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ThermoDyne Microporous Insulation Product Forms
General Information:
All of ThermoDyne’s microporous insulation systems are similar in that they are essentially composed at their core of a finely ground substance comprised of a blend of ceramic powders and fibers. These materials, along with other additives that fluctuate with the application for which they are being employed, combine to form a high temperature material that provides excellent thermal stability, low thermal diffusivity and a thermal conductivity that is lower than that of still air.
Often, the microporous material is encased in a fabric or metal shell for improved handling and added strength, but it can also be quilted (for improved flexibility), molded, machined or fabricated for intricate part requirements. The material can also be pressed into metal castings or casings and then hollowed out in order to provide insulation for piping, electronics equipment and power units. It is ideal for any high temperature environment (up to its continuous service temperature of 1800°F), and has been used historically in aerospace, automotive, industrial and commercial markets where space and weight conservation are critical necessities without compromising thermal performance.
Determining which product form is best for a customer’s specific application is largely dependent upon the customer’s individual goals and objectives. What follows below is a summary of each product type, the various product lines in which it is offered, and a synopsis of the types of applications in which it often used and historically beneficial.
Specific Product Forms: Flexible Systems
Excelflex FlexibleThermoDyne’s flexible microporous systems are designed to provide the benefits of microporous materials around objects that possess curves, contours or other angled surfaces and do not lend themselves well to rigid systems.They are initially manufactured similarly to rigid systems,but are different in that once compressed, they are quiltedby an automated process that both breaks the continuity ofthe material (giving it its flexibility), while at the same time holding it in place. The quilting process utilizes high temperature thread in a standard lock-stitch pattern, and is usually supplied either in 1” center square-stitch patterns, or 1” parallel stitch patterns, depending on the preference of the customer and the size of the part being manufactured (e.g. a 36”x72” material is only available in parallel stitched patterns because the length of the part is too long for the quilting mechanism).
Excelflex® Flexible Microporous Insulation-
Excelflex® flexible microporous insulation systems are specially designed for use in aerospace environments, and are formulated and manufactured to meet the rigorous demands characterized by high flexibility, high temperature, high vibration, high stress commercial and military aerospace applications. In addition, Excelflex( flexible microporous insulation systems and raw materials are traced, tested and qualified to the highest degree of quality and purity, and can be customized to meet high temperature applications as high as 2,000°F, with cloth and thread selections ranging to 2,500°F.
Excelflex® flexible aerospace grade microporous materials are easily supplied either in standard sheet sizes, tapes, or custom fabricated sizes and shapes.
Excelflex® flexible microporous materials are most often utilized in applications such as aircraft heat shields and engine nacelles, aircraft APU’s, aircraft thrust reversers, and high temperature ducts and pipes.
DynaGuard® Flexible Microporous Insulation-
DynaGuard™ Flexible microporous insulation systems are specially designed for use in industrial and commercial environments, and are formulated and manufactured to provide the benefits of microporous materials at the lowest possible prices.
DynaGuard™ Flexible microporous materials are easily supplied either in standard sheet sizes, tapes, or custom fabricated sizes and shapes.
DynaGuard™ Flexible microporous materials are most often utilized in applications where a decrease in the insulation thickness (without compromising thermal efficiency) provides an increase in overall capacity, efficiency or throughput of the operating equipment or facility, and include molten metal manufacturing, furnace and ovens, hobby kilns, grease ducts and pipes, boilers, steam generation/co-generation systems and a variety of automotive and marine applications.
DynaGuard® Ladle Liner Microporous Insulation-
DynaGuard Ladle LinerDynaGuard™ Ladle Liner microporous insulation systems are specially designed for use in industrial and commercial environments where the presence of substantial water (or other moisture) prohibits the use of other microporous systems through the use of a special hydrophobic additive to the core formulation. This additive protects the microporous structure of the material until it reaches approx 900°F, but then burns out of the material. Once gone, the material continues to function as a superior thermal management tool, but is no longer hydrophobic.
Because DynaGuard™ Ladle Liner materials are usually requested, supplied and fabricated in larger sizes, they are most readily available in 16# density, 36”x72” (parallel stitched, 1” centers – see photo) and 36”x36” (square stitched, 1” centers) standard sheets, with thicknesses ranging from 1/8” to 1/2”. Other dimensions, densities and thicknesses are available upon request.
DynaGuard™ Ladle Liner materials are most often utilized in molten materials manufacturing (i.e. steel, aluminum, glass), but also pose substantial benefits to virtually any environment where substantial moisture poses a problem to the use of traditional microporous systems.
Specific Product Forms: Rigid Systems
Excelblok MoldableThermoDyne’s rigid microporous systems are designed to provide the maximum of benefits associated with microporous materials, and are supplied either as singularblock, panel or board pieces, or, depending upon the materialand the needs of the application, pressed and machined into supplied or sourced metal casings. They possess an extremely high resistance to compression, both low and high thermal shock levels, and can be easily jointed, stacked, or utilized as part of a composite.
Excelblok® Moldable Microporous Insulation-
Excelblok® moldable microporous insulation systems are aerospace grade rigid systems that are designed for use in applications where a high strength material with exceptional compression resistance is of the greatest benefit for the application. They are often employed in conjunction with customer supplied or ThermoDyne sourced metal castings or casings, and are filled with microporous material and then machined to specific dimensions. Depending upon the requirements of the application and the intricacy of the machining required, moldable forms of microporous insulation are supplied standard at 20 pcf (most often for “free standing” parts not molded into castings/casings), 35 pcf and 45 pcf.
Excelblok® is currently available either in standard block sizes of 18”x36” (to thicknesses of up to 3”) or to customer prints and/or dimensions.
Excelblok® is an ideal material for thermal battery insulation, avionics housings, aircraft microturbine units, emergency power backup units, and data storage devices.
Excelblok® Data Recorder Moldable Microporous Insulation-
Like the standard Excelblok® aerospace grade moldable microporous insulation materials, Excelblok® Data Recorder materials are easily moldable and machinable, and provide excellent compression resistance and strength for high temperature environments. However, Excelblok® Data Recorder materials are more specialized in that they are specifