or less, about 0.7 mm or less, about 0.6 mm or less, about 0.55 mm or less, about 0.5 or less, about 0. 4 mm or less, or about 0.3 mm or less.

[0030] In embodiments, the substrate 120 is selected to be transparent. In embodiments, a transparent substrate is one in which at least 70% of light having a wavelength from about 390 nm to about 700 nm that is incident upon the first major surface 126 is transmitted through the second major surface 128. In further embodiments of a transparent substrate, at least 80% of such light is transmitted from the first major surface 126 through the second major surface 128, and in still other embodiments, at least 90% of such light is transmitted from the first major surface 126 through the second major surface 128.

[0031] The polymer layer 122 is disposed on the first surface 126 of the substrate 120 and is selected to have a low glass transition temperature (T_g) and a high coefficient of thermal expansion (CTE). Additionally, in embodiments, the polymer layer 122 is also selected to be transparent as described above with respect to the substrate 120.

[0032] The T_g of a polymer can be determined using differential scanning calorimetry (DSC), thermal mechanical analysis (TMA), or dynamic mechanical analysis (DMA), and the T_g for a particular polymer may be over a range of temperatures. In embodiments, a "low" T_g means that the T_g of the polymer or polymers comprising the polymer layer 122 is less than or has a range that begins at a temperature less than 150 °C. In other embodiments, the T_g of the polymer or polymers comprising the polymer layer 122 is less than or has a range that begins at a temperature less than 125 °C, and in still other embodiment, the T_g of the polymer or polymers comprising the polymer layer 122 is less than or has a range that begins at a temperature less than 100 °C.

[0033] The CTE of a polymer is generally measured using TMA. Further, as used herein, the term“coefficient of thermal expansion,” or“CTE,” refers to the average coefficient of thermal expansion unless otherwise indicated. Additionally, as used herein, the term “average coefficient of thermal expansion,” or“average CTE,” refers to the average coefficient of linear thermal expansion of a given material or layer between 0 °C and 300 °C. The measurement of CTE as given herein is in units of ppm/°C, which is equivalent to 10 ⁶ m/m°C. In embodiments, a "high" CTE is at least 50 ppm/°C. In other embodiments, the CTE is at least 60 ppm/°C, and in still other embodiments, the CTE is at least 70 ppm/°C.

[0034] Exemplary polymers suitable for use in the polymer layer 122 include PMMA (T_g = 85-165 °C; CTE = 50 ppm/°C) and polystyrene (T_g = 80-90 °C; CTE = 70 ppm/°C), among others. In embodiments, the polymer layer 122 has a thickness, e.g., from 0.1 pm to 10 pm, from 0.2 to 7 pm, or from 0.5 pm to 5 pm. In embodiments, the polymer layer 122 is disposed on the first surface 126 of the substrate 120 via dip coating, spin coating, roller coating, slot coating, thermal evaporation, aerosol spray, plasma spray, and the like. In embodiments, a polymer protection overcoat is applied to the polymer layer 122. In embodiments having multiple polymer layers 122, the polymer protection overcoat is applied after each polymer layer 122 is applied or after applying all of the polymer layers 122.

[0035] In an exemplary embodiment of spin coating, the polymer or polymers of the polymer layer 122 are dissolved in a solvent at a ratio of polymer to solvent of from 6.4: 1 to 30: 1, applied to the substrate 120, and then spun at a speed of, e.g., 1000 to 5000 RPM. Exemplary solvents usable for polystyrene spin coating include benzene, toluene, xylene,

tetrahydrofuran, chloroform, l,3-butanediol, 2-butanol, linalool, geraniol, d-limonene, p- cymene, terpinene, phellandrene, terpineol, menthol, eucalyptol, cinnamaldehyde,

nitrobenzene, N,N-dimehtyl-formamide, and water. Exemplary solvents usable for PMMA spin coating include methylene chloride, di chlorobenzene, and methyl ethyl ketone (2- butanone). Additional solvents include dichloromethane and l,l-dichloroethane.

Nitromethane and/or nitroethane can be added in the amount of 10 to 65% to improve quality. Other solvents include methyl acetate, ethyl acetate, and butyl acetate, optionally with the addition of 10 to 50% of nitromethane and/or nitroethane or of 50 to 90% of N,N- dimethylformamide to improve quality. Still other solvents include methyl formate and ethyl formate, optionally with the addition of 10 to 75% of nitromethane and/or nitroethane to improve quality.

[0036] The metal layer 124 is disposed on the polymer layer 122. In embodiments, the metal layer 124 is no more than 100 nm. In further embodiments, the metal layer 124 is no more than 50 nm, and in still further embodiments, the metal layer 124 is no more than 30 nm. In embodiments, the metal layer 124 is at least 1 nm thick. The thickness of the metal layer 124 determines the amount of light transmitted through the deadfront 106. In particular and as will be discussed more fully below, the transmittance of the deadfront 106 decreases as the thickness of the metal layer 124 increases.

[0037] The metal layer 124 is composed of pure metals (including, e.g., acceptable levels of impurities), alloys, metalloids, metal oxides, metal nitrides, and/or graphite. Exemplary materials for the metal layer 124 include nickel, chromium, iron, molybdenum, cobalt, and alloys of one or more thereof, especially nickel-chromium alloys, such as nichrome alloys (e.g., 20wt% Ni and 80wt% Cr, hereinafter "nichrome 20/80") and the Inconel family of alloys. Other materials suitable for use in the metal layer 124 include, for example chromium oxide and titanium oxide, among others. Additionally, the metal layer can be a metalloid, such as silicon or germanium. In general, these materials will have a low CTE, e.g., a CTE of less than 20 ppm/°C. For example, nickel, chromium, Iconel, an ni chrome 20/80 have CTE of 13.1 ppm/°C, 6.2 ppm/°C, 11.5 ppm/°C, and 17.3 ppm/°C, respectively. In embodiments, the composition of the metal layer 124 is selected such that the CTE is no more than 20 ppm/°C, no more than 15 ppm/°C, or no more than 10 ppm/°C. The metal layer 124 is deposited onto the polymer layer 122 via physical vapor deposition, e.g., non-conductive vacuum metallization (NCVM).

[0038] In embodiments having multiple polymer layers 122 and metal layers 124, the deadfront 106 undergoes alternating coating/deposition processes for each of the polymer layers 122 and the metal layers 124. In general, as the number of polymer layers 122 and metal layers 124 increases, the thickness for each metal layer 124 can be made thinner, e.g., 1 nm to 5 nm thick per layer, which allows for easier cracking during subsequent annealing (discussed below). Further, in embodiments, the polymer layer 122 is varied in thickness between each layer, which helps the deadfront 106 develop a broadband, neutral density black coating. Additionally, in embodiments having a single polymer layer 122 and metal layer 124 or having multiple polymer layers 122 and metal layers 124, the surface reflectance and color of the deadfront 106 can be controlled through manipulation of the layer thicknesses.

[0039] After applying the metal layer 124, the deadfront 106 is annealed. In embodiments, annealing involves heating the deadfront 106 in a furnace under vacuum, inert gas, or air to a temperature of 50 °C to 300 °C for a time of ten seconds to five minutes, e.g., a shorter time at a higher temperature or a longer time at a lower temperature. Because of the difference in CTE between the polymer layer 122 and the metal layer 124, the polymer layer 122 will expand more than the metal layer 124. The greater expansion of the polymer layer 122 causes the thinner metal layer 124 to develop a network of cracks across the surface area of the metal layer 124. Advantageously, this network of cracks prevents the metal layer 124 from conducting, which might otherwise affect the operation of the touch interface 102. In this way, the metal layer 124 is a NCVM coating that helps produce the deadfront effect of the deadfront 106.

[0040] FIG. 3 depicts an exemplary embodiment of a deadfront 106 in which a network of cracks 130 was formed in the metal layer 124. In three exemplary deadfronts 106, a polystyrene polymer layer 122 was deposited on an alkali aluminosilicate glass substrate 120 via spin coating. Thereafter, each of the three deadfronts 106 received a nichrome 20/80 metal layer 124 having a thickness of 10 nm, 20 nm, and 30 nm, respectively. The metal layers 124 were applied via electron beam physical vapor deposition (PVD EB). Annealing of the three deadfronts 106 was performed at 80 °C using an IR lamp in which the lamp was slowly brought up to temperature and then turned off upon reaching 80 °C. As can be seen in FIG. 3, the network of cracks 130 extends across the surface area of the metal layer 124.

[0041] FIG. 4 provides a graph of the light transmittance (T) expressed as a percentage of light between the wavelengths of 400 nm and 800 nm that passes through the deadfronts 106 having various thicknesses of the metal layer 124. In particular, three deadfronts 106 were prepared with each having a nichrome 20/80 metal layer 124. The thicknesses were 3 nm, 10 nm, and 20 nm. As can be seen from the graph, the transmittance decreases with increasing thickness of the metal layer 124. Advantageously, the transmittance curves for each deadfront 106 between 400 nm and 800 nm are relatively flat, indicating that coating is close to neutral with respect to color transmittance.

[0042] FIG. 5 provides a side-by-side comparison of two deadfronts 106. Both deadfronts 106 have the same alkali aluminosilicate glass substrate 120 and the same polystyrene polymer layer 122. However, the deadfront 106 on the left has a nichrome 20/80 metal layer 124 with a thickness of 20 nm, whereas the deadfront 106 on the right has a nichrome 20/80 metal layer 124 of 10 nm. As can be seen, both deadfronts 106 provide a half mirror finish as a result of the 15-30% reflectance. In FIG. 6, the deadfronts 106 from FIG. 5 were placed in front of a computer screen such that the computer screen acts as a display unit 108. FIG. 6 confirms that the thinner metal layer 124 has better transmittance.

[0043] FIG. 7 depicts another embodiment of the deadfront 106. As with the previous embodiment shown in FIG. 2, this embodiment of the deadfront 106 includes a substrate 120, a polymer layer 122, and a metal layer 124. In the embodiment of FIG. 7, the deadfront 106 further includes a surface treatment 132 that is formed into or applied onto the second surface 128 of the substrate 120. For example, the surface treatment 132 can be an antiglare treatment, etching, etching with antireflection coating, or etching with durable antireflection coating. Additionally, an ink layer 134 is printed (e.g., inkjet printed) on the first surface 126. The ink layer 134 helps to hide the network of cracks 130 in the metal layer 124.

Further, in embodiments, the ink layer 134 provides a visual pattern or solid color that is visible to a viewer when the display unit 108 is not active. In embodiments, the ink layer 134 is a semitransparent layer. As further depicted in FIG. 7, an optically clear adhesive layer 136 is disposed on the metal layer 124 in order to facilitate joining the deadfront 106 to a display unit 108.

[0044] FIG. 8 depicts one of the experimental deadfronts 106 from FIG. 5 with an ink layer 134 overlaid. As can be seen, the cracks in the portion of the deadfront 106 that is exposed are visible, whereas the cracks in the portion of the deadfront 106 obscured by the ink layer 134 cannot be seen.

[0045] In any of the various embodiments described herein, the deadfront 106 attempts to minimize any distortions to the underlying image, graphic, icon, etc. on the display unit 108 as perceived by a user of the electronic device 100 in which the deadfront 106 is

incorporated. That is, colors visible to a viewer through the deadfront 106 are substantially similar to the colors output by the display unit 108 of the electronic device. With reference to the CIE L*a*b* color system, the difference in each of the L*, a*, and b* values from those values output by the display unit and those values perceived by a viewer is less than 10 in embodiments. In further embodiments, the difference for each of the L*, a*, and b* values is less than 5, and in still other embodiments, the difference for each of the L*, a*, and b* values is less than 2. Using the CIE L*a*b* color system, differences between two colors can be quantified using AE*_ab, which can be calculated in various ways according to CIE76, CIE94, and CIE00. Using any one of the calculation methods for AE*_ab, the color difference is less than 20 in embodiments. In further embodiments, the color difference AE*_ab is less than 10, and in still other embodiments, the color difference AE*_ab is less than 2.

