本研究旨在開發一新型異質結合方法 (Heterogeneous Bonding)，藉由界面陽極氧化鋁 (Anodic Aluminum Oxide, AAO)之次微米孔洞結構以物理機械性接合方式結合塑膠及玻璃材料，並由嵌件射出成形 (Insert Injection Molding, IIM)製作出平面透鏡、非球面透鏡及非球面陣列透鏡之異質結合產品。研究方法將先針對純AAO薄膜之光學性質進行分析，透過鋁板製作出AAO/Al之純AAO薄膜，並由光學分析結果得知，390 nm的AAO薄膜光穿透率約為75 %，另製作均勻陽極反應的6吋AAO/Glass模仁，其AAO孔洞直徑為70 nm及薄膜厚度為370 nm，可大量製備異質結合之AAO/Glass嵌件，再透過AAO製程後高溫熱退火 (500°C)，可有效改善AAO/Glass光衰減問題，光衰減由18 %降低至3 %；由嵌件射出成形模流分析結果得知，越薄的模腔厚度可有效增加充填階段的模內壓力及降低體積收縮率；由異質結合強度分析結果得知，拉伸強度可由2 MPa (無AAO結構PC/Glass)提升至31.9 MPa (具AAO結構PC/AAO/Glass)，剪切強度由0.1 MPa (無AAO結構PC/Glass)提升至0.83 MPa (具AAO結構PC/AAO/Glass)；由高溫環境測試結果得知，本研究之PC/AAO/Glass異質結合產品可耐高溫至125°C，當150°C時會產生PC白化問題；由光穿透率分析結果得知，PC/AAO/Glass之光穿透率為衰減10~15 %；由成像品質MTF分析結果得知，PC/AAO/Glass非球面透鏡可使MTF30由2.9 c/mm提升至4.4 c/mm、MTF50由2.1 c/mm提升至3.5 c/mm，具有較佳的對比成像品質。本研究成果未來可應用於高亮度LED光學元件等相關產品。

This study aims to develop a novel heterogeneous bonding method by using mechanical adhesion mechanism to combine polymer and glass by submicron pores structure of anodic aluminum oxide (AAO). This research is to fabricate heterogeneous bonding products like Plano lens, Aspherical lens, and Aspherical lens array by insert injection molding (IIM). An AAO film has been fabricated on Al plate and then back etching to single AAO film. The optical performance shows that the light transmittance of AAO film with thickness 390 nm is around 75 %. Then, the 6" AAO/Glass with uniform anode reaction is fabricated with pore diameter is around 70 nm and the film thickness is around 370 nm. The 6" AAO/Glass can be divided into 70 pieces as part or mold insert and can be applied on heterogeneous bonding. Results also showed that the light attenuation problem can be improved by thermal annealing at 500°C after AAO processing, where the light attenuation decreased from 18 % to 3 %. According to simulation result of insert injection molding by Moldex3D, the thinner cavity thickness can effectively increase the in-mold pressure during filling and then reduce volume shrinkage ratio. Results of heterogeneous bonding strength tests show that the tensile strength increases from 2 MPa (PC/Glass) to 31.9 MPa (PC/AAO/Glass) and shear strength increases from 0.1 MPa (PC/Glass) to 0.83 MPa (PC/AAO/Glass) due to AAO structure. According to light transmittance analysis, PC/AAO/Glass light attenuation is only decayed about 10~15 %, and image quality analysis of MTF shows that the aspherical lens (PC/AAO/Glass) increases the MTF30 from 2.9 c/mm to 4.4 c/mm, where MTF50 increased from 2.1 c/mm to 3.5 c/mm. The PC/AAO/Glass lens fabricated in this study can withstand high temperature up to 125°C, however, whitening problem of PC polymer occurs at 150°C obtained by high-temperature environment test. Results of this study can be applied on further sustainable and high-brightness LED lens application.

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