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Optimal Thermal Management for Molds with the Isosprue Spreader - Thermoset Mold Design
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Optimal Thermal Management for Molds with the Isosprue Spreader - Thermoset Mold Design

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Acrolab technology: A new presentation for 2011 which outlines the Acrolab thermal management system for tooling. Included is a more detailed overview of the Isosprue spreader, an integrally heated …

Acrolab technology: A new presentation for 2011 which outlines the Acrolab thermal management system for tooling. Included is a more detailed overview of the Isosprue spreader, an integrally heated sprue speader part of a total thermal package designed to optimize the molding process, compression and injection.

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  • 1. ©Acrolab 2011Technology ... from Acrolab Research & Development 1 Composite Materials and Manufacturing
  • 2. Innovative Technology for Composite Materials and Manufacturing Technology ... Recognized as leaders in thermal engineering, advanced research and development, Acrolab has developed an integrally heated mold component, which contains its own miniature precision thermocouple that can be heated and controlled to any discrete Isosprue temperature to assure fast effective curing of the sprue, resulting in Spreader™ shortened cycle times and improved mold cycling.©Acrolab – Feb. 2011 2
  • 3. Overview Heating injection thermoset molds in a uniform manner to achieve near isothermal mold face conditions is a critical requirement for dimensionally sensitive engineered products. This presentation will highlight a unique product within a technologically advanced heating system which provides near isothermal mold face conditions in conjunction with rapid thermal energy throughput. This system offers faster overall molding cycles, more consistent product performance outcomes, simplified maintenance and reduced down time.©Acrolab 2011 3
  • 4. Isosprue Spreader™ - Injection and Compression Molding Acrolab has . provided a unique solution to the challenge of predictable high speed curing of the sprue section. An innovative improvement for molding processes. ©Acrolab 2011 4
  • 5. What is the Isosprue Spreader™ ?  An integrally heated sprue spreader pin is constructed as a swaged distributed wattage heater integrally heated and controlled with its own on-board replaceable thermocouple.  The Isosprue™ spreader is made of D2 steel and nitrided for toughness.  It is integrally heated with 400Watts of power at 240 VAC allowing it to be easily and directly incorporated into the control system typically used to heat the mold.©Acrolab 2011 5
  • 6. What is the Isosprue spreader™ ?  The Isosprue™ spreader has its own internal and replaceable precision type J thermocouple which permits closed loop control to the resins optimum operating temperature.  A proprietary technology provides a method for a replaceable 0.020" type J thermocouple to be located within the Isosprue™ spreaders tapered tip to provide the close control needed to produce the high speed cure of the spreader section  The Isosprue™ spreader is manufactured using a proprietary process.©Acrolab 2011 6
  • 7. How does the Isosprue spreader™ work?  The heated sprue pin actively cures the sprue while directing the resin to the runners and gates.  Typically the resin sprue is the thickest cross section and takes the longest time to cure.  The isosprue spreader controls the cure right in the sprue.©Acrolab 2011 7
  • 8. Advantages of the Isosprue spreader™ Thermal management of the tool resulting in …  Faster cycle times  Better quality parts  Reduced scrap rate  Lower tool maintenance costs* *This is achieved because the sprue area never needs cleaning, since the thermoset material in the sprue is cured out completely.©Acrolab 2011 8
  • 9. Installation of the Isosprue spreader™?  Acrolab custom fits the Isosprue spreader™ by adjusting the spreader to the stack height of the tool to ensure the best possible results for each customers specific application.  This is accomplished by threading it on to the end of a cut to length hollow extension sleeve typically and easily made from an ejector sleeve.  A proprietary technology provides a method for a replaceable 0.020" type J thermocouple to be located within the ISOSPRUE™ Spreaders tapered tip to provide the close control needed to produce the high speed cure of the spreader section. ©Acrolab 2011 9
  • 10. Acrolab – Advanced Energy Transfer System Isosprue spreader Pin Heaters Thermocouples Heatpipes Sprue spreader extension©Acrolab 2011 10
  • 11. Acrolab Thermal Management Systems In addition to improving part quality and a reduction in scrap, Acrolab’s total thermal management system including the Isosprue™ spreaders with Isobar® heat pipe technology can potentially increase cycle time in excess of 15%*.  *This varies with process and materials©Acrolab 2011 11
  • 12. Acrolab – Advanced Heating Systems The Acrolab System The heating system consists of a matrix of isoball® heatpipes embedded in the mold inserts incorporating the working faces of the mold. The mass energy input for the mold is provided through a series of distributed watt density cartridge heaters located remote from the mold face. These heaters interact with the heatpipe matrix to provide a uniform thermal energy transfer to the mold face. Thermocouples mounted proximate to the mold face control power to the heaters. A unique heated mold component provides heat to the sprue cone to decrease the cure time of the sprue. ©Acrolab 2011 12
  • 13. System Components for optimal thermal management Integrally heated Sprue spreader c/w thermocouple Isoball® heat pipes Type J adjustable bayonet thermocouples Distributed watt density cartridge heaters ©Acrolab 2011 13
  • 14. Isosprue ™spreader – System design example Sprue spreader Sprue bushing installed to core out The sprue cone and cure the cone independently Sprue spreader extension cut to size and made Local terminal block from a core sleeve section for the Sprue spreader and thermocouple©Acrolab 2011 14
  • 15. System Design – 4 configurations Configuration 1 Configuration 2 Configuration 3 Optimal Configuration©Acrolab 2011 15
  • 16. System Design Heatpipes remain within the inserts to integrate with heaters also within the inserts. Isoball heat pipes Guard heaters located in the holder block Optimal Configuration©Acrolab 2011 16
  • 17. Acrolab Contact Information Call Acrolab Engineering today! 1 800 265 9542 Toll free in North America 1 800 465 9674 Fax 519 944 5900 Direct www.acrolab.com©Acrolab 2011 17

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