擠出滾壓複合製程的開發研究

Development of Hybrid Extrusion Rolling Process for Replication of Microstructures

邱建仁(Jian-Ren Ciou)

指導教授 ： 楊申語

國立臺灣大學/工學院/機械工程學研究所/碩士(2007年)

https://doi.org/10.6342/NTU.2007.02113

摘要

本論文致力於結合微結構滾輪壓印與塑膠薄膜擠出成型新製程之研究。利用擠出成型製造光學塑膠膜，且在塑膠膜還在高溫時，直接進入滾輪微壓印設備，把滾輪上的微結構轉寫到塑膠薄膜的表面上。此製程不但可以達到roll-to-roll大量生產，而且簡化、省能源。本研究自行開發組立一套整合擠出與滾壓微壓印的設備系統，並且設計擠出模具配合擠出機，與製作微結構滾輪，試驗本系統的性能。

微結構滾輪分別以車床車削和樹脂灌模兩種方式來製作有微結構的滾輪，滾輪直徑74mm、長50mm。微結構有週期性微凹弧痕與V溝微結構。擠出模是衣架型模頭，擠出膜的寬度為120mm，厚度可在1.5mm到0.5mm之間調整，實驗的材料為光學用聚碳酸脂（Polycarbonate）。

兩種微結構經表面輪廓儀與SEM觀察量測證實均可成功地複製到塑膠膜上。本研究並探討模頭溫度、驅動滾輪轉速、氣壓缸推力等製程參數對塑膠膜厚度的影響、及對微結構成型性的影響。在塑膠膜厚度方面，經實驗設計的系統化探討，發現驅動滾輪的轉速是最重要的因子。在微結構成型性方面，實驗結果發現驅動滾輪轉速越快，塑膠膜中間微結構成型性會變差；然而氣壓缸推力越大、模頭溫度越高，塑膠膜中間成型性會變好。擠出滾壓目前得到的最佳的成型參數為模頭溫度290℃、轉速4.3 rpm、壓力100Kg/cm。

關鍵字

擠出滾壓複合製程 ； 衣架型模頭 ； 微結構滾輪 ； 光擴散膜

並列摘要

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.

並列關鍵字

Hybrid extrusion rolling process ； Coat-hanger die ； Roller with microstructures ； Optical diffusion film

參考文獻

方煌盛，“滾輪式微結構轉印製程開發研究”，臺灣大學碩士論文，民國94年6月。

朱明輝，“軟模低壓滾輪式轉印製程的研發與應用”，臺灣大學碩士論文，民國95年6月。

張致遠，“創新型微奈米軟模轉印技術之研發與應用”，臺灣大學博士論文,民國95年6月。

謝正倫，“滾輪微結構壓印製程開發研究”，臺灣大學碩士論文，民國94年6月。

ASTM D1003,“Standard Test Method for Haze and Luminous Transmittance of Transparent Plastic”.