應用模流分析探討模內裝飾製程參數優化對薄殼件之研究

A Study of Mold Flow Analysis in In-Mold Decoration Process Parameters for Shell

模內裝飾是一新興的塑料裝飾技術，其製程優點可減少產品後續裝飾程序，如熱轉印、印刷、噴塗、電鍍、雷雕等等。模內裝飾製程中常見的成形缺陷有因冷卻不均所引起的翹曲變形、塑料充填不當造成薄膜沖刷及剪切應力問題。本研究利用模流分析工具幫助解決模內裝飾製程中所遭遇到的成形缺陷，並配合田口方法，以翹曲變形問題作為探討重點，以求迅速獲得各製程參數對成形特性的影響。從分析結果可知，影響翹曲變形主要的製程參數為保壓時間、冷卻時間及保壓段數。

In-Mold Decoration (IMD) is a new plastic decoration technology, which has the advantages of reducing the product follow-up decoration processes, such as thermal transfer, printing, spraying, electroplating etc. Moreover, the film scour and shear stress defects are common problems which are caused by cooling non-uniform in the plastic material filling process. This study was using mold flow analysis to solve forming problem in the IMD process. In addition, the Taguchi method was used to evaluate the warpage problem in order to maximize the process parameters. From the analysis results, we found that main process parameters for warpage were the packing time, cooling time and packing segments.