[0046] Embodiments of the deadfront 106 disclosed herein provide several advantages. For example, the deadfront 106 allows uniform visual properties from macro to micro areas as well as tunable optical performance. Further, the deadfront 106 can be overlaid on any bright display with minimal change of the electronic device's functions and attributes, such as touch functionality, screen resolution, and color. Additionally, the deadfront 106 allows for the creation of extra functionality, such as half-mirror finish, extra switching, low-reflective neutral color, or metallic and special color effect when display(s) is(are) off. Further, in certain embodiments, the deadfront 106 is lamination ready with optical clear adhesive (OCA) to any type of display application, such as home electronics, auto-interior, medical, industrial device control and displays, etc. Moreover, standard industrial coating processes are utilized in constructing the deadfront 106, which allows for ease in scaling for mass production.

[0047] Referring to FIGS. 9-13, various sizes, shapes, curvatures, glass materials, etc. for a glass-based deadfront along with various processes for forming a curved glass-based deadfront are shown and described. It should be understood, that while FIGS. 9-13 are described in the context of a simplified curved deadfront structure 2000 for ease of explanation, deadfront structure 2000 may be any of the deadfront embodiments discussed herein.

[0048] As shown in FIG. 9, in one or more embodiments, deadfront 2000 includes a curved outer glass layer 2010 (e.g., substrate 120) having at least a first radius of curvature, Rl, and in various embodiments, curved outer glass layer 2010 is a complex curved sheet of glass material having at least one additional radius of curvature. In various embodiments, Rl is in a range from about 20 mm to about 10,000 mm (e.g., from about 20 mm to about 9,000 mm, from about 20 mm to about 8,000 mm, from about 20 mm to about 7,000 mm, from about 20 mm to about 6,000 mm, from about 20 mm to about 5,500 mm, from about 20 mm to about 5,000 mm, from about 20 mm to about 4,500 mm, from about 20 mm to about 4,000 mm, from about 20 mm to about 3,500 mm, from about 20 mm to about 3,000 mm, from about 20 mm to about 2,500 mm, from about 20 mm to about 2,000 mm, from about 20 mm to about 1,500 mm, from about 20 mm to about 1,400 mm, from about 20 mm to about 1,300 mm, from about 20 mm to about 1,200 mm, from about 20 mm to about 1,100 mm, from about 20 mm to about 1,000 mm, from about 50 mm to about 10,000 mm, from about 75 mm to about 10,000 mm, from about 100 mm to about 10,000 mm, from about 150 mm to about 10,000 mm, from about 200 mm to about 10,000 mm, from about 250 mm to about 10,000 mm, from about 300 mm to about 10,000 mm, from about 350 mm to about 10,000 mm, from about 400 mm to about 10,000 mm, from about 450 mm to about 10,000 mm, from about 500 mm to about 10,000 mm, from about 550 mm to about 10,000 mm, from about 600 mm to about 10,000 mm, from about 650 mm to about 10,000 mm, from about 700 mm to about 10,000 mm, from about 750 mm to about 10,000 mm, from about 800 mm to about 10,000 mm, from about 850 mm to about 10,000 mm, from about 900 mm to about 10,000 mm, from about 950 mm to about 10,000 mm, from about 1,000 mm to about 10,000 mm, from about 1,500 mm to about 10,000 mm, from about 2,000 mm to about 10,000 mm, from about 2,500 mm to about 10,000 mm, from about 3,000 mm to about 10,000 mm, from about 4,000 mm to about 10,000 mm, from about 5,000 mm to about 10,000 mm, from about 6,000 mm to about 10,000 mm, from about 7,000 mm to about 10,000 mm, from about 8,000 mm to about 10,000 mm, from about 9,000 mm to about 10,000 mm, from about 250 mm to about 5,000 mm, from about 250 mm to about 2,000 mm, or from about 250 mm to about 1,000 mm.

[0049] Curved deadfront 2000 includes a polymer layer 2020 located along an inner, major surface of curved outer glass layer 2010. Curved deadfront 2000 also includes metal layer 2030. Still further, curved deadfront 2000 may also include any of the other layers described above, such as the surface treatment, the ink layer, and the optically clear adhesive.

Additionally, curved deadfront 2000 may include such layers as, e.g., high optical density layers, light guide layers, reflector layers, display module(s), display stack layers, light sources, etc. that otherwise may be associated with an electronic device as discussed herein.

[0050] As will be discussed in more detail below, in various embodiments, curved deadfront 2000 including glass layer 2010, polymer layer 2020, metal layer 2030, and any other optional layers may be cold-formed together to a curved shape, as shown in FIG. 9. In other embodiments, glass layer 2010 may be formed to a curved shape, and then layers 2020 and 2030 are applied following curve formation.

[0051] Referring to FIG. 10, outer glass layer 2010 is shown prior to being formed to the curved shape shown in FIG. 10. In general, Applicant believes that the articles and processes discussed herein provide high quality deadfront structures utilizing glass of sizes, shapes, compositions, strengths, etc. not previously provided.

[0052] As shown in FIG. 10, outer glass layer 2010 includes a first major surface 2050 and a second major surface 2060 opposite first major surface 2050. An edge surface or minor surface 2070 connects the first major surface 2050 and the second major surface 2060. Outer glass layer 2010 has a thickness (t) that is substantially constant and is defined as a distance between the first major surface 2050 and the second major surface 2060. In some

embodiments, the thickness (t) as used herein refers to the maximum thickness of the outer glass layer 2010. Outer glass layer 2010 includes a width (W) defined as a first maximum dimension of one of the first or second major surfaces orthogonal to the thickness (t), and outer glass layer 2010 also includes a length (L) defined as a second maximum dimension of one of the first or second surfaces orthogonal to both the thickness and the width. In other embodiments, the dimensions discussed herein are average dimensions.

[0053] In one or more embodiments, outer glass layer 2010 has a thickness (t) that is in a range from 0.05 mm to 2 mm. In various embodiments, outer glass layer 2010 has a thickness (t) that is about 2mm or less, or about 1.5 mm or less. For example, the thickness may be in a range from about 0.1 mm to about 2 mm, from about 0.15 mm to about 2 mm, from about 0.2 mm to about 2 mm, from about 0.25 mm to about 2 mm, from about 0.3 mm to about 2 mm, from about 0.35 mm to about 2 mm, from about 0.4 mm to about 2 mm, from about 0.45 mm to about 2 mm, from about 0.5 mm to about 2 mm, from about 0.55 mm to about 2 mm, from about 0.6 mm to about 2 mm, from about 0.65 mm to about 2 mm, from about 0.7 mm to about 2 mm, from about 0.8 mm to about 2 mm, from about 0.9 mm to about 2 mm, from about 1 mm to about 2 mm, from about 1.1 mm to about 2 mm, from about 1.2 mm to about 2 mm, from about 1.3 mm to about 2 mm, from about 1.4 mm to about 2 mm, from about 1.5 mm to about 2 mm, from about 0.1 mm to about 1.5 mm, from about 0.15 mm to about 1.5 mm, from about 0.2 mm to about 1.5 mm, from about 0.25 mm to about 1.5 mm, from about 0.3 mm to about 1.5 mm, from about 0.35 mm to about 1.5 mm, from about 0.4 mm to about 1.5 mm, from about 0.45 mm to about 1.5 mm, from about 0.5 mm to about 1.5 mm, from about 0.55 mm to about 1.5 mm, from about 0.6 mm to about 1.5 mm, from about 0.65 mm to about 1.5 mm, from about 0.7 mm to about 1.5 mm, from about 0.1 mm to about 2 mm, from about 0.1 mm to about 1.9 mm, from about 0.1 mm to about 1.8 mm, from about 0.1 mm to about 1.7 mm, from about 0.1 mm to about 1.6 mm, from about 0.1 mm to about 1.5 mm, from about 0.1 mm to about 1.4 mm, from about 0.1 mm to about 1.3 mm, from about 0.1 mm to about 1.2 mm, from about 0.1 mm to about 1.1 mm, from about 0.1 mm to about 1.05 mm, from about 0.1 mm to about 1 mm, from about 0.1 mm to about 0.95 mm, from about 0.1 mm to about 0.9 mm, from about 0.1 mm to about 0.85 mm, from about 0.1 mm to about 0.8 mm, from about 0.1 mm to about 0.75 mm, from about 0.1 mm to about 0.7 mm, from about 0.1 mm to about 0.65 mm, from about 0.1 mm to about 0.6 mm, from about 0.1 mm to about 0.55 mm, from about 0.1 mm to about 0.5 mm, from about 0.1 mm to about 0.4 mm, from about 0.3 mm to about 0.7 mm, from about 0.7 mm to about 1.6 mm, or from about 1.1 mm to about 1.6 mm.

[0054] In one or more embodiments, outer glass layer 2010 has a width (W) in a range from about 5 cm to about 250 cm, from about 10 cm to about 250 cm, from about 15 cm to about 250 cm, from about 20 cm to about 250 cm, from about 25 cm to about 250 cm, from about 30 cm to about 250 cm, from about 35 cm to about 250 cm, from about 40 cm to about 250 cm, from about 45 cm to about 250 cm, from about 50 cm to about 250 cm, from about 55 cm to about 250 cm, from about 60 cm to about 250 cm, from about 65 cm to about 250 cm, from about 70 cm to about 250 cm, from about 75 cm to about 250 cm, from about 80 cm to about 250 cm, from about 85 cm to about 250 cm, from about 90 cm to about 250 cm, from about 95 cm to about 250 cm, from about 100 cm to about 250 cm, from about 1 10 cm to about 250 cm, from about 120 cm to about 250 cm, from about 130 cm to about 250 cm, from about 140 cm to about 250 cm, from about 150 cm to about 250 cm, from about 5 cm to about 240 cm, from about 5 cm to about 230 cm, from about 5 cm to about 220 cm, from about 5 cm to about 210 cm, from about 5 cm to about 200 cm, from about 5 cm to about 190 cm, from about 5 cm to about 180 cm, from about 5 cm to about 170 cm, from about 5 cm to about 160 cm, from about 5 cm to about 150 cm, from about 5 cm to about 140 cm, from about 5 cm to about 130 cm, from about 5 cm to about 120 cm, from about 5 cm to about 110 cm, from about 5 cm to about 100 cm, from about 5 cm to about 90 cm, from about 5 cm to about 80 cm, or from about 5 cm to about 75 cm.

[0055] In one or more embodiments, outer glass layer 2010 has a length (L) in a range from about 5 cm to about 250 cm, from about 10 cm to about 250 cm, from about 15 cm to about 250 cm, from about 20 cm to about 250 cm, from about 25 cm to about 250 cm, from about 30 cm to about 250 cm, from about 35 cm to about 250 cm, from about 40 cm to about 250 cm, from about 45 cm to about 250 cm, from about 50 cm to about 250 cm, from about 55 cm to about 250 cm, from about 60 cm to about 250 cm, from about 65 cm to about 250 cm, from about 70 cm to about 250 cm, from about 75 cm to about 250 cm, from about 80 cm to about 250 cm, from about 85 cm to about 250 cm, from about 90 cm to about 250 cm, from about 95 cm to about 250 cm, from about 100 cm to about 250 cm, from about 110 cm to about 250 cm, from about 120 cm to about 250 cm, from about 130 cm to about 250 cm, from about 140 cm to about 250 cm, from about 150 cm to about 250 cm, from about 5 cm to about 240 cm, from about 5 cm to about 230 cm, from about 5 cm to about 220 cm, from about 5 cm to about 210 cm, from about 5 cm to about 200 cm, from about 5 cm to about 190 cm, from about 5 cm to about 180 cm, from about 5 cm to about 170 cm, from about 5 cm to about 160 cm, from about 5 cm to about 150 cm, from about 5 cm to about 140 cm, from about 5 cm to about 130 cm, from about 5 cm to about 120 cm, from about 5 cm to about 110 cm, from about 5 cm to about 100 cm, from about 5 cm to about 90 cm, from about 5 cm to about 80 cm, or from about 5 cm to about 75 cm.

[0056] As shown in FIG. 9, outer glass layer 2010 is shaped to a curved shaping having at least one radius of curvature, shown as Rl. In various embodiments, outer glass layer 2010 may be shaped to the curved shape via any suitable process, including cold-forming and hot- forming.

