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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 case study that will address 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 downtime.
Citation preview
1/31/2011 © Acrolab 20111
Acrolab
Energy Transfer Systems
for
Thermoset Injection Molds
Joe Ouellette
Chief Technology Officer
Acrolab Ltd.
Advanced Thermal Engineering Research & Development
Products and Services
1/31/2011 © Acrolab 20112
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 case study that will
address 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.
1/31/2011 © Acrolab 20113
Case Study #1: Headlight Housing
Automotive headlight
reflector housings present
a particular challenge in
injection thermoset mold
processing.
The following presentation
will specifically deal with
these types of molds.
1/31/2011 © Acrolab 20114
Thermoset headlight reflector bodies/ headlight assembly
1/31/2011 © Acrolab 20115
Acrolab - Advanced heating system methodology
The heating system consists of a matrix of 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.
1/31/2011 © Acrolab 20116
Integrally Heated
Sprue Spreader Pin
Sprue Spreader
extension
Heaters
Heatpipes
Thermocouples
Acrolab – Advanced energy transfer system
1/31/2011 © Acrolab 20117
System Components
Isoball® heat pipes
Distributed watt density cartridge heaters
Type J adjustable bayonet thermocouples
Integrally heated Sprue Spreader c/w thermocouple
1/31/2011 © Acrolab 20118
Component Features and Benefits
Distributed Watt Density Cartridge Heaters
Cartridge heaters are of a swaged construction to permit the most efficient transfer of heat to the O.D. of the heater
The pitch of the winding within the element is increased at each end to provide a linear thermal output over the length of the heater.
Uniform Temperature
Length
Temp
Cartridge Heater
1/31/2011 © Acrolab 20119
Standard Heater
Linear pitched winding with the standard cartridge results
in a nonlinear heat output with 50% of the energy of the heater
being generated in the center 33% of the heater length.
D TTemp
Length
Component Features and Benefits
Cartridge Heater
1/31/2011 © Acrolab 201110
Normal pitch
windings
Distributed wattage
pitched windings
Component Features and Benefits
Distributed Watt Density Cartridge Heaters
1/31/2011 © Acrolab 201111
Component Features and Benefits
Type J adjustable bayonet thermocouples
Adjustable thermocouples (TCs) are installed in proximity tothe mold face.
TCs are installed in pairs to provide an on boardreplacement in the event of TC failure.
1/31/2011 © Acrolab 201112
Type J adjustable bayonet thermocouples
Spring Loaded
Type J
Ungrounded Thermocouple
Component Features and Benefits
1/31/2011 © Acrolab 201113
Integrally heated Sprue Spreader and onboard thermocouple
Using a proprietary process, the Heated Sprue Spreader Pin isconstructed as a swaged distributed wattage heater integrally heated andcontrolled with its own on board replaceable TC.
The heated sprue pin now actively cures the sprue while directing theresin to the runners and gates.
Typically the resin sprue is the thickest cross section and takes the longesttime to cure.
Component Features and Benefits – Isosprue™ Spreader
1/31/2011 © Acrolab 201114
Component Features and Benefits – Isosprue™ Spreader
1/31/2011 © Acrolab 201115
Ball Radiused Heatpipes
Heatpipes are super thermal conductors whichtransfer energy at rates in excess of 10,000time the speed of metals.
Heatpipes are isothermal devices that do notrequire electrical power.
Ball radiused heatpipes are designed to beinstalled in holes with matching ball radii. Theradii prevent stress cracks from forming.
A matrix of heatpipes draw energy from aremote bank of heating elements and uniformlytransfer that energy to the mold face.
Component Features and Benefits – The Isoball™
1/31/2011 © Acrolab 201116
Heatpipe Function Schematic
Component Features and Benefits – The Isoball™
1/31/2011 © Acrolab 201117
Heating System Methodology
The next graph shows the time to steady state and themagnitude of that thermal steady state for one inch diameterby six inch long bars of various materials as well as anIsoball™ heatpipe of the same geometry.
All bars were uninsulated and oriented vertically on atemperature controlled hot plate maintained at 350º F.Thermal bridging compound of the type used in installing theheating system was used to bridge the gap between the hotplate and the end of the bars.
1/31/2011 © Acrolab 201118
Isoball™ heatpipe vs. various metal bars of common geometries
Thermal Transients to Steady State
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
230
0 5 10 15 20 25 30 35 40 45 50 55 60 65
Time (minute)
Tem
p. (
deg
. F)
Isobar-Top
Copper rod-Top
Steel rod-Top
Alu. Rod-Top
Tem
p°
F
Time [min]
1/31/2011 © Acrolab 201119
Heating System Methodology
Historically each of these materials have, at one time or another, been installed in hardened inserts to promote rapid heat transfer.
