Technology ... from Acrolab Research & Development

Composite Materials and Manufacturing

©Acrolab 2011

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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

temperature to assure fast effective

curing of the sprue, resulting in

shortened cycle times and

improved mold cycling.

Isosprue

Spreader™

Innovative Technology for Composite Materials and Manufacturing

©Acrolab – Feb. 2011 2

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

.Acrolab has provided a unique solution to the challenge of predictable high speed curing of the sprue section.

Isosprue Spreader™ - Injection and Compression Molding

©Acrolab 2011

An innovative improvement for molding processes.

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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.

What is the Isosprue Spreader™ ?

©Acrolab 2011 5

©Acrolab 2011

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.

What is the Isosprue spreader™ ?

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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

How does the Isosprue spreader™ work?

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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.

Advantages of the Isosprue spreader™

©Acrolab 2011

Thermal management of the tool resulting in …

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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

Installation of the Isosprue spreader™?

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Isosprue spreader Pin

Sprue spreader

extension

Heaters

Heatpipes

Thermocouples

Acrolab – Advanced Energy Transfer System

©Acrolab 2011 10

©Acrolab 2011

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 Thermal Management Systems

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Acrolab – Advanced Heating Systems

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.

The Acrolab System

©Acrolab 2011 12

System Components for optimal thermal management

Isoball® heat pipes

Distributed watt density cartridge heaters

Type J adjustable bayonet

thermocouples

Integrally heated Sprue spreader c/w thermocouple

©Acrolab 2011 13

Sprue spreader

installed to core out

The sprue cone

and cure the cone

independently

Sprue bushing

Local terminal block

for the Sprue spreader

and thermocouple

Sprue spreader extension

cut to size and made

from a core sleeve section

Isosprue ™spreader – System design example

©Acrolab 2011 14

System Design – 4 configurations

Optimal Configuration

©Acrolab 2011 15

Configuration 1 Configuration 2

Configuration 3

Heatpipes remain within the inserts to integrate with heaters also within

the inserts.

Guard heaters located

in the holder block

System Design

©Acrolab 2011 16

Optimal Configuration

Isoball heat pipes

Acrolab Contact Information

©Acrolab 2011

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

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