塑膠光學元件模具與射出成型電腦模擬之最佳化研究

微型投影機鏡頭組之外殼(Barrel)是光學系統中僅次於鏡片的重要零件，尺寸的精度將影響組裝之後的光學品質，本論文以研究鏡頭組之Barrel的設計與成形品質，由於Barrel的目的在於組裝各光學元件的對位，精準度要求高，但是受限於產品的造型，容易造成收縮翹曲和殘留應力，導致組裝之後的光學品質變差。本論文透過適當的電腦輔助工具、模具設計與配合最佳化成型參數找出成型出品質佳的成形條件。本研究目的是利用Visi flow模流分析軟體進行模擬，接著再對射出成型上分析成型條件對品質影響，最後將成型元件進行量測再將量測結果與設計值進行比較得到最佳光學塑膠元件。本產品在未改善前與改善後搭配鏡片後投影解析結果發現改善後整個投影鏡頭組整體投影評價比為改善前提高許多，其原因主要為改善前因產品整體收縮過於嚴重，導致產品本身尺寸精度誤差量增大而降低整個投影光學品質，在成形條件方面影響產品品質最為顯著的要因影響大小依次是保壓壓力、模具溫度、保壓時間、射出壓力、射出速度最後為冷卻時間。

關鍵字

射出成型；模流分析

並列摘要

Barrel, one of the important components of the mini projector lens module, influences the quality of the whole modulus and as important as lens. In this study, the development methodology for barrel is proposed. The purpose of the barrel is to provide the assembly space and alignment for the lens. The barrel is made by injection molding process and some defects resulting from this manufacture method influence the accuracy of it. Due to the design shape, a uneven thickness of the barrel will produce unbalanced shrinkage and the warpage make the accuracy of alignment poor. In this study, a computer aided engineering (CAE) analysis approach for the development of the barrel is proposed. The VISI-FlOW is applied to determine the optimal parameters and predict what result will happen before mold machining. The analysis data shows that the thicker part of the barrel influence the accuracy of that. Some experimental results are used to verify the design parameters, and conclusion are proposed to show the difference original and improved studies.

並列關鍵字

Injection Molding ； CAE

參考文獻

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[5] Lu,X.;Lau Soo Khim,“A statistical experimental study of injection molding of optical lenses”,Journal of Materials Peocessing Technology, Vol.113,No.1-3,PP.189-195(2001)

[6] C. Zhaoand F. Gao, “Melt Temperature Profile Prediction for Thermoplastic Injection Molding”, Polymer Engineering and Science, Vol. 39, No. 9, pp. 1787-1801(1999)

[10] 柯仕盈，大口徑非球面塑膠光學鏡片成型技術之研究，國立虎尾科技大學光電與材料科技研究所，碩士論文，民國九十六年。

[12] Huang, M.C. and Tai, C. C. (2001) “The effective factors in the warpage problem of an injection- molded part with a thin shell feature,” Journal of Materials Processing Technology.

國際替代計量

塑膠光學元件模具與射出成型電腦模擬之最佳化研究

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