The heatpipe achieved the highest level of thermal steady state after the shortest interval.
1/31/2011 © Acrolab 201120
Of particular note, all of the metal bars with the exception of
the heatpipe demonstrated a significant delta T from end to
end both during the transient to steady state and at steady
state.
The heatpipe remained Isothermal during both the transient
and at steady state.
The difference between the steady state temperature of the
heatpipe and the temperature of the hot plate is due to losses
to the atmosphere.
Heating System Methodology
1/31/2011 © Acrolab 201121
Core and Cavity
Left and Right hand – “theoretical headlamp reflector mold”
System Design
1/31/2011 © Acrolab 201122
Heating System Methodology
Every heating system is custom engineered to insure the
matrix of heatpipes is optimally developed to provide heat
energy uniformly to the mold working faces based on the
geometry of the part being molded.
A remotely located heater bank is situated either within the
mold inserts, within the holder block or within the holder block
backing plate.
In all instances these heaters are positioned to thermally
integrate with the heatpipe array so that all the energy
generated is redistributed at high speed by the heatpipes.
1/31/2011 © Acrolab 201123
Heating System Methodology
When design considerations require that the heaters are not
integral with the inserts, heatpipes are designed with lengths
to bridge the thermal break which occurs at the mating
surfaces of the inserts. Heatpipe lengths extend to permit
close proximity with the remote heaters.
Heatpipes incorporate a spherical radiused end to mate with
a spherical radius at the bottom of all installation holes. This
assures no stress cracking and places the thermodynamic
action for the heatpipe closest to the mold face.
1/31/2011 © Acrolab 201124
Heating System Methodology
When heaters are installed within the inserts, their length is
defined by the insert. Spacers are installed at either end of
through holes that line up with the insert heater holes. These
spacers position the heater within the insert.
In all cases, heaters are installed in through-holes to permit
extraction via push rods if necessary.
All heaters are wired to local terminal blocks mounted in the wire
channel. The wiring harness is attached to these terminal blocks
and resides permanently in the mold.
1/31/2011 © Acrolab 201125
Heating System Methodology
Thermocouples are mounted through the back plate of the
tool and are wired to local terminal blocks. All control zones
have both an active thermocouple and a spare, both wired to
the wire harness.
The terminations for the thermocouples can be found in the
terminal box for each half of the mold.
If a thermocouple fails, its spare can be connected to the
control system by jumpering to the spare terminals.
1/31/2011 © Acrolab 201126
Heatpipe Matrix
in a
cavity insert[prior to insertion]
Example:
1/31/2011 © Acrolab 201127
System Design
Core insert Isoball™ heatpipe array
1/31/2011 © Acrolab 201128
Cavity insert Isoball™ heatpipe array
System Design
1/31/2011 © Acrolab 201129
Heating System Methodology
The isoball™ heatpipe matrix is custom engineered to
assure that the whole insert is dynamically responsive to
temperature changes and reactive to thermal throughput
demands.
The next slide shows an acceptable and unacceptable
array configuration.
1/31/2011 © Acrolab 201130
Detailed view: Heatpipe Matrix
3.875
2.652
6.8xØ
2.652
6.8xØ
Additional Cooling Required
1.624
2.6xØ
1.875
3xØ
1.875
3xØ
1.875
3xØ
ARRAY DESIGN FOR Ø5/8
1.875
3xØ
1.875
3xØ
3.875
System Design
Non reactive heated areas
1/31/2011 © Acrolab 201131
Ball radiused
heatpipes
Distributed wattage
cartridge heaters
Type J adjustable
thermocouples
Electrical
Terminal Boxes
System Design
1/31/2011 © Acrolab 201132
System Design – 4 configurations
1/31/2011 © Acrolab 201133
Heatpipes remain within the inserts to integrate with heaters also within
the inserts.
Guard heaters
in the holder block
System Design
1/31/2011 © Acrolab 201134
Heatpipes within the inserts. Heaters located in the holder block
System Design
1/31/2011 © Acrolab 201135
Heatpipes extending from the inserts through the holder block to
integrate with heaters in the holder block.
System Design
1/31/2011 © Acrolab 201136
Heatpipes extending from the inserts through the holder block to
integrate with heaters in the holder block clamp plates
System Design
1/31/2011 © Acrolab 201137
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
1/31/2011 © Acrolab 201138
Isosprue spreader animation is located on this disk in a separate AVI file.
