Curved plastic panel and its processing method and processing device

Abstract

The present invention discloses a curved plastic panel, a processing method thereof and a processing device. The processing method is to first form a hard layer, an optical functional layer and a printing layer on a flat plastic substrate, cut it into a predetermined shape, and then perform curved hot pressing on it with a curved hot pressing device to make it a plastic substrate with a curved surface. Since the processing of the hard layer, the optical functional layer, the printing layer and CNC cutting are all carried out on the flat plastic substrate, the yield is very high. The curved hot pressing device can perform hot pressing and forming synchronously during the heating process, and has the functions of real-time monitoring of the local temperature and real-time monitoring of the local curvature forming state, and then feeds back to the local heating mechanism for adjustment, so as to improve the production yield. The present invention further improves the extendable characteristics of the polymer surface to the level of thermoforming through the design of polymer material formula, coating formula and precision coating technology, and can maintain the original optical and physical properties after passing various weather resistance tests.

Description

Technical Field

[0001] The present invention relates to a curved plastic panel, a processing method thereof and a processing device, and particularly relates to a processing method and a processing device for thermally pressing a flat plastic substrate after a hard layer and an optical functional layer are provided to form a curved plastic panel. Background Art

[0002] Most traditional automobiles use glass as the material for sunroofs, windshield glass, and the front panel of in-vehicle displays. However, due to the disadvantages of glass such as high weight, fragility, and difficulty in shaping, in recent years, some people have developed light-transmitting plastic sheets to replace traditional glass for making automobile sunroofs, windshield glass, and the front panel of in-vehicle displays. Among them, since in-vehicle displays need to better conform to the curved design of the in-vehicle streamline interior, in recent years, some manufacturers have come up with the idea of using curved in-vehicle displays to replace traditional flat in-vehicle displays. However, one of the greatest difficulties in the product design of curved in-vehicle displays is the curved panel material covering the front of the curved in-vehicle display and its manufacturing process.

[0003] Traditional curved glass panels need to first thermoform flat glass into curved glass at ultra-high temperature, then grind and polish the surface of the curved glass, and finally perform optical surface treatment (such as anti-glare or anti-reflection coating, etc.). Since it is very difficult to control the coating uniformity during optical surface treatment on a curved substrate, especially the thickness uniformity of the anti-reflection coating must reach a coating tolerance specification of + / - 10 nm to meet the requirement of a reflectivity of < 1% for the in-vehicle front panel. It is quite difficult to achieve this specification in flat panel coating, and it is almost impossible to achieve on a curved panel.

[0004] Of course, in recent years, technologies for using plastic materials to make in-vehicle display panels have also been developed. There are many types of plastics. Among them, engineering plastics made of polycarbonate (abbreviated as PC) are more suitable for making transparent substrates with curved surfaces or special structures to replace fragile and difficult-to-shape glass sheets because they have advantages such as high transparency, free dyeability, high strength and elastic modulus, high impact strength, a wide use temperature range, low molding shrinkage rate, good dimensional stability, good weather resistance, odorless, harmless to the human body, and easy to shape. However, polycarbonate (PC) also has disadvantages such as poor wear resistance and easy yellowing under ultraviolet light irradiation. Therefore, in the prior art, the method of adding a wear-resistant hard layer and an optical functional layer on the outer surface of the polycarbonate (PC) substrate is used to improve its wear resistance, ultraviolet resistance, anti-glare, and anti-reflection capabilities.

[0005] However, the prior art still encounters very difficult dilemmas in the technology of making curved plastic panels. Such as Figure 1As shown in the figure, it is a schematic structural diagram of a typical plastic panel with a curved surface. Generally speaking, the curved plastic panel applicable to a curved vehicle-mounted display structurally includes: a plastic substrate, a hard coating (abbreviated as HC), an optical functional layer, and a printing layer. Among them, the plastic substrate is usually made of a polycarbonate (PC) sheet as the main layer, and a polymethyl methacrylate (PMMA) sheet is respectively arranged on the upper and lower surfaces of the PC sheet to strengthen its physical properties. The hard coating is usually formed on the outer surface of the plastic substrate to improve the wear resistance of the plastic panel. The optical functional layer is usually formed on the hard coating to improve the optical performance of the plastic panel, such as but not limited to: ultraviolet light resistance, anti-glare, and anti-reflection, etc. The printing layer is usually printed on the inner surface of the plastic substrate to display the function pointers of the vehicle-mounted display.

[0006] As Figure 2 shown, it is a schematic diagram of the processing method of the existing plastic panel with a curved surface, which includes the following steps:

[0007] Step 21: Produce a flat plastic substrate (commonly known as a raw board) by plastic extrusion molding; this plastic substrate may be a single-layer PC sheet, or a PMMA / PC double-layer composite sheet, or a PMMA / PC / PMMA triple-layer composite sheet;

[0008] Step 22: Thermally press the flat plastic substrate into a plastic substrate with a curved surface by thermoforming with a curved surface;

[0009] Step 23: Perform HC surface treatment on the plastic substrate with a curved surface to form an HC hard coating on the upper surface of the plastic substrate with a curved surface; however, because it is very difficult to perform HC surface treatment on the curved plastic substrate, the yield is not good;

[0010] Step 24: Perform optical surface treatment on the plastic substrate with a curved surface to form an optical functional layer on the HC hard coating of the plastic substrate with a curved surface; however, because it is very difficult to perform optical surface treatment on the curved plastic substrate, the yield is not good;

[0011] Step 25: Perform printing treatment on the plastic substrate with a curved surface to form a printing layer on the lower surface of the plastic substrate with a curved surface; however, because it is very difficult to perform printing treatment on the curved plastic substrate, the yield is not good;

[0012] Step 26: The plastic substrate with a curved surface is machined by a Computer Numerical Control (CNC) milling machine to cut it into a predetermined external contour. However, since it is very difficult to perform planar CNC cutting on the curved plastic substrate, the yield is not good.

[0013] Step 27: The finished plastic panel with a curved surface is completed. Due to the cumulative effect of the defective rates in Steps 23 to 26, the yield of the finally completed product is directly very low, so there is still room for improvement.

[0014] As Figure 3A , Figure 3B and Figure 3C shown, it is a schematic diagram of an existing method for hot-pressing a planar plastic substrate into a plastic substrate with a curved surface. In the existing method of hot-pressing a planar plastic substrate 221 into a plastic substrate with a curved surface, first, the planar plastic substrate 221 is heated in an oven to a predetermined temperature to soften it, and then the heated and softened planar plastic substrate is transferred to a die pressing machine. The die pressing machine has upper and lower dies 222, 223 with a fixed shape and unchangeable curvature. The heated planar plastic substrate 221 is placed between the upper and lower dies 222, 223 (as Figure 3A ), and then the upper and lower dies 222, 223 are driven by an oil cylinder to be stacked and press the plastic substrate 221a located therein (as Figure 3B ), so that the external shape of the plastic substrate 221a is deformed into a plastic substrate 221a with a curved surface that fits the upper and lower dies, and then it is taken out (as Figure 3C ). In this existing hot-pressing technology, there are not only problems of uneven temperature of the plastic substrate 221. The heat dissipation is fast in the peripheral area, so the temperature is lower during die pressing, but the heat dissipation is slow in the central area and the temperature is higher. Moreover, there is a problem of stress concentration at the bending portion 229 with a larger curvature of the plastic substrate 221a. Therefore, if a planar plastic substrate with a hard layer and an optical functional layer is hot-pressed using this existing technology, major defects such as brittle cracking of the hard layer and uneven thickness of the optical functional layer will occur at the bending portion 229 with a larger curvature, resulting in the unusability of the hot-pressed plastic substrate 221a product and failure to pass the product test.