[0057] In specific embodiments, outer glass layer 2010 is shaped to the curved shape shown in FIG. 9, either alone, or following attachment of layers 2020 and 2030, via a cold-forming process. As used herein, the terms“cold-bent,”“cold-bending,”“cold-formed” or“cold- forming” refers to curving the glass deadfront at a cold-form temperature which is less than the softening point of the glass (as described herein). A feature of a cold-formed glass layer is an asymmetric surface compressive between the first major surface 2050 and the second major surface 2060. In some embodiments, prior to the cold-forming process or being cold- formed, the respective compressive stresses in the first major surface 2050 and the second major surface 2060 are substantially equal. [0058] In some such embodiments in which outer glass layer 2010 is unstrengthened, the first major surface 2050 and the second major surface 2060 exhibit no appreciable compressive stress, prior to cold-forming. In some such embodiments in which outer glass layer 2010 is strengthened (as described herein), the first major surface 2050 and the second major surface 2060 exhibit substantially equal compressive stress with respect to one another, prior to cold- forming. In one or more embodiments, after cold-forming (shown, for example, in FIG. 18) the compressive stress on the second major surface 2060 (e.g., the concave surface following bending) increases (i.e., the compressive stress on the second major surface 2050 is greater after cold-forming than before cold-forming).

[0059] Without being bound by theory, the cold-forming process increases the compressive stress of the glass article being shaped to compensate for tensile stresses imparted during bending and/or forming operations. In one or more embodiments, the cold-forming process causes the second major surface 2060 to experience compressive stresses, while the first major surface 2050 (e.g., the convex surface following bending) experiences tensile stresses. The tensile stress experienced by surface 2050 following bending results in a net decrease in surface compressive stress, such that the compressive stress in surface 2050 of a strengthened glass sheet following bending is less than the compressive stress in surface 2050 when the glass sheet is flat.

[0060] Further, when a strengthened glass sheet is utilized for outer glass layer 2010, the first major surface and the second major surface (2050,2060) are already under compressive stress, and thus first major surface 2050 can experience greater tensile stress during bending without risking fracture. This allows for the strengthened embodiments of outer glass layer 2010 to conform to more tightly curved surfaces (e.g., shaped to have smaller Rl values).

[0061] In various embodiments, the thickness of outer glass layer 2010 is tailored to allow outer glass layer 2010 to be more flexible to achieve the desired radius of curvature.

Moreover, a thinner outer glass layer 2010 may deform more readily, which could potentially compensate for shape mismatches and gaps that may be created by the shape of a support or frame (as discussed below). In one or more embodiments, a thin and strengthened outer glass layer 2010 exhibits greater flexibility especially during cold-forming. The greater flexibility of the glass articles discussed herein may allow for consistent bend formation without heating.

[0062] In various embodiments, outer glass layer 2010 (and consequently deadfront 2000) may have a compound curve including a major radius and a cross curvature. A complexly curved cold-formed outer glass layer 2010 may have a distinct radius of curvature in two independent directions. According to one or more embodiments, the complexly curved cold- formed outer glass layer 2010 may thus be characterized as having“cross curvature,” where the cold-formed outer glass layer 2010 is curved along an axis (i.e., a first axis) that is parallel to a given dimension and also curved along an axis (i.e., a second axis) that is perpendicular to the same dimension. The curvature of the cold-formed outer glass layer 2010 can be even more complex when a significant minimum radius is combined with a significant cross curvature, and/or depth of bend.

[0063] Referring to FIG. 11, display assembly 2100 is shown according to an exemplary embodiment. In the embodiment shown, display assembly 2100 includes frame 2110 supporting (either directly or indirectly) both a light source, shown as a display module 2120, and deadfront structure 2000. As shown in FIG. 11, deadfront structure 2000 and display module 2120 are coupled to frame 2110, and display module 2120 is positioned to allow a user to view light, images, etc. generated by display module 2120 through deadfront structure 2000. In various embodiments, frame 2110 may be formed from a variety of materials such as plastic (PC/ABS, etc.), metals (Al-alloys, Mg-alloys, Fe-alloys, etc.). Various processes such as casting, machining, stamping, injection molding, etc. may be utilized to form the curved shape of frame 2110. While FIG. 11 shows a light source in the form of a display module, it should be understood that display assembly 2100 may include any of the light sources discussed herein for producing graphics, icons, images, displays, etc. through any of the dead front embodiments discussed herein. Further, while frame 2110 is shown as a frame associated with a display assembly, frame 2110 may be any support or frame structure associated with a vehicle interior system.

[0064] In various embodiments, the systems and methods described herein allow for formation of deadfront structure 2000 to conform to a wide variety of curved shapes that frame 2110 may have. As shown in FIG. 11, frame 2110 has a support surface 2130 that has a curved shape, and deadfront structure 2000 is shaped to match the curved shape of support surface 2130. As will be understood, deadfront structure 2000 may be shaped into a wide variety of shapes to conform to a desired frame shape of a display assembly 2100, which in turn may be shaped to fit the shape of a portion of a vehicle interior system, as discussed herein.

[0065] In one or more embodiments, deadfront structure 2000 (and specifically outer glass layer 2010) is shaped to have a first radius of curvature, Rl, of about 20 mm or greater or about 60 mm or greater. For example, Rl may be in a range from about 20 mm to about 10,000 mm (e.g., from about 20 mm to about 9,000 mm, from about 20 mm to about 8,000 mm, from about 20 mm to about 7,000 mm, from about 20 mm to about 6,000 mm, from about 20 mm to about 5,500 mm, from about 20 mm to about 5,000 mm, from about 20 mm to about 4,500 mm, from about 20 mm to about 4,000 mm, from about 20 mm to about 3,500 mm, from about 20 mm to about 3,000 mm, from about 20 mm to about 2,500 mm, from about 20 mm to about 2,000 mm, from about 20 mm to about 1,500 mm, from about 20 mm to about 1,400 mm, from about 20 mm to about 1,300 mm, from about 20 mm to about 1,200 mm, from about 20 mm to about 1,100 mm, from about 20 mm to about 1,000 mm, from about 50 mm to about 10,000 mm, from about 75 mm to about 10,000 mm, from about 100 mm to about 10,000 mm, from about 150 mm to about 10,000 mm, from about 200 mm to about 10,000 mm, from about 250 mm to about 10,000 mm, from about 300 mm to about 10,000 mm, from about 350 mm to about 10,000 mm, from about 400 mm to about 10,000 mm, from about 450 mm to about 10,000 mm, from about 500 mm to about 10,000 mm, from about 550 mm to about 10,000 mm, from about 600 mm to about 10,000 mm, from about 650 mm to about 10,000 mm, from about 700 mm to about 10,000 mm, from about 750 mm to about 10,000 mm, from about 800 mm to about 10,000 mm, from about 850 mm to about 10,000 mm, from about 900 mm to about 10,000 mm, from about 950 mm to about 10,000 mm, from about 1,000 mm to about 10,000 mm, from about 1,500 mm to about 10,000 mm, from about 2,000 mm to about 10,000 mm, from about 2,500 mm to about 10,000 mm, from about 3,000 mm to about 10,000 mm, from about 4,000 mm to about 10,000 mm, from about 5,000 mm to about 10,000 mm, from about 6,000 mm to about 10,000 mm, from about 7,000 mm to about 10,000 mm, from about 8,000 mm to about 10,000 mm, from about 9,000 mm to about 10,000 mm, from about 250 mm to about 5,000 mm, from about 250 mm to about 2,000 mm, or from about 250 mm to about 1,000 mm.

[0066]

[0067] In one or more embodiments, support surface 2130 has a second radius of curvature of about 20 mm or greater or about 60 mm or greater. For example, the second radius of curvature of support surface 2130 may be in a range from about 20 mm to about 10,000 mm (e.g., from about 20 mm to about 9,000 mm, from about 20 mm to about 8,000 mm, from about 20 mm to about 7,000 mm, from about 20 mm to about 6,000 mm, from about 20 mm to about 5,500 mm, from about 20 mm to about 5,000 mm, from about 20 mm to about 4,500 mm, from about 20 mm to about 4,000 mm, from about 20 mm to about 3,500 mm, from about 20 mm to about 3,000 mm, from about 20 mm to about 2,500 mm, from about 20 mm to about 2,000 mm, from about 20 mm to about 1,500 mm, from about 20 mm to about 1,400 mm, from about 20 mm to about 1,300 mm, from about 20 mm to about 1,200 mm, from about 20 mm to about 1,100 mm, from about 20 mm to about 1,000 mm, from about 50 mm to about 10,000 mm, from about 75 mm to about 10,000 mm, from about 100 mm to about 10,000 mm, from about 150 mm to about 10,000 mm, from about 200 mm to about 10,000 mm, from about 250 mm to about 10,000 mm, from about 300 mm to about 10,000 mm, from about 350 mm to about 10,000 mm, from about 400 mm to about 10,000 mm, from about 450 mm to about 10,000 mm, from about 500 mm to about 10,000 mm, from about 550 mm to about 10,000 mm, from about 600 mm to about 10,000 mm, from about 650 mm to about 10,000 mm, from about 700 mm to about 10,000 mm, from about 750 mm to about 10,000 mm, from about 800 mm to about 10,000 mm, from about 850 mm to about 10,000 mm, from about 900 mm to about 10,000 mm, from about 950 mm to about 10,000 mm, from about 1,000 mm to about 10,000 mm, from about 1,500 mm to about 10,000 mm, from about 2,000 mm to about 10,000 mm, from about 2,500 mm to about 10,000 mm, from about 3,000 mm to about 10,000 mm, from about 4,000 mm to about 10,000 mm, from about 5,000 mm to about 10,000 mm, from about 6,000 mm to about 10,000 mm, from about 7,000 mm to about 10,000 mm, from about 8,000 mm to about 10,000 mm, from about 9,000 mm to about 10,000 mm, from about 250 mm to about 5,000 mm, from about 250 mm to about 2,000 mm, or from about 250 mm to about 1,000 mm.

[0068]

[0069] In one or more embodiments, deadfront structure 2000 is cold-formed to exhibit a first radius curvature, Rl, that is within 10% (e.g., about 10% or less, about 9% or less, about 8% or less, about 7% or less, about 6% or less, or about 5% or less) of the second radius of curvature of support surface 2130 of frame 2110. For example, support surface 2130 of frame 2110 exhibits a radius of curvature of 1000 mm, deadfront structure 2000 is cold-formed to have a radius of curvature in a range from about 900 mm to about 1100 mm.

[0070] In one or more embodiments, first major surface 2050 and/or second major surface 2060 of glass layer 2010 includes a surface treatment or a functional coating. The surface treatment may cover at least a portion of first major surface 2050 and/or second major surface 2060. Exemplary surface treatments include at least one of a glare reduction coating, an anti glare coating, a scratch resistance coating, an anti -reflection coating, a half-mirror coating, or easy-to-clean coating.

[0071] Referring to FIG. 12, a method 2200 for forming a display assembly that includes a cold-formed deadfront structure, such as deadfront structure 2000 is shown. At step 2210, a deadfront stack or structure, such deadfront structure 2000, is supported and/or placed on a curved support. In general, the curved support may be a frame of a display, such as frame 2110, that defines a perimeter and curved shape of a vehicle display. In general, the curved frame includes a curved support surface, and one of the major surfaces 2050 and 2060 of deadfront structure 2000 is placed into contact with the curved support surface.

[0072] At step 2220, a force is applied to the deadfront structure while it is supported by the support causing the deadfront structure to bend into conformity with the curved shape of the support. In this manner, a curved deadfront structure 2000, as shown in FIG. 9, is formed from a generally flat deadfront structure. In this arrangement, curving the flat deadfront structure forms a curved shape on the major surface facing the support, while also causing a corresponding (but complimentary) curve to form in the major surface opposite of the frame. Applicant believes that by bending the deadfront structure directly on the curved frame, the need for a separate curved die or mold (typically needed in other glass bending processes) is eliminated. Further, Applicant believes that by shaping the deadfront directly to the curved frame, a wide range of curved radii may be achieved in a low complexity manufacturing process.

[0073] In some embodiments, the force applied in step 2220 may be air pressure applied via a vacuum fixture. In some other embodiments, the air pressure differential is formed by applying a vacuum to an airtight enclosure surrounding the frame and the deadfront structure. In specific embodiments, the airtight enclosure is a flexible polymer shell, such as a plastic bag or pouch. In other embodiments, the air pressure differential is formed by generating increased air pressure around the deadfront structure and the frame with an overpressure device, such as an autoclave. Applicant has further found that air pressure provides a consistent and highly uniform bending force (as compared to a contact-based bending method) which further leads to a robust manufacturing process. In various embodiments, the air pressure differential is between 0.5 and 1.5 atmospheres of pressure (atm), specifically between 0.7 and 1.1 atm, and more specifically is 0.8 to 1 atm.

