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.

1. ©Acrolab 2011
Technology ... 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 resin's optimum operating
temperature.
 A proprietary technology provides a method for a
replaceable 0.020" type J thermocouple to be located within
the Isosprue™ spreader's 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 customer's 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™ Spreader's 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™
spreader's 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