Development of Hybrid Extrusion Rolling Process for Replication of Microstructures
Date Issued
2007
Date
2007
Author(s)
Ciou, Jian-Ren
DOI
zh-TW
Abstract
This thesis is devoted to the development a new system and process of hybrid extrusion rolling process for replication of microstructures. The goal is to simplify the process by integration and to save energy to avoid re-heating ready-made films. Extrusion molding is used to fabricate the plastic films, and then the plastic film is directly fed into the roller micro-embossing facility before it cools down. Rollers with microstructures on the surface transfer the patterns onto the hot plastic film while the film is rolled through.
A roller micro-embossing facility is setup, consisting of a driving roller and a roller with microstructures. The rollers with microstructures are prepared by turning an aluminum cylinder and by casting thermosetting polymer in a cylinder mold with microstructures on the wall. An extrusion machine with a coat-hanger die is used for extruding thin films. The plastic film with width of 120mm and thickness between 1.5mm and 0.5mm can be extruded. The extrusion rolling system is developed and tested.
In this study, it is found that the thickness of the film is mainly determined by the rotation speed of rollers. Regarding the replication of the micro-structures, as the rotation speed of drive cylinder is increasing, the replication of micro-structures in the center of the plastic film is poor. However, increasing the thrust of air pressure cylinder and the temperature of coat-hanger die, the replication of micro-structures in the center of the film improves. The best replication results are obtained with a die temperature of 290℃, a rotation speed of 4.3 rpm, and a thrust of air pressure cylinder of 100Kg/cm. The extrusion rolling has been proven an effective and efficient process in fabrication of optical diffusion films.
Subjects
擠出滾壓複合製程
衣架型模頭
微結構滾輪
光擴散膜
Hybrid extrusion rolling process
Coat-hanger die
Roller with microstructures
Optical diffusion film
Type
thesis
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