臺灣博碩士論文加值系統

熱塑性塑膠微射出成型技術的主要關鍵在於高性能的微射出成型機、微模仁加工、精密模具設計製作、脫模輔助裝置與輔助成型技術。微射出成型機的需求是準確的計量能力、高射出率、反應快與穩定的機構等。
本研究為了發展熱塑性塑膠微射出成型技術，分別以開發一外掛式微射出成型模組以及輔助成型的紅外線變模溫系統與真空模穴系統來進行探討。首先，發展一個新概念的外掛式微射出成型模組。此系統設計成一個分離模組，其具有熱澆道柱塞式射出成型單元且可被應用在小噸數 (30~100噸)油壓或全電往複式螺桿射出成型機上。外掛式微射出成型模組固定在射出機的固定板與模具中間。如此一來往複式螺桿射出單元便轉換成押出單元。經由此外掛式微射出成型模組，大部份的往複式螺桿射出成型機便提升為高精度兩階段射出成型機且具有微射出精密計量的能力。
第二個部份是紅外線模具表面快速加熱系統於射出成型之研究。在此發展一個混合三維光線軌跡與暫態熱傳模擬的方法來計算受到紅外線加熱模具表面的熱狀態。其中商用光學分析軟體TracePro被用來模擬吸收紅外線模面的熱通量。之後使用ANSYS來計算模仁表面二維與三維的暫態熱傳。紅外線加熱模面時，也使用數種型式的反射鏡面來研究其加熱效果。所模擬的溫度結果與使用熱影像儀的實驗測量值相當接近。之後，利用此模擬方法來研究對於微射出成型紅外線快速表面加熱反射鏡面的幾何影響，並使用田口方法來找出近似最佳的反射鏡面。
此外，針對射出成型設計並驗證一個低成本與實用的紅外線快速表面加熱系統。此系統被設計來組裝在模具上並使用一個控制系統來操作燈座的運動與鹵素燈的開關。使用四個鹵素燈(每個1kW)做為加熱模仁表面的光源。採用一個修改的螺旋流模具來驗證紅外線快速表面加熱系統在實際射出成型的效益。分別使用三種塑膠材料聚丙烯(PP)、壓克力(Acrylic)與聚碳酸脂(PC)來進行螺旋流射出成型實驗。假如使用近似球面反射鏡與燈泡集中排列的方式加熱，模仁表面的溫度可以被加熱到最高。模仁中央的溫度經過15秒紅外線加熱可以從83°C上升到188°C。因為模仁表面的模具在充填前高於塑料的熱變形溫度，因此螺旋流成品的長度會增長。也進行研究對於薄長件成品模穴其紅外線加熱位置的影響，如此驗證使用較小紅外線加熱面積於較大模具表面的可能性。同時，使用紅外線模仁快速表面加熱也能相當有效地輔助微針陣列結構的射出成型，其微針尖端的複製性相當高。
最後，建立一個簡單的真空模穴系統並用來研究真空模穴對射出成型的影響。在實驗中，射出前模穴壓力可以達到25 torr。從成型的結果可知，使用真空模穴的成品複製性比未使用真空模穴的還要好。經由抽真空，未充填完成的現象便消失。
經由本文中的研究結果，對於熱塑性塑膠微射出成型技術的成品複製性與解決方法確實有所助益。

The keys of the micro injection molding technology are high performance injection molding machine, micro mold insert, precise micro mold base, demolding device and auxiliary system. The requirements of the micro injection molding machine are accurate metering (dosing), high injection rate, short response time and stable mechanism etc.

In this research, in order to study the thermoplastic micro-injectiom molding technology, an external micro-injection molding module, an infrared variotherm system and a vacuum mold system were developed and investigated. At the beginning, a novel concept of external micro-injection molding module was presented. The system was design as a separate module, which was a hot runner plunger-type injection molding module and could be applied on small (30~100 tons) reciprocating screw hydraulic or fully electric injection molding machines. The micro injection molding module was fixed between the stationary platen and mold of a reciprocating screw injection molding machine. The function of the reciprocating screw injection molding machine was used as an extrusion unit. With this micro injection molding module, most reciprocating screw injection molding machines could be upgraded as high precision two-stage injection molding machines and have the capability of precise metering for micro injection molding.