[0015] In traditional curvilinear forming of polymer substrates, the polymer substrate is first heated to a temperature higher than the softening point (Tg; glass transition temperature) of the polymer, and then transferred to a hot pressing mold for curvilinear hot pressing. During the transfer process, the temperature change of the substrate caused by the heat convection of room-temperature air will affect the curvature and contour accuracy of the hot pressing. The longer the transfer time, the longer the cooling time, which is less conducive to controlling the uniform temperature of the substrate, and the worse the control of the curvature and contour accuracy of the hot pressing. Therefore, reducing the transfer time and the cooling time is more conducive to controlling the accuracy of the curvature and contour. The most ideal process design is to perform high-temperature heating and curvature forming synchronously in an automated mold. The key point of the present invention is a sensing component that can monitor the local temperature and local curvature in real time, and feedback to the heating mechanism and the hot pressing mechanism to adjust in real time until the sheet reaches the optimal forming temperature and the target forming curvature. Summary of the Invention

[0016] The main object of the present invention is to provide a processing method for a curved plastic panel. First, a hard layer, an optical functional layer, and a printing layer are formed on a flat plastic substrate, and the flat plastic substrate is cut into a predetermined shape by a CNC cutting machine. Then, it is subjected to curved hot pressing processing by a curved hot pressing device to form a curved plastic substrate with a curved surface, having the hard layer, the optical functional layer, the printing layer, and the predetermined shape. The processing method of the present invention can not only manufacture multifunctional polymer material panels for partial-curved or full-curved displays, but also has the advantages of optical functions (anti-reflection or anti-glare) and safety without breaking. Moreover, since the processing of the hard layer, the optical functional layer, the printing layer, and CNC cutting are all carried out on the flat plastic substrate, the yield is very high, overcoming various deficiencies of the prior art.

[0017] Another object of the present invention is to provide a processing device for a curved plastic panel, which includes an original curved hot pressing device that can perform hot pressing forming synchronously during the heating process, and has the functions of monitoring the local temperature and the local curvature forming state in real time, and then feeding back to the local heating mechanism for adjustment. The monitoring of temperature and curvature can be divided into multiple stages, monitoring each stage one by one and performing heating or curvature forming adjustment, so as to improve the production yield of hot pressing a flat plastic substrate with a hard layer, an optical functional layer, and a printing layer into a curved plastic panel, and more importantly, to realize the hot pressing forming processing of full-curved or partial-curved plastic panels.

[0018] Another object of the present invention is to provide a material composition of the hard layer and the optical functional layer of a curved plastic panel suitable for the processing method of the present invention. Through polymer material formulation, coating formulation design, and precision coating technology, the surface extensibility of the polymer can be improved to the level of thermoforming, and the original optical and physical properties can be maintained after passing various weather resistance tests.

[0019] To achieve the above object, the present invention discloses a processing method for a curved plastic panel, comprising: providing a flat plastic substrate; forming a flat hard coating (abbreviated as HC) on at least one surface of the flat plastic substrate; forming a flat optical functional layer on the hard coating of the flat plastic substrate; forming a flat printing layer on at least one surface of the flat plastic substrate; cutting the flat plastic substrate with a cutting machine into the flat plastic substrate with a predetermined shape; and performing curved hot pressing on the flat plastic substrate having the hard coating, the optical functional layer and the printing layer and having the predetermined shape with a curved hot pressing device to make it into a curved plastic panel having a curved surface and having the hard coating, the optical functional layer and the printing layer and having the predetermined shape.

[0020] Wherein, the curved hot pressing device includes: an upper mold with variable curvature, a lower mold with variable curvature, a plurality of upper heaters, a plurality of upper temperature sensors, a plurality of lower heaters, and a plurality of lower temperature sensors; the plurality of upper heaters and the plurality of upper temperature sensors are distributed in each area of the upper mold, and the plurality of lower heaters and the plurality of lower temperature sensors are distributed in each area of the lower mold; the upper mold and the lower mold are correspondingly matched and can at least locally adjust their curvatures; the curved hot pressing device performs curved hot pressing on the flat plastic substrate in the following steps:

[0021] Adjust the curvatures of the upper mold and the lower mold to be flat, clamp the flat plastic substrate between the upper mold and the lower mold, and heat the temperature of the flat plastic substrate to a predetermined temperature by the plurality of upper heaters and the plurality of lower heaters, and use the plurality of upper temperature sensors and the plurality of lower temperature sensors to sense and confirm that the temperature of each area of the flat plastic substrate is maintained at the predetermined temperature;

[0022] Adjust the curvatures of the upper mold and the lower mold to a first curvature, so that the flat plastic substrate clamped between the upper mold and the lower mold is processed by the upper mold and the lower mold into the curved plastic panel with the first curvature; meanwhile, the plurality of upper temperature sensors and the plurality of lower temperature sensors still continuously sense and confirm that the temperature of each area of the curved plastic panel with the first curvature is maintained at the predetermined temperature; and

[0023] Adjust the curvature of the upper mold and the lower mold to a second curvature, so that the curved plastic substrate sandwiched between the upper mold and the lower mold is processed by the upper mold and the lower mold into a curved plastic substrate with the second curvature; meanwhile, the plurality of upper temperature sensors and the plurality of lower temperature sensors still continuously sense and confirm that the temperature of each area of the curved plastic substrate with the second curvature is maintained at the predetermined temperature; wherein, the curvature of the second curvature is greater than the first curvature.

[0024] Preferably, the curved hot pressing device further includes a plurality of cameras for capturing the curvature images of the upper mold and the lower mold, so as to judge whether the curvature of the curved plastic substrate has reached a predetermined curvature.

[0025] Preferably, the upper mold at least includes a first upper template, a second upper template and a third upper template; the first upper template and the second upper template are connected by a first upper joint, so that the first upper template can perform a curvature adjustment movement relative to the second upper template through the first upper joint; the second upper template and the third upper template are connected by a second upper joint, so that the third upper template can perform a curvature adjustment movement relative to the second upper template through the second upper joint; the lower mold at least includes a first lower template, a second lower template and a third lower template; the first lower template and the second lower template are connected by a first lower joint, so that the first lower template can perform a curvature adjustment movement relative to the second lower template through the first lower joint; the second lower template and the third lower template are connected by a second lower joint, so that the third lower template can perform a curvature adjustment movement relative to the second lower template through the second lower joint; wherein, the shape and position of the first upper template correspond to those of the first lower template, the shape and position of the second upper template correspond to those of the second lower template, and the shape and position of the third upper template correspond to those of the third lower template.

[0026] Preferably, the upper heaters and the upper temperature sensors are respectively provided in the first upper template, the second upper template and the third upper template; the lower heaters and the lower temperature sensors are respectively provided in the first lower template, the second lower template and the third lower template; the first upper joint, the second upper joint, the first lower joint and the second lower joint each include a linear slide rail, and the curvature between adjacent two templates is adjusted by the way of the linear slide rail driving torque.

[0027] Preferably, the material composition of the planar plastic substrate is one of the following: Polymethyl Methacrylate (PMMA) sheet, Polycarbonate (PC) sheet, PMMA / PC double-layer composite sheet, or PMMA / PC / PMMA triple-layer composite sheet; the composition of the hard layer at least includes one of the following: organic-inorganic hybrid ultraviolet oligomer / monomer, inorganic particle material, or ultraviolet curable long-chain oligomer / monomer with high elongation characteristics (elongation rate > 200%); among them, the organic-inorganic hybrid ultraviolet oligomer / monomer includes one of the following: ultraviolet curable elastic oligomer with high Glass Transition Temperature (Tg) and Tg ≥ 120°C, or high Tg monomer (Tg ≥ 240°C); the composition of the optical functional layer at least includes one of the following: ultraviolet curable oligomer / monomer with high Refractive Index (RI), high RI inorganic material, ultraviolet curable oligomer / monomer with low RI, or low RI inorganic material; among them, the high RI inorganic material includes one of the following: titanium dioxide (TiO2) or niobium pentoxide (Nb2O5); the low RI inorganic material includes one of the following: silicon dioxide (SiO2) or magnesium fluoride (MgF2); among them, the RI value range of the ultraviolet curable oligomer / monomer with high refractive index (RI) is: RI = 1.55 - 1.75; the RI value range of the ultraviolet curable oligomer / monomer with low RI is: RI = 1.4 - 1.48; the RI value range of the high RI inorganic material is: RI = 1.8 - 2.5; the RI value range of the low RI inorganic material is: RI = 1.2 - 1.45. Description of the Drawings

[0028] Figure 1 It is a schematic structural diagram of a typical plastic panel with a curved surface.

