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標題: | 雙面石墨烯複材加熱器應用於變模溫射出成型曲面導光板微 結構成型及曲率控制 Injection Molding for Curved Light Plates Microstructure Formation and Curvature Control by Using Double-Sided Graphene Heaters |
作者: | 郭哲瑋 Zhe-Wei Guo |
指導教授: | 楊申語 Sen-Yeu Yang |
關鍵字: | 石墨烯複材加熱器,曲率控制,曲面導光板,雙邊變模溫射出成型,微結構, double-sided graphene composites heater,curvature control,curved light guide plane,mold temperature control in injection molding,microstructure, |
出版年 : | 2023 |
學位: | 碩士 |
摘要: | 射出成型技術具備高自動化及成型複雜形狀的優點,但不易成型具有表面微結構之薄件,且不均勻的冷卻使成品翹曲嚴重而影響成品精度。由於充填過程中,熔膠與冷模壁產生固化層而需加熱器輔助成型,但往往加熱器會導致成品冷卻階段中的溫度不均。本研究開發公母模仁之石墨烯複材 (Graphene composites, GCs) 加熱系統,並使用射出成型製作具有光學微結構之曲面導光板,並透過電供調整加熱器功率,使公母模兩側加熱器配合而產生模面溫差藉此來控制成品曲率。
本研究開發之模具目標為使加熱器能夠快速傳遞熱、模面溫度均勻性佳,而選擇高熱傳導模具材料,並使用模擬分析熔膠壓力對於模仁產生的變形而設計出適當的模仁厚度;石墨烯加熱器優化方面,則透過塗佈材料、塗佈方向、線棒大小、加熱器面積來優化升溫速率以及升溫溫度均勻性。 透過Moldex3D模流分析軟體,對於微結構曲面導光板進行成型模擬分析,透過成型視窗得到基礎參數範圍,再經由單因子分析實驗,探討不同參數對於曲面導光板成型之翹曲影響,並從中挑選四個影響較高之敏感因子,配合田口法實驗L9直交表來優化成型參數,使曲面導光板成型具較低之翹曲變形。 實際成型實驗中,V-cut結構在無GCs加熱器時,結構複製轉寫率僅44%,而使用GCs加熱器在功率260 W、30 sec時,能夠將模具表面由95℃提高至140℃使微結構轉寫率可達99%;接著透過加入母模側石墨烯加熱器來控制模溫差,當母模側加熱器功率為100 W、30 sec,其曲面導光板之曲率半徑最接近模穴曲率半徑,故本研究透過雙面石墨烯加熱器來控制成品曲率以及微結構成型。 Injection molding technology offers the advantages of high automation and the ability to mold complex shapes. However, it faces challenges in molding components with surface microstructures and the uneven cooling process leading to severe warpage and reduced precision of the final products. This study focuses on developing a GCs heating system for core and cavity in injection molding, which fabricate curved light guide plates with microstructures. By adjusting the power supply for the heater on both sides of the male and female molds so that they work together to generate a temperature difference on the mold surface. This temperature difference is used to control the curvature of the final product. The goal of this research is to enable rapid heat transfer and achieve good temperature uniformity on mold surfaces. To achieve this, high thermal conductivity mold materials are selected, and simulation analysis is used to design an appropriate core and cavity thickness that takes into account the deformation caused by injection pressure. In terms of optimizing the GCs film heater, coating materials, coating direction, wire rod size, and heater area are optimized to improve the heating rate and temperature uniformity during the heating process. For molding experiments, the replication rate of the V-cut structure was only 44% without using GCs heater. However, by utilizing GCs heater at a power of 260 W for 30 seconds, the surface temperature of the core increased from 95°C to 140°C, resulting in a microstructure replication rate of 99%. Subsequently, by integrating GCs heater in the cavity, the temperature difference of the mold surface was controlled. When the power of the GCs heaters in the cavity was set to 100 W for 30 seconds, the curvature radius of the curved light guide plate approaches that of the mold cavity. Therefore, in this study, double-sided GCs heaters were used to control the final curvature and microstructure formation of the product. |
URI: | http://tdr.lib.ntu.edu.tw/jspui/handle/123456789/90688 |
DOI: | 10.6342/NTU202302507 |
全文授權: | 同意授權(限校園內公開) |
顯示於系所單位: | 機械工程學系 |
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