射出成型參數對於LED Lens收縮變形之研究

成型條件與模具設計對於成品具有關鍵性的影響，兩者的關係也是左右生產效率的主要因素。本次研究主要探討LED Lens射出成型時成型參數對於收縮變形的情況，並觀察成品厚度較大時，成型後塑膠所產生收縮現象的變化，實驗材料選用PC (POLY-CARBONATE)，實驗方式首先進行電腦輔助模擬(Moldex 3D)，接著進行實際射出成型部分，兩階段實驗皆運用田口設計方式作為實驗架構，品質特性為成品表面收縮變形量，量測點分別為七個位置，皆位於成品之表面處，而理想目標為望小特性。射出成型實驗後發現，Lens表面收縮率，熔膠溫度對於收縮現象為最具影響的控制因子，而最佳化製程設計則是以符合公差範圍且收縮變形量最少之實驗參數，收縮率趨近於零，最接近期望值之目標，進而了解到成型參數中因子的影響與趨勢，並藉由實際驗證來證實品質特性之可靠性，也符合實驗預測值之目標，最後進行照度量測實驗，發現使用Lens後聚光效果提升約五倍之成效。

關鍵字

射出成型； LED Lens ；收縮變形；田口方法；不等厚度充填

並列摘要

The molding conditions and mold designing are key influences for the finished mold. The production efficiency is also affected by the two factors. This study was conferred the molding parameters affects the mold shrink when LED Lens injected. After molding, we also observed the phenomenon of plastic shrinkage on the thickness production. We chose the PC (POLY-CARBONATE) as the experimental material. Then, we utilized the computer-assisted simulation (Moldex 3D) and injection molding. Both of the two experiments were used the Taguchi design as an experimental framework. The observing point was the surface shrinkage of products. Measuring points for the seven positions were all located on the surface of finished products. The ideal goal was Smaller-The-Better. After the injection molding experiments, we found that the melting temperature for Lens surface shrinkage was an important factor. And the optimum processing design was based on the experimental parameters, which was conformed the tolerance range and made the shrinkage minimum to zero. And then, we realized the influence and tendency of molding parameters. By using the experiment, we could prove the reliable of quality characteristics and fit in the goal of predictive value. Finally, according to the illumination measurement experiments, we found that the light focusing ability increased five times by using Lens.