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標題: | 微射出壓縮成型微透鏡陣列於基盤之製程開發 Fabrication of Microlens Array on Disk Using Micro-Injection Compression Molding Process |
作者: | Ting-Yu Cheng 鄭廷裕 |
指導教授: | 楊申語 |
關鍵字: | 微透鏡陣列,射出壓縮成型,田口方法,可替換模仁,雙面, Microlens array,Injection compression molding,Taguchi method,Replaceable mold inserts,Double-sided, |
出版年 : | 2017 |
學位: | 碩士 |
摘要: | 雙面微透鏡是光場相機、微投影機、近眼顯示器的關鍵光學元件。本研究提出以微射出壓縮成型微透鏡陣列於基盤之製程,達到快速、均勻性佳和光學性質良好的雙面微透鏡陣列,本研究分為模擬分析與實際驗證兩大部分。
本研究首先以Moldex3D模流分析軟體,比較傳統一模多穴與基盤設計,發現基盤設計省料省時,且可在4吋面積上佈滿雙面微透鏡陣列,大幅提升生產效率。接著進行基盤雙面微透鏡陣列告操作參數敏感性實驗,探討射出成型(IM)與射出壓縮(ICM)不同參數的影響程度,各找出四個最敏感因子,使用田口法實驗設計的L9直交表,找出最佳成型參數組合後,進一步將模擬結果進行實際驗證。 實際成型驗證實驗中,使用高精密三軸加工中心機,製作各4×4凹、凸透鏡於兩個模仁上,將模仁安裝於可射出成型(IM)與射出壓縮成型(ICM)模具,為驗證4吋基盤上成型性,以近澆口與遠澆口各一雙面微透鏡陣列為代表,證實ICM比IM可得較佳轉寫均勻度與低殘留應力,驗證敏感因子與模擬結果相似,成型微透鏡陣列具備聚焦功能且成像清晰。 本研究使用模擬分析輔助設計,並以實際成型驗證,成功製作雙面微透鏡陣列於4吋基盤,且證實ICM比IM有更好轉寫率、光學性能與低殘留應力。本研究提升雙面微透鏡陣列成型技術與效率,滿足現今光學產業透鏡高性能且微小輕薄的需求。 The double-sided microlens array is a key optical component of the light field camera, the micro projector and the near eye display etc. To enhance the productivity, this study developed a design of wafer-level double-sided microlens array. In this study, Moldex3D simulation analysis software was used to simulate the design between traditional multi-cavity and disc mold. The result shows that the disc mold can save plastic and molding time. The 4-inch disc with double-sided microlens array can greatly enhance the production efficiency. The four most sensitive processing parameters of injection molding (IM) and injection compression molding (ICM) for microlens disc were discovered. Then L9 orthogonal method of Taguchi method was employed to find the best combination of molding parameters. For molding experiments, 2 mold inserts with 4×4 convex and concave lens array were machined by the high-precision three-axis machining center. They were mounted into molds in one of two locations: one close to gate and the other away from gate. The mold was designed to be used in both IM and ICM. The molding experiments confirmed that the ICM is better than the IM with higher precision and lower residual stress. The results of experiments confirmed the results of simulation. The ICM molded microlens array has focal length 2.549 mm and spot size 50μm. This study compared the simulation analysis and molding experiment in IM and ICM. ICM process successfully produced the double-sided microlens array on the 4-inch disc with high precision, low residual stress and good optical quality. This study proves the feasibility of fabricating wafer-level double-sided microlens array using injection compression molding. |
URI: | http://tdr.lib.ntu.edu.tw/jspui/handle/123456789/69008 |
DOI: | 10.6342/NTU201703376 |
全文授權: | 有償授權 |
顯示於系所單位: | 機械工程學系 |
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