臺灣博碩士論文加值系統

現今運動鞋中底設計主要是以運動員於運動過程中，除了防止足部受傷，還具備緩衝、穩定、吸震及反彈力等功能。運動鞋中底材料從過去的PU發泡到近年來常用的EVA發泡，而EVA發泡材料之製程又可分為兩種，分別為二次模壓成型及一次發泡射出成形，前者的製程不僅浪費材料使得環境汙染且需要大量人力來完成，後者的製程擁有環保、大量減少廢料及自動化的特性，讓各大品牌運動鞋廠商陸續將其作為新的製程方式。EVA一次發泡射出成形是將射出與發泡兩段製程合而為一，中底在模具開模時利用模內外壓力差在模外發泡成型，但該製程非常難控制其尺寸與功能物性。目前所有鞋廠都是以試誤法進行，該法會讓鞋廠耗費很多時間及材料在製程參數的調整上。
本研究利用模具內建感測器的方式，即時擷取EVA一次發泡射出成形過程中模具內的壓力及溫度數據，並且利用壓縮、壓縮能及永久壓縮變形標準測試規範，觀察EVA試片在不同製程參數下的品質特性變化，找出製程參數與品質數據的關聯性。先以田口法取得不同運動鞋功能特性之品質，將不同的品質特性利用灰關聯分析來整合，考量到籃球鞋及慢跑鞋的品質特性不同，因此最佳製程參數會有兩組，最後對這兩組的品質特性進行預測，並透過實驗來驗證。
根據感測器量測結果發現當壓力處於穩定狀況下，溫度會比設定值高1~2°C，而模具內部壓力數值會影響試片的成形狀況，在直交表的實驗結果裡，當模具溫度為175°C時，試片之耐重強度及抗壓縮變形最好，但過大的射出壓力會使試片之耐重強度變差。而籃球鞋及慢跑鞋品質特性的灰關聯分析結果，透過ANOVA分析成功建立出最佳製程參數，並找出影響兩者品質特性最大之因子皆為模具溫度，經實驗驗證，兩者的品質特性皆接近實驗前之預測值。

Nowadays, the midsole design of sneakers is mainly designed for athletes in the process of exercise, in addition to preventing foot injuries, it also has the functions of cushioning, stability, shock absorption, and rebound force. The sneaker midsole material has changed from the past PU foam to EVA foam is commonly used in recent years. The process of EVA foam material can be divided into two types, namely secondary heat-pressure molding and direct injection-foam molding. Former is the waste of materials polluting the environment and requires a lot of manpower to complete, the latter's manufacturing process has the characteristics of environmental protection, a large amount of waste reduction, and automation, so that major brand sports shoe manufacturers have successively adopted it as a new manufacturing method. EVA direct injection-foam molding combines the injection and foaming processes into one. The midsole is foamed outside the mold using the pressure difference between the inside and outside of the mold when the mold is opened. However, this process is very difficult to control its size and functional properties. At present, all shoe factories use the trial & error method, which will make the shoe factory spend a lot of time and materials on the adjustment of process parameters.
The study uses the built-in sensor of the mold to capture the pressure and temperature data in the mold in the EVA injection-foam molding process in real-time and uses the compression, compression energy, and compression set deformation standard test specifications to observe the EVA test piece changes in quality characteristics under different process parameters to find out the correlation between process parameters and quality data. First, the Taguchi method is used to obtain the quality of different sneakers' functional characteristics, and the different quality characteristics are integrated using gray correlation analysis. Taking into account the different quality characteristics of basketball shoes and jogging shoes, there will be two sets of optimal process parameters. Finally, predict the quality characteristics of the two, and then verify through experiments.
According to the measurement results of the sensor, it is found that when the pressure is in a stable condition, the temperature will be 1 to 2°C higher than the set value, and the internal pressure value of the mold will affect the forming condition of the test piece. In the experimental results of the orthogonal table, when the mold temperature is 175°C, the weight strength and compression deformation resistance of the test piece are the best, but excessive injection pressure will make the weight resistance strength of the test piece worse. The gray relational analysis results of the quality characteristics of basketball shoes and jogging shoes successfully established the best process parameters through ANOVA analysis and found that the most important factor affecting the quality characteristics of the two is the mold temperature. The quality characteristics of the two are verified by experiments. All are close to the predicted value before the experiment.