Isosprue spreader animation
1/31/2011 © Acrolab 201139
System Assembly
1/31/2011 © Acrolab 201140
The system is electrically installed using locally mountedterminal blocks located in wiring troughs adjacent to the exits ofthe heaters and thermocouples.
Each thermocouple and heaters are independently wired to itsindividual terminal block. A wiring harness is permanently set intothe wiring trough to bring the connections to the main terminalbox for the core and cavity.
Multipin receptacles mounted on the box ends provide interfacewith a multizone control system.
System Assembly
1/31/2011 © Acrolab 201141
Termination
box showing
the wiring
harness,
terminal strips
and multipin
receptacles
System Assembly
1/31/2011 © Acrolab 201142
Heating System
Multipin
Receptacle
Multipin receptacles are
used for both power and
thermocouple connections
on both the cavity and core
halves of the mold.
System Assembly
1/31/2011 © Acrolab 201143
System Schematic Methodology
The covers of the main termination boxes on the
mold are placarded with both physical location
schematics of the heater and thermocouple exit
points.
An electrical schematic of the heater wiring and
thermocouple wiring scheme from the terminal
strips to the multipin receptacles on the box
ends is also mounted.
1/31/2011 © Acrolab 201144
ZONE#9 ZONE#10 ZONE#13ZONE#14
ZONE#11 ZONE#12 ZONE#16 ZONE#15
HTR
#3
9,
HTR
#3
8,
HTR
#3
7,
CORE HALF (MOVEABLE)DCX 09DS H/L REFL
Ø5
/8
x 1
1.0
0", 2
00
0W
Ø5
/8
x 1
5.7
5", 2
00
0W
Ø5
/8
x 1
5.7
5", 2
00
0W
Ø5
/8
x 1
5.7
5", 2
00
0W
HTR
#4
0,
Ø5
/8
x 1
5.7
5", 2
00
0W
HTR
#4
1,
HTR
#4
2,
Ø5
/8
x 1
1.0
0", 2
00
0W
Ø5
/8
x 1
5.7
5", 2
00
0W
HTR
#4
3,
HTR
#4
5,
Ø5
/8
x 1
1.0
0", 2
00
0W
HTR
#4
6,Ø
5/
8 x
15
.7
5", 2
00
0W
Ø5
/8
x 1
5.7
5", 2
00
0W
HTR
#4
7,
HTR
#4
4,Ø
5/
8 x
15
.7
5", 2
00
0W
Ø5
/8
x 1
1.0
0", 2
00
0W
HTR
#4
8,
HTR
#2
5,
Ø5
/8
x 1
5.7
5", 2
00
0W
Ø5
/8
x 1
1.0
0", 2
00
0W
HTR
#2
7,
Ø5
/8
x 1
5.7
5", 2
00
0W
HTR
#2
6,
HTR
#2
8,
Ø5
/8
x 1
5.7
5", 2
00
0W
HTR
#2
9,
Ø5
/8
x 1
5.7
5", 2
00
0W
Ø5
/8
x 1
1.0
0", 2
00
0W
HTR
#3
0,
HTR
#3
1,
Ø5
/8
x 1
5.7
5", 2
00
0W
HTR
#3
2,
Ø5
/8
x 1
5.7
5", 2
00
0W
HTR
#3
4,
Ø5
/8
x 1
5.7
5", 2
00
0W
HTR
#3
5,
Ø5
/8
x 1
5.7
5", 2
00
0W
HTR
#3
6,
Ø5
/8
x 1
1.0
0", 2
00
0W
Ø5
/8
x 1
1.0
0", 2
00
0W
HTR
#3
3,
TC
#1
3A
TC
#1
3S
TC
#1
4A
TC
#1
4S
TC
#1
6A
TC
#1
6S
TC
#1
5A
TC
#1
5S
TC
#1
2S
TC
#1
2A
TC
#1
1A
TC
#1
1S
TC
#1
0A
TC
#1
0S
TC
#9
STC
#9
A
DCX 09DS H/L REFL
CAVITY HALF (STATIONARY)
ZONE#4ZONE#3 ZONE#8 ZONE#7
ZONE#6
Ø5
/8
x 1
5.7
5", 1
50
0W
Ø5
/8
x 1
5.7
5", 1
50
0W
HTR
#6
,
HTR
#5
,
ZONE#2 ZONE#5Ø
5/
8 x
13
.0
0", 1
50
0W
HTR
#4
,
Ø5
/8
x 1
5.7
5", 1
50
0W
HTR
#3
,
Ø5
/8
x 1
5.7
5", 1
50
0W
HTR
#2
,
Ø5
/8
x 1
5.7
5", 1
50
0W
HTR
#1
,
ZONE#1
HTR
#1
7,
Ø5
/8
x 1
5.7
5", 1
50
0W
HTR
#1
8,
Ø5
/8
x 1
5.7
5", 1
50
0W
HTR
#1
6,Ø
5/
8 x
13
.0
0", 1
50
0W
HTR
#1
5,
Ø5
/8
