Effective Cooling for Molding Thermosplastics

Thermoplastic Molding usingDirect, Indirect Isobar®

& Isobaffle™

Cooling Systems Acrolab 2010©

Effective Mold CoolingEffective Mold Cooling

Isobar® – Cooling Function Acrolab 2010©

Isobar® General Parameters

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

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.

Isobar® Indirect Cooling Acrolab 2010©

Isobar® Direct Cooling Acrolab 2010©

Isobaffle™- Direct Cooling Acrolab 2010©

Core cooling with Isobars

Baffle

Effective Cooling -- Thermoplastic Molding

Bubbler Isobar

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.

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.

Faster, more uniform cooling to the entire mold surface for shorter molding cycles 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.

More efficient and effective mold cooling Acrolab 2010©

Direct Isobar Cooling Indirect Isobar Cooling

Direct vs. Isobar® Indirect Cooling Acrolab 2010©

Isobar over Baffle Finned Isobars

Acrolab 2010©Mold Section Cooling

Isobaffle™ Direct Cooling Acrolab 2010©

Isobaffle™ Acrolab 2010©

Isobaffle™ Acrolab 2010©

Isobar® Core Pin Cooling Example

Isobar Installation and DesignCopper Powder - isobar hole diameter +0.005/0.010Thermal Paste - Isobar hole diameter +0.002/0.004Minimum Isobar Cooling Length 20% of entire length Acrolab 2010©

Acrolab 2010©

Notes

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 andstress 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.

FAQ’s Acrolab 2010©

FAQ’s

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.

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

Acrolab Applications Engineering Acrolab 2010©

üEfficient super-thermal coolingüNo o-rings, fluid leaks, complex water channels or bubblersüUniform temperature distribution on the cavity surfaceüSignificantly reduces maintenance downtimeüNo calcification/waterline build-upüSignificantly reduces pressure drop üImproves coolant flow rateüSimplifies mold design and reduces construction costsüPays for itself as fast as it coolsüEasy to install

Acrolab Cooling Systems – Check list Acrolab 2010©

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©