Injection molding of micro patterned PMMA plate

• Published in: Transactions of Nonferrous Metals Society of China 2011-03, Vol.21 (1), p.148-152
• Main Authors: YOO, Yeong-Eun, KIM, Tae-Hoon, JE, Tae-Jin, CHOI, Doo-Sun, KIM, Chang-Wan, KIM, Sun-Kyung
• Format: Article
• Language: English
• Subjects: injection molding; micro prism pattern; PMMA; pressure profile; replication; temperature profile; 位置测量; 加工模式; 压力上升; 图案; 塑料板; 注塑成型; 聚甲基丙烯酸甲酯
• ISSN: 1003-6326
• DOI: 10.1016/S1003-6326(11)61079-0

A plastic plate with surface micro features was injection molded to investigate the effect of pressure rise of melt on the replication of the micro structures. Prism pattern, which is used in many optical applications, was selected as a model pattern. The prism pattern is 50 μm in pitch and 108° in the vertical angle. The overall size of the plate was 335 minx213 mm and the thickness of the plate varied linearly from 2.6 mm to 0.7 ram. The prism pattern was firstly machined on the nickel plated core block using micro diamond tool and this machined pattern core was installed in a mold for injection molding of prism patterned plate. Polymethyl methacrylate （PMMA） was used as a molding material. The pressure and temperature of the melt in the cavity were measured at different positions in the cavity and the replication of the pattern was also measured at the same positions. The results show that the pressure or temperature profile through the process depends on the shape and the size of the plate. The replication is affected by the temperature and pressure profiles at the early stage of filling, which is right after the melt reaches the position to be measured.