Moulding masterclass | processing feature

Connectors and couplings can be a weak spot in cooling system

design. Moulding expert John Goff explains how to select wisely

Mould cooling make sure

you are going with the flow
For effective heat removal from the mould tool to be

tool and the female socket connected to the associated

realised, careful attention needs to be paid to several

flexible hose or copper pipework of the cooling system

key areas relating to the connection and arrangement of

to allow the mould cooling fluid to be directed from the

mould cooling circuits. Prime among these considera-

mould temperature controller (MTC), through the mould

tions is cooling fluid flow rate. This can be dramatically

tool and then back to the MTC.

affected by the use of quick release mould cooling

The thread form of the male plug will vary according

circuit connectors, which are fast becoming the norm as

to the local market. The metric M10x1.0 or M14x1.5

pressure on moulders increases to speed up mould

pitch sizes are widely used around the world but

changes.

common alternatives include the British Standard Pipe

Many processors today adopt the principles of SMED

(BSP) sizes of 1/4, 3/8 and inch diameter and the US

(Single Minute Exchange of Die). While speed of

National Pipe Thread (NPT) form equivalents. Aside

connection of mould service couplings is considered in

from the thread form, the selection of the connector

SMED operations, the operational performance of the

thread is typically determined by the size and complexity

coupling can be overlooked. Figure 1 shows a typical

of the mould, the number of impressions within the tool,

mould cooling circuit coupling assembly consisting of a

and available space to accommodate the cooling circuit.

male connector plug and female socket. The male plug

is screwed into its respective thread within the mould
www.injectionworld.com 

Selection of the coupling greatly influences the

cooling medium flow rate and cannot be determined
March 2012 | injection world

55

processing feature | Moulding masterclass

Table 1: Measured mould impression coolant flow rate v

circuit coupling type
9mm straight-through quick connect

20.0 litres/min

6mm straight-through quick connect

11.0 litres/min

6mm self-closing quick connect

7.5 litres/min

will be at the coupling. The greater the number of

6mm couplings employed in such a system, the lower
the resultant flow rate that will be achieved.
A number of mould tool accessory suppliers today
promote the use of self-closing couplings (often
called shut-off sockets) that feature spring-loaded
shut-off systems, see Figure 3. When the male plug is

Source: G&A Moulding Technology

detached from the female socket, these devices

automatically activate to minimise fluid loss from the
Figure 1:

system. Their use, while convenient,

A typical

can reduce flow rate when compared

mould

to an unrestricted straight-through

cooling circuit

bore by as much as 30%.

connector

Paying so much attention to such

assembly

basic mould components might be considered unnecessary but a simple experiment carried out at
G&A Moulding Technology shows just how big an impact
connector selection can have on the process. Using a
four-cavity mould tool in which each cavity/core combisimply by thread diameter, as can be seen in the two

nation was individually cooled and supplied by a mould

quick connector assemblies shown in Figure 2. The two

temperature controller regulated to supply a consistent

connectors both feature the same thread form, in this

flow rate of cooling medium, the company measured the

case inch BSP, but have very different bores - 6mm

flow rate achieved across each impression with different

diameter in the case of connector A and 9mm diameter

connectors fitted (this also highlights the importance of

for connector B.

specifying correct ancillary equipment such as MTCs

The flow of coolant through the connector will be

which will be discussed in a further article).

The measurements (Table 1) showed for 9mm

influenced by the cross-sectional area of the bore

(equivalent to multiplied by the square of the bore

diameter bore couplings, the respective flow rate

radius). For the 6mm bore in connector A the cross

achieved across each impression was 20 litres per

sectional area is 28.28mm2 whereas the 9mm bore of

minute. Switching to 6 mm diameter couplings reduced

connector B has a cross sectional area of 63.63mm .

flow across each impression to 11 litres per minute.

The power relationship between diameter and area

Replacing the 6 mm straight-through couplings with a

means, in this example, that a 50% increase in bore

6 mm self-closing type reduced the flow rate to 7.5

diameter gives a 125% increase in the cross sectional

litres per minute.

area of the flow channel.

The cooling medium flow rate through a 9mm

Such reductions in cooling fluid flow rate are

significant and are often reflected in poor component

coupling assembly will be greater than that through a

quality and/or variability due to the inability to effec-

Figure 2:

6mm alternative. At G&A Moulding Technology, the

tively remove thermal energy from the mould. These

Connector

authors business, it has been found this increase is

quality and variability problems can be correlated with a

bores can vary

usually more than 40% when comparing a 9mm bore

component temperature increase which necessitates

considerably

coupling to a 6mm coupling. Furthermore, if the

more time to dissipate, resulting in longer cycle times.

within the

diameter of the cooling channel machined within the

same thread

mould tool is 10mm but the coupling used has a 6mm

rate available, the greater the opportunity to achieve

size range

bore, then the maximum flow restriction experienced

optimal heat removal and shorter cycle times. Spring

In general terms, the higher the cooling fluid flow

loaded couplings are excellent for minimising coolant

spillage and wastage but will inhibit the flow rate
and this inhibition is greater with smaller coupling
diameters. This should be taken into account
during selection. Furthermore, when using selfsealing couplings it is important that the water trapped
within the cooling channels of the mould tool is
removed (blown out using compressed air) prior to
the cooling pipes being removed and the mould tool
56

injection world | March 2012

www.injectionworld.com

Moulding masterclass | processing feature

put into storage to avoid corrosion taking place in the

channels and inserts, particularly if these are not
manufactured from stainless steel or aluminium.
Before closing this article, it is worth a few words of
discussion about mould temperature control. Irrespective of what thermoplastic material is processed, the
temperature of the fluid passing around and through
the mould tool is much lower than the temperature
required to achieve its molten status and for this
reason the term coolant is always used.
4oC as the maximum value that should be encountered

Figure 3: Flow

polypropylene range from 15-35 C, depending upon the

to achieve optimum heat removal. The lower the

restrictions in

type of component being moulded. When processing

value across the mould, the more effective the heat

self-closing

polycarbonate, the coolant temperature is typically 80-

transfer rate must be, in turn necessitating greater

quick connec-

120oC and may require the use of pressurised water or

coolant medium flow rates through and around the tool.

Typical coolant temperatures used to process

o

oil as the cooling medium. Coolant is a relative term

compared to polycarbonates processing temperatures

This discussion will be continued in the next article

tors must be
considered

in the Moulding Masterclass series.

of between 280-340oC, mould temperatures of 80-120oC

About the author

are quite cold.

Whatever polymer is being processed, the change in

John Goff is managing director of G&A Moulding

coolant temperature () between the fluid entering and

Technology. This is the nineteenth instalment in the

exiting the mould is considered an important process

Moulding Masterclass series. You can read the most

parameter to monitor. Many processors regard a of

recent previous articles here, here, and here

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