[0074] At step 2230, the temperature of the deadfront structure is maintained below the glass transition temperature of the material of the outer glass layer during the bending. As such, method 2200 is a cold-forming or cold-bending process. In particular embodiments, the temperature of the deadfront structure is maintained below 500 degrees C, 400 degrees C,

300 degrees C, 200 degrees C or 100 degrees C. In a particular embodiment, the deadfront structure is maintained at or below room temperature during bending. In a particular embodiment, the deadfront structure is not actively heated via a heating element, furnace, oven, etc. during bending, as is the case when hot-forming glass to a curved shape. [0075] As noted above, in addition to providing processing advantages such as eliminating expensive and/or slow heating steps, the cold-forming processes discussed herein are believed to generate curved deadfront structures with a variety of properties that are believed to be superior to those achievable via hot-forming processes. For example, Applicant believes that, for at least some glass materials, heating during hot-forming processes decreases optical properties of curved glass sheets, and thus, the curved glass based deadfronts formed utilizing the cold-bending processes/sy stems discussed herein provide for both curved glass shape along with improved optical qualities not believed achievable with hot-bending processes.

[0076] Further, many glass coating materials (e.g., anti-glare coatings, anti -reflective coatings, etc.) are applied via deposition processes, such as sputtering processes, that are typically ill-suited for coating on to a curved surface. In addition, many coating materials, such as the polymer layer, also are not able to survive the high temperatures associated with hot-bending processes. Thus, in particular embodiments discussed herein, layer 2020 is applied to outer glass layer 2010 prior to cold-bending. Thus, Applicant believes that the processes and systems discussed herein allow for bending of glass after one or more coating material has been applied to the glass, in contrast to typical hot-forming processes.

[0077] At step 2240, the curved deadfront structure is attached or affixed to the curved support. In various embodiments, the attachment between the curved deadfront structure and the curved support may be accomplished via an adhesive material. Such adhesives may include any suitable optically clear adhesive for bonding the deadfront structure in place relative to the display assembly (e.g., to the frame of the display). In one example, the adhesive may include an optically clear adhesive available from 3M Corporation under the trade name 8215. The thickness of the adhesive may be in a range from about 200 pm to about 500 pm.

[0078] The adhesive material may be applied in a variety ways. In one embodiment, the adhesive is applied using an applicator gun and made uniform using a roller or a draw down die. In various embodiments, the adhesives discussed herein are structural adhesives. In particular embodiments, the structural adhesives may include an adhesive selected from one or more of the categories: (a) Toughened Epoxy (Masterbond EP21TDCHT-LO, 3M Scotch Weld Epoxy DP460 Off-white); (b) Flexible Epoxy (Masterbond EP21TDC-2LO, 3M Scotch Weld Epoxy 2216 B/A Gray); (c) Acrylic (LORD Adhesive 410/ Accelerator 19 w / LORD AP 134 primer, LORD Adhesive 852/LORD Accelerator 25GB, Loctite HF8000, Loctite AA4800); (d) Urethanes (3M Scotch Weld Urethane DP640 Brown, DP604NS, DP620NS available from 3M®, Saint Paul, MN, Loctite HHD 3542, Betamate 73100/002, 73100/005, 73100/010, Betaseal X2500, and Betalink K2, from Dupont®, Wilmington, DE); and (e) Silicones (Dow Corning 995). In some cases, structural glues available in sheet format (such as B-staged epoxy adhesives) may be utilized. Furthermore, pressure sensitive structural adhesives such as 3M VHB tapes may be utilized. In such embodiments, utilizing a pressure sensitive adhesive allows for the curved deadfront structure to be bonded to the frame without the need for a curing step.

[0079] Referring to FIG. 13, method 2300 for forming a display utilizing a curved deadfront structure is shown and described. In some embodiments, the glass layer (e.g., outer glass layer 2010) of a deadfront structure is formed to curved shape at step 2310. Shaping at step 2310 may be either cold-forming or hot-forming. At step 2320, the deadfront polymer layer 2020, metal layer 2030, and any of the other optional layers are applied to the glass layer following shaping. Next at step 2330, the curved deadfront structure is attached to a frame, such as frame 2110 of display assembly 2100, or other frame that may be associated with a vehicle interior system.

[0080] Glass Materials

[0081] The various glass layer(s) of the deadfront structures discussed herein, such as outer glass layer 2010, may be formed from any suitable glass composition including soda lime glass, aluminosilicate glass, borosilicate glass, boroaluminosilicate glass, alkali-containing aluminosilicate glass, alkali-containing borosilicate glass, and alkali-containing

boroaluminosilicate glass.

[0082] Unless otherwise specified, the glass compositions disclosed herein are described in mole percent (mol%) as analyzed on an oxide basis.

[0083] In one or more embodiments, the glass composition may include S1O2 in an amount in a range from about 66 mol% to about 80 mol%, from about 67 mol% to about 80 mol%, from about 68 mol% to about 80 mol%, from about 69 mol% to about 80 mol%, from about 70 mol% to about 80 mol%, from about 72 mol% to about 80 mol%, from about 65 mol% to about 78 mol%, from about 65 mol% to about 76 mol%, from about 65 mol% to about 75 mol%, from about 65 mol% to about 74 mol%, from about 65 mol% to about 72 mol%, or from about 65 mol% to about 70 mol%, and all ranges and sub-ranges therebetween.

[0084] In one or more embodiments, the glass composition includes AI2O3 in an amount greater than about 4 mol%, or greater than about 5 mol%. In one or more embodiments, the glass composition includes AI2O3 in a range from greater than about 7 mol% to about 15 mol%, from greater than about 7 mol% to about 14 mol%, from about 7 mol% to about 13 mol%, from about 4 mol% to about 12 mol%, from about 7 mol% to about 11 mol%, from about 8 mol% to about 15 mol%, from 9 mol% to about 15 mol%, from about 9 mol% to about 15 mol%, from about 10 mol% to about 15 mol%, from about 11 mol% to about 15 mol%, or from about 12 mol% to about 15 mol%, and all ranges and sub-ranges

therebetween. In one or more embodiments, the upper limit of AI2O3 may be about 14 mol%, 14.2 mol%, 14.4 mol%, 14.6 mol%, or 14.8 mol%.

[0085] In one or more embodiments, glass layer(s) herein are described as an aluminosilicate glass article or including an aluminosilicate glass composition. In such embodiments, the glass composition or article formed therefrom includes S1O2 and AI2O3 and is not a soda lime silicate glass. In this regard, the glass composition or article formed therefrom includes AI2O3 in an amount of about 2 mol% or greater, 2.25 mol% or greater, 2.5 mol% or greater, about 2.75 mol% or greater, about 3 mol% or greater.

[0086] In one or more embodiments, the glass composition comprises B2O3 (e.g., about 0.01 mol% or greater). In one or more embodiments, the glass composition comprises B2O3 in an amount in a range from about 0 mol% to about 5 mol%, from about 0 mol% to about 4 mol%, from about 0 mol% to about 3 mol%, from about 0 mol% to about 2 mol%, from about 0 mol% to about 1 mol%, from about 0 mol% to about 0.5 mol%, from about 0.1 mol% to about 5 mol%, from about 0.1 mol% to about 4 mol%, from about 0.1 mol% to about 3 mol%, from about 0.1 mol% to about 2 mol%, from about 0.1 mol% to about 1 mol%, from about 0.1 mol% to about 0.5 mol%, and all ranges and sub-ranges therebetween. In one or more embodiments, the glass composition is substantially free of B2O3.

[0087] As used herein, the phrase“substantially free” with respect to the components of the composition means that the component is not actively or intentionally added to the composition during initial batching, but may be present as an impurity in an amount less than about 0.001 mol%.

[0088] In one or more embodiments, the glass composition optionally comprises P2O5 (e.g., about 0.01 mol% or greater). In one or more embodiments, the glass composition comprises a non-zero amount of P2O5 up to and including 2 mol%, 1.5 mol%, 1 mol%, or 0.5 mol%. In one or more embodiments, the glass composition is substantially free of P2O5.

[0089] In one or more embodiments, the glass composition may include a total amount of R2O (which is the total amount of alkali metal oxide such as L12O, Na20, K2O, Rb20, and CS2O) that is greater than or equal to about 8 mol%, greater than or equal to about 10 mol%, or greater than or equal to about 12 mol%. In some embodiments, the glass composition includes a total amount of R2O in a range from about 8 mol% to about 20 mol%, from about 8 mol% to about 18 mol%, from about 8 mol% to about 16 mol%, from about 8 mol% to about 14 mol%, from about 8 mol% to about 12 mol%, from about 9 mol% to about 20 mol%, from about 10 mol% to about 20 mol%, from about 11 mol% to about 20 mol%, from about 12 mol% to about 20 mol%, from about 13 mol% to about 20 mol%, from about 10 mol% to about 14 mol%, or from 11 mol% to about 13 mol%, and all ranges and sub-ranges therebetween. In one or more embodiments, the glass composition may be substantially free of Rb20, CS20 or both Rb20 and CS2O. In one or more embodiments, the R2O may include the total amount of L12O, Na20 and K2O only. In one or more embodiments, the glass composition may comprise at least one alkali metal oxide selected from L12O, Na20 and K2O, wherein the alkali metal oxide is present in an amount greater than about 8 mol% or greater.

[0090] In one or more embodiments, the glass composition comprises Na20 in an amount greater than or equal to about 8 mol%, greater than or equal to about 10 mol%, or greater than or equal to about 12 mol%. In one or more embodiments, the composition includes Na20 in a range from about from about 8 mol% to about 20 mol%, from about 8 mol% to about 18 mol%, from about 8 mol% to about 16 mol%, from about 8 mol% to about 14 mol%, from about 8 mol% to about 12 mol%, from about 9 mol% to about 20 mol%, from about 10 mol% to about 20 mol%, from about 11 mol% to about 20 mol%, from about 12 mol% to about 20 mol%, from about 13 mol% to about 20 mol%, from about 10 mol% to about 14 mol%, or from 11 mol% to about 16 mol%, and all ranges and sub-ranges therebetween.

[0091] In one or more embodiments, the glass composition includes less than about 4 mol% K2O, less than about 3 mol% K2O, or less than about 1 mol% K2O. In some instances, the glass composition may include K2O in an amount in a range from about 0 mol% to about 4 mol%, from about 0 mol% to about 3.5 mol%, from about 0 mol% to about 3 mol%, from about 0 mol% to about 2.5 mol%, from about 0 mol% to about 2 mol%, from about 0 mol% to about 1.5 mol%, from about 0 mol% to about 1 mol%, from about 0 mol% to about 0.5 mol%, from about 0 mol% to about 0.2 mol%, from about 0 mol% to about 0.1 mol%, from about 0.5 mol% to about 4 mol%, from about 0.5 mol% to about 3.5 mol%, from about 0.5 mol% to about 3 mol%, from about 0.5 mol% to about 2.5 mol%, from about 0.5 mol% to about 2 mol%, from about 0.5 mol% to about 1.5 mol%, or from about 0.5 mol% to about 1 mol%, and all ranges and sub-ranges therebetween. In one or more embodiments, the glass composition may be substantially free of K2O.

[0092] In one or more embodiments, the glass composition is substantially free of L12O.

[0093] In one or more embodiments, the amount of Na20 in the composition may be greater than the amount of L12O. In some instances, the amount of Na20 may be greater than the combined amount of LriO and K2O. In one or more alternative embodiments, the amount of L12O in the composition may be greater than the amount of Na20 or the combined amount of Na20 and K2O.

