This document discusses cooling systems for thermoplastic molds, specifically Acrolab's Isobar® and IsobaffleTM direct and indirect cooling systems. Isobars are passive super-thermal conductors that conduct heat 10,000 times faster than copper. They provide uniform, rapid cooling to molds. Isobars and Isobaffles simplify mold design, improve cooling efficiency, and reduce maintenance costs compared to traditional baffled systems. Acrolab can assist with designing optimized cooling systems using these technologies.

1. Effective Mold Cooling
Thermoplastic Molding using
Direct, Indirect Isobar®
&
Isobaffle™
Cooling Systems Acrolab 2010©

2. Isobar® – Cooling Function Acrolab 2010©

3. Isobar® General Parameters Acrolab 2010©
Passive Device
- No electrical connectors
• Superthermal Conductors
- Conducts up to 10,000 times faster than copper
Thermally Uniform in Temperature
- Temperature Variation on surface +/- 1 °F
Operating Temperature Dependent
- Two temperature ranges 32 – 120 °F and 100 – 550 °F
Can be cooled directly or indirectly

4. Isobar® Indirect Cooling Acrolab 2010©
Within the context of
thermoplastic molding,
the unique heat
transfer
characteristics of the
Isobar ® super-
thermal conductor,
when designed into
the mold, ensures that
energy build-up on the
mold face is rapidly
directed to the mold’s
cooling channels.

5. Isobar® Direct Cooling Acrolab 2010©

6. Isobaffle™- Direct Cooling Acrolab 2010©

7. Effective Cooling - Thermoplastic Molding Acrolab 2010©
Core cooling with Isobars
Baffle Bubbler Isobar

8. Faster, more uniform cooling to the entire
mold surface for shorter molding cycles Acrolab 2010©
Rapid, uniform surface cooling
also eliminates hot and cold spots
on the working face, which in turn
results in molded parts that are
free from short shots, irregular
shrinkage, and molded-in residual
stress and warp.
It is not necessary to have the in
Isobars® direct contact with a
waterline to effect cooling;
although Isobars® can be
incorporated into the cooling
channel, in may cases they need
only be in proximity to a water line
to promote effective cooling.

9. Faster, more uniform cooling to the entire
mold surface for shorter molding cycles Acrolab 2010©
•Isobars® and Isobaffles™ allow the mold designer
greater flexibility for positioning cooling lines in
locations remote from complex core and cavity
inserts, thus simplifying tool design and eliminating
seals required to prevent coolant leakage.
•Water lines that are uninhibited by bubblers and
bafflers also permit faster turbulent flow that
minimizes mineral deposits and promotes a higher
level of effective heat removal.

10. More efficient and effective mold cooling Acrolab 2010©
• Because Isobar® systems eliminate the need
for bubblers and baffles which are associated
with such problems as “o ring” leakage, mineral
build-ups, pressure drops, uneven cooling and
complex water line designs, maintenance
requirements and problems – which can result in
unscheduled downtime – are significantly
reduced or eliminated.
• Isobar® super-thermal conductors are
manufactured in many diameters and lengths
and can be custom built, when necessary, to
precisely fit your application.

11. Direct vs. Isobar® Indirect Cooling Acrolab 2010©
Direct Isobar Cooling Indirect Isobar Cooling

12. Isobaffle™ Direct Cooling Acrolab 2010©
Acrolab 2010©
Mold Section Cooling
Isobar over Baffle Finned Isobars

13. Isobaffle™ Acrolab 2010©

14. Isobaffle™ Acrolab 2010©

15. Isobar® Core Pin Cooling Example Acrolab 2010©
Isobar Installation and Design
Copper Powder - isobar hole diameter +0.005/0.010
Thermal Paste - Isobar hole diameter +0.002/0.004
Acrolab 2010©
Minimum Isobar Cooling Length 20% of entire length

16. FAQ’s Notes Acrolab 2010©
1. Where is the best place to use this technology?
Deep cores for products such as hypodermic syringes, long bosses,
pen barrels, PET performs any part that has a deep core in its
molding tool. In SMC tools the same issue is present but requiring
heating of the core pin.
2. Comment on Warpage and shrinkage?
Isobar® and Isobaffle™ technologies provides for stable, uniform
cooling on the working faces of the mold will eliminate warp and
stress conditions Part shrinkage is usually a function of wall stock
thickness and injection pressure however uneven cooling can
influence the shrinkage of a part locally due to uneven cooling.

17. FAQ’s Acrolab 2010©
3. What is the percent that the baffle section is exposed
to water?
The longer the better but the general optimum is one third of the
Isobar in the core and two thirds in the cooling medium.
4. Isobaffle™ vs. Isobar®? Why go with one over the
other?
The baffle redirects cooling water ( or heating oil/steam) around the
Isobar up one side of the baffle and down the other. Because of this
the inlet and outlet line can be one hole intersecting with the Isobar
hole rather than two lines at different levels to allow for coolant (
heating ) flow over a portion of the Isobar. The larger the cooling
area the better it will cool.

18. Acrolab Applications Engineering Acrolab 2010©
Acrolab’s applications engineering team
can assist you in designing simplified,
highly effective mold cooling systems for
your mold. Our applications specialists
will recommend optimum sizing and
placement, and will provide all the
requisite details regarding drill sizes and
installation requirements.
All engineering drawings, electrical
schematics, heating elements, Isobars©,
thermocouples, wiring, terminal boxes,
electrical connectors and control cables
are provided with Acrolab’s Isobar©
systems, and field installation can always
be arranged to meet your specifications
and requirements

19. Acrolab Cooling Systems – Check list Acrolab 2010©
üEfficient super-thermal cooling
üNo o-rings, fluid leaks, complex water channels or bubblers
üUniform temperature distribution on the cavity surface
üSignificantly reduces maintenance downtime
üNo calcification/waterline build-up
üSignificantly reduces pressure drop
üImproves coolant flow rate
üSimplifies mold design and reduces construction costs
üPays for itself as fast as it cools
üEasy to install

20. The Competitive Advantage
Improve part quality and heighten the
efficiency of your molding operation through
effective management of temperature
control.
Acrolab’s Isobar® & Isobaffle™ cooling
systems are an excellent, affordable and
maintenance-free way to gain the…
“Competitive Edge”
Acrolab 2010©