thermal solutions

THERMAL SOLUTIONS

Acrolab has a diverse and comprehensive database consisting of thousands of application solutions that have aided our customers in resolving thermal management processing challenges, increasing their production rates and the bottom line. We work with your team to supply thermal management expertise, along with all the services and components to provide a complete application solution.

HEATING SOLUTIONS

DEVELOPMENT OF ISOBAR HEAT PIPE ASSEMBLIES FOR LARGE FORMAT MOLDS

  • Challenge: To develop Isobar® heat pipe assemblies for insertion into large format molds for composite processing to improve the part curing process (in-autoclave).
  • Application: Composite Tooling

The use of Isobar heat pipes in the production of large composite parts (In-Autoclave) demonstrated a significant improvement in the manufacturing process by reducing cycle time by up to 50% while also increasing product quality.  The entire process was monitored throughout and a quantitative assessment determined that improvements, specifically related to product quality and cycle time, were remarkable and repeatable.  Contact Acrolab’s engineering team to discuss how we can improve your processing challenges.

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HEATER DEVELOPMENT PROJECT

  • Challenge: To develop a multi-zone split heater (3 zones) capable of operating at a temperature of 700°C. This style of heater was not available from any of the existing heater manufacturers.
  • Application: Composite Tooling-Custom Heater Development and Design for Automotive Parts Manufacturing.

Acrolab’s engineering team anticipated that the maximum operating temperature required for the heater would be a limitation with this new design. The heaters were tested and we confirmed that the multi-zone design was effective with respect to wattage distribution, however operating temperature was limited.

COOLING SOLUTIONS

ANALYSES OF THE PERFORMANCE OF THE COOLING CHAMBER FOR PREPREG MANUFACTURING

  • Challenge: To analyze the performance of the cooling chamber for one of our customer’s pre-preg manufacturing machines and to provide recommendation on how to improve it.
  • Application: Carbon Fiber Pre-Preg Manufacturing.

Acrolab analyzed the performance of the cooling chamber for pre-preg manufacturing and provided modification measures to improve it.  A detailed report summarizing the findings and recommended modification measures to the machine build was proposed and sent to the client. This solution solved their cooling problem on the new pre-preg machine.

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DEVELOPMENT OF COOLING TUNNEL

  • Challenge: To develop an industrial part washer system, with an engineered solution focused on the cooling tunnel design that would ensure that the automotive engine parts were sufficiently cooled in the process.
  • Application: Automotive Metal Engine Part Production.

The objective of this case would be to develop an engineered solution for the cooling chamber as part of a complete industrial part washer system. Acrolab engaged one of our technology partners to assist with the project and we completed a detailed heat transfer analysis on the cooling system.

THERMAL UNIFORMITY SOLUTIONS

DEVELOPMENT OF A VAPOR CHAMBER MOLD WITH INTERNAL COOLING CHANNELS

  • Challenge: To develop a rapid heating/cooling mold platform for out-of-autoclave composite curing.
  • Application: Composite Tooling.

Acrolab engineers designed and built a mold base with uniform temperature distribution that met the specifications of the customer for rapid heating/cooling for out-of-autoclave composite part production.  Acrolab provided a detailed report to the client outlining the performance parameters of the vapor chamber composite mold and operating instructions for the mold.

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DEVELOPMENT OF ISOTHERMAL ROTATIONAL MOLDS

  • Challenge: To develop isothermal rotary molds to reduce production cycle time, reduce mold weight and reduce energy consumption.
  • Application: Composite Processing – Thermal Uniformity

By developing a system that provides uniform heating and cooling to the mold, several production processes could be improved such as reduction in cycle time, increased productivity and a reduction in energy consumption.  One of the results during the analysis by the client was the correlation in their data where they were able to develop a scalable model for the rotary mold design utilizing this new concept design.

HEATER DEVELOPMENT PROJECT

  • Challenge: Acrolab was asked to design and build a new heater to overcome the thermal problems associated with the client’s production equipment and recommend other changes to make the process more efficient.
  • Application: Packaging & Sealing System.

Acrolab provided design recommendations including assistance to the client in understanding how the heater design could be optimized to suit their application. Based on the data collected our heater design proved to be both very effective and efficient in the application.

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HEAT DISSIPATION SOLUTIONS

DEVELOPMENT OF BATTERY THERMAL MANAGEMENT SYSTEMS FOR ELECTRIC VEHICLES

  • Challenge: To develop a new thermal management concept to improve the efficiency and reliability of the battery electric (BE) thermal management system used in Battery Electric Vehicles (BEV).
  • Application: Electronics Cooling.

Acrolab’s initial concept would be a two-phase flow BE thermal management system, providing a higher heat transfer coefficient inside the cold plate and a more compact design. Three concepts were investigated in this case; a simplified Isobar® heat pipe (HP) concept, a capillary pumped loop (CPL) heat pipe concept, and a mechanical pump assisted two-phase loop (2MPDL) concept.

HEAT RECOVERY SOLUTIONS

AN ADVANCED WASTE HEAT RECOVERY AND ENERGY GENERATION SYSTEM FOR PIZZA OVENS (COOPERATED WITH McMASTER UNIVERSITY)

  • Challenge: To develop a pizza oven waste energy recovery (POWER) system that would capture waste heat (thermal energy) and convert it to electricity for in-store operations.
  • Application: Waste Heat Recovery.

An important element in one of the components of this waste heat recovery system was Isobar® heat pipes. The waste heat energy would be captured by the heat pipe and transferred to the thermoelectric generator (TEG) to convert it to electricity.  This could then be used in-store to meet lighting, point-of-sale terminals and hot water and heating needs.

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HEAT PIPE ASSEMBLY DEVELOPMENT

  • Challenge: To implement Isobar® heat pipes into a rotational molding application to advance the heating process and improve part quality.
  • Application: Plastic Injection.

To make the process more efficient, the customer requested that we design and implement Isobar heat pipes to absorb the heat energy and effectively transfer it over the tool surface.

CUSTOM SOLUTIONS

DEVELOPMENT OF THERMAL FRAMES WITH EMBEDDED HEAT PIPES

  • Challenge: To manufacture a custom Isobar® heat pipe according to the client’s specification, this heat pipe had to meet certain geometric constraints, specific to shape and overall dimensions.
  • Application: Electronics Cooling.

Acrolab needed to fabricate these heat pipes according to the customer’s requirements. More specifically, these heat pipes were required to be bent and flattened.

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DEVELOPMENT OF A RAPID CURE SYSTEM TO PRODUCE CARBON FIBER REINFORCED PLASTIC (CFRP) PARTS

  • Challenge: To assist our client with the development of an automated, rapid cure process for producing a Carbon Fiber Reinforced Plastic (CFRP) part.
  • Application: Filament Winding.

The new production process using Acrolab Isomandrel technology would cure the composite faster resulting in a more efficient and cost effective production cycle.

Acrolab Thermal Solutions