x 1
5.7
5", 1
50
0W
HTR
#1
4,
Ø5
/8
x 1
5.7
5", 1
50
0W
HTR
#1
3,
Ø5
/8
x 1
5.7
5", 1
50
0W
HTR
#7
,Ø
5/
8 x
15
.7
5", 1
50
0W
HTR
#8
,Ø
5/
8 x
15
.7
5", 1
50
0W
HTR
#9
,Ø
5/
8 x
15
.7
5", 1
50
0W
HTR
#1
0,Ø
5/
8 x
13
.0
0", 1
50
0W
HTR
#1
1,
Ø5
/8
x 1
5.7
5", 1
50
0W
HTR
#1
2,
Ø5
/8
x 1
5.7
5", 1
50
0W
HTR
#2
4,
Ø5
/8
x 1
5.7
5", 1
50
0W
HTR
#2
3,
Ø5
/8
x 1
5.7
5", 1
50
0W
HTR
#2
2,Ø
5/
8 x
13
.0
0", 1
50
0W
HTR
#2
1,
Ø5
/8
x 1
5.7
5", 1
50
0W
HTR
#2
0,
Ø5
/8
x 1
5.7
5", 1
50
0W
HTR
#1
9,
Ø5
/8
x 1
5.7
5", 1
50
0W
TC
#2
STC
#2
A
TC
#1
ATC
#1
STC
#3
ATC
#3
S
TC
#4
ATC
#4
S
TC
#5
ATC
#5
S
TC
#6
STC
#6
A
TC
#7
A
TC
#8
STC
#8
A
TC
#7
S
WF WF
Location schematics for heaters & thermocouples grouped by zone
System Schematic Methodology
1/31/2011 © Acrolab 201145
THERMOCOUPLE
CONNECTORMULTI-PIN
PIN
NU
MB
ER
ZO
NE N
UM
BER
PIN
NU
MB
ER
TER
MIN
AL N
UM
BER
POWERMULTI-PIN
CONNECTOR
TOTAL WATTAGE FOR STATIONARY HALF = 36,000W
BCTOTAL AMPS
ZONE 4
CAVITY HALF (STATIONARY)ZONE 1
R
AC
AB
WATTS
ZONE 3ZONE 2 ZONE 5 ZONE 6
TOTAL
(WATTS)
12000
12000
12000
E
ZONE 1
1A
ZONE 1
(ACTIVE)
-CO 210 RED
8 WHITE
RED16
IR
1
RED
WHITE
RED
WHITE
RED
WHITE
RED
WHITE
RED
WHITE
5
14
15
7
6
13
12
4
11
3
+IR5
-CO
IR
CO
+
-
6
CO
IR
-
+
CO
IR
-
+
4
3
WHITE
RED
WHITE1
2
9
+IR
IR
CO
+
- 1
3B8
CO
ZONE 5
(SPARE)
ZONE 3
(SPARE)
ZONE 3
(ACTIVE)
10
CO
ZONE 2
(ACTIVE)
CO
ZONE 1
(SPARE)
IRCO
9
IR
2
CO
ZONE 2
(SPARE)
IR IR CO
3 11
IR
ZONE 4
(SPARE)
IR
ZONE 4
(ACTIVE)
COIR CO
124
ZONE 5
(ACTIVE)
CO IR
5
IRCO
13
IR
ZONE 8
(ACTIVE)
ZONE 6
(SPARE)
14
CO
ZONE 6
(ACTIVE)
IR
6
COIR
ZONE 7
(SPARE)
IR CO
ZONE 7
(ACTIVE)
COIR
19
24IR
ZONE 8
(SPARE)
CO CO
2223
21
20
13
16
1817
1514
11
12
10
9
5A
6A6B6C
5B
5C
4B
4C
4A
3C
ZONE 5
5C
CAVITY HALF (STATIONARY)ZONE 3
3B
ZONE 2
1C1B 2A 2B 2C 3A
ZONE 4
4A3C 4B 5A4C 5B 8A6B6A 6C
ZONE 6
7B7A 7C
ZONE 73
8B5
7
6
8C 4
ZONE 8 2
1
1C
2B
3A
2C
2A
1B1A
ZONE 8ZONE 7
CO
IR
CO
IR +
-
+
-
7
87A
7B
7C8A8B
8C7 15 8 16
1
RE
WATTS WATTS
ER
1500
23.5
11.4
WATTS
ERER
WATTS WATTS
ER
WATTS
ER
WATTS
ER
1500W,230V
Ø5/8 x 15.75"
2
3 6
5
4
9
8
7
12
11
10
15
14
13
18
17
16
21
20
19
24
23
22
DCX 09DS H/L REFL
DCX 09DS H/L REFL
1500W,230V
1500W,230V
1500
1500
Ø5/8 x 15.75"
Ø5/8 x 15.75"
23.5
23.5 23.5
1500
23.5
1500
1500
23.5
23.5
1500
23.5
1500
1500
23.5
23.5
1500
23.5
1500
1500
23.5
23.5
1500
23.5
1500
1500
23.5
23.5
1500
23.5
1500
1500
23.5
23.5
1500
23.5
1500
1500
23.5
23.5
1500
23.5
1500
1500
23.5
11.4 11.4 11.4 11.4 11.4 11.4 11.4
1500W,230V
Ø5/8 x 15.75"
1500W,230V
Ø5/8 x 15.75"
1500W,230V
Ø5/8 x 13.00"
1500W,230V
Ø5/8 x 15.75"
1500W,230V
Ø5/8 x 15.75"
1500W,230V
Ø5/8 x 15.75"
1500W,230V
Ø5/8 x 15.75"
1500W,230V
Ø5/8 x 15.75"
1500W,230V
Ø5/8 x 13.00"
1500W,230V
Ø5/8 x 15.75"
1500W,230V
Ø5/8 x 15.75"
1500W,230V
Ø5/8 x 15.75"
1500W,230V
Ø5/8 x 15.75"
Ø5/8 x 15.75"
1500W,230V
1500W,230V
Ø5/8 x 13.00"
1500W,230V
Ø5/8 x 15.75"
Ø5/8 x 15.75"
