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Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
Improving Processing of Rubber in Injection, Transfer and Compression Molding Process Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
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Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
Introduction Mold heating time is the biggest contributor to the overall cycle time in almost all rubber molding applications. Many molders fail to claim additional savings that can be achieved through optimized heating process. Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
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Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
Molding Process Mold heating generally accounts for more than two thirds of total cycle time Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
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Benefits of Optimum Heating Process
Temperature Uniformity Reduced Residual Part Stress Cycle Time Reduction Scrap Rate Reduction Energy Savings Reduced Maintenance Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
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Factors Affecting Mold Heating
Material Thermal properties Part Geometry Thermal breaks between plates or inserts Location of Thermocouple RUBBER PART Thermal properties Part Thickness Geometry Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
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Thermal Conductivity of Materials
Thermal Conductivity (W/m K) at 20 C Factor ISOBAR 390 – 15,000 **** Copper 390 1x Aluminum 237 1.6x Beryllium Copper 105 3.7x Steel 20 – 40 13x Water 0.60 650x Plastics 0.15 – 0.30 2,400x RUBBER 0.13 – 0.16 2,600x Air 0.025 15,600x Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
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Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
Types of Isobars STANDARD FINNED STEPPED HOLLOW Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
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Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
Isobar - Function HEAT IN METAL WICK HEAT OUT LIQUID FLOW VAPOUR FLOW ISOBAR SHELL HEAT IN HEAT OUT Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
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Isobar Function and Orientation
VERTICAL HORIZONTAL / INCLINED HEAT OUT HEAT IN HEAT OUT HEAT IN HEAT INPUT MUST BE BELOW HEAT OUTPUT HEAT INPUT AND OUTPUT CAN BE ANYWHERE ALONG THE ISOBAR LENGTH Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
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Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
Isobars Passive Device Superthermal Conductors Thermal Uniformity of +/- 1 °C Orientation Dependent Operating Temperature 0 – 280 °C Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
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Thermal Performance of 25mm Diameter x 150mm Long Core
WITH ISOBAR CORE SOLID MOLDED PART CORE PIN ISOBAR HEATED MOLD PLATE HEATER Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
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Thermal Performance of 25mm Diameter x 150mm Long Core
Steady State Steady State Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
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Thermal Performance of 25mm Diameter x 150mm Long Core
Core Base Core Top Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
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Examples of Cores with Isobars
CORE PIN Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
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Isobar Design in Heated Cores
TEMPERATURE UNIFORMITY OF HEATED CORE No Isobars With 4 Isobars Indirect Heating of Isobars Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
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Isobar Design in Heated Cores
Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
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Isobar Design in Transfer Molding Tree Bar Mold
Core Pin Isobar Heater Tree Bar Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
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Isobar Design in Heated Cores
Epoxy Plug ISOBAR Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
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Rubber Molding over Flat Plates
Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
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Acrolab Ltd. – Copyright 2003 – Introduction to Mold Cooling & Heating
ISOPLATEN Bi-Level Matrix of Heaters and Isobars Acrolab Ltd. – Copyright 2003 – Introduction to Mold Cooling & Heating
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Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
STANDARD PLATEN 24” x 24” x 3” With 5 heaters Heaters ON Thermocouples Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
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STANDARD PLATEN 24” x 24” x 3” With 5 heaters One Heater disconnected
Heater OFF Thermocouples Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
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HEATER TEMPERATURE PROFILE VS LENGTH
Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
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Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
ISOPLATEN 24” x 24” x 3” With 5 Heaters and 13 Isobars Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
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One heater disconnected
ISOPLATEN 24” x 24” x 3” With 5 Heaters und 13 Isobars One heater disconnected Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
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Acrolab Ltd. – Copyright 2003 – Introduction to Mold Cooling & Heating
Standard Platen Isoplaten Acrolab Ltd. – Copyright 2003 – Introduction to Mold Cooling & Heating
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Isoplaten vs Platen Consideration
Thermal uniformity dynamic +/- 2 °C vs static +/- 17 °C Single Zone vs Multiple Zone Control Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
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Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
ISOPLATEN Mounting Holes Isobar Heater Thermocouple Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
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Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
ISOPLATEN T - Slots Isobar Heater Thermocouple Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
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Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
ISOPLATEN Center Hole Isobar Heater Thermocouple Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
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Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
ISOPLATEN Thermocouple Thermoswitch Isobar Heater Acrolab Ltd. – Copyright 2003 – Improving Processing of Rubber
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