[0094] In one or more embodiments, the glass composition may include a total amount of RO (which is the total amount of alkaline earth metal oxide such as CaO, MgO, BaO, ZnO and SrO) in a range from about 0 mol% to about 2 mol%. In some embodiments, the glass composition includes a non-zero amount of RO up to about 2 mol%. In one or more embodiments, the glass composition comprises RO in an amount from about 0 mol% to about 1.8 mol%, from about 0 mol% to about 1.6 mol%, from about 0 mol% to about 1.5 mol%, from about 0 mol% to about 1.4 mol%, from about 0 mol% to about 1.2 mol%, from about 0 mol% to about 1 mol%, from about 0 mol% to about 0.8 mol%, from about 0 mol% to about 0.5 mol%, and all ranges and sub-ranges therebetween.

[0095] In one or more embodiments, the glass composition includes CaO in an amount less than about 1 mol%, less than about 0.8 mol%, or less than about 0.5 mol%. In one or more embodiments, the glass composition is substantially free of CaO. In some embodiments, the glass composition comprises MgO in an amount from about 0 mol% to about 7 mol%, from about 0 mol% to about 6 mol%, from about 0 mol% to about 5 mol%, from about 0 mol% to about 4 mol%, from about 0.1 mol% to about 7 mol%, from about 0.1 mol% to about 6 mol%, from about 0.1 mol% to about 5 mol%, from about 0.1 mol% to about 4 mol%, from about 1 mol% to about 7 mol%, from about 2 mol% to about 6 mol%, or from about 3 mol% to about 6 mol%, and all ranges and sub-ranges therebetween.

[0096] In one or more embodiments, the glass composition comprises Zr02 in an amount equal to or less than about 0.2 mol%, less than about 0.18 mol%, less than about 0.16 mol%, less than about 0.15 mol%, less than about 0.14 mol%, less than about 0.12 mol%. In one or more embodiments, the glass composition comprises Zr02 in a range from about 0.01 mol% to about 0.2 mol%, from about 0.01 mol% to about 0.18 mol%, from about 0.01 mol% to about 0.16 mol%, from about 0.01 mol% to about 0.15 mol%, from about 0.01 mol% to about 0.14 mol%, from about 0.01 mol% to about 0.12 mol%, or from about 0.01 mol% to about 0.10 mol%, and all ranges and sub-ranges therebetween.

[0097] In one or more embodiments, the glass composition comprises SnCk in an amount equal to or less than about 0.2 mol%, less than about 0.18 mol%, less than about 0.16 mol%, less than about 0.15 mol%, less than about 0.14 mol%, less than about 0.12 mol%. In one or more embodiments, the glass composition comprises Sn02 in a range from about 0.01 mol% to about 0.2 mol%, from about 0.01 mol% to about 0.18 mol%, from about 0.01 mol% to about 0.16 mol%, from about 0.01 mol% to about 0.15 mol%, from about 0.01 mol% to about 0.14 mol%, from about 0.01 mol% to about 0.12 mol%, or from about 0.01 mol% to about 0.10 mol%, and all ranges and sub-ranges therebetween.

[0098] In one or more embodiments, the glass composition may include an oxide that imparts a color or tint to the glass articles. In some embodiments, the glass composition includes an oxide that prevents discoloration of the glass article when the glass article is exposed to ultraviolet radiation. Examples of such oxides include, without limitation oxides of: Ti, V,

Cr, Mn, Fe, Co, Ni, Cu, Ce, W, and Mo.

[0099] In one or more embodiments, the glass composition includes Fe expressed as Fe2Cb, wherein Fe is present in an amount up to (and including) about 1 mol%. In some

embodiments, the glass composition is substantially free of Fe. In one or more embodiments, the glass composition comprises Fe2Cb in an amount equal to or less than about 0.2 mol%, less than about 0.18 mol%, less than about 0.16 mol%, less than about 0.15 mol%, less than about 0.14 mol%, less than about 0.12 mol%. In one or more embodiments, the glass composition comprises Fe2Cb in a range from about 0.01 mol% to about 0.2 mol%, from about 0.01 mol% to about 0.18 mol%, from about 0.01 mol% to about 0.16 mol%, from about 0.01 mol% to about 0.15 mol%, from about 0.01 mol% to about 0.14 mol%, from about 0.01 mol% to about 0.12 mol%, or from about 0.01 mol% to about 0.10 mol%, and all ranges and sub-ranges therebetween.

[00100] Where the glass composition includes T1O2, T1O2 may be present in an amount of about 5 mol% or less, about 2.5 mol% or less, about 2 mol% or less or about 1 mol% or less. In one or more embodiments, the glass composition may be substantially free of TiCh.

[00101] An exemplary glass composition includes S1O2 in an amount in a range from about 65 mol% to about 75 mol%, AI2O3 in an amount in a range from about 8 mol% to about 14 mol%, Na20 in an amount in a range from about 12 mol% to about 17 mol%, K2O in an amount in a range of about 0 mol% to about 0.2 mol%, and MgO in an amount in a range from about 1. 5 mol% to about 6 mol%. Optionally, Sn02 may be included in the amounts otherwise disclosed herein.

[00102] Strengthened Glass Properties

[00103] In one or more embodiments, outer glass layer 2010 or other glass layer of any of the deadfront embodiments discussed herein may be formed from a strengthened glass sheet or article. In one or more embodiments, the glass articles used to form the layer(s) of the deadfront structures discussed herein may be strengthened to include compressive stress that extends from a surface to a depth of compression (DOC). The compressive stress regions are balanced by a central portion exhibiting a tensile stress. At the DOC, the stress crosses from a positive (compressive) stress to a negative (tensile) stress.

[00104] In one or more embodiments, the glass articles used to form the layer(s) of the deadfront structures discussed herein may be strengthened mechanically by utilizing a mismatch of the coefficient of thermal expansion between portions of the glass to create a compressive stress region and a central region exhibiting a tensile stress. In some

embodiments, the glass article may be strengthened thermally by heating the glass to a temperature above the glass transition point and then rapidly quenching.

[0100] In one or more embodiments, the glass articles used to form the layer(s) of the deadfront structures discussed herein may be chemically strengthening by ion exchange. In the ion exchange process, ions at or near the surface of the glass article are replaced by - or exchanged with - larger ions having the same valence or oxidation state. In those embodiments in which the glass article comprises an alkali aluminosilicate glass, ions in the surface layer of the article and the larger ions are monovalent alkali metal cations, such as Li⁺, Na⁺, K⁺, Rb⁺, and Cs⁺. Alternatively, monovalent cations in the surface layer may be replaced with monovalent cations other than alkali metal cations, such as Ag⁺ or the like. In such embodiments, the monovalent ions (or cations) exchanged into the glass article generate a stress.

[0101] Ion exchange processes are typically carried out by immersing a glass article in a molten salt bath (or two or more molten salt baths) containing the larger ions to be exchanged with the smaller ions in the glass article. It should be noted that aqueous salt baths may also be utilized. In addition, the composition of the bath(s) may include more than one type of larger ion (e.g., Na+ and K+) or a single larger ion. It will be appreciated by those skilled in the art that parameters for the ion exchange process, including, but not limited to, bath composition and temperature, immersion time, the number of immersions of the glass article in a salt bath (or baths), use of multiple salt baths, additional steps such as annealing, washing, and the like, are generally determined by the composition of the glass layer(s) of a deadfront structure (including the structure of the article and any crystalline phases present) and the desired DOC and CS of the glass layer(s) of a deadfront structure that results from strengthening.

[0102] Exemplary molten bath composition may include nitrates, sulfates, and chlorides of the larger alkali metal ion. Typical nitrates include KNO3, NaME, LiN03, NaS0₄ and combinations thereof. The temperature of the molten salt bath typically is in a range from about 380°C up to about 450°C, while immersion times range from about 15 minutes up to about 100 hours depending on the glass thickness, bath temperature and glass (or monovalent ion) diffusivity. However, temperatures and immersion times different from those described above may also be used.

[0103] In one or more embodiments, the glass articles used to form the layer(s) of the deadfront structures may be immersed in a molten salt bath of 100% NaNCb, 100% KNCb, or a combination of NaNCb and KNCb having a temperature from about 370 °C to about 480 °C. In some embodiments, the glass layer(s) of a deadfront structure may be immersed in a molten mixed salt bath including from about 5% to about 90% KNCb and from about 10% to about 95% NaNCb. In one or more embodiments, the glass article may be immersed in a second bath, after immersion in a first bath. The first and second baths may have different compositions and/or temperatures from one another. The immersion times in the first and second baths may vary. For example, immersion in the first bath may be longer than the immersion in the second bath.

[0104] In one or more embodiments, the glass articles used to form the layer(s) of the deadfront structures may be immersed in a molten, mixed salt bath including NaNCb and KNCb (e.g., 49%/ 51 %, 50%/50%, 5l%/49%) having a temperature less than about 420 °C (e.g., about 400 °C or about 380 °C). for less than about 5 hours, or even about 4 hours or less.

[0105] Ion exchange conditions can be tailored to provide a“spike” or to increase the slope of the stress profile at or near the surface of the resulting glass layer(s) of a deadfront structure. The spike may result in a greater surface CS value. This spike can be achieved by single bath or multiple baths, with the bath(s) having a single composition or mixed composition, due to the unique properties of the glass compositions used in the glass layer(s) of a deadfront structure described herein.

[0106] In one or more embodiments, where more than one monovalent ion is exchanged into the glass articles used to form the layer(s) of the deadfront structures, the different monovalent ions may exchange to different depths within the glass layer (and generate different magnitudes stresses within the glass article at different depths). The resulting relative depths of the stress-generating ions can be determined and cause different characteristics of the stress profile.

[0107] CS is measured using those means known in the art, such as by surface stress meter (FSM) using commercially available instruments such as the FSM-6000, manufactured by Orihara Industrial Co., Ltd. (Japan). Surface stress measurements rely upon the accurate measurement of the stress optical coefficient (SOC), which is related to the birefringence of the glass. SOC in turn is measured by those methods that are known in the art, such as fiber and four point bend methods, both of which are described in ASTM standard C770-98 (2013), entitled“Standard Test Method for Measurement of Glass Stress-Optical

Coefficient,” the contents of which are incorporated herein by reference in their entirety, and a bulk cylinder method. As used herein CS may be the“maximum compressive stress” which is the highest compressive stress value measured within the compressive stress layer.

In some embodiments, the maximum compressive stress is located at the surface of the glass article. In other embodiments, the maximum compressive stress may occur at a depth below the surface, giving the compressive profile the appearance of a“buried peak.”

[0108] DOC may be measured by FSM or by a scattered light polariscope (SCALP) (such as the SCALP-04 scattered light polariscope available from Glasstress Ltd., located in Tallinn Estonia), depending on the strengthening method and conditions. When the glass article is chemically strengthened by an ion exchange treatment, FSM or SCALP may be used depending on which ion is exchanged into the glass article. Where the stress in the glass article is generated by exchanging potassium ions into the glass article, FSM is used to measure DOC. Where the stress is generated by exchanging sodium ions into the glass article, SCALP is used to measure DOC. Where the stress in the glass article is generated by exchanging both potassium and sodium ions into the glass, the DOC is measured by SCALP, since it is believed the exchange depth of sodium indicates the DOC and the exchange depth of potassium ions indicates a change in the magnitude of the compressive stress (but not the change in stress from compressive to tensile); the exchange depth of potassium ions in such glass articles is measured by FSM. Central tension or CT is the maximum tensile stress and is measured by SCALP.