[0029] Figure 2 It is a schematic diagram of the processing method of the existing plastic panel with a curved surface.

[0030] Figure 3A , Figure 3B and Figure 3C They are respectively schematic diagrams of three steps of the existing method for thermally pressing a planar plastic substrate into a plastic substrate with a curved surface.

[0031] Figure 4 It is a schematic flowchart of the processing method of the plastic panel with a curved surface of the present invention.

[0032] Figure 5A , Figure 5B , Figure 5C andFigure 5D These are schematic diagrams of several processes for thermally pressing a flat plastic substrate into a curved plastic substrate according to the present invention.

[0033] Figure 5E This is a top view schematic diagram of the upper die (or lower die) of the curved thermocompression device according to the present invention.

[0034] Figure 6 This is a schematic diagram of the process for the curved thermocompression device according to the present invention to monitor the local temperature in real time and the forming state of the local curvature in real time.

[0035] Figure 7A and Figure 7B These are schematic diagrams of an embodiment of the processing device for the curved plastic panel according to the present invention in the states of the door panel being opened and the door panel being closed respectively.

[0036] Figure 8A and Figure 8B These are schematic diagrams of the upper and lower dies with variable curvature of the curved thermocompression device according to the present invention in the flat state and the bent state respectively.

[0037] Symbol description:

[0038] 10 - plastic panel, 11 - plastic substrate

[0039] 111 - PC board, 112, 113 - PMMA board

[0040] 12 - hard layer, 13 - optical functional layer

[0041] 14 - printing layer

[0042] 21 - 27, 31 - 37, 3611 - 3614, 3621 - 3624, 3631 - 3634 - steps, 221, 221a - plastic substrate, 222, 223 - die

[0043] 229 - bending part, 361 - 364 - stages

[0044] 41 - plastic substrate, 42, 43 - die

[0045] 420a, 420b, 430a, 430b - joints, 4201, 4301 - linear slide rails

[0046] 421, 431 - heaters, 422, 432 - temperature sensors

[0047] 49 - bending part, 50 - curved thermocompression device

[0048] 51 - machine body, 52 - door panel

[0049] 53, 54 - hydraulic devices, 531, 541 - die locking mechanisms

[0050] 55 - Camera 60 - Control unit

[0051] 61 - Heating module 62 - Temperature sensing module

[0052] 63 - Driving device 64 - Image capturing module

[0053] 65 - Database 66 - Analysis module

[0054] 67 - Control module 68 - Power supply module

[0055] 69 - Human - machine interface Detailed implementation manners

[0056] The present invention provides a processing method for a curved plastic panel. First, a hard layer, an optical functional layer, and a printing layer are formed on a flat plastic substrate. After the flat plastic substrate is cut into a predetermined shape by a CNC cutting machine, it is then subjected to curved hot - pressing processing by a curved - surface hot - pressing device to form a curved plastic substrate with a curved surface and having the hard layer, the optical functional layer, the printing layer, and the predetermined shape. The processing method of the present invention can be used to fabricate multi - functional polymer material panels for displays with partial or full - curved surfaces, and at the same time has the advantages of optical functions (anti - reflection or anti - glare) and safety against breakage. Moreover, since the processing of the hard layer, the optical functional layer, the printing layer, and CNC cutting are all carried out on the flat plastic substrate, the yield is very high, overcoming various deficiencies of the prior art. The curved - surface hot - pressing device of the present invention can perform hot - pressing forming synchronously during the heating process, and has the functions of real - time monitoring of local temperature and real - time monitoring of the local curvature forming state, and then feeds back to adjust the local heating mechanism. The monitoring of temperature and curvature can be divided into multiple stages, monitoring each stage one by one and performing heating or curvature forming adjustment, so as to improve the production yield of hot - pressing a flat plastic substrate with a hard layer, an optical functional layer, and a printing layer into a curved plastic panel, and more importantly, to realize the hot - pressing forming processing of full - curved or partial - curved plastic panels. The present invention also provides a material composition for the hard layer and the optical functional layer of the plastic panel. Through polymer material formulation, coating formulation design, and precision coating technology, the surface extensibility of the polymer can be improved to the level of being thermally bendable, and the original optical and physical properties can be maintained after passing various weather resistance tests.

[0057] In order to more clearly describe the structure of the light - transmissive plastic plate with a curved surface and its manufacturing method proposed by the present invention, the following will be described in detail with reference to the drawings.

[0058] The plastic panel with a curved surface described in the present invention, in terms of structure, is also as Figure 1The typical plastic panel 10 generally applicable to a curved in-vehicle display shown also includes: a plastic substrate 11, a hard coating layer 12 (Hard Coating; hereinafter referred to as HC), an optical functional layer 13, and a printing layer 14. The plastic substrate 11 can be a single-layer PC sheet, a single-layer PMMA sheet, a coextruded PMMA / PC double-layer composite sheet, a coextruded PMMA / PC / PMMA triple-layer composite sheet, or other existing plastic sheet structures in terms of material composition. In this embodiment, the plastic substrate 11 has a polycarbonate (PC) sheet 111 as the main layer, and a polymethyl methacrylate (PMMA) sheet 112, 113 are respectively disposed on the upper and lower surfaces of the PC sheet 111 to strengthen its physical properties. The hard coating layer 12 is usually formed on the outer surface (upper surface) of the plastic substrate 11, or hard coating layers 12 are provided on both the outer and inner surfaces (upper and lower surfaces) to improve the wear resistance of the plastic panel 11. In this embodiment, the composition of the hard coating layer 12 at least includes one of the following: an organic-inorganic hybrid ultraviolet oligomer / monomer, an inorganic particle material, or an ultraviolet-curable long-chain oligomer / monomer with high elongation characteristics (elongation rate > 200%); wherein, the organic-inorganic hybrid ultraviolet oligomer / monomer includes one of the following: an ultraviolet-curable elastic oligomer with a high glass transition temperature (Glass Transition Temperature, hereinafter referred to as Tg) and Tg ≥ 120°C, or a high-Tg monomer (Tg ≥ 240°C). The optical functional layer 13 is usually formed on the outer surface of the hard coating layer 12 to improve the optical performance of the plastic panel 11, such as but not limited to: functions such as ultraviolet resistance, antiglare, and antireflection. In this embodiment, the composition of the optical functional layer 13 at least includes one of the following: an ultraviolet-curable oligomer / monomer with a high refractive index (Refractive Index; hereinafter referred to as RI), a high-RI inorganic material, an ultraviolet-curable oligomer / monomer with a low RI, or a low-RI inorganic material; wherein, the high-RI inorganic material includes one of the following: titanium dioxide (TiO2) or niobium pentoxide (Nb2O5); the low-RI inorganic material includes one of the following: silicon dioxide (SiO2) or magnesium fluoride (MgF2). The printing layer 14 is usually printed on the inner surface of the plastic substrate 11 with colored ink to display the function pointers of the in-vehicle display. Although the plastic panel 10 of the present invention is similar to the prior art in structure, the present invention particularly and originally uses a material formulation with a high Tg value (Tg ≥ 120°C) and high elongation characteristics (elongation rate > 200%) in the material selection of the hard coating layer 12 and the optical functional layer 13.By using a UV-curable elastic oligomer or high Tg monomer (Tg≥240°C) material formulation with a high Tg value (Tg≥120°C) in the hard layer 12, a formable plastic panel 10 with a curved surface can be provided, which has high impact resistance, high flexibility, and stability at high temperatures, and can improve the reliability during high-temperature environmental testing or high-temperature and high-humidity environmental testing. By using a material formulation of a UV-curable long-chain oligomer or monomer with high elongation characteristics (elongation rate > 200%) in the hard layer 12, a formable plastic panel 10 with a curved surface can be provided, which has high elongation characteristics and high-temperature formability, and can avoid cracking or uneven thickness of the optical functional layer 13 during the thermoforming process.

