the isoplaten -"thermal performance of electrically heated platens" - may 2011
DESCRIPTION
Acrolab’s Isoplaten (“The Intuitive Platen”) redistributes the energy generated by standard cartridge heaters to give molders rapid thermal recovery and unparalleled and linear temperature distribution along the whole platen surface. Your tools operate with reduced energy demands, produce better quality molded parts and allow you to use faster curing compounds with narrower thermal processing windows. Uniformly Cure Parts Resulting In Better Quality • Reduce cycle time• Reduce Thermal Energy Required From Heaters• Energy Cost Savings• Save On Time• Evenly Heat Thermal Sensitive Parts• Eliminate Hot Spots• Reduce Scrap Acrolab’s Isoplatens provide high levels of thermal stability to press platen applications and can be designed for electric, oil, or steam heating. Integral water cooling lines for fast process temperature changes are available. The standard Isoplaten is electronically heated and has an operating range of ambient to 500°F. Acrolab engineered bi-level Isoplatens can hold a thermal uniformity of +/- 5°F over 90% of the surface of the Isoplaten. These results allow a substantial improvement in cycle times, start up times, thermal recovery rates, and improved part quality. The Isoplaten’s Unique thermal uniformity permits the use of one single zone temperature controller for the entire platen. No special multi-zone controls, heaters, or thermocouples are required.TRANSCRIPT
Acrolab Ltd.© May 2011
Heated platens are fundamental components in
the molding process of a variety of composites.
Platens provide heat necessary to complete the
molding /curing reaction.
Conventionally heated platens consist of a single
level of heaters housed in a plate.
Acrolab’s Isoplaten® is a bi-level matrix of
heaters and Isobar® heat pipes housed in a metal
plate.
Introduction to Isoplatens®
Acrolab Ltd.© May 2011
2
Standard Platen With Heaters
3
Standard
electrically
heated platen
with five
cartridge
heaters and one
thermocouple
Acrolab Ltd.© May 2011
Standard Platen With Heaters
4
Electrically
heated
Isoplaten® with
5 cartridge
heaters (yellow)
and 17 Isobars®
(white & red)
Acrolab Ltd.© May 2011
Standard platens do not
provide uniform temperature
distribution on the plate
surface.
Temperatures can vary by
up to 25 C along the surface
of the platen.
Non-uniformity can result
in insufficient curing,
increased cycle times,
decreased thermal recovery,
and poor part quality.
Standard Platens
5
Thermogram of a standard electrically
heated platen
Acrolab Ltd.© May 2011
Temperature uniformity results in:
1. Decrease in under and over
cured parts
2. Rapid temperature recovery
3. Decreased cycle times
4. Reduced energy consumption
5. Improved overall part quality
Temperature distribution varies
only 2 C across 95% of the
platen.
Isoplatens®
6
Thermogram of an electrically
heated Isoplaten®
Acrolab Ltd.© May 2011
“Provide for exceptional temperature uniformity”
Objective:
A comparative analysis of an
electrically heated Isoplaten® vs. a
conventional or standard electrically
heated platen of the same physical
dimensions, the same thermal energy
in-put and with the same load
conditions.
Research Experiment
7
Acrolab Ltd.© May 2011
Steady state, loading, boiling/thermal
footprint growth, beginning of recovery,
recovery, complete recovery.
Isoplaten® with 20mL of water in 4” load
container; central loading location (5)
Raw data from “Thermacam Researcher” as
seen during experiment.
Experiment Stages
8Acrolab Ltd.© May 2011
1. To characterize the difference in thermal response between
conventional standard platens and Isoplatens® when subjected to
various thermal loads, at different load positions.
2. A comparative examination of the surface thermal uniformity of
either platen when they are subjected to random cartridge heater
failures.
Standard Platen Isoplaten ®
Overview: Research Experiment
Acrolab Ltd.© May 2011
9
Equipment
18” x 18” Isoplaten
IR Camera: FLIR
SC3000
Sampling rate: 1 Hz
Image size: 320 x
180
DAC: Real-time
monitoring
Recording of IR
image sequence
Experiment - Set up
Acrolab Ltd.© May 2011
10
Loading Container Loading Positions
Load
Chamber
Configuration common to both platens
Acrolab Ltd.© May 2011
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Phase 1: Comparative dynamic thermal load analysis
a) Steady state
b) Loading
c) Boiling/thermal footprint growth,
d) Beginning of recovery
e) Recovery
f) Complete recovery
Experiment Phases (3)
Acrolab Ltd.© May 2011
12
20 mL of water in 4” load chamber; central loading position #5
(both platens)
Load
Chamber
Position# 5
Acrolab Ltd.© May 2011
Phase 2 – Position #5
13
Loading at location 5 (center of platen)
T(t)-T0 are plotted during the recovery period
Position #5 - Temperature difference Isotherms
Acrolab Ltd.© May 2011
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Absolute Temperature
Platen Isoplaten
Position #5 - Animated sequences
Acrolab Ltd.© May 2011
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Temperature Difference
Platen Isoplaten
Position #5 - Animated sequences
Acrolab Ltd.© May 2011
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1. Steady state
2. Loading
3. Boiling/thermal footprint growth,
4. Beginning of recovery
5. Recovery
6. Complete recovery
Thermographic video sequence
Acrolab Ltd.© May 2011
17
Position #5 - Thermal video
Acrolab Ltd.© May 2011
18
20 mL of water in 4” load chamber; central loading position #7
(Both platens)
Phase 2 – Position #7
Load
Chamber
Position# 7
Acrolab Ltd.© May 2011
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Absolute Temperature
Platen Isoplaten
Position #7 - Animated sequences
The true measured temperature
Acrolab Ltd.© May 2011
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Temperature Difference
IsoplatenPlaten
Position #7 - Animated sequences
The temperature difference between the two platens
Acrolab Ltd.© May 2011
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Uniform heat distribution = Quality improvement
Reduction of hot spots in molds = Quality Improvement
Uniform cure rate = Quality Improvement
Improvement of cycle time = Productivity improvement
Reduction of thermal energy required from heaters = Energy Savings
Conventional Platen Acrolab Isoplaten®
Isoplaten:
Conventional platen vs. Isoplaten®
Acrolab Ltd.© May 2011
22
Steady-state performance of the Isoplaten is
improved over that of the platen, even with
heater failure.
Recovery time is reduced in all loading modes:
C (θ = 63%) 7 – 26 %
T (within 1 C of SS) 14 – 30 % (or more)
The recovery time is mostly affected by load
position.
23
Summary
Acrolab Ltd.© May 2011
The Isoplaten® provides for curing times that
are shorter than the standard platen.
The Isoplaten® provides for a 44-54% faster
curing time over the standard platen.
The Isoplaten® also has a faster recovery
time.
The Isoplaten® will decrease cycle times and
energy consumption.
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Results
Acrolab Ltd.© May 2011
©Acrolab 2011 25
Acrolab R & D Labs & Manufacturing Centre
Advanced Research & Development
1 800 265 9542 Toll free in North America
1 800 465 9674 Fax
519 944 5900 Direct
www.acrolab.com
Let our team at Acrolab optimize your thermal footprint … call today.