1500W,230V
1500W,230V
Ø5/8 x 15.75"
1500W,230V
Ø5/8 x 15.75"
Ø5/8 x 15.75"
1500W,230V
1500W,230V
Ø5/8 x 13.00"
Electrical schematics showing wiring connections for heaters and
thermocouples grouped by zone
System Schematic
1/31/2011 © Acrolab 201146
Case Study # 2: Breaker Housing
Subject to confidentiality, specific mold designs, system layouts or detailed molding parameters
will not be presented. The photos above are only a general representation.
1/31/2011 © Acrolab 201147
Case Study # 2: Breaker Housing
Square D Corporation molds commercial, industrial andresidential switch gear and electrical breakers.
A six cavity residential breaker housing mold was builtfor operation in a 200T Bucher injection thermoset moldingmachine.
The material being molded was a polyester BMC.Injection thermoset was chosen over a manually loadedvertical press in order to reduce scrap and increaseproduction and part uniformity.
1/31/2011 © Acrolab 201148
This complex mold incorporated slide actions andwas constructed using mold face inserts.
These inserts presented intrinsic thermal gaps at theircontact surfaces. The mold was electrically heated bypositioning cartridge heaters in locations that were asclose as possible to the contact surfaces of the inserts.
When heated, the mold indicated temperaturevariations from random point to point on the workingfaces from 300º F to 350º F, a 50º F delta T. Theresultant cycle time for the mold was unacceptable. Themold part exhibited heat stress and blistering.
Case Study # 2: Breaker Housing
1/31/2011 © Acrolab 201149
The mold was modified to accept a matrix ofover 150 heatpipes in various diameters tobridge the inserts with the heater array.
The mold was machined to accept the retrofit bythe mold maker, Artag Plastics Corp of Chicago.The heatpipe matrix and associated componentswere installed.
The mold was then installed in the same pressand operated using the same parameters loadedinto the PLC as in the first instance.
Case Study # 2: Breaker Housing
1/31/2011 © Acrolab 201150
Major improvements were noted immediately.
1) The mold face delta T random point to point dropped from 50º F to 10º F.2) The cure time was reduced by 13 seconds.3) The overall cycle time was reduced by 22 – 23%.4) The surface appearance of the housings were improved and now met Square D standards.
As a result of the uniform temperature and rapid energythroughput provided by the heating system, Square D wasable to reduce the process temperature by over 40º F witha corresponding reduction in energy costs.
Case Study # 2: Breaker Housing
1/31/2011 © Acrolab 201151
Thank YouAdvanced Heatpipe Energy Transfer Systems
for Thermoset Injection Molds
Joe OuelletteChief Technology Officer
Acrolab Ltd.Advanced Thermal Engineering Research & Development
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