[0109] In one or more embodiments, the glass articles used to form the layer(s) of the deadfront structures maybe strengthened to exhibit a DOC that is described a fraction of the thickness t of the glass article (as described herein). For example, in one or more

embodiments, the DOC may be equal to or greater than about 0.05t, equal to or greater than about 0. lt, equal to or greater than about 0.1 lt, equal to or greater than about 0. l2t, equal to or greater than about 0. l3t, equal to or greater than about 0. l4t, equal to or greater than about 0.15t, equal to or greater than about 0.16t, equal to or greater than about 0.17t, equal to or greater than about 0.18t, equal to or greater than about 0.19t, equal to or greater than about 0.2t, equal to or greater than about 0.2 lt. In some embodiments, The DOC may be in a range from about 0.08t to about 0.25t, from about 0.09t to about 0.25t, from about 0.18t to about 0.25t, from about 0.1 lt to about 0.25t, from about 0. l2t to about 0.25t, from about 0. l3t to about 0.25t, from about 0. l4t to about 0.25t, from about 0.15t to about 0.25t, from about 0.08t to about 0.24t, from about 0.08t to about 0.23t, from about 0.08t to about 0.22t, from about 0.08t to about 0.211, from about 0.08t to about 0.2t, from about 0.08t to about 0. l9t, from about 0.08t to about 0.18t, from about 0.08t to about 0.l7t, from about 0.08t to about 0.16t, or from about 0.08t to about 0.15t. In some instances, the DOC may be about 20 mih or less. In one or more embodiments, the DOC may be about 20 mih or greater, 30 mih or greater, or about 40 mih or greater (e.g., from about 20 gm to about 300 gm, from about 50 gm to about 300 gm, from about 60 gm to about 300 gm, from about 70 gm to about 300 gm, from about 80 gm to about 300 gm, from about 90 gm to about 300 gm, from about 100 gm to about 300 gm, from about 110 gm to about 300 gm, from about 120 gm to about 300 gm, from about 140 gm to about 300 gm, from about 150 gm to about 300 gm, from about 20 gm to about 290 gm, from about 20 gm to about 280 gm, from about 20 gm to about 260 gm, from about 20 gm to about 250 gm, from about 20 gm to about 220 gm, from about 20 gm to about 230 gm, from about 20 gm to about 220 gm, from about 20 gm to about 210 gm, from about 20 gm to about 200 gm, from about 20 gm to about 180 gm, from about 20 gm to about 160 gm, from about 20 gm to about 150 gm, from about 20 gm to about 120 gm, from about 20 gm to about 130 gm, from about 20 gm to about 120 gm, from about 20 gm to about 110 gm, or from about 20 gm to about 100 gm.

[0110] In one or more embodiments, the glass articles used to form the layer(s) of the deadfront structures may have a CS (which may be found at the surface or a depth within the glass article) of about 200 MPa or greater, 300 MPa or greater, 400 MPa or greater, about 500 MPa or greater, about 600 MPa or greater, about 700 MPa or greater, about 800 MPa or greater, about 900 MPa or greater, about 930 MPa or greater, about 1000 MPa or greater, or about 1050 MPa or greater. In one or more embodiments, the CS at the surface in a range from about 800 MPa to about 1200 MPa.

[0111] In one or more embodiments, the glass articles used to form the layer(s) of the deadfront structures may have a maximum tensile stress or central tension (CT) of about 20 MPa or greater, about 30 MPa or greater, about 40 MPa or greater, about 45 MPa or greater, about 50 MPa or greater, about 60 MPa or greater, about 70 MPa or greater, about 75 MPa or greater, about 80 MPa or greater, or about 85 MPa or greater. In some embodiments, the maximum tensile stress or central tension (CT) may be in a range from about 20 MPa to about 100 MPa, from about 20 MPa to about 80 MPa, from about 20 MPa to about 60 MPa, from about 20 MPa to about 50 MPa, or from about 20 MPa to about 40 MPa. [0112] In some embodiments, the strengthened glass substrate exhibits a stress profile along the depth or thickness thereof that exhibits a parabolic-like shape, as described in U.S. Patent No. 9,593,042, entitled“Glasses and glass ceramics including metal oxide concentration gradient”, which is hereby incorporated by reference in its entirety.“Stress profile” refers to the changes in stress from the first major surface to the second major surface. The stress profile may be described in terms of MPa at a given micrometer of thickness or depth from the first major surface or the second major surface. In one or more specific embodiments, the stress profile is substantially free of a flat stress (i.e., compressive or tensile) portion or a portion that exhibits a substantially constant stress (i.e., compressive or tensile). In some embodiments, the region of the glass substrate exhibiting a tensile stress has a stress profile that is substantially free of a flat stress or free of a substantially constant stress. In one or more embodiments, all points of the stress profile between a thickness range from about Ot up to about 0.2»t and greater than 0.8 * t (or from about 0_*t to about 0.3 * t and greater than 0 7_*t) comprise a tangent that is less than about -0.1 MPa/micrometers or greater than about 0.1 MPa/micrometers. In some embodiments, the tangent may be less than about -0.2

MPa/micrometers or greater than about 0.2 MPa/micrometers. In some more specific embodiments, the tangent may be less than about -0.3 MPa/micrometers or greater than about 0.3 MPa/micrometers. In an even more specific embodiment, the tangent may be less than about -0.5 MPa/micrometers or greater than about 0.5 MPa/micrometers. In other words, the stress profile of one or more embodiments along these thickness ranges (i.e., 0_*t up to about 2_*t and greater than 0.8t, or from about Ot to about 0 3_*t and 0 7_*t or greater) exclude points having a tangent, as described herein. In contrast, stress profiles that exhibit error function or quasi-linear shapes have points along these thickness ranges (i.e., 0^»t up to about 2^»t and greater than 0.8*t, or from about 0_*t to about 0.3 -t and 0 7_*t or greater) that have a tangent that is from about -0.1 MPa/micrometers to about 0.1 MPa/micrometers, from about -0.2 MPa/micrometers to about 0.2 MPa/micrometers, from about -0.3 MPa/micrometers to about 0.3 MPa/micrometers, or from about -0.5 MPa/micrometers to about 0.5 MPa/micrometers (indicating a flat or zero slope stress profile along such thickness ranges, as shown in Figure 2, 220). The stress profiles of one or more embodiments of this disclosure do not exhibit such a stress profile having a flat or zero slope stress profile along these thickness ranges.

[0113] In one or more embodiments, the strengthened glass substrate exhibits a stress profile a thickness range from about 0. l^»t to 0.3 * t and from about 0 7_*t to 0 9_*t that comprises a maximum tangent and a minimum tangent. In some instances, the difference between the maximum tangent and the minimum tangent is about 3.5 MPa/micrometers or less, about 3 MPa/micrometers or less, about 2.5 MPa/micrometers or less, or about 2 MPa/micrometers or less.

[0114] In one or more embodiments, the stress profile of the strengthened glass substrate may be substantially free of any linear segments that extend in a depth direction or along at least a portion of the thickness t of the glass substrate. In other words, the stress profile is substantially continuously increasing or decreasing along the thickness t. In some embodiments, the stress profile is substantially free of any linear segments in a depth or thickness direction having a length of about 10 micrometers or more, about 50 micrometers or more, or about 100 micrometers or more, or about 200 micrometers or more. As used herein, the term“linear” refers to a slope having a magnitude of less than about 5

MPa/micrometer, or less than about 2 MPa/micrometer along the linear segment. In some embodiments, one or more portions of the stress profile that are substantially free of any linear segments in a depth direction are present at depths within the strengthened glass substrate of about 5 micrometers or greater (e.g., 10 micrometers or greater, or 15

micrometers or greater) from either one or both the first major surface or the second major surface. For example, along a depth or thickness of about 0 micrometers to less than about 5 micrometers from the first surface, the stress profile may include linear segments, but from a depth of about 5 micrometers or greater from the first surface, the stress profile may be substantially free of linear segments.

[0115] In some embodiments, the stress profile may include linear segments at depths from about Ot up to about O.lt and may be substantially free of linear segments at depths of about O.lt to about 0.4t. In some embodiments, the stress profile from a thickness in the range from about Ot to about 0. lt may have a slope in the range from about 20 MPa/microns to about 200 MPa/microns. As will be described herein, such embodiments may be formed using a single ion-exchange process by which the bath includes two or more alkali salts or is a mixed alkali salt bath or multiple (e.g., 2 or more) ion exchange processes.

[0116] In one or more embodiments, the strengthened glass substrate may be described in terms of the shape of the stress profile along the CT region or the region in the glass substrate that exhibits tensile stress. For example, in some embodiments, the stress profile along the CT region (where stress is in tension) may be approximated by equation. In some

embodiments, the stress profile along the CT region may be approximated by equation (1):

[0117] Stress(x) = MaxCT - (((MaxCT · (n+l))/0.5n) |(x/t)-0.5|n) (1)

[0118] In equation (1), the stress (x) is the stress value at position x. Here the stress is positive (tension). MaxCT is the maximum central tension as a positive value in MPa. The value x is position along the thickness (t) in micrometers, with a range from 0 to t; x=0 is one surface, x=0.5t is the center of the glass substrate, stress(x)=MaxCT, and x=t is the opposite surface (i.e., the first major surface or the second major surface). MaxCT used in equation (1) may be in the range from about 50 MPa to about 350 MPa (e.g., 60 MPa to about 300 MPa, or from about 70 MPa to about 270 MPa), and n is a fitting parameter from 1.5 to 5 (e.g., 2 to 4, 2 to 3 or 1.8 to 2.2) whereby n=2 can provide a parabolic stress profile, exponents that deviate from n=2 provide stress profiles with near parabolic stress profiles.

[0119] In one or more embodiments, the parabolic-like stress profile is generated due to a non-zero concentration of a metal oxide(s) that varies along a portion of the thickness. The variation in concentration may be referred to herein as a gradient. In some embodiments, the concentration of a metal oxide is non-zero and varies, both along a thickness range from about 0_*t to about 0 3_*t. In some embodiments, the concentration of the metal oxide is non zero and varies along a thickness range from about 0_*t to about 0.35^»t, from about 0_*t to about 0.4*t, from about 0_*t to about 0 45_*t or from about 0_*t to about 0 48_*t. The metal oxide may be described as generating a stress in the strengthened glass substrate. The variation in concentration may be continuous along the above-referenced thickness ranges. Variation in concentration may include a change in metal oxide concentration of about 0.2 mol% along a thickness segment of about 100 micrometers. This change may be measured by known methods in the art including microprobe. The metal oxide that is non-zero in concentration and varies along a portion of the thickness may be described as generating a stress in the strengthened glass substrate.

[0120] The variation in concentration may be continuous along the above-referenced thickness ranges. In some embodiments, the variation in concentration may be continuous along thickness segments in the range from about 10 micrometers to about 30 micrometers.

In some embodiments, the concentration of the metal oxide decreases from the first surface to a point between the first surface and the second surface and increases from the point to the second surface.

[0121] The concentration of metal oxide may include more than one metal oxide (e.g., a combination of Na20 and K20). In some embodiments, where two metal oxides are utilized and where the radius of the ions differ from one or another, the concentration of ions having a larger radius is greater than the concentration of ions having a smaller radius at shallow depths, while the at deeper depths, the concentration of ions having a smaller radius is greater than the concentration of ions having larger radius. For example, where a single Na- and K- containing bath is used in the ion exchange process, the concentration of K+ ions in the strengthened glass substrate is greater than the concentration of Na+ ions at shallower depths, while the concentration of Na+ is greater than the concentration of K+ ions at deeper depths. This is due, in part, due to the size of the ions. In such strengthened glass substrate, the area at or near the surface comprises a greater CS due to the greater amount of larger ions at or near the surface. This greater CS may be exhibited by a stress profile having a steeper slope at or near the surface (i.e., a spike in the stress profile at the surface).

[0122] The concentration gradient or variation of one or more metal oxides is created by chemically strengthening the glass substrate, for example, by the ion exchange processes previously described herein, in which a plurality of first metal ions in the glass substrate is exchanged with a plurality of second metal ions. The first ions may be ions of lithium, sodium, potassium, and rubidium. The second metal ions may be ions of one of sodium, potassium, rubidium, and cesium, with the proviso that the second alkali metal ion has an ionic radius greater than the ionic radius than the first alkali metal ion. The second metal ion is present in the glass substrate as an oxide thereof (e.g., Na20, K20, Rb20, Cs20 or a combination thereof).

[0123] In one or more embodiments, the metal oxide concentration gradient extends through a substantial portion of the thickness t or the entire thickness t of the strengthened glass substrate, including the CT region. In one or more embodiments, the concentration of the metal oxide is about 0.5 mol% or greater in the CT region. In some embodiments, the concentration of the metal oxide may be about 0.5 mol% or greater (e.g., about 1 mol% or greater) along the entire thickness of the strengthened glass substrate, and is greatest at the first major surface and/or the second major surface and decreases substantially constantly to a point between the first major surface and the second major surface. At that point, the concentration of the metal oxide is the least along the entire thickness t; however the concentration is also non-zero at that point. In other words, the non-zero concentration of that particular metal oxide extends along a substantial portion of the thickness t (as described herein) or the entire thickness t. In some embodiments, the lowest concentration in the particular metal oxide is in the CT region. The total concentration of the particular metal oxide in the strengthened glass substrate may be in the range from about 1 mol% to about 20 mol%.

