隨著加工技術的不斷提昇與導光板等產品的特殊要求之下，射出成品不但需要達到巨觀的幾何尺寸複製以符合裝配要求，更需達到微觀微結構的轉寫已達光學之要求，因此本研究目的在分析平板出成形之表面微觀結構轉寫及巨幾何尺寸之複製，主要在同時考量成品微觀的微結構轉寫率與巨觀的幾何形狀之關係；使用三種不同程度表面粗糙度來近似隨機分佈之微結構，分別為 3.2μm、 0.8μm及 0.2μm，搭配雙集區實驗規劃，分析不同程度之表面微結構對於不同水準實驗參數設定之複製性研究探討，本研究採用射出速度、塑料溫度、保壓壓力及冷卻時間為實驗因子。研究結果在微結構轉寫率實驗中發現，微結構的轉寫率對於射出速度和塑料溫度在此參數設定下近似為線性變化。另在幾何尺寸複製性實驗中發現，保壓壓力和冷卻時間亦為近似線性之變化。並且可利用由實驗數據及迴歸分析所得之性能指標方程式準確預測微結構轉寫率與幾何尺寸複製性，因此本研究結果可應用在不同成形模具之表面粗糙度要求，並可進一步應用在含微結構光學產品的模造技術。

This research is to investigate the replication of micro surface features and macro geometry in injection molding of flat plates. There are three mold inserts with different levels of random surface textures including Ra 3.2 μm, Ra 0.8 μm, and Ra 0.2 μm. Experimental design for mold insert is proceed with two block tests, one is to evaluate the average filling ratio (AFR) and another is to evaluate average non-uniformity (ANU). Experimental factors for AFR are melting temperature (Tmelt) and injection velocity (Vinj), while the factors for ANU are packing pressure (Ppacking) and cooling time (tcooling). Experimental results of AFR tests can be estimated as a linear regression of Tmelt and Vinj. Experimental results of ANU tests also derive a linear regression model of Ppacking and tcooling. Moreover, Tmelt is a significant factor for ANU, as the ANU increas rapidly with increasing Tmelt . The regression model of performance index can be used to predict the AFR and ANU accurately. Therefore, results of this study could be explored to multi-scale replication in injection molding, such as light guide panel (LGP) with micro features used in backlight module of liquid crystal display (LCD) panels.

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