射出成形應用於具菲涅爾結構之全內反射透鏡以改善準直效果

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研究生：	ARIAN DWI PUTRA ARIAN - DWI PUTRA
論文名稱：	射出成形應用於具菲涅爾結構之全內反射透鏡以改善準直效果 Injection Molding of Total Internal Reflection Lens with Fresnel Structure for Improving Collimation of LED Illumination
指導教授：	陳炤彰 Chao Chang A. Chen
口試委員:	Allen Jong-Woei Whang Allen Jong-Woei Whang Dr. Wei-Yao Hsu Dr. Wei-Yao Hsu
學位類別：	碩士 Master
系所名稱：	工程學院 - 機械工程系 Department of Mechanical Engineering
論文出版年：	2014
畢業學年度：	102
語文別：	英文
論文頁數：	140
中文關鍵詞：	TIR光學元件、準直透鏡、LED照明、射出成形、菲涅爾結構
外文關鍵詞：	TIR lens, collimation lens, LED illumination, injection molding, Fresnel structure
相關次數：	點閱：372 下載：41
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本研究在原有的total internal reflection全反射 (TIR) 透鏡加入自行設計的菲涅爾結構提升固態照明或發光二極體(LED)照明之準直性能。在設計菲涅爾結構部分，其焦距(focal length)和間距(pitch)是兩個重要參數，焦距是經由幾何光學和司乃耳折射定律來計算，間距則是取決於光學模擬的結果。通常光學設計理論方法是建立在一個點光源，但由於LED具有一定的尺寸，所以須以光學模擬先驗證所使用LED光源的可能性，其芯片的尺寸為1mm ×1mm，在光學設計流程中，均勻度和平均照明在距離LED一公尺的目標平面上之結果，可用來決定與優化最佳的焦距和菲涅爾結構的間距。實驗方法以射出成形來驗證具菲涅爾結構TIR透鏡設計的實際性，以PMMA射出成形有TIR和修改後的TIR(TIR-F)光學元件。藉由模流軟體(Moldex3D)的模擬結果發現，最小的Z軸翹曲量為0.032mm，保壓壓力110MPa，射出速度為1 mm/s，其中最小的翹曲量公差為0.115mm，另使用射出速度和保壓壓力兩個參數來繪製成形視窗。射出速度的最佳範圍是1mm/s至5mm/s，如果大於5mm/s，TIR的表面將產生流痕會影響後續的量測結果。對於原有TPR和修改後的TIR-F光學元件，保壓壓力的最佳範圍是90MPa到110MPa。在光學檢測部分，修改後的TIR-F光學元件的最大光強度比原來的TIR高了15.785 ％。而修改後的平均發光角度為4.69°，原來的TIR發光角度為5.55°，與原來相比修改後的多聚焦了0.86°，增進約15.5%。本研究成果未來可應用於高階TIR透鏡或高亮度準直光照明需求之產品。

This study is devoted to develop a composited lens to redesign collimation effect of a Light Emitting Diode (LED) illumination. The composited lens is a Total Internal Reflection (TIR) lens combined with a Fresnel structure. The focal length and pitch value are two important variables in designing the Fresnel structure. The focal length is calculated by geometrical optics and Snell’s law. The pitch is determined by an optical simulation of software. The theoretical method is based on a point source first and then adapted to a specific size of LED chip. Thus an optical simulation is conducted to verify the feasibility of such model of an LED chip size as 1 mm x 1 mm. In the optical design step, the uniformity and the average illumination on the target plane are two results of collimation performance which are used to determine the compromised focal length and the pitch of Fresnel structure. An injection molding process is used to manufacture the original TIR lens and the modified TIR-F lens to verify the actual performance of the desired lens design. A Moldex3D simulation shows that the minimum warpage of Z direction is 0.032 mm for packing pressure as 110 MPa and injection velocity as 1 mm/s, where the minimum warpage tolerance is constrained as 0.115 mm. The injection velocity and packing pressure are two parameters to construct a molding window. The optimal range of injection velocity is from 1 mm/s to 5 mm/s in this study where a flow mark may be generated over 5 mm/s. The optimal range of packing pressure for both the original and the modified TIR-F lens are 90 MPa to 110 MPa. In the optical test, the maximum light intensity of the modified TIR-F lens is 15.79% higher than the maximum light intensity of the original TIR lens, with the average light angle of the modified TIR-F lens is 4.69o while the light angle of the original TIR lens is 5.55o. Results of this study can be applied on high-brightness LED illumination with specific collimation.

ABSTRACT	3
ACKNOWLEDGEMENT	4
TABLE OF CONTENTS	5
LIST OF FIGURES	7
LIST OF TABLE	11
NOMENCLATURES	12
CHAPTER 1	INTRODUCTION	13
1.1	Background	13
1.2	Research Objectives	14
1.3	Approach	15
1.4	Research Framework	19
CHAPTER 2	LITERATURE REVIEW	21
2.1	Reflection and Refraction Fundamental	21
2.2	Fresnel lens	21
2.3	Total Internal Reflection Lens as a Secondary Optic for LED Illumination	22
2.4	Injection Molding Process	32
2.5	Shrinkage and Warpage	32
2.6	Injection Molding Process	34
CHAPTER 3	OPTICAL SIMULATION	36
3.1	TIR Lens Inlet and Outlet Convex Introduction	36
3.2	Optical Simulation	37
3.2.1	TracePro Introduction	37
3.2.2	Light Source and Detail Simulation Parameters	38
3.2.3	Target Plane	39
3.2.4	Original and Modified TIR-F lens Profile	40
3.2.5	TracePro Simulation Result	42
CHAPTER 4	MOLD DESIGN AND MOLDEX SIMULATION	53
4.1	Mold Design	53
4.2	Core Pin Design	55
4.3	Core Pin Measurement Result	56
4.4	Moldex Simulation	59
CHAPTER 5	EXPERIMENTAL EQUIPMENT AND METHOD	63
5.1	Injection Molding Machine and Sample Preparation	63
5.1.1	Injection Molding Equipment	63
5.1.2	Molding Window Experiment	67
5.1.3	Short Shot Experiment	68
5.1.4	Warpage Calculation	68
5.2	Optical Testing Preparation	69
CHAPTER 6	RESULT AND DISCUSSION	72
6.1	Moldex Simulation Result	72
6.2	Injection Molding Experiment Result	76
6.3	Short Shot Simulation and Experiment Result	79
6.4	Molding Window Result	83
6.5	Optical Inspection Result	84
CHAPTER 7	CONCLUSION AND RECCOMENDATION	89
7.1 Conclusions	89
7.2	Recommendations	89
REFERENCES	92
APPENDIX A Lens Design Calculation	94
APPENDIX B Tracepro simulation result	111
APPENDIX C DRAWING	118
APPENDIX D Fanuc Roboshot α-15Ia Specification	122
APPENDIX E PMMA Asahi Kasei Delpet 80 NH Property	123
APPENDIX F Mechanical Dimension & Typical Spatial Distribution	125
APPENDIX G Optical Inspection Result	127
CURRICULUM VITAE	140

                                

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