[0124] In one or more embodiments, the strengthened glass substrate includes a first metal oxide concentration and a second metal oxide concentration, such that the first metal oxide concentration is in the range from about 0 mol% to about 15 mol% along a first thickness range from about Ot to about 0.5t, and the second metal oxide concentration is in the range from about 0 mol% to about 10 mol% from a second thickness range from about 0 micrometers to about 25 micrometers (or from about 0 micrometers to about 12

micrometers). The strengthened glass substrate may include an optional third metal oxide concentration. The first metal oxide may include Na20 while the second metal oxide may include K20.

[0125] The concentration of the metal oxide may be determined from a baseline amount of the metal oxide in the glass substrate prior to being modified to include the concentration gradient of such metal oxide.

[0126] Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is in no way intended that any particular order be inferred. In addition, as used herein, the article“a” is intended to include one or more than one component or element, and is not intended to be construed as meaning only one.

[0127] Aspect (1) of this disclosure pertains to a deadfront article, comprising: a substrate having a first major surface and a second major surface, the second major surface being opposite the first major surface; at least one polymer layer disposed on the second major surface of the transparent substrate, each polymer layer having a first coefficient of thermal expansion (CTE); and at least one metal layer disposed on each of the at least one polymer layer; wherein each of the at least one metal layer comprises a surface area and a network of cracks that extend through a thickness of each metal layer and are disposed across at least a portion of the surface area; wherein each metal layer has a second CTE; and wherein each first CTE is greater than each second CTE.

[0128] Aspect (2) of this disclosure pertains to the deadfront article of Aspect (1), wherein the substrate is transparent.

[0129] Aspect (3) of this disclosure pertains to the deadfront article of Aspect (1), wherein the substrate is a plastic that is at least one of polymethylmethacrylate, polyethylene terephthalate, or cellulose triacetate.

[0130] Aspect (4) of this disclosure pertains to the deadfront article of Aspect (1), wherein the substrate is a glass or glass-ceramic material.

[0131] Aspect (5) of this disclosure pertains to the deadfront article of Aspect (1), wherein the substrate comprises at least one of soda lime glass, aluminosilicate glass, borosilicate glass, boroaluminosilicate glass, alkali-containing aluminosilicate glass, alkali-containing borosilicate glass, or alkali-containing boroaluminosilicate glass.

[0132] Aspect (6) of this disclosure pertains to the deadfront article of any one of Aspects (1) through (5), wherein each first CTE is at least 50 ppm/°C.

[0133] Aspect (7) of this disclosure pertains to the deadfront article of any one of Aspects (1) through (6), wherein each second CTE is no more than 20 ppm/°C.

[0134] Aspect (8) of this disclosure pertains to the deadfront article of any one of Aspects (1) through (7), wherein each polymer layer comprises at least one of polystyrene or

polymethylmethacrylate.

[0135] Aspect (9) of this disclosure pertains to the deadfront article of any one of Aspects (1) through (8), wherein each polymer layer comprises a polymer having a glass transition temperature of no more than 200 °C.

[0136] Aspect (10) of this disclosure pertains to the deadfront article of any one of Aspects (1) through (9), wherein each polymer layer comprises a polymer having a glass transition temperature of no more than 100 °C.

[0137] Aspect (11) of this disclosure pertains to the deadfront article of any one of Aspects (1) through (10), wherein each metal layer comprises at least one of nickel, chromium, titanium, iron, cobalt, or molybdenum.

[0138] Aspect (12) of this disclosure pertains to the deadfront article of any one of Aspects (1) through (11), wherein the surface area of each metal layer is at least 25% of the first major surface.

[0139] Aspect (13) of this disclosure pertains to the deadfront article of any one of Aspects (1) through (12), wherein the surface area of each metal layer is at least 50% of the first major surface.

[0140] Aspect (14) of this disclosure pertains to the deadfront article of any one of Aspects (1) through (13), wherein each metal layer is at least 90% of the first major surface.

[0141] Aspect (15) of this disclosure pertains to the deadfront article of any one of Aspects (1) through (14), wherein the network of cracks is disposed on at least 25% of the surface area of each metal layer.

[0142] Aspect (16) of this disclosure pertains to the deadfront article of any one of Aspects (1) through (15), wherein the network of cracks is disposed on at least 50% of the surface area of each metal layer. [0143] Aspect (17) of this disclosure pertains to the deadfront article of any one of Aspects (1) through (16), wherein the network of cracks is disposed on at least 90% of the surface area of each metal layer.

[0144] Aspect (18) of this disclosure pertains to the deadfront article of any one of Aspects (1) through (17), further comprising an ink coating applied to the second major surface of the transparent substrate.

[0145] Aspect (19) of this disclosure pertains to the deadfront article of Aspect (18), wherein the ink layer is a solid color.

[0146] Aspect (20) of this disclosure pertains to the deadfront article of Aspect (18), wherein the ink layer is a pattern of two or more colors.

[0147] Aspect (21) of this disclosure pertains to the deadfront article of any one of Aspects (1) through (20), further comprising a surface treatment disposed on the first major surface of the transparent substrate.

[0148] Aspect (22) of this disclosure pertains to the deadfront article of Aspect (21), wherein the surface treatment is at least one of antiglare, etching, antireflection coating, or durable antireflection coating.

[0149] Aspect (23) of this disclosure pertains to the deadfront article of any one of Aspects (1) through (22), wherein the transparent substrate is 2 mm or less in thickness.

[0150] Aspect (24) of this disclosure pertains to the deadfront article of any one of Aspects (1) through (23), wherein each metal layer is at most 20 nm thick.

[0151] Aspect (25) of this disclosure pertains to the deadfront article of any one of Aspects (1) through (24), comprising up to ten polymer layers and up to ten metal layers, wherein the polymer layers and the metal layers are altematingly stacked such that each polymer layer is adjacent to at least one metal layer.

[0152] Aspect (26) pertains to a method of manufacturing a deadfront, comprising the steps of: applying at least one polymer layer on a first side a transparent substrate, each polymer layer having a first coefficient of thermal expansion (CTE) and a glass transition temperature of less than 200 °C; depositing at least one metal layer onto each polymer layer, each metal layer having a second CTE that is less than the first CTE; and annealing the transparent substrate, the at least one polymer layer, and the at least one metal layer at a temperature of from 50 °C to 300 °C so as to create a network of cracks through the thickness of each metal layer and across a surface area of each metal layer.

[0153] Aspect (27) of this disclosure pertains to the method of Aspect (26), wherein the step of applying each of the at least one polymer layer to the first side of the transparent substrate further comprises dip forming, spin coating, roller coating, slot coating, thermal evaporating, aerosol spraying, or plasma spraying the polymer layer on the first side of the transparent substrate.

[0154] Aspect (28) of this disclosure pertains to the method of Aspect (26), wherein the step of applying each of the at least one polymer layer to the first side of the transparent substrate further comprises spin-coating each polymer layer the first side of the transparent substrate after dissolving a polymer in a solvent at a weight ratio of polymer to solvent of from 6.4: 1 to 30: 1.

[0155] Aspect (29) of this disclosure pertains to the method of any one of Aspects (26) through (28), wherein the polymer is at least one of polystyrene or polymethylmethacrylate.

[0156] Aspect (30) of this disclosure pertains to the method of any one of Aspects (26) through (29), wherein depositing the metal layer onto the polymer layer is performed via physical vapor deposition.

[0157] Aspect (31) of this disclosure pertains to the method of any one of Aspects (26) through (30), wherein each metal layer comprises at least one of nickel, chromium, titanium, iron, molybdenum, or cobalt.

[0158] Aspect (32) of this disclosure pertains to the method of any one of Aspects (26) through (31), further comprising the step of selecting each polymer layer and each metal layer such that the difference between each first CTE and each second CTE is at least 30 ppm/°C.

[0159] Aspect (33) of this disclosure pertains to the method of any one of Aspects (26) through (32), wherein the transparent substrate is at least one of polymethylmethacrylate, polyethylene terephthalate, cellulose triacetate, aluminosilicate, borosilicate, soda lime glass, boroaluminosilicate glass, alkali-containing aluminosilicate glass, alkali-containing borosilicate glass, or alkali-containing boroaluminosilicate glass.

[0160] Aspect (34) of this disclosure pertains to the method of any one of Aspects (26) through (33), further comprising the step of printing an ink layer on the first side of the transparent substrate prior to applying the polymer layer.

[0161] Aspect (35) of this disclosure pertains to the method of any one of Aspects (26) through (34), further comprising the step of applying a surface treatment to a second side of the transparent substrate, the second side being opposite to the first side.

[0162] Aspect (36) of this disclosure pertains to the method of Aspect (35), where the surface treatment is at least one of antiglare, etching, antireflection coating, or durable antireflection coating. [0163] Aspect (37) of this disclosure pertains to the method of any one of Aspects (26) through (36), wherein the steps of applying at least one polymer layer and applying at least one metal layer are alternatingly performed up to ten times.

[0164] Aspect (38) of this disclosure pertains to a deadfront article, comprising: a transparent substrate having a first major surface and a second major surface, the second major surface being opposite the first major surface; a first polymer layer disposed on the second major surface of the transparent substrate; and a first metal layer disposed on the first polymer layer such that the first polymer layer is between the transparent substrate and the first metal layer; a touch panel disposed on the first metal layer; wherein the first metal layer includes a network of cracks through a thickness of the first metal layer and across a surface area of the first metal layer.

[0165] Aspect (39) of this disclosure pertains to the deadfront article of Aspect (38), wherein the transparent substrate is at least one of polymethylmethacrylate, polyethylene

terephthalate, cellulose triacetate, soda lime glass, aluminosilicate glass, borosilicate glass, boroaluminosilicate glass, alkali-containing aluminosilicate glass, alkali-containing borosilicate glass, or alkali-containing boroaluminosilicate glass.

[0166] Aspect (40) of this disclosure pertains to the method of Aspect (38) or Aspect (39), wherein the first polymer layer has a first coefficient of thermal expansion (CTE), wherein the first metal layer has a second CTE, and wherein the first CTE is greater than the second CTE.

[0167] Aspect (41) of this disclosure pertains to the method of Aspect (40), wherein the first CTE is at least 30 ppm/°C greater than the second CTE.

[0168] Aspect (42) of this disclosure pertains to the method of any one of Aspects (38) through (41), wherein the first polymer layer comprises at least one of polystyrene or polymethylmethacrylate.

[0169] Aspect (43) of this disclosure pertains to the method of any one of Aspects (38) through (42), wherein the first polymer layer comprises a polymer having a glass transition temperature of no more than 200 °C.

[0170] Aspect (44) of this disclosure pertains to the method of any one of Aspects (38) through (43), wherein the first metal layer comprises at least one of nickel, chromium, titanium, iron, molybdenum, or cobalt.

[0171] Aspect (45) of this disclosure pertains to the method of any one of Aspects (38) through (44), further comprising an ink coating applied to the second major surface of the transparent substrate. [0172] Aspect (46) of this disclosure pertains to the method of Aspect (45), wherein the ink layer is a solid color.

[0173] Aspect (47) of this disclosure pertains to the method of Aspect (45), wherein the ink layer is a pattern of two or more colors.

[0174] Aspect (48) of this disclosure pertains to the method of any one of Aspects (38) through (47), further comprising a surface treatment disposed on the first major surface of the transparent substrate.

[0175] Aspect (49) of this disclosure pertains to the method of Aspect (48), wherein the surface treatment is at least one of antiglare, etching, antireflection coating, or durable antireflection coating.

[0176] Aspect (50) of this disclosure pertains to the method of any one of Aspects (38) through (49), wherein the transparent substrate is 2 mm or less in thickness.

[0177] Aspect (51) of this disclosure pertains to the method of any one of Aspects (38) through (50), wherein the first metal layer is at most 20 nm thick.

[0178] Aspect (52) of this disclosure pertains to the method of any one of Aspects (38) through (51), further comprising at least a second polymer layer and at least a second metal layer; wherein each polymer layer is alternating stacked with each metal layer.