[0059] In the present invention, the material formulation of the hard layer 12 (HC) comprises an organic-inorganic hybrid UV oligomer, which has a relatively low crosslinking density compared to the traditional HC formulation with a high crosslinking density, and can form a wear-resistant hard coating 12 with a low shrinkage rate and good flexibility. Among them, the inorganic material can contribute to the surface physical properties, making the coating have high hardness and high abrasion resistance. In addition, the material formulation of the hard layer 12 (HC) in the present invention comprises a high Tg UV elastomer oligomer and a high Tg monomer, which has better high-temperature stability compared to the traditional HC formulation with a high crosslinking density. Therefore, it has better thermoformability during high-temperature processes and can bend the formable polymer front panel material after UV curing into a free curvature. The material formulation of the hard layer 12 (HC) in the present invention comprises a UV-curable long-chain oligomer or monomer with high elongation characteristics (>200%), which has better high elongation compared to the traditional HC formulation with a high crosslinking density. Therefore, it has better thermoformability during the thermoforming process and can bend the formable polymer front panel material after UV curing into a free curvature. Before the flat plastic panel 10 with the hard layer 12 and the optical functional layer 13 is subjected to thermoforming processing in the present invention, flat ink printing and flat contour CNC machining will be carried out first, and then combined with the curved surface thermoforming process of the present invention, a curved surface finished product with optical functions can be directly produced after thermoforming. Different from the general production process of curved front panels, which are first subjected to curved surface thermoforming, then curved surface surface treatment, curved surface optical treatment, curved surface printing, and curved surface contour CNC machining, the yield of each station is poor due to the difficult processing of the curved surface process, and the through rate is reduced, resulting in too high production costs. In the present invention, since all processing technologies are completed on a flat surface, the yield and through rate of each station are high, so the processing cost is low. In this embodiment, the RI value range of the UV-curable oligomer / monomer with a high refractive index (RI) is: RI = 1.55 - 1.75; the RI value range of the UV-curable oligomer / monomer with a low RI is: RI = 1.4 - 1.48; the RI value range of the high RI inorganic material is: RI = 1.8 - 2.5; the RI value range of the low RI inorganic material is: RI = 1.2 - 1.45. Anti-reflection is defined as: reflectance Reflection < 2%; anti-glare is defined as: gloss < 100.

[0060] Please refer to Figure 4 , which is a schematic diagram of the processing method of the plastic panel with a curved surface of the present invention, and includes the following steps:

[0061] Step 31: Manufacture a flat plastic substrate (commonly known as a raw board) by plastic extrusion molding; this plastic substrate may be a single-layer PC board, a single-layer PMMA board, or a PMMA / PC double-layer composite board, or a PMMA / PC / PMMA three-layer composite board;

[0062] Step 32: Perform HC surface treatment on the flat plastic substrate to form an HC hard layer on the upper surface of the flat plastic substrate; because the flat plastic substrate is easy to perform HC surface treatment, the yield is very high;

[0063] Step 33: Perform optical surface treatment on the flat plastic substrate to form an optical functional layer on the HC hard layer of the flat plastic substrate; because the flat plastic substrate is easy to perform optical surface treatment, the yield is very high;

[0064] Step 34: Perform printing treatment on the flat plastic substrate to form a printing layer on the lower surface of the flat plastic substrate; because the flat plastic substrate is easy to perform printing treatment, the yield is very high;

[0065] Step 35: Perform cutting on the flat plastic substrate with a flat computer numerical control (CNC) processing machine (cutting machine) to cut the flat plastic substrate into a flat plastic substrate with a predetermined outer contour; because the flat plastic substrate is very easy to perform flat CNC cutting treatment, the yield is very high;

[0066] Step 36: Perform curved surface hot pressing on the flat plastic substrate that has formed the hard layer, the optical functional layer, and the printing layer and has the predetermined outer shape with a curved surface hot pressing device to make it a curved plastic substrate with a curved surface and having the hard layer, the optical functional layer, and the printing layer and having the predetermined outer shape;

[0067] Step 37: Complete the finished product of the plastic panel with a curved surface; because the processing yields of steps 32 to 35 are all very high, the yield and accuracy of the finally completed finished product are also very high, and it can pass the subsequent product tests.

[0068] Such as Figure 5A , Figure 5B , Figure 5C and Figure 5DAs shown, they are schematic diagrams of several processes for hot-pressing a planar plastic substrate into a plastic substrate with a curved surface according to the present invention. The processing method of the present invention is to perform curved surface hot-pressing on the planar plastic substrate that has formed the hard layer, the optical functional layer, and the printing layer and has the predetermined shape by using a curved surface hot-pressing device, so as to make it into a curved surface plastic substrate 41 with a curved surface and having the hard layer, the optical functional layer, the printing layer, and the predetermined shape. The curved surface hot-pressing device includes: an upper mold 42 with variable curvature, a lower mold 43 with variable curvature, a plurality of upper heaters 421, a plurality of upper temperature sensors 422, a plurality of lower heaters 431, and a plurality of lower temperature sensors 432. Please see Figure 5E It is a top view schematic diagram of the upper mold (or lower mold) of the curved surface hot-pressing device described in the present invention. In this embodiment, the plurality of upper heaters 421 and the plurality of upper temperature sensors 422 are uniformly and staggeredly distributed in an array in each area of the upper mold 42, and the plurality of lower heaters 431 and the plurality of lower temperature sensors 432 are uniformly and staggeredly distributed in an array in each area of the lower mold 43. The outer shape structures of the upper mold 42 and the lower mold 43 are correspondingly matched and can at least locally adjust their curvatures. In this embodiment, the curved surface hot-pressing device performs curved surface hot-pressing on the planar plastic substrate 41 through the following steps:

[0069] As Figure 5A shown, first, the curvatures of the upper mold 42 and the lower mold 43 are adjusted to a plane (curvature = 0), and the planar plastic substrate 41 is clamped between the upper mold 42 and the lower mold 43, and the temperature of the planar plastic substrate 41 is heated to a predetermined temperature by the plurality of upper heaters 421 and the plurality of lower heaters 431, and the plurality of upper temperature sensors 422 and the plurality of lower temperature sensors 432 are used to sense, confirm, or feedback and control that the temperature of each area of the planar plastic substrate 41 is maintained at the predetermined temperature.

[0070] As Figure 5B shown, then, the curvatures of the upper mold 42 and the lower mold 43 are adjusted to a first curvature (relatively small curvature), so that the planar plastic substrate 41 clamped between the upper mold 42 and the lower mold 43 becomes a curved surface plastic substrate 41 with the first curvature due to being hot-pressed by the upper mold 42 and the lower mold 43; meanwhile, the plurality of upper temperature sensors 422 and the plurality of lower temperature sensors 432 still continuously sense, confirm, and feedback and control that the temperature of each area of the curved surface plastic substrate 41 with the first curvature is maintained at the predetermined temperature.

[0071] As Figure 5CAs shown, then, the curvature of the upper mold 42 and the lower mold 43 is adjusted to a second curvature (a relatively larger curvature), so that the curved plastic substrate 41 sandwiched between the upper mold 42 and the lower mold 43 is hot-pressed by the upper mold 42 and the lower mold 43 into the curved plastic substrate 41 with the second curvature; meanwhile, multiple upper temperature sensors 422 and multiple lower temperature sensors 432 still continuously sense and confirm that the temperature of each area of the curved plastic substrate 41 with the second curvature is maintained at the predetermined temperature; wherein, the curvature of the second curvature is greater than the first curvature.

