利用鹽的剛性與糖的黏性製成的鹽芯，讓溶芯射出(Lost core injection molding)可用於製作複雜特徵的一體成形塑膠產品，但目前鹽芯的準備過程與強度仍有待提升。過去作法將糖與鹽粒常溫混合，利用烤箱加熱使糖熔化後與鹽黏結，再經過降溫取出鹽芯，耗時又面臨均勻度不足的問題。本研究改變鹽芯的準備過程，先以少許的水輔助，讓砂糖加熱至 150°C 製成的黏結劑，之後再拌入鹽粒，快速攪拌之後，填入溶芯射出會使用的芯殼(Core shell)，研究過程中討論糖/鹽比例和鹽粒粒徑的配比對於鹽芯強度的影響，找到最佳條件之後，將呈現膏狀的鹽填入芯殼，最後將鹽芯放入模具進行皮層的埋入射出，取出之後放置水中，即可將鹽芯溶出。鹽芯的配比與製程參數已完成研究並找出最佳條件，鹽芯可承受超過 30MPa的抗壓強度，鹽芯製作的時間也從過去 165 min 降為 45 min ；以多截面射出產品進行實驗，驗證射出過程使用田口實驗法找出最佳射出參數組合，完成後的產品也進行尺寸量測產品尺寸精度可控制偏差值 0.05mm 以內，芯殼與皮層的厚薄度比例均勻度可達 98.5%，完成後的鹽芯溶解時間也不因為製程改變而增加，證明本研究的方法改善過去耗時的鹽芯製作。

The utilization of salt cores combined with the viscosity of sugar in Lost Core Injection Molding (LCIM) enables the fabrication of plastic products with intricate features in a single mold. However, the preparation process and strength of salt cores are areas requiring enhancement. Previous methods involved ambient temperature mixing of sugar and salt grains, followed by heating in an oven to melt the sugar for bonding with salt, and subsequent cooling for salt core extraction, which was time-consuming and faced challenges related to uniformity. This study modifies the preparation process of salt cores by initially using a small amount of water to facilitate the heating of sand sugar to 150°C to form a binding agent. Subsequently, salt grains are mixed in, swiftly stirred, and then filled into core shells for LCIM. The research investigates the influence of sugar-to-salt ratios and salt grain sizes on the strength of salt cores. Once optimal conditions are identified, the paste-like salt is filled into core shells, embedded in molds for injection molding, and subsequently dissolved in water post-extraction. The salt core's composition and process parameters have been thoroughly investigated, leading to the identification of optimal conditions. Salt cores can withstand compressive strengths exceeding 30MPa, and the production time has been reduced from 165 minutes to 45 minutes. Experimental validation using multi-sectional injection molded products, employing Taguchi experimental design to identify optimal injection parameters, and dimensional measurements indicate a dimensional accuracy within ±0.05mm. The uniformity of core shell and skin thickness ratios can reach 98.5%. Furthermore, the dissolution time of salt cores post-process remains unaffected, demonstrating the efficacy of the proposed method in streamlining the time-consuming salt core fabrication process.

摘要……i
Abstract……ii
誌謝……iv
目錄……v
表目錄……vii
圖目錄……viii
第一章、緒論……1
1.1研究背景……1
1.2文獻回顧……3
1.3研究動機與目的……6
第二章、製程與產品設計……8
2.1製程介紹……8
2.2產品與兩個模型之設計……11
2.3模流分析……14
2.3.1 Position Ⅰ 芯型偏移分析……16
2.3.2 Position Ⅱ 芯型偏移分析……21
2.3.3模流分析小結……26
第三章、實驗方法與步驟……29
3.1研究流程……29
3.2芯材製程……30
3.2.1糖/鹽比與粗/細鹽比壓縮試片製作及實驗方法……32
3.2.2溶化時間實驗方法……36
3.3模具設計……37
3.4射出實驗……40
3.4.1芯型製作……40
3.4.2射出條件……41
3.5尺寸量測方式……43
第四章、結果與討論……48
4.1鹽芯壓縮試驗……48
4.1.1糖/鹽比壓縮試驗……48
4.1.2粗/細鹽比壓縮試驗……52
4.2溶化實驗……55
4.2.1糖/鹽比壓縮試片溶化實驗……55
4.2.2粗/細鹽比壓縮試片溶化實驗……57
4.2.3產品內鹽芯溶化實驗……59
4.2.4壓縮實驗與溶化實驗小結……61
4.3 產品尺寸與真圓度量測……62
4.4 田口最佳參數組合……75
第五章、結論……84
參考文獻……85
附錄A……88
Extended Abstract……94
1. Introduction……95
2. Fabrication process and product design……95
2.1. Fabrication process……95
3. Water-soluble core development……97
3.1. Specimen preparation and characteristics……97
4. Experimental Procedure……99
4.1 The demonstrated product and its mold design……99
4.2 Materials and injection molding……103
4.3 Evaluation of the molded product (Thickness uniformity, Dimensional measurement, Core removal rate)……103
5. Results and discussion……105
5.1 Effects of sugar on adhesive preparation and coarse/fine mixture on compressive strength……105
5.2. Dimensional measurement of the molded product……107
6. Conclusions……108

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