臺灣博碩士論文加值系統

在淨零碳排需求下，如何有效使用回收再生塑料生產與新料相仿之良好成型品質並維持量產穩定性及一致性至關重要。由於塑料在加工過程受溫度、壓力及剪切應力影響，致使二次料微觀分子量及其分布狀態相較新料有所差異，從而導致二次料相較新料生產之成品品質(重量及幾何尺寸)差異，而其透過適當保壓條件設置雖可補償品質缺陷，但對L/t比較大之射出成型過程因模穴壓力傳遞不易而補償效果有限；取而代之，透過塑化品質控制從源頭改變熔膠的性質，且在固定螺桿幾何設計下，藉由塑化參數迅速控制塑化品質在二次料射出成型預期可提升射出成型品質一致性。本文旨在基於模穴壓力感測曲線、萃取品質指標、監測二次料射出成型過程之變化、並調整塑化參數以達致二次料射出成品與新料具備相同品質一致性。實驗結果顯示：壓力積分值相對壓力峰值更有效反映射出成品品質變化，並在二次料成型過程，透過背壓調整於6模次後製作出與新料相仿之射出成品品質，並據此在量產過程進行製程監控以維持射出成品品質一致性。此外，雖然在相同感測指標值具有射出成品重量一致性，但幾何尺寸隨著回收次數增加而變大，藉由感測多次料回收成型之品質指標並比對與新料之間的差異，可調整背壓條件以迅速維持射出成品幾何尺寸一致性。

On the demand for net zero carbon emission (carbon neutral), it is crucial to effectively fabricate plastic components with regrind polymer resins and keep the quality consistency and stability in mass production as that with virgin polymer materials. Since the polymer resin is affected by temperature, pressure and shear stress in the polymer processing, the microscopic molecular weight with polydispersity of regrind polymer is different in comparison with virgin polymer. As a result, the quality (weight and geometric dimensions) of the molded component produced by regrind polymers is different from that made by virgin polymer. Although this defect is compensated by an appropriate packing condition setting, the effectiveness is limited for the injection molded component with a larger flow length to wall thickness ratio (L/t ratio) due to the poor propagation of cavity pressure. Instead, it is expected to enhance the quality consistency of the molded component by melt quality control during the plasticization in regrind polymer injection molding. In this research, based on the pressure profile measured in the mold cavity, the variation of extracted quality characteristics was monitored in the regrind polymer injection molding, and the plasticizing parameters were adjusted to approach the quality consistency of molded components between the regrind and virgin polymer injection moldings. From the experiment results, the pressure integral was more effective to reflect the quality variation of molded component in comparison with pressure peak in regrind polymer injection molding. The quality of molded component was approached to that fabricated with virgin polymer after 6 shots by adjusting back pressure and kept the quality consistency in mass production. Although the molded part weight was consistent according to the same quality index, the dimension was tended to be larger as the recycling number of regrind polymer increases. Based on the difference of quality index of different recycling of regrind polymers comparing to virgin polymer, the back pressure was quickly adjusted to keep the dimension consistency of molded components.

摘要 i
Abstract ii
致謝 iii
目錄 iv
表目錄 vii
圖目錄 ix
第1章 緒論 1
1-1 前言 1
1-2 問題描述 3
1-3 研究動機與目的 4
1-4 論文架構 5
第2章 文獻回顧 6
2-1 回收ABS材料性質變化相關研究 6
2-2 回收料射出成型參數優化技術 10
2-3 熔膠品質監控相關研究 15
2-4 塑化品質對於熔膠流變性質影響相關研究 19
2-5 基於感測資訊監控成型品質相關研究 22
第3章 研究方法 27
3-1 研究方法 27
3-2 監測品質指標 30
3-2-1 壓力峰值指標(Pp) 30
3-2-2 壓力積分指標(PI) 30
3-3 相關性分析 32
3-4 二次料射出成型塑化品質控制策略 33
第4章 實驗設置 36
4-1 實驗設備與材料 36
4-1-1 實驗機台 36
4-1-2 實驗載具 38
4-1-3 實驗材料 39
4-2 線上量測系統建置 42
4-3 成品品質量測設備及位置 45
4-4 材料性質量測設備 47
第5章 結果與討論 50
5-1 機台穩定性及感測資訊重現性分析 50
5-2 新料及二次料成型差異 53
5-3 實驗材料添加劑分析 59
5-4 塑化參數對成型品質影響 63
5-4-1 螺桿轉速影響 63
5-4-2 背壓影響 68
5-5 品質指標響應及監測效益 73
5-6 成品品質監測方法及實驗結果 75
5-7 塑化品質控制策略與實驗結果 81
5-8 塑化品質控制策略多次回收料應用可行性分析 85
第6章 結論與未來展望 90
6-1 結論 90
6-2 未來展望 92
參考文獻 93

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