The second part of the research was the study of a rapid infrared surface heating system for injection molding. A three-dimension ray tracing and transient thermal simulation was developed to evaluate the thermal condition of injection mold surface with infrared surface rapid heating system. Several types of reflectors were applied to study the heating capability of the rapid surface heating system. A commercially available optical analysis program, TracePro, was used to simulate the infrared absorption of the mold surface. The surface temperature of the mold insert was evaluated by 2D and 3D transient thermal analysis with a commercial software, ANSYS. The results from simulation and thermal image measurement system agree well. Then, the geometry influence of reflectors for infrared rapid surface heating on micro-injection molding was studied. Taguchi method was adopted to find the close to optimal reflector geometry for rapid surface heating of micro-injection molding.

A low cost and practical infrared rapid surface heating system for injection molding was designed and investigated. The system was designed to assemble on the mold and a control system was used to operate the motion of the lamp holder. Four infrared halogen lamps (1kW each) were used as the radiative source to heat the surface of the mold insert. A modified spiral flow mold was used to test the enhancing filling ability of the rapid surface heating system. Three resins, PP, Acrylic and PC were molded in the spiral flow injection molding experiments. If spherical reflector and centralized lamp configuration were used, the temperature at the center of the mold surface is the highest. The temperature of mold center surface was raised from 83°C to 188°C with 15 seconds of infrared heating. Because the surface temperature of the mold insert was higher than the heat deflection temperature of resins before filling, the flow distance of resins in the modified spiral flow mold would be increased. The location effect of the infrared surface heating system on a thin-long cavity was studied to demonstrate the possibility of using smaller infrared heating area on a large mold surface. A micro-probe cavity also demonstrated that with the assistance of infrared heating technology the replication ability of a micro-probe can be greatly improved.

Finally, a simple vacuum mold cavity system was established to study the effect of the vacuum mold cavity for injection molding. In the experiment, the pressure of the mold cavity could reach 25 torr before injection. From the result of the molding, it was observed that the replication ability of vacuum mold cavity was better than that without vacuum. With vacuum, the unfilled area in the part was gone.

According to the results of the study, the technique and replication of the thermalplastic micro-injection molding can be improved.

摘要 I
Abstract III
致謝 V
圖目錄 X
表目錄 XIII
方程式表 XIV
符號表 XV
第一章 緒 論
1.1 前言 1-1
1.2 文獻回顧 1-3
1.2.1 微射出成型機 1-3
1.2.2 變模溫製程 1-6
1.2.3 具有變模溫系統的模具之熱傳狀態 1.9
1.3 研究目的與方法 1-11

第二章 外掛式微射出成型模組之設計與實驗
2.1 外掛式微射出成型模組之設計 2-1
2.1.1 熱澆道、溫度控制與閥門 2-7
2.1.2 柱塞與閥門的傳動機構 2-9
2.1.3 閥門傳動機構與位置感應器 2-13
2.1.4 控制與射出製程整合 2-15
2.2 成型測試 2-19
2.2.1 外掛式射出成型模組功能試驗 2-19
2.2.2 計量體積測試 2-22
2.2.3 螺旋流成品之成型 2-23
2.2.4 短澆道模仁試驗 2-24

第三章 紅外線模仁表面快速加熱技術之研究
3.1 模具表面紅外線加熱溫度模擬 3-1
3.1.1 紅外線軌跡分析 3-1
3.1.2 模面溫度模擬 3-3
3.1.3 模面溫度測量 3-4
3.1.4 結果與討論 3-5
3.2 紅外線反射鏡的幾何影響 3-16
3.2.1 不同幾何反射鏡的分析 3-16
3.2.2 近似球面鏡的構成參數分析 3-17
3.3 紅外線加熱輔助射出成型之實驗驗證 3-26
3.3.1 紅外線系統與修改之螺旋流模具 3-26
3.3.2 螺旋流模具輔助快速表面加熱之成型測試 3-27
3.3.3 快速表面加熱位置之研究 3-28
3.3.4 微特徵結構射出成型驗證 3-30

第四章 真空模穴系統之研究
4.1 輔助真空模穴之小體積成品射出成型 4-1

第五章 結論與未來發展
5.1 外掛式微射出成型模組 5-1
5.2 紅外線快速模仁表面加熱 5-1
5.3 真空模穴系統 5-3
5.4 未來發展 5-4
參考文獻 i
附錄 A 外掛式微射出單元規格性能計算 viii
附錄 B 荷重計規格 x
附錄 C 光學尺規格 xi
附錄 D 伺服馬達規格 xiii
附錄 E 滾珠螺桿規格 xv
附錄 F 紅外線鹵素燈泡規格 xvi
附錄 G 2D與3D模型熱通量改寫程式 xvii
附錄 H 2D與3D模型ANSYS可讀取批次檔 xix
附錄 I PP、壓克力與PC塑膠粒規格 xxiii
附錄 J 真空幫浦規格 xxvi
中文索引 xxvii
自介 xxx

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