本研究主要在研發級進式射出壓縮成形(Progressive Injection Compression Molding, PICM)成形方式配合模具設計，針對具有次波長微米結構(Sub-wavelength Micro Structures)之複合式菱鏡之成形與光學品質作探討，針對成品厚度之不同，利用具有不同壓縮行程之模仁以級進的方式做壓縮，並比較射出成形、射出壓縮成形與級進式射出壓縮成形三種不同成形方式對複合式菱鏡的模穴壓力變化，以及成品入光面之平面度探討，最後進行殘留應力檢測。此外藉由具有次波長微奈米結構之矽晶圓模仁進行級進式射出壓縮成形實驗，以探討微結構對於光學品質之影響。實驗結果得知PICM可有效降低成品入光面平面度誤差，相對於傳統射出成形最佳值提升了46.34%，而在次微米結構複製性實驗中最佳微結構複製性為86.15%，且其接觸角由原先83.3°提升至118.7°，提升了42.50 %。光學檢測方面，藉由照度量測可得知添加次微米結構之成品可吸收更多光能量並有效將光集中，相較於無添加次微米結構之成品照度提升80.8%。本研究成果未來可進一步使用在成品厚度變化較為複雜的菱鏡型光學元件與非球面透鏡元件。

This research is to design a progressive injection compression molding (PICM) for hybrid prism with micro structures to obtain better surface uniformity for improving optical quality. The compression stroke is based on the different part thickness of prism and the mold cavity pressure has been observed by two sets of pressure sensor modules to acquire the relationship of pressure and compression effects. In this research, three kinds of molding process including injection molding (IM), injection compression molding (ICM) and progressive injection compression molding (PICM) have been investigated to discuss the parameters of injection velocity, mold temperature, and compression time based on performance of non-uniformity (NU) and sub-wavelength micro structures (SWMS) of filling ratio (SFR) by experimental design. The SWMS is replicated by a silicon mold insert with nano or sub-micro structures of porous anodic alumina (PAA). Residual stress has been measured by photoelastic instrument and discussed. Experimental results show that the PICM could effectively improve the incident surface uniformity 46.34% as compared with IM process and also improve the SFR from 82% to 92%, The contact angle incident surfaces of prism by IM and PICM increased from 83.3ﾟto 118.7 ﾟ, as increased by 42.50%. The hybrid prism with best SFR can improve the illumination 80.8 % as compared with prism without sub-microstructure. Further study can apply on injection molding of the hybrid thickness of prism aspheric elements.

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