摘要.......................................................................i
Abstract..................................................................ii
誌謝......................................................................iv
目錄.......................................................................v
表目錄....................................................................ix
圖目錄....................................................................xi
第一章 緒論.................................................................1
1.1前言....................................................................1
1.2研究動機與目的...........................................................2
1.3文獻回顧.................................................................3
1.3.1 EVA一次發泡射出成形相關研究............................................3
1.3.2模內建置感測器於射出成形上之應用.........................................5
1.3.3射出成形模具結構.......................................................6
1.4研究流程.................................................................8
1.5論文架構.................................................................9
第二章 基礎理論............................................................10
2.1運動鞋中底..............................................................10
2.1.1 PU中底介紹...........................................................11
2.1.2 EVA中底介紹..........................................................12
2.2 EVA一次發泡射出成形....................................................13
2.2.1 EVA中底早期製程......................................................13
2.2.2 EVA一次發泡射出成形問題...............................................14
2.2.3影響EVA中底特性的主要因素..............................................14
2.3感測器裝置..............................................................15
2.3.1溫度感測器............................................................15
2.3.2壓力感測器............................................................15
2.4鞋中底物理性質測試標準...................................................16
2.4.1壓縮測試..............................................................16
2.4.2壓縮能測試............................................................17
2.4.3永久壓縮歪測試........................................................19
2.5田口法理論..............................................................22
2.5.1因子種類..............................................................22
2.5.2田口直交表............................................................22
2.5.3訊號雜訊比............................................................23
2.5.4變異數分析............................................................24
2.5.5預測最佳化品質特性.....................................................25
2.6灰關聯分析..............................................................26
2.6.1灰關聯生成............................................................26
2.6.2灰關聯差序列..........................................................26
2.6.3灰關聯係數............................................................27
2.6.4灰關聯度值............................................................27
第三章 EVA發泡試片與模具設計................................................28
3.1 EVA發泡試片設計........................................................28
3.2模具設計................................................................29
3.2.1模穴設計..............................................................29
3.2.2模具型式..............................................................29
3.3感測器伸長管與排線槽設計.................................................32
3.3.1感測器伸長管設計......................................................32
3.3.2感測器排線槽設計......................................................33
第四章 實驗設計與方法.......................................................34
4.1實驗設備................................................................34
4.1.1射出成形設備..........................................................34
4.1.2模內溫度與壓力量測設備.................................................36
4.1.3物性測試實驗設備......................................................38
4.2田口實驗設計規劃........................................................40
4.2.1 EVA一次發泡射出成型實驗...............................................40
4.2.2製程參數設置..........................................................45
4.2.3田口實驗規劃..........................................................46
4.3壓縮測試實驗介紹........................................................48
4.3.1實驗介紹..............................................................48
4.3.2實驗流程.............................................................48
4.4壓縮能測試實驗介紹.......................................................49
4.4.1實驗介紹..............................................................49
4.4.2實驗流程..............................................................50
4.5永久壓縮歪測試實驗介紹...................................................52
4.5.1實驗介紹..............................................................52
4.5.2實驗流程..............................................................53
第五章 實驗結果與討論.......................................................54
5.1 EVA發泡試片製作結果....................................................54
5.2物理性質試驗結果與分析...................................................55
5.2.1壓縮測試實驗結果......................................................55
5.2.2壓縮能測試實驗結果.....................................................58
5.2.3永久壓縮歪測試實驗結果.................................................59
5.2.4實驗結果之S/N比.......................................................60
5.2.5灰關聯分析............................................................61
5.2.6因子水準反應..........................................................64
5.2.7 ANOVA分析...........................................................66
5.3最佳化參數實驗預測與驗證.................................................68
5.3.1實驗預測..............................................................68
5.3.2實驗驗證..............................................................68
5.4模內壓力及溫度與製程參數及功能物性之關聯性.................................69
5.4.1模內壓力與溫度測量數據曲線說明..........................................69
5.4.2壓力與功能物性關聯性...................................................69
5.4.3溫度與功能物性關聯性...................................................72
第六章 結論及未來展望.......................................................74
6.1結論...................................................................74
6.2未來展望................................................................74
參考文獻...................................................................75
Extended Abstract.........................................................78

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