[0179] Aspect (53) of this disclosure pertains to a deadfront article, comprising: a substrate having a first major surface and a second major surface, the second major surface being opposite the first major surface; a polymer layer disposed on the second major surface of the transparent substrate, the polymer layer having a first coefficient of thermal expansion (CTE); and a metal-containing layer disposed on the polymer layer such that the polymer layer is between the transparent substrate and the metal-containing layer; wherein, when the deadfront article is disposed over a light source, the deadfront article exhibits a transmittance of 15% or greater when the light source emits a light.

[0180] Aspect (54) of this disclosure pertains to the deadfront article of Aspect (53), wherein each of L*a*b* values of light emitted from the light source is within 10 of the respective L*a*b* values of light transmitted through the article.

[0181] Aspect (55) of this disclosure pertains to the deadfront article Aspect (53) or Aspect (54), wherein each of L*a*b* values of light emitted from the light source is within 5 of the respective L*a*b* values of light transmitted through the article.

[0182] Aspect (56) of this disclosure pertains to the deadfront article of any one of Aspects (53) through (55), wherein each of L*a*b* values of light emitted from the light source is within 2 of the respective L*a*b* values of light transmitted through the article. [0183] Aspect (57) of this disclosure pertains to the deadfront article of any one of Aspects (53) through (56), wherein a color difference AE*ab between light emitted from the light source and light transmitted through the article is less than 20.

[0184] Aspect (58) of this disclosure pertains to the deadfront article of any one of Aspects (53) through (57), wherein a color difference AE*ab between light emitted from the light source and light transmitted through the article is less than 10.

[0185] Aspect (59) of this disclosure pertains to the deadfront article of any one of Aspects (53) through (58), wherein a color difference AE*ab between light emitted from the light source and light transmitted through the article is less than 2.

[0186] Aspect (60) of this disclosure pertains to the deadfront article of any one of Aspects (53) through (59), wherein the light source is at least one of a light emitting diode (LED) display, an organic LED (OLED) display, a liquid crystal display (LCD), or a plasma display.

[0187] It will be apparent to those skilled in the art that various modifications and variations can be made without departing from the spirit or scope of the disclosed embodiments. Since modifications, combinations, sub-combinations and variations of the disclosed embodiments incorporating the spirit and substance of the embodiments may occur to persons skilled in the art, the disclosed embodiments should be construed to include everything within the scope of the appended claims and their equivalents.

Claims

What is claimed is:

1. A deadfront article, comprising: a substrate having a first major surface and a second major surface, the second major surface being opposite the first major surface; at least one polymer layer disposed on the second major surface of the transparent substrate, each polymer layer having a first coefficient of thermal expansion (CTE); and at least one metal layer disposed on each of the at least one polymer layer; wherein each of the at least one metal layer comprises a surface area and a network of cracks that extend through a thickness of each metal layer and are disposed across at least a portion of the surface area; wherein each metal layer has a second CTE; and wherein each first CTE is greater than each second CTE.

2. The deadfront article of claim 1, wherein the substrate is transparent.

3. The deadfront article of claim 1, wherein the substrate is a plastic that is at least one of polymethylmethacrylate, polyethylene terephthalate, or cellulose triacetate.

4. The deadfront article of claim 1, wherein the substrate is a glass or glass- ceramic material.

5. The deadfront article of claim 1, wherein the substrate comprises at least one of soda lime glass, aluminosilicate glass, borosilicate glass, boroaluminosilicate glass, alkali- containing aluminosilicate glass, alkali-containing borosilicate glass, or alkali-containing boroaluminosilicate glass.

6. The deadfront article of any one of the preceding claims, wherein each first CTE is at least 50 ppm/°C.

7. The deadfront article of any one of the preceding claims, wherein each second CTE is no more than 20 ppm/°C.

8. The deadfront article of any one of the preceding claims, wherein each polymer layer comprises at least one of polystyrene or polymethylmethacrylate.

9. The deadfront article of any one of the preceding claims, wherein each polymer layer comprises a polymer having a glass transition temperature of no more than 200 °C.

10. The deadfront article of any one of the preceding claims, wherein each polymer layer comprises a polymer having a glass transition temperature of no more than 100 °C.

11. The deadfront article of any one of the preceding claims, wherein each metal layer comprises at least one of nickel, chromium, titanium, iron, cobalt, or molybdenum.

12. The deadfront article of any one of the preceding claims, wherein the surface area of each metal layer is at least 25% of the first major surface.

13. The deadfront article of any one of the preceding claims, wherein the surface area of each metal layer is at least 50% of the first major surface.

14. The deadfront article of any one of the preceding claims, wherein each metal layer is at least 90% of the first major surface.

15. The deadfront article of any one of the preceding claims, wherein the network of cracks is disposed on at least 25% of the surface area of each metal layer.

16. The deadfront article of any one of the preceding claims, wherein the network of cracks is disposed on at least 50% of the surface area of each metal layer.

17. The deadfront article of any one of the preceding claims, wherein the network of cracks is disposed on at least 90% of the surface area of each metal layer.

18. The deadfront article of any one of the preceding claims, further comprising an ink coating applied to the second major surface of the transparent substrate.

19. The deadfront article of claim 18, wherein the ink layer is a solid color.

20. The deadfront article of claim 18, wherein the ink layer is a pattern of two or more colors.

21. The deadfront article of any one of the preceding claims, further comprising a surface treatment disposed on the first major surface of the transparent substrate.

22. The deadfront article of claim 21, wherein the surface treatment is at least one of antiglare, etching, antireflection coating, or durable antireflection coating.

23. The deadfront article of any one of the preceding claims, wherein the transparent substrate is 2 mm or less in thickness.

24. The deadfront article of any one of the preceding claims, wherein each metal layer is at most 20 nm thick.

25. The deadfront article of any one of the preceding claims, comprising up to ten polymer layers and up to ten metal layers, wherein the polymer layers and the metal layers are altematingly stacked such that each polymer layer is adjacent to at least one metal layer.

26. A method of manufacturing a deadfront, comprising the steps of: applying at least one polymer layer on a first side a transparent substrate, each polymer layer having a first coefficient of thermal expansion (CTE) and a glass transition temperature of less than 200 °C; depositing at least one metal layer onto each polymer layer, each metal layer having a second CTE that is less than the first CTE; and annealing the transparent substrate, the at least one polymer layer, and the at least one metal layer at a temperature of from 50 °C to 300 °C so as to create a network of cracks through the thickness of each metal layer and across a surface area of each metal layer.

27. The method of claim 26, wherein the step of applying each of the at least one polymer layer to the first side of the transparent substrate further comprises dip forming, spin coating, roller coating, slot coating, thermal evaporating, aerosol spraying, or plasma spraying the polymer layer on the first side of the transparent substrate.

28. The method of claim 26, wherein the step of applying each of the at least one polymer layer to the first side of the transparent substrate further comprises spin-coating each polymer layer the first side of the transparent substrate after dissolving a polymer in a solvent at a weight ratio of polymer to solvent of from 6.4: 1 to 30: 1.

29. The method of any one of claims 26-28, wherein the polymer is at least one of polystyrene or polymethylmethacrylate.

30. The method of any one of claims 26 to 29, wherein depositing the metal layer onto the polymer layer is performed via physical vapor deposition.

31. The method of any one of claims 26 to 30, wherein each metal layer comprises at least one of nickel, chromium, titanium, iron, molybdenum, or cobalt.

32. The method of any one of claims 26 to 31, further comprising the step of selecting each polymer layer and each metal layer such that the difference between each first CTE and each second CTE is at least 30 ppm/°C.

33. The method any one of claims 26 to 32, wherein the transparent substrate is at least one of polymethylmethacrylate, polyethylene terephthalate, cellulose triacetate, aluminosilicate, borosilicate, soda lime glass, boroaluminosilicate glass, alkali-containing aluminosilicate glass, alkali-containing borosilicate glass, or alkali-containing

boroaluminosilicate glass.

34. The method of any one of claims 26 to 33, further comprising the step of printing an ink layer on the first side of the transparent substrate prior to applying the polymer layer.

35. The method of any one of claims 26 to 34, further comprising the step of applying a surface treatment to a second side of the transparent substrate, the second side being opposite to the first side.

36. The method of claim 35, where the surface treatment is at least one of antiglare, etching, antireflection coating, or durable antireflection coating.

37. The method of any one of claims 26 to 36, wherein the steps of applying at least one polymer layer and applying at least one metal layer are altematingly performed up to ten times.

38. A deadfront article, comprising: a transparent substrate having a first major surface and a second major surface, the second major surface being opposite the first major surface; a first polymer layer disposed on the second major surface of the transparent substrate; and a first metal layer disposed on the first polymer layer such that the first polymer layer is between the transparent substrate and the first metal layer; a touch panel disposed on the first metal layer; wherein the first metal layer includes a network of cracks through a thickness of the first metal layer and across a surface area of the first metal layer.

39. The deadfront article of claim 38, wherein the transparent substrate is at least one of polymethylmethacrylate, polyethylene terephthalate, cellulose triacetate, soda lime glass, aluminosilicate glass, borosilicate glass, boroaluminosilicate glass, alkali-containing aluminosilicate glass, alkali-containing borosilicate glass, or alkali-containing

boroaluminosilicate glass.

40. The deadfront article of claim 38 or 39, wherein the first polymer layer has a first coefficient of thermal expansion (CTE), wherein the first metal layer has a second CTE, and wherein the first CTE is greater than the second CTE.

41. The deadfront article of claim 40, wherein the first CTE is at least 30 ppm/°C greater than the second CTE.

42. The deadfront article of any one of claims 38 to 41, wherein the first polymer layer comprises at least one of polystyrene or polymethylmethacrylate.

43. The deadfront article of any one of claims 38 to 42, wherein the first polymer layer comprises a polymer having a glass transition temperature of no more than 200 °C.

44. The deadfront article of any one of claims 38 to 43, wherein the first metal layer comprises at least one of nickel, chromium, titanium, iron, molybdenum, or cobalt.

45. The deadfront article of any one of claims 38 to 44, further comprising an ink coating applied to the second major surface of the transparent substrate.

46. The deadfront article of claim 45, wherein the ink layer is a solid color.

47. The deadfront article of claim 45, wherein the ink layer is a pattern of two or more colors.

48. The deadfront article of any one of claims 38 to 47, further comprising a surface treatment disposed on the first major surface of the transparent substrate.

49. The deadfront article of claim 48, wherein the surface treatment is at least one of antiglare, etching, antireflection coating, or durable antireflection coating.

50. The deadfront article of any one of claims 38 to 49, wherein the transparent substrate is 2 mm or less in thickness.

51. The deadfront article of any one of claims 38 to 50, wherein the first metal layer is at most 20 nm thick.

52. The deadfront article of any one of claims 38 to 51, further comprising at least a second polymer layer and at least a second metal layer; wherein each polymer layer is alternating stacked with each metal layer.

53. A deadfront article, comprising: a substrate having a first major surface and a second major surface, the second major surface being opposite the first major surface; a polymer layer disposed on the second major surface of the transparent substrate, the polymer layer having a first coefficient of thermal expansion (CTE); and a metal-containing layer disposed on the polymer layer such that the polymer layer is between the transparent substrate and the metal-containing layer; wherein, when the deadfront article is disposed over a light source, the deadfront article exhibits a transmittance of 15% or greater when the light source emits a light.

54. The deadfront article of claim 53, wherein each of L*a*b* values of light emitted from the light source is within 10 of the respective L*a*b* values of light transmitted through the article.

55. The deadfront article of claim 53 or 54, wherein each of L*a*b* values of light emitted from the light source is within 5 of the respective L*a*b* values of light transmitted through the article.

56. The deadfront article of any one of claims 53 to 55, wherein each of L*a*b* values of light emitted from the light source is within 2 of the respective L*a*b* values of light transmitted through the article.

57. The deadfront article of any one of claims 53 to 56, wherein a color difference AE*ab between light emitted from the light source and light transmitted through the article is less than 20.

58. The deadfront article of any one of claims 53 to 57, wherein a color difference AE*ab between light emitted from the light source and light transmitted through the article is less than 10.

59. The deadfront article of any one of claims 53 to 58, wherein a color difference AE*ab between light emitted from the light source and light transmitted through the article is less than 2.

60. The deadfront article of any one of claims 53 to 59, wherein the light source is at least one of a light emitting diode (LED) display, an organic LED (OLED) display, a liquid crystal display (LCD), or a plasma display.