塑膠微結構元件熱壓/射出成形時材料高次構造的發展及其對成形特性與產品性質的影響

Abstract

本計畫將進行數種類型塑膠的微結構熱壓和射出成形實驗，以及成形體材料高次構造的 各種顯微鏡分析，並配合數值模擬的輔助，以探討塑膠微結構元件在熱壓和射出成形時的材 料高次構造的發展，及其對成形特性與產品性質的影響。本計畫的研究成果對於提升各種類 型塑膠的微結構的成形品質與效率非常重要，並可做為發展創新功能性的微結構元件的重要 基礎。計畫分三年來進行。 第一年：設計製作ㄧ組微結構模仁和模具來對非結晶性和結晶性兩種塑膠進行熱壓和射 出成形實驗，以調查微模穴的充填行為以及微結構的成形特性；並且利用偏光顯微鏡和掃瞄 電子顯微鏡來觀察微結構成形體的外觀缺陷以及材料高次構造。根據對這些結果的比較和分 析，瞭解材料的結晶性質、微結構的尺寸等級、製程條件等因素對於模穴充填行為和微結構 成形特性以及材料高次構造的影響。 第二年：首先，針對液晶性、聚摻物、以及具有極性分子的塑膠重覆與上年度相同的實 驗、量測及分析。其次，合併將上年度與本年所有種類塑膠的微結構成形體做穿透式顯微鏡 分析與原子力顯微鏡分析；探討是否產生差排線與更微細的高次構造狀態；以及調查微結構 成形體的收縮率和硬度、楊氏係數等物性的狀況。然後，進行輔助的數值模擬並與實驗量測 數據做比對，以得到微結構成形過程中的塑膠的溫度與壓力的數據。最後，綜合各項數據以 推斷微結構成形過程中的材料高次構造的發展，並用以解釋微模穴的充填行為以及微結構的 成形特性。 第三年：使用本研究室所開發完成的可快速自發熱的模仁進行各種類型塑膠的微結構射 出成形實驗，並於成形過程中利用該模仁對於模穴內的塑膠實行精密的動態溫度場控制，以 及施予塑膠電磁場的作用。其次對實驗所得的微結構成形體進行與前面兩年的研究相同的顯 微觀察分析。最後，進行各項資料與數據的整理比較及分析，以瞭解動態溫度場控制以及電 磁場作用對於微結構射出成形所帶來的效果。

In this project, we will conduct a series of experiments of hot-embossing/injection-molding of microstructures with various types of plastics.We will observe the phases and the supramolecular structure of the molded microstructures by the optical and electron microscopes. An auxiliary simulation will be used, too. The purpose of our study is to explore the development of supramolecular structure in hot-embossing/ injection-molding of microstructures. The effects of the development of supramolecular structure on the molding characteristics and the properties of the product will be investigated, too. The accomplishment of this project is vital to the improvement of the molding quality of the microstructures of various plastics. Moreover, fundamentals for the development of microstructure parts with novel functions can be presented. The project will be carried out for three years. In the first year, we will design and make a set of mold and mold inserts for the experiments of hot embossing/injection molding of microstructures. Crystalline and non-crystalline plastics will be used in the molding experiments.We will investigate the filling behavior in the micro mold cavity and the molding characteristics of the microstructures. In addition, we will observe the defects and the supramolecular structure of the molded microstructures by the polarization optical microcopy and the scanning electron microscopy. According these results, we can figure out the effects of whether the plastic is crystallizable, the order of the thickness of the microstructure, and the processing conditions on the filling behavior, the molding characteristics, and the phase distribution of the microstructures. In the second year, various plastics including LCP, polymer blend, and polar polymer will be studied using the same experiments and analysis methods as those used in the first year, firstly. Then, further characterization of the molded microstructures of all five types of plastics used in this project will be performed by the transmission electron microscopy and the atomic force microscopy. We will explore whether the dislocation will appear in the molded microstructures, and exam the delicate supramolecular structure. The physical characters of the molded microstructures including the shrinkage ratio, the hardness and the Young』s modulus will be measured, too. The comparison between the auxiliary simulation and the experimental results will be done. Therefore, we can get the data of temperature and pressure of the plastic in the molding process of the microstructures. Last, we will reason out the development of supramolecular structure of these plastics in the molding process of the microstructure. The filling behavior and the molding characteristics of the microstructures will be clarified. In the third year, we will use the heat-generable mold insert, which has been developed by our research group, to do the injection molding experiments of microstructures of all five types of plastics. During the molding process of the experiment, the temperature field of the molding plastic will be controlled dynamically with the heat-generable mold insert, and the molding plastic will be exposed in an electromagnetic field.We will investigate the filling behavior, the molding characteristics, and the supramolecular structure of the molded microstructures by various types of microscopes. The results obtained in this year will be compared to those obtained in the first and second years, so as to understand the effects of the dynamic control of temperature and the electromagnetic field on the injection molding of microstructures.