模內裝飾IMD(In-Mold Decoration)是現行表面裝飾工藝中,最具發展性的技術之一,也普遍運用在3C產業中,其中的IMR(In-Mold Roller)模內轉印技術,因為製程具備自動化之優點,且可擁有表面質感多樣化與耐磨耗等特性,非常適合被用來大量生產製造。自2006年起業界廠商開始嘗試在原本只能應用於和緩曲面的IMR產品上做出較大改變。但對模內轉印這項技術來說,產品外觀的形狀、模具設計與成形參數等,均會直接影響薄膜引伸的狀況,使得在射出成形時產生皺摺的情況,造成外觀上品質的不良。 本研究運用田口實驗方法配合實際射出成形之實驗,求得產品最小皺摺量,再以田口實驗方法L4(23)二水準的直交表進行射出成形參數之選用,以得到最佳射出成形參數供實際射出實驗之參考。經由田口法求出之最佳射出成形參數組合,在實際射出成形時,可以得到最佳之成形操作視窗。經由射出實驗顯示,當產品外觀形狀的轉折R角值,不足其高度之1.5倍時,產品皺摺的情形不易控制,成形參數的調整只能有限度的減低皺摺情形。本研究之結果能得到模內轉印產品外觀R角之最佳化設計,將有助於業界在相關產品開發時,做為設計參考之依據。
In current surface decorating technology, IMD (In-Mold Decoration) is one of the most extendable technologies. It is also commonly used in 3C industry. Because of the advantage of automatic process and the property of variety and attrition resistance of surface texture, the IMR (In-Mold Roller) technology is very suitable for mass production manufacture. Since 2006, manufacturers have begun to try a great change in IMR products that can only be applied to smooth surface originally. Nevertheless, the shape, the mold design and molding parameter of product appearance will affect the film extension directly. As the result, there will be fold on product appearance and bad quality while injection molding. In this study, we utilized Taguchi Method to go with the experiment of actual injection molding to find the minimum of the product’s fold volume. And then, we used Taguchi Experimental Method L4 (23) tow-Level orthogonal arrays to select parameters of injection molding to get the best parameters of injection molding as the reference of practical injection experiment. The best combination of injection molding parameters obtained from the Taguchi Method helped us to get the best forming operation window. The injection experiment indicated that when the turning R value of the shape of product appearance was less than 1.5 times of its height, the folding level of product was not controllable. The adjustment of molding parameters can only reduce the fold limited. The result of this study can provide us the best design of round corner R of IMR product appearance and help industry to develop the related products as reference.