[0072] As Figure 5D shown, when the curvature of the curved plastic substrate 41 (i.e., the curvature of the upper mold 42 and the lower mold 43) reaches the predetermined curvature, the upper and lower molds 42, 43 can be opened and the curved plastic substrate 41 with the predetermined curvature can be taken out. Since the curved hot pressing device of the present invention is provided with multiple heaters 421, 431 and temperature sensors 422, 432 on the upper and lower molds 42, 43 respectively for heating and temperature control, and each heater 421, 431 and temperature sensor 422, 432 can operate independently for temperature control, so the temperature of each area of the plastic substrate 41 is very stable and uniform during the hot pressing process. Moreover, the curved hot pressing device can perform hot pressing and forming synchronously during the heating process, and has the functions of real-time monitoring of the local temperature and real-time monitoring of the local curvature forming state, and then feeds back to the local heating mechanism for adjustment. The monitoring of temperature and curvature can be divided into multiple stages, and each stage is monitored and the heating or curvature forming is adjusted, so as to avoid the phenomenon of stress concentration or hard layer cracking at the bending part 49 of the curved plastic substrate 41, and improve the production yield. The present invention further improves the extensible characteristics of the polymer surface (especially the hard layer) to the level of thermo-bending processing through the design of polymer material formula, coating formula and precision coating technology, and still maintains the original optical and physical properties even after the curved plastic panel is formed by hot pressing and can pass various weather resistance tests.

[0073] Please refer to Figure 6 , which is a schematic flow chart of the curved hot pressing device of the present invention for real-time monitoring of local temperature and real-time monitoring of local curvature forming state. As Figure 6 shown and in combination with Figures 5A to 5D the content, during the process of hot pressing and forming a curved surface, first, in the first stage (1st Step) 361, as Figure 5AAs shown, the upper and lower molds 42 and 43 are still in a low-temperature and flat (curvature is 0) state; at this time, the respective parts of the plastic substrate are locally heated by a plurality of heaters 421 and 431 (step 3611), and a plurality of temperature sensors 422 and 432 are used to respectively sense the local temperature of the respective parts of the plastic substrate (Sensor). If a certain temperature sensor 422 or 432 senses that the temperature of any part (area) has not reached the predetermined temperature, then feedback control is performed on the corresponding heaters 421 and 431 for heating (step 3612) until the temperature of each part (area) of the plastic substrate reaches the predetermined temperature; at the same time, the curved surface hot pressing device also uses a curvature sensor to continuously monitor the curvature of each local position of the upper and lower molds 42 and 43 (step 3613). If it is monitored that the curvature of any part (area) has not reached the first curvature, then feedback control is performed on the upper and lower molds 42 and 43 for local bending of this part (step 3614) until the curvature of each part (area) of the plastic substrate reaches the first curvature. Then, it will enter the second stage (2nd Step) 362. At this time, as Figure 5B shown, the upper and lower molds 42 and 43 have been maintained at the predetermined temperature and have a relatively small first curvature; at this time, the plurality of heaters 421 and 431 still continuously locally heat the respective parts of the plastic substrate (step 3621), and the plurality of temperature sensors 422 and 432 still continuously sense the local temperature of the respective parts of the plastic substrate. If a certain temperature sensor 422 or 432 senses that the temperature of any part (area) has not reached the predetermined temperature, then feedback control is performed on the corresponding heaters 421 and 431 for heating (step 3622) until the temperature of each part (area) of the plastic substrate reaches and is maintained at the predetermined temperature; at the same time, the curved surface hot pressing device also continues to use a curvature sensor to continuously monitor the curvature of each local position of the upper and lower molds 42 and 43 (step 3623). If it is monitored that the curvature of any part (area) has not reached the second curvature, then feedback control is performed on the upper and lower molds 42 and 43 for local bending of this part (step 3624) until the curvature of each part (area) of the plastic substrate reaches the second curvature; wherein, the second curvature is greater than the first curvature. After that, it will enter the third stage (3rd Step) 363. At this time, as Figure 5CAs shown in the figure, the upper and lower molds 42 and 43 have been maintained at a predetermined temperature and have a relatively larger second curvature; at this time, the plurality of heaters 421 and 431 still continuously perform local heating on each part of the plastic substrate (step 3631), and the plurality of temperature sensors 422 and 432 still continuously perform local temperature sensing on each part of the plastic substrate. If a certain temperature sensor 422 or 432 senses that the temperature of any part (area) has not reached the predetermined temperature, then feedback control is performed on the corresponding heater 421 or 431 for heating (step 3632) until the temperature of each part (area) of the plastic substrate reaches and is maintained at the predetermined temperature; at the same time, the curved surface hot pressing device also continues to use the curvature sensor to monitor the curvature of each local position of the upper and lower molds 42 and 43 in real time (step 3633). If it is monitored that the curvature of any part (area) has not reached the predetermined curvature, then feedback control is performed on the upper and lower molds 42 and 43 for local bending of this part (step 3634) until the curvature of each part (area) of the plastic substrate reaches the predetermined curvature; wherein, the predetermined curvature is greater than or equal to the second curvature. Finally, a curved surface plastic panel product with a predetermined curvature can be obtained (the fourth stage 364).

[0074] Please refer to Figure 7A and Figure 7B , which are schematic diagrams of an embodiment of the processing device for the curved surface plastic panel of the present invention in the state where the door panel is opened and the door panel is closed. In this embodiment, the processing device for the curved surface plastic panel of the present invention includes the curved surface hot pressing device. The curved surface hot pressing device 50 further includes the following components in addition to the aforementioned upper mold 42 with variable curvature, lower mold 43 with variable curvature, a plurality of upper heaters 421, a plurality of upper temperature sensors 422, a plurality of lower heaters 431, and a plurality of lower temperature sensors 432: a machine body 51, an openable and closable door panel 52, a plurality of hydraulic devices 53 and 54, a plurality of cameras 55, and a control unit 60. Among them, the control unit 60 further includes: a heating module 61, a detection module (including a temperature sensing module 62 and an image capturing module 64), a driving device 63, a database 65, an analysis module 66, a control module 67, a power supply module 68, and a human-machine interface 69.

[0075] In this embodiment, the door panel 52 is installed on the machine body 51. When the door panel 52 is opened (as shown in Figure 7A ), the flat plastic panel 41 to be hot pressed can be placed between the upper and lower molds 42 and 43 inside the machine body 51, or the processed curved surface plastic substrate 41 can be taken out of the machine body 51 from between the upper and lower molds 42 and 43; and when the door panel 52 is closed (as shown in Figure 7BAs shown in the figure, hot press bending processing of the plastic substrate 41 can be performed. The upper and lower molds 42 and 43 are respectively coupled to a plurality of hydraulic devices 53 and 54 through mold locking mechanisms 531 and 541. By driving the hydraulic devices 53 and 54 to actuate with a driving device 63, a pushing and pulling force is provided to the upper and lower molds 42 and 43, which is used to drive the upper mold and the lower mold to apply pressure or perform local bending (changing the curvature) movement, and then perform hot press bending processing on the plastic panel 41 clamped between the upper and lower molds 42 and 43.

[0076] A plurality of cameras 55 constitute a curvature sensor, which can capture (shoot) the curvature (appearance) images of the upper and lower molds 42 and 43 in real time during the hot press bending processing. By analyzing the curvature (appearance) images of the upper and lower molds 42 and 43, the bending state, that is, the curvature state, of the plastic panel 41 clamped between the upper and lower molds 42 and 43 at that time can be obtained, and then it can be judged in real time whether the curvature of the curved plastic substrate 41 has reached the predetermined curvature. The heating module 61 is electrically connected to a plurality of the upper heaters 421 and a plurality of the lower heaters 431, and is used to control the heating operations of a plurality of the upper heaters 421 and a plurality of the lower heaters 431. The detection module further includes a temperature sensing module 62 and an image capturing module 64. The temperature sensing module 62 is electrically connected to a plurality of the upper temperature sensors 422 and a plurality of the lower temperature sensors 432, and is used to obtain the temperature information sensed by a plurality of the upper temperature sensors 422 and a plurality of the lower temperature sensors 432. The image capturing module 64 is electrically connected to a plurality of the cameras 55, and is used to capture the curvature (appearance) images of the upper mold 42 and the lower mold 43 captured by a plurality of the cameras 55. The database 65 stores the computer software and related parameters required to control the actuation of the curved surface hot press device 50, including the data of the predetermined temperature and the predetermined curvature.

