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초록· 키워드
오류제보하기
진공 열성형은 필름을 이용한 플라스틱 제품의 생산 공정 중 하나이다. 열성형을 통해
제품 형상에 맞게 변형된 필름을 In-Mold Labeling(IML), In-Mold Electronics(IME) 등의
공정을 통해 필름이 제품 표면에 부착하게 되면서 제품화가 이뤄진다. 제품화가 되기
전, 열성형에 활용되는 필름에 대한 기계적 물성 파악 및 성형 한계를 예측하는 것이
중요하다. 또한 컴퓨터 해석 프로그램을 통해 열성형 시 나타나는 스트레치를 예측하는
과정도 매우 중요하다.
본 연구에서는 PC/PMMA 다층 필름의 물성 측정 및 진공 열성형성을 고찰하였다. 우선
필름 제작에 활용된 원 소재 PC, PMMA resin을 통해 물성을 파악하여 필름의 기계적
물성 분석 전 소재의 특성을 파악하였다. PC/PMMA 다층 필름의 기계적 특성을 파악하
기 위해 인장시험을 수행하여 상온 및 고온에서 기계적 물성을 측정하였다. PMMA 층
두께별 기계적 강도의 차이를 확인하였으며, 압출 방향에 따른 물성의 차이는 전체적으
로 MD의 기계적 강도가 TD보다 비교적 강했지만, 온도 상승 시 압출 방향에 따른 물성
이 유사해지는 것을 파악했다. 그리고 유리전이온도 이상의 온도에서 나타나는 기계적
거동 및 물성 변화를 분석하였다. 다음으로 진공 열성형 실험을 진행하여 필름의 스트
레치를 통해 열성형성을 파악하였다. 열성형 시 형상의 변화를 주어 PC/PMMA 다층 필
름의 PMMA 층 두께에 따른 성형성 비교 및 필름 온도에 따른 성형성 비교, 그리고 압
출 방향에 따른 성형성에 대해 파악하였다. 마지막으로 구조해석을 통해 열성형 공정을
모사함으로 필름에 나타나는 스트레치를 파악하였다. 필름의 물성으로 등방성(Isotropic),
직교 이방성(Orthotropic)을 고려한 스트레치 해석을 진행하였다. 또한 초탄성
(Hyperelastic)을 적용하여 위치에 따른 스트레치를 파악하였고, 실험 결과와 비교를 진
행하여 해석의 일치성을 확인하였다.
본 연구는 필름의 물성 설계 및 열성형 공정 조건 설정에 활용될 수 있으며, 실제 열
성형에 앞서 CAE 해석을 통해 필름의 스트레치 예측에 도움이 될 것으로 기대한다.
제품 형상에 맞게 변형된 필름을 In-Mold Labeling(IML), In-Mold Electronics(IME) 등의
공정을 통해 필름이 제품 표면에 부착하게 되면서 제품화가 이뤄진다. 제품화가 되기
전, 열성형에 활용되는 필름에 대한 기계적 물성 파악 및 성형 한계를 예측하는 것이
중요하다. 또한 컴퓨터 해석 프로그램을 통해 열성형 시 나타나는 스트레치를 예측하는
과정도 매우 중요하다.
본 연구에서는 PC/PMMA 다층 필름의 물성 측정 및 진공 열성형성을 고찰하였다. 우선
필름 제작에 활용된 원 소재 PC, PMMA resin을 통해 물성을 파악하여 필름의 기계적
물성 분석 전 소재의 특성을 파악하였다. PC/PMMA 다층 필름의 기계적 특성을 파악하
기 위해 인장시험을 수행하여 상온 및 고온에서 기계적 물성을 측정하였다. PMMA 층
두께별 기계적 강도의 차이를 확인하였으며, 압출 방향에 따른 물성의 차이는 전체적으
로 MD의 기계적 강도가 TD보다 비교적 강했지만, 온도 상승 시 압출 방향에 따른 물성
이 유사해지는 것을 파악했다. 그리고 유리전이온도 이상의 온도에서 나타나는 기계적
거동 및 물성 변화를 분석하였다. 다음으로 진공 열성형 실험을 진행하여 필름의 스트
레치를 통해 열성형성을 파악하였다. 열성형 시 형상의 변화를 주어 PC/PMMA 다층 필
름의 PMMA 층 두께에 따른 성형성 비교 및 필름 온도에 따른 성형성 비교, 그리고 압
출 방향에 따른 성형성에 대해 파악하였다. 마지막으로 구조해석을 통해 열성형 공정을
모사함으로 필름에 나타나는 스트레치를 파악하였다. 필름의 물성으로 등방성(Isotropic),
직교 이방성(Orthotropic)을 고려한 스트레치 해석을 진행하였다. 또한 초탄성
(Hyperelastic)을 적용하여 위치에 따른 스트레치를 파악하였고, 실험 결과와 비교를 진
행하여 해석의 일치성을 확인하였다.
본 연구는 필름의 물성 설계 및 열성형 공정 조건 설정에 활용될 수 있으며, 실제 열
성형에 앞서 CAE 해석을 통해 필름의 스트레치 예측에 도움이 될 것으로 기대한다.
목차
요약 ··································································································································ⅰ표목차 ·······························································································································iv그림목차 ···························································································································ivI. 서 론 ······························································································································11.1 연구 배경 ···················································································································11.2 연구 목적 및 내용 ···································································································2II. 이론적 고찰 ···············································································································32.1 고분자 필름 분류 ·····································································································32.2 필름 제조 공정 ·········································································································42.3 필름의 이방 물성 ·····································································································52.4 선행 연구 ···················································································································7III. 필름의 물성측정 ········································································································93.1 인장시험 ·····················································································································93.2 PC, PMMA 소재의 물성 ························································································153.3 PC/PMMA 다층 필름의 물성 ················································································18IV. 필름의 열성형 실험 ·······························································································244.1 열성형 개요 및 실험 모델 ·····················································································244.2 PC/PMMA 다층 필름의 구성에 따른 스트레치 경향 ·····································304.3 열성형 온도 변화에 따른 스트레치 비교 ··························································354.3 압출 방향에 따른 스트레치 비교 ·······································································38V. 필름의 스트레치 모사 ····························································································455.1 열성형 스트레치 해석 ·····························································································455.2 등방 및 직교 이방성 해석 ·····················································································535.3 초탄성 등방 해석 ····································································································685.4 실험 및 해석 비교 ···································································································89Ⅵ. 결론 ···························································································································97참고문헌 ··························································································································98영문초록(Abstract) ·······································································································103감사의 글 ····················································································································105
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