熱澆道流道與熱嘴尺寸對融膠流動行為影響之研究

摘要由於熱澆道系統不會有流道的廢料產生，並可提高生產效能與品質，因此在塑膠模具業被廣泛的使用，而目前液晶電視的前框面積小但熱澆道的熱嘴使用數量確很多，所以如何正確設計使用數量以控制成本越來越受重視，因此本研究將針對熱澆道系統對於薄件產品的融膠流動長度影響，做為本研究的主要研究分析課題。論文中主要針對熱澆道系統的熱流道及熱嘴尺寸對融膠流動長度的影響進行研究與探討，同時設計在不同產品厚度、不同的模具溫度與熱澆道系統溫度的製程條件下進行成型實驗，並以模流分析先進行各項參數的融膠流動長度變化分析，再進行射出成型實驗，以有系統的完整研究分析影響融膠流動長度的原因。實驗的配置上主要有3項組別，分別是A組-熱流道3mm配上熱嘴尺寸為3mm、B組-熱流道5mm配上熱嘴尺寸為3mm與C組-熱流道5mm配上熱嘴尺寸為5mm，並分別進行0.6mm、0.8mm與1.0mm的3種產品厚度成型實驗。實驗結果顯示模具溫度愈高、熱澆道系統溫度愈高、熱流道尺寸愈大、熱嘴尺寸愈大及產品肉厚愈厚對於融膠流動長度皆具有增加的效益；雖然模擬與實驗結果皆具有相同的趨勢，但在模擬的結果上則顯示將熱嘴從3mm更換成5mm的尺寸，具有增加29%的融膠流動長度的最大效益，而實驗的結果則是顯示產品肉厚是影響融膠流動長度的關鍵因素，在本研究中當產品肉厚從0.6mm變成0.8mm時具有高達132.6%的最大增加效益。而經由實驗結果的完整分析，在模具溫度與熱澆道溫度對於融膠流長變化的實驗結果上，顯示熱澆道溫度具有較高的影響，其影響比例大約從27.72%至38.46%。從本研究中可以清楚的了解熱澆道系統中影響融膠流動行為的特性，相關研究成果並可提供相關人員和使用此塑料開發精密薄件射出成型的業者們進行參考而能有助於降低成本與提升良率。

關鍵字

熱澆道系統；融膠流動長度；模具溫度；熱澆道溫度

並列摘要

Abstract With hot runner system, there will no material waste form runner and can increase production efficiency and quality during injection molding. But now the LCD front frame have met some problems in how much melt flow length is filled by one hot drop and how many hot drops are enough to support the melt to fully fill the cavity. In this study, the hot runner system has been applied to study the melt flow length with variant hot runner/hot drop design, part thickness, mold temperature and hot runner system temperature. The mold flow simulation also been used to ravel the effects of variant hot runner and hot drop design, part thickness and molding parameters in melt flow length. There are three groups of the experiment, the 3mm hot runner with 3mm hot drop, the 5mm hot runner with 3mm hot drop and the 5mm hot runner with 5mm hot drop. It was found that the higher mold temperature, the higher hot runner system temperature, the bigger hot runner, the bigger hot drop and the thicker part will result in more melt flow length in both simulation and experiment. The simulation has shown the highest effect of melt flow length is change hot drop from 3mm to 5mm and result in 29% increase. But the experiment has shown the highest effect of melt flow length is change the part thickness from 0.6mm to 0.8mm and result in 132.6% increase. The experiment results also showed the hot runner system temperature has higher effect than mold temperature and the increment is from 27.72% to 38.46%. From this study, it has clearly understood the effect of hot runner system on melt flow length. The related research results also can provide a guideline for hot runner system development and use.

並列關鍵字

Hot runner system ； mold temperature ； hot runner system temperature ； melt flow length

參考文獻

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參考文獻