[0077] The analysis module 66 can receive the temperature information and the curvature image from the detection module, and can retrieve the data of the predetermined temperature and the predetermined curvature from the database 65. The analysis module 66 can compare the temperature information with the predetermined temperature. When the temperature of the temperature information is lower than the predetermined temperature, the analysis module 66 generates a heating signal to the heating module 61, prompting the heating module 61 to control the plurality of upper heaters 421 and the plurality of lower heaters 431 to perform a heating operation on the plastic substrate 41. The heating operation described herein can be a comprehensive or local heating. In other words, according to the heating signal from the analysis module 66, the heating module 61 can, in addition to controlling all the heaters to perform a comprehensive heating on the plastic substrate 41, on the other hand, of course, the heating module 61 can also control only several of the heaters to perform a local heating on the plastic substrate 41 according to the heating signal from the analysis module 66, and this function cannot be achieved by the prior art. In addition, the analysis module 66 can also compare the curvature image with the predetermined curvature. When the curvature of the curvature image is less than the predetermined curvature, the analysis module 66 generates a curvature increasing signal to the driving device 63, prompting the driving device 63 to drive the hydraulic devices 53 and 54 to drive the upper mold 42 and the lower mold 43 to perform a hot pressing operation for comprehensively or locally increasing the bending curvature. The human-machine interface 69 can provide a user operation and at least allow the user to input or set information such as the predetermined temperature and the predetermined curvature into the database 65. In this embodiment, the human-machine interface 69 includes a transmission port for connecting to an external computer device, and the user can operate the computer device to transmit and store the predetermined temperature, the predetermined curvature, and other processing parameters into the database 65 through the human-machine interface 69. In another embodiment, the human-machine interface 69 can also include a touch screen and / or a keyboard, and the user can operate the touch screen and / or the keyboard to set the predetermined temperature, the predetermined curvature, and other processing parameters into the database 65. The control module 67 includes a microcontroller (MCU) or a central processing unit (CPU), which is electrically connected to and can control the operations of the driving device 63, the heating module 61, the detection module, the database 65, the analysis module 66, and the human-machine interface 69. The power supply module 68 is connected to the control module 67 for providing power to the control unit 60.

[0078] Please refer to Figure 8A and Figure 8B, which are schematic diagrams of the upper and lower molds with variable curvature of the curved surface hot pressing device of the present invention in the planar state and the bent state. In the present invention, the upper and lower molds 42 and 43 of the curved surface hot pressing device 50 are both with variable curvature; and, the upper and lower molds 42 and 43 need to be designed according to the bending drawing of the curved plastic panel to be produced, and the relative movement is achieved by the linear slide rail driving torque method to bend the upper and lower molds 42 and 43. In an embodiment, the upper mold 42 at least includes a first upper template on the left, a second upper template in the middle, and a third upper template on the right. The first upper template and the second upper template are connected by a first upper joint 420a, so that the first upper template can perform a curvature adjustment movement relative to the second upper template through the first upper joint 420a. The second upper template and the third upper template are connected by a second upper joint 420b, so that the third upper template can perform a curvature adjustment movement relative to the second upper template through the second upper joint 420b. Similarly, the lower mold 43 at least includes a first lower template on the left, a second lower template in the middle, and a third lower template on the right. The first lower template and the second lower template are connected by a first lower joint 430a, so that the first lower template can perform a curvature adjustment movement relative to the second lower template through the first lower joint 430a. The second lower template and the third lower template are connected by a second lower joint 430b, so that the third lower template can perform a curvature adjustment movement relative to the second lower template through the second lower joint 430b. Among them, the shape and position of the first upper template correspond to the first lower template, the shape and position of the second upper template correspond to the second lower template, and the shape and position of the third upper template correspond to the third lower template. The upper heaters 421 and the upper temperature sensors 422 are respectively provided in the first upper template, the second upper template and the third upper template; the lower heaters 431 and the lower temperature sensors 432 are respectively provided in the first lower template, the second lower template and the third lower template. The first upper joint 420a, the second upper joint 420b, the first lower joint 430a and the second lower joint 430b each include a linear slide rail 4201 and 4301, and the bending curvature between adjacent two templates is adjusted by the linear slide rail 4201 and 4301 driving torque method.

[0079] The present invention uses PMMA / PC / PMMA or PMMA / PC composite materials as the substrate, and combines the stretchable composite material front panel produced by the wet coating process of the stretchable coating formula. After all surface treatments are completed, hot pressing and curved surface forming can be performed. All surface treatments will not produce any appearance and functional abnormalities in this process stage. The key to the breakthrough of this process lies in the combination of the stretchable coating formula. The stretchable coating formula includes: a stretchable high-hardness coating, a stretchable high-refractive index coating, and a stretchable low-refractive index coating. The stretchable coating formula can change the process that the original glass must first be subjected to curved surface hot pressing and then optical surface treatment, greatly reducing the defective rate of the curved surface coating process. The surface hardness of the stretchable composite material front panel after curved surface hot pressing can be increased to more than 4H (4H~9H), the chemical wear resistance test can pass the automotive standard level, and the UV yellowing resistance test (1000 hours) can maintain the specification of ΔE<3.

[0080] The present invention tests various plastic substrates with different structures and hard layers and optical functional layers made of different materials. The following Table 1 shows the structural information of each sample tested. For example, for the substrate of Sample 6 in Table 1, in field A, either A3 / A4 structure, i.e., "PMMA / PC double-layer board structure" or "PMMA / PC / PMMA three-layer board structure" is selected; in field B, whether "Inorganichybrid composition (organic-inorganic hybrid oligomer / monomer)" is added to the hard layer is selected B2, i.e., "Inorganichybrid composition (organic-inorganic hybrid oligomer / monomer)" is added; in field C, whether "HighTg composition (high glass transition temperature oligomer / monomer)" is added to the hard layer is selected C2, i.e., "High Tg composition (high glass transition temperature oligomer / monomer)" is added; in field D, whether "HighElongation Composition (high elongation characteristic oligomer / monomer)" is added to the hard layer is selected D2, i.e., "HighElongation Composition (high elongation characteristic oligomer / monomer)" is added; in field E, whether "Optical Function Composition (optical function)" is added to the optical function layer is selected In the field F, whether the "new mold and hot pressing molding process" created by the present invention are used is selected as F2, which means "new mold and hot pressing molding process are used". The structures of other samples (Samples 0-5, 8 and 9) can be obtained in the same way, so they are not repeated here.

[0081] Table 1: Structural Information of Each Sample for Testing the Plastic Panel

[0082]

[0083] As can be seen from Table 1, the curved plastic panel of Sample 6 has good hardness, heat resistance, and formability, and has optical functions, making it the relatively best sample of the curved plastic panel. In contrast, the other samples 0-5, 8, and 9 have more or less deficiencies.

[0084] In this embodiment, the material compositions described in each of the fields A-E can be selected from currently commercially available products. For example, the "Inorganic hybrid composition (organic-inorganic hybrid oligomer / monomer)" described in Field B can be Allenx EBECRYL 8311 or other products of the same nature of other models or brands; the "High Tg composition (high glass transition temperature oligomer / monomer)" described in Field C can be Allenx EBECRYL 4859 or other products of the same nature of other models or brands; the "High Elongation Composition (high elongation property oligomer / monomer)" described in Field D can be Allenx EBECRYL 8804 or other products of the same nature of other models or brands; the "Optical Function Composition (optical function component)" described in Field E can be Nippon Shokubai ZIRCOSTAR series products or other products of the same nature of other models or brands.

[0085] Table 2: Test Results of Each Sample of the Curved Plastic Panel

[0086]

[0087] ◎: Excellent; ○: Good; △: Normal; X: Fail; OK: Good; NG: Not Good

[0088] From the test results of each sample of the curved plastic panel shown in Table 2 above, it can be seen that Sample 6 uses a composite board of PC / PMMA or PMMA / PC / PMMA as the plastic substrate, and has a hard layer and an optical function layer containing organic-inorganic hybrids, high Tg, and high elongation property oligomers / monomers, and uses the "novel mold and hot pressing forming process" unique to the present invention for curved hot pressing, that is, similar to Figure 4 , Figures 5A to 5C and Figure 6In the illustrated embodiments, excellent or good performance was obtained in all tests. In contrast, other samples (Samples 0 to 5, 7, and 8) had more or less poor performance in some test items. This proves that the curved plastic panel made by the processing method of the present invention can indeed obtain better test results compared with the prior art.

[0089] However, the above-described embodiments should not be used to limit the scope of application of the present invention. The scope of protection of the present invention should be based on the technical spirit defined by the content of the patent application scope of the present invention and the scope covered by its equivalent changes. That is, any equivalent changes and modifications made in accordance with the patent application scope of the present invention will still not lose the essence of the present invention, nor will they deviate from the spirit and scope of the present invention. Therefore, they should all be regarded as further implementation situations of the present invention.

Claims

1. A processing method for a curved plastic panel, characterized in that, Comprising: Providing a flat plastic substrate; Forming a flat hard coating on an outer surface of the flat plastic substrate; Forming a flat optical functional layer on the hard coating of the flat plastic substrate; Forming a flat printing layer on an inner surface of the flat plastic substrate by ink printing; Cutting the flat plastic substrate having the hard coating, the optical functional layer and the printing layer formed thereon by a cutting machine into the flat plastic substrate having the hard coating, the optical functional layer and the printing layer formed thereon and having a predetermined shape; and Performing a curved surface hot pressing process on the flat plastic substrate having the hard coating, the optical functional layer and the printing layer formed thereon and having the predetermined shape by a curved surface hot pressing device to make it into a curved plastic substrate having a curved surface and having the hard coating, the optical functional layer and the printing layer and having the predetermined shape; Wherein, the curved surface hot pressing device has: an upper mold with variable curvature, a lower mold with variable curvature, a plurality of upper heaters, a plurality of upper temperature sensors, a plurality of lower heaters, and a plurality of lower temperature sensors; the plurality of upper heaters and the plurality of upper temperature sensors are distributed in each area of the upper mold, and the plurality of lower heaters and the plurality of lower temperature sensors are distributed in each area of the lower mold; the upper mold and the lower mold are correspondingly matched and can at least locally adjust their curvatures; the curved surface hot pressing device performs the curved surface hot pressing process on the flat plastic substrate having the hard coating, the optical functional layer and the printing layer formed thereon and having the predetermined shape in the following steps: Adjusting the curvatures of the upper mold and the lower mold to be flat, clamping the flat plastic substrate having the hard coating, the optical functional layer and the printing layer formed thereon and having the predetermined shape between the upper mold and the lower mold, and heating the temperature of the flat plastic substrate having the hard coating, the optical functional layer and the printing layer formed thereon and having the predetermined shape to a predetermined temperature by the plurality of upper heaters and the plurality of lower heaters, and using the plurality of upper temperature sensors and the plurality of lower temperature sensors to sense and confirm that the temperatures of the respective areas of the flat plastic substrate having the hard coating, the optical functional layer and the printing layer formed thereon and having the predetermined shape are maintained at the predetermined temperature; Adjusting the curvatures of the upper mold and the lower mold to a first curvature, so that the flat plastic substrate having the hard coating, the optical functional layer and the printing layer formed thereon and having the predetermined shape clamped between the upper mold and the lower mold is processed by the upper mold and the lower mold into a curved plastic substrate having the hard coating, the optical functional layer and the printing layer formed thereon and having the predetermined shape and having the first curvature; meanwhile, the plurality of upper temperature sensors and the plurality of lower temperature sensors still continuously sense and confirm that the temperatures of the respective areas of the curved plastic substrate having the hard coating, the optical functional layer and the printing layer formed thereon and having the predetermined shape and having the first curvature are maintained at the predetermined temperature; and Adjust the curvature of the upper mold and the lower mold to a second curvature, so that the curved plastic substrate with the first curvature, which has the hard layer, the optical functional layer and the printing layer formed thereon and has the predetermined shape, and is clamped between the upper mold and the lower mold, is processed by the upper mold and the lower mold into a curved plastic substrate with the second curvature, which has the hard layer, the optical functional layer and the printing layer formed thereon and has the predetermined shape; meanwhile, the plurality of upper temperature sensors and the plurality of lower temperature sensors still continuously sense and confirm that the temperature of each area of the curved plastic substrate with the second curvature, which has the hard layer, the optical functional layer and the printing layer formed thereon and has the predetermined shape, is maintained at the predetermined temperature; wherein, the curvature of the second curvature is greater than the curvature of the first curvature.

2. The processing method of the curved plastic panel according to claim 1, characterized in that, The curved hot pressing device further includes a plurality of cameras for capturing curvature images of the upper mold and the lower mold, so as to judge whether the curvature of the curved plastic substrate with the hard layer, the optical functional layer and the printing layer formed thereon and having the predetermined shape has reached a predetermined curvature.

3. The processing method of the curved plastic panel according to claim 1, wherein: The upper mold at least includes a first upper template, a second upper template and a third upper template; the first upper template and the second upper template are connected by a first upper joint, so that the first upper template can perform a curvature adjustment movement relative to the second upper template through the first upper joint; the second upper template and the third upper template are connected by a second upper joint, so that the third upper template can perform a curvature adjustment movement relative to the second upper template through the second upper joint; The lower mold at least includes a first lower template, a second lower template and a third lower template; the first lower template and the second lower template are connected by a first lower joint, so that the first lower template can perform a curvature adjustment movement relative to the second lower template through the first lower joint; the second lower template and the third lower template are connected by a second lower joint, so that the third lower template can perform a curvature adjustment movement relative to the second lower template through the second lower joint; Wherein, the shape and position of the first upper template correspond to those of the first lower template, the shape and position of the second upper template correspond to those of the second lower template, and the shape and position of the third upper template correspond to those of the third lower template.

4. The processing method of the curved plastic panel according to claim 3, characterized in that, The upper heater and the upper temperature sensor are respectively provided in the first upper template, the second upper template and the third upper template; the lower heater and the lower temperature sensor are respectively provided in the first lower template, the second lower template and the third lower template; the first upper joint, the second upper joint, the first lower joint and the second lower joint each include a linear slide rail, and the curvature between adjacent two templates is adjusted by the way of the linear slide rail driving torque.

5. The processing method of the curved plastic panel according to claim 1, wherein: The material composition of the planar plastic substrate is one of the following: polymethyl methacrylate (PMMA) sheet, polycarbonate (PC) sheet, PMMA / PC double-layer composite sheet, or PMMA / PC / PMMA triple-layer composite sheet; The composition of the hard layer includes at least one of the following: organic-inorganic hybrid ultraviolet oligomer / monomer, inorganic particle material, or ultraviolet-curable long-chain oligomer / monomer with an elongation rate > 200%; wherein, the organic-inorganic hybrid ultraviolet oligomer / monomer includes one of the following: ultraviolet-curable elastic oligomer with a high glass transition temperature Tg and Tg ≥ 120°C, or high-Tg monomer with Tg ≥ 240°C; The composition of the optical functional layer includes at least one of the following: ultraviolet-curable oligomer / monomer with a high refractive index RI, high-RI inorganic material, ultraviolet-curable oligomer / monomer with a low RI, or low-RI inorganic material; wherein, the high-RI inorganic material includes one of the following: titanium dioxide (TiO2) or niobium pentoxide (Nb2O5); the low-RI inorganic material includes one of the following: silicon dioxide (SiO2) or magnesium fluoride (MgF2); Wherein, the RI value range of the ultraviolet-curable oligomer / monomer with a high refractive index RI is: RI = 1.55 - 1.75; the RI value range of the ultraviolet-curable oligomer / monomer with a low RI is: RI = 1.4 - 1.48; the RI value range of the high-RI inorganic material is: RI = 1.8 - 2.5; the RI value range of the low-RI inorganic material is: RI = 1.2 - 1.

45.

6. A processing device for a curved plastic panel, characterized in that, It includes a curved surface hot pressing device; the curved surface hot pressing device includes: an upper mold with variable curvature, a lower mold with variable curvature, multiple upper heaters, multiple upper temperature sensors, multiple lower heaters, and multiple lower temperature sensors; multiple of the upper heaters and multiple of the upper temperature sensors are distributed in each area of the upper mold, and multiple of the lower heaters and multiple of the lower temperature sensors are distributed in each area of the lower mold; the upper mold and the lower mold are correspondingly matched and can at least partially adjust their curvatures; the curved surface hot pressing device performs curved surface hot pressing processing on a planar plastic substrate through the following steps: Adjust the curvatures of the upper mold and the lower mold to be planar, clamp the planar plastic substrate between the upper mold and the lower mold, and heat the temperature of the planar plastic substrate to a predetermined temperature by multiple of the upper heaters and multiple of the lower heaters, and use multiple of the upper temperature sensors and multiple of the lower temperature sensors to sense and confirm that the temperature of each area of the planar plastic substrate is maintained at the predetermined temperature; Adjust the curvatures of the upper mold and the lower mold to a first curvature, so that the planar plastic substrate clamped between the upper mold and the lower mold is processed by the upper mold and the lower mold into a curved surface plastic substrate with the first curvature; meanwhile, multiple of the upper temperature sensors and multiple of the lower temperature sensors still continuously sense and confirm that the temperature of each area of the curved surface plastic substrate with the first curvature is maintained at the predetermined temperature; and Adjust the curvature of the upper mold and the lower mold to a second curvature, so that the curved plastic substrate sandwiched between the upper mold and the lower mold is processed by the upper mold and the lower mold into a curved plastic substrate with the second curvature; at the same time, the plurality of upper temperature sensors and the plurality of lower temperature sensors still continuously sense and confirm that the temperature of each area of the curved plastic substrate with the second curvature is maintained at the predetermined temperature; wherein, the curvature of the second curvature is greater than the first curvature.

7. The processing device for the curved plastic panel according to claim 6, characterized in that, The curved hot pressing device further includes a plurality of cameras for capturing the curvature images of the upper mold and the lower mold, so as to judge whether the curvature of the curved plastic substrate has reached a predetermined curvature.

8. The processing device for a curved plastic panel according to claim 6, wherein: The upper mold at least includes a first upper template, a second upper template and a third upper template; a first upper joint is connected between the first upper template and the second upper template, so that the first upper template can perform a curvature adjustment movement relative to the second upper template through the first upper joint; a second upper joint is connected between the second upper template and the third upper template, so that the third upper template can perform a curvature adjustment movement relative to the second upper template through the second upper joint; The lower mold at least includes a first lower template, a second lower template and a third lower template; a first lower joint is connected between the first lower template and the second lower template, so that the first lower template can perform a curvature adjustment movement relative to the second lower template through the first lower joint; a second lower joint is connected between the second lower template and the third lower template, so that the third lower template can perform a curvature adjustment movement relative to the second lower template through the second lower joint; Wherein, the shape and position of the first upper template correspond to the first lower template, the shape and position of the second upper template correspond to the second lower template, and the shape and position of the third upper template correspond to the third lower template.

9. The processing device for the curved plastic panel according to claim 8, characterized in that, The upper heater and the upper temperature sensor are respectively provided in the first upper template, the second upper template and the third upper template; the lower heater and the lower temperature sensor are respectively provided in the first lower template, the second lower template and the third lower template; the first upper joint, the second upper joint, the first lower joint and the second lower joint each include a linear slide rail, and the curvature between adjacent two templates is adjusted by means of the driving torque of the linear slide rail.

10. The processing device for the curved plastic panel according to claim 7, characterized in that, The curved hot pressing device further includes: A driving device for driving the upper mold and the lower mold to perform hot pressing; A heating module electrically connected to the plurality of upper heaters and the plurality of lower heaters for controlling the heating operations of the plurality of upper heaters and the plurality of lower heaters; A detection module, which further includes a temperature sensing module and an image capturing module; the temperature sensing module is electrically connected to the plurality of upper temperature sensors and the plurality of lower temperature sensors for capturing the temperature information sensed by the plurality of upper temperature sensors and the plurality of lower temperature sensors; the image capturing module is electrically connected to the plurality of cameras for capturing the curvature images of the upper mold and the lower mold captured by the plurality of cameras; A database storing at least the data of the predetermined temperature and the predetermined curvature; An analysis module for receiving the temperature information and the curvature image from the detection module, and capable of retrieving the data of the predetermined temperature and the predetermined curvature from the database; the analysis module can compare the temperature information with the predetermined temperature, and when the temperature of the temperature information is lower than the predetermined temperature, the analysis module generates a heating signal to the heating module to prompt the heating module to control the plurality of upper heaters and the plurality of lower heaters to perform a heating operation; the analysis module can compare the curvature image with the predetermined curvature, and when the curvature of the curvature image is less than the predetermined curvature, the analysis module generates a curvature increasing signal to the driving device to prompt the driving device to drive the upper mold and the lower mold to perform a hot pressing operation for increasing the curvature; A human-machine interface for providing a user operation and at least enabling the user to set the predetermined temperature and the predetermined curvature in the database; and A control module electrically connected to and capable of controlling the driving device, the heating module, the detection module, the database, the analysis module, and the human-machine interface.

11. A curved plastic panel manufactured by the processing method of claim 1, characterized in that, The curved plastic panel includes: A plastic substrate, the material composition of which is one of the following: polymethyl methacrylate (PMMA) sheet, polycarbonate (PC) sheet, PMMA / PC double-layer composite sheet, or PMMA / PC / PMMA three-layer composite sheet; A hard layer formed on an outer surface of the plastic substrate; the composition of the hard layer at least includes one of the following: organic-inorganic hybrid ultraviolet oligomer / monomer, inorganic particle material, or ultraviolet curable long-chain oligomer / monomer with an elongation rate > 200%; wherein, the organic-inorganic hybrid ultraviolet oligomer / monomer includes one of the following: ultraviolet curable elastic oligomer with a high glass transition temperature Tg and Tg ≥ 120°C, or high-Tg monomer with Tg ≥ 240°C; An optical functional layer formed on the hard layer; the composition of the optical functional layer at least includes one of the following: ultraviolet curable oligomer / monomer with a high refractive index RI, high RI inorganic material, ultraviolet curable oligomer / monomer with a low RI, or low RI inorganic material; wherein, the high RI inorganic material includes one of the following: titanium dioxide (TiO2) or niobium pentoxide (Nb2O5); the low RI inorganic material includes one of the following: silicon dioxide (SiO2) or magnesium fluoride (MgF2); A printing layer formed on an inner surface of the plastic substrate; Wherein, the RI value range of the ultraviolet curable oligomer / monomer with a high refractive index RI is: RI = 1.55 - 1.75; The RI value range of the ultraviolet curable oligomer / monomer with a low RI is: RI = 1.4 - 1.48; the RI value range of the high RI inorganic material is: RI = 1.8 - 2.5; the RI value range of the low RI inorganic material is: RI = 1.2 - 1.45.

Images