本研究目的為設計製造一光源之光學均勻器(Homogenizer)，並探討不同的射出成形製程參數對於體積收縮率、軸向收縮率與光學均勻性之影響，使用之分析方法為迴歸分析法。在光學均勻器設計部分，利用高斯光束特性做定量設計，與TracePro軟體之驗證分析得到光學均勻器之幾何外形形狀。然後利用Moldflow軟體分析成品之充填與收縮現象，並與射出實驗作結果比對。在光學均勻器製造部份本研究使用Fanuc Roboshot α15-ίA全電式射出成形機及Asahi Kasei 80NH PMMA塑料進行實驗，實驗結果得知本研究成功驗證光學上之設計需求及將光準直器、透鏡陣列與投影透鏡三個元件整合成一個含微結構之光學元件，並以射出成形技術製造出此光學元件之想法。另由圓柱件之三維收縮實驗得知，增加保壓壓力可以獲得較佳的幾何外形尺寸，但會增加產品之殘留應力。而冷卻時間之增加會使產品收縮量變大，但可減少殘留應力。再由模流分析與實驗設計得知影響體積收縮的參數因子為保壓壓力，保壓壓力越大，可降低體積之收縮；而影響光軸高度之收縮的參數因子為冷卻時間，較長的冷卻時間能得到較高的光軸高度值。同時光學均勻器之均勻性與微溝槽成形性成正比之關係，而保壓壓力越大與冷卻時間越久可增加微溝槽成形率。本研究最佳之微溝槽成形率為88.98%，光學均勻性為68%，光效率為91.88%，未來研究期望能研發適用LED光源之光學均勻器。

This research is to design and manufacture optical homogenizer for light source, and use regression analysis to investiate different parameters for effects of volumetric shrinkage and Z-axis shrinkage. The homogenizer was designed with Gaussian laser beam and the geometry of homogenizer was verified with TracePro software. Simulation of injection molding by Moldflow was proceeded to evaluate the filling stage and volumetric shrinkage. A Fanuc Roboshot injection molding machine and Asahi Kasei 80NH PMMA were selected to perform the experiment. Experimental results show that the hybrid design of collimator, lens array, and projection lens into one optics for homogenizer has been implemented by injection molding and verified. Form experiments of shrinkage of cylinder part, the packing pressure can be increased to obtain better dimension of geometry, but the residual stress will increase. Increasing the cooling time will induce shrinkage, but that can decrease the residual stress. Form Moldflow simulation and regression analysis of experimental results of the optical homogenizer, important parameter of volumetric shrinkage is packing pressure. Increasing packing pressure can be decrease volumetric shrinkage, but longer cooling time can decrease Z-axis shrinkage. Uniformity of homogenizer and transfer ratio of grooves (TRG) have relationship of direct proportion, increase packing pressure and cooling time can obtain good TRG. This research has achieved the TRG as 88.98%, optical uniformity as 68% and the optical efficiency as 91.88%. Future work focus on development of an optical homogenizer for LED light source.

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