2003-08-012024-05-17https://scholars.lib.ntu.edu.tw/handle/123456789/693362摘要：近年來塑膠成型加工已廣泛的應用於光電元件的製造，但隨著產品輕薄短小化與高精度之要求，射出成型件在尺寸精確性、分子定向、翹曲、及光學性質上的品質要求亦日益嚴苛。加上光電產品表面往往具有精密微結構的設計，這對於傳統的塑膠成型技術而言將是一大挑戰。本研究為一個兩年性計畫。研究主題為LCD背光模組用之導光元件的開發與研究，第一年主要為應用3-D模流分析軟體，針對射出成型楔形模具所需之澆口形式、大小及位置和水道的配置，作一初步的模擬，以作為實際模具設計之參考。模具製作完成後，進行精密射出成型實驗，探討塑膠射出過程中熔膠的充填情形，在不同的模具設計與不同製程參數設計下對於產品品質有何重大的影響。第二年主要工作為依循第一年傳統射出成型之結果，設計出一正確且精密的模具，並且進一步探討射出壓縮成型對於光學零件品質之影響。雖然射出壓縮成形結合射出及壓縮緻密化的機構，可改善尺寸收縮、殘留應力及分子定向等問題，在表面微結構成型亦可獲得較高的拷貝度。但導光板為一幾何厚度不同的楔形板件，其壁厚不均一的外型，在射出壓縮成型的過程中會使厚薄端產生不同壓縮量而使產品尺寸精密度無法達到要求。因此本研究提出一不等行程射出壓<br> Abstract: With the progress in optoelectronic industry, the optical plastic parts demand high contour accuracy, low residual strain and low production cost. Many precision parts have micro features on surface. This presents an ever-increasing challenge. The molding of the light panel for LED modules is an typical case. The wedge-shaped PMMA plates have micro v-grooves on the surface. It demands flatness, uniform thickness and accurate replication of the features.In this two-year joint project, this sub-project is devoted to the experimental investigation on the precision molding of v-grooved wedge plates. In the first year, the 3-D finite-element simulation of the flow will first be performed for predicting melt fronts during filling by another sub-project. After the optimal design of the filling system is reached, the simulation of the temperature field and the prediction of warpage after cooling will be followed for optimal packing and cooling for precision. The mold design and manufacture will be carried out. During the mold trial-out, the short shots showing the progression of melt fronts will be collected and compared to the predictions. The specifications of the flatness and uniformity will be fulfilled after modifications.In the second year, the compression will be added to the injection molding process. The so-called injection compression molding (ICM) incorporates both packing- and compression-based densification mechanisms. The capacity for precision molding can be preatly enhanced. However, wedge plate is not uniform in thickness. Compression with uniform stroke will yield non-uniform degree of densification. In this study, compression with non-uniform stroke will also be implemented. The quality of the v-grooved wedge plates fabricated with conventional injection molding, ICM with uniform stroke and ICM with non-uniform stroke will be compared. The effectiveness of adding compression to the injection molding of micro-featured wedge plates will be evaluated and justified.楔形板射出成型射出壓縮成型不等行程射出壓縮成型微結構wedge platesinjection moldinginjection compression moldingmicrostructure