光学高聚物超薄导光板连注连轧成型机理及质量控制

The project proposes a novel continuous injection and direct rolling (CIDR) method for producing optical polymer ultra-thin light guiding plate. In this method, the injection molding and embossing rolling were creatively combined into a simple and integrated process. Compared with conventional methods, CIDR can continuously effectively produce a large-scaled and ultra-thin light guiding plate through prefilled injection and embossing precision rolling, which has high production efficiency, low cost, high quality of microstructure and good optical property. .Based on the previous study on equipment and processing, the major task of this project is to investigate the forming mechanisms of the CIDR process. (a) Through intensive study on the temperature evolution of the forming zone, to reveal the transitions of the optical polymer PMMA (Polymethyl methacrylate) from the viscous state in the injection rolling nozzle, to the elastomeric state in the rolling zone, and then finally to the glass state at the exit side of the mill, and quantitative characterize the distribution regularities of the transformation lines between different states of the CIDR process; (b) Through systematic study on the relationship between the material properties and the processing parameter, such as the pressure, temperature, filing speed and rotation speed, to elucidate the forming mechanisms of the optical microstructure and optimize processing technology process; so ensure the forming quality of the light guiding plate; (c) Through focused study on the evolution of adhesion and friction stress between polymer and roller during the demolding process, to reveal the demoulding mechanism and improve the demolding quality of the light guiding plate. The results of present project will provide a new method and theoretical basis of CIDR for the large-scaled and ultra-thin light guiding plate.

本项目提出一种光学高聚物超薄导光板连注连轧成型方法，创造性地把注射压缩成型、轧制压印成型结合在一起。与目前主流微结构导光板成型方法相比，连注连轧成型通过注射压缩预充填、轧制压印精成型，可连续生产超薄、宽幅大型导光板，生产效率高，成本低，微结构质量及光学性能好。.本项目在前期工艺和装备开发的基础上，通过深入研究注轧区温度分布状态，定量表征连注连轧成型过程中光学高聚物PMMA从注轧嘴入口的黏流态、轧制区的高弹态到轧制出口的玻璃态的状态转变线分布规律。通过系统研究在连注连轧三个区域中高聚物材料特性与压力、温度、流速和轧辊转速等参数的关系，探明宏观板型/厚差及光学微结构充填成型机理，优化成型工艺，以保证导光板成型质量。通过聚焦研究脱模过程中材料与轧辊之间的黏附力、摩擦力，揭示微结构导光板脱模机理，提高其脱模质量。本项目研究可为我国大型超薄导光板连续成型的理论研究和应用提供新的方法和理论基础。

提出一种光学高聚物超薄导光板连注连轧成型方法，创造性地把注射压缩成型、轧制压印成型结合在一起。以导光板常用高聚物材料，聚甲基丙烯酸甲酯（PMMA，polymethyl methacrylate），为研究对象，主要研究注轧区高聚物流变性能/粘弹形变性能和状态转变线分布规律，包括在不同温度条件下，光学高聚物PMMA在黏流态时黏度随速度、温度和力变化的规律；高分子材料微观壁面滑移模型；高弹态转变线和玻璃态转变线分布规律。研究注轧嘴结构及其材料，包括优化设计衣架型和鱼尾型混合注轧嘴流道结构，保证出口位置高聚物流速一致；注轧嘴材料采用非晶合金，提高注轧嘴耐磨性，先期主要研究通过弹性加载同时施加高频振动加速方式使非晶合金快速产生回春效果，从而大幅度提高非晶合金在常温下的塑性变形能力。研究基于高分子动力学的注射速度和注射压力对光学高聚物微结构填充率的影响规律。研究单点金刚石轧辊微结构加工精度及其对注射成型的影响规律，包括单点金刚石加工精度；加工精度对注射成型的影响以及不锈钢轧辊耐腐蚀性能影响。最后对注轧成形方法进行了扩展应用研究，包括依据注轧成形热传递温度模型，研究高聚物熔融沉积制造；注轧成型光学镜片强度及模型研究。研究实施为我国大型超薄导光板连续成型的理论研究和应用提供新的方法和理论基础。.通过项目实施，准确获得了光学高聚物超薄导光板连注连轧成型的原始实验数据和黏度随速度、温度和力变化的规律，及其高弹态转变线和玻璃态转变线分布规律，优化注轧嘴结构设计，建立了注轧成型温度模型，基于高分子动力学的表面传热系数模型，基于特征尺寸的黏度模型及非牛顿指数模型。.项目执行过程中共发表相关论文22篇，其中SCI收录16篇（中科院二区以上8篇），EI收录1篇，核心期刊1篇，会议论文4篇。共培养毕业博士生1名，硕士研究生6名。申请发明专利4件，授权2件；申请并获得实用新型专利1件。项目研究成果获得广东省科技进步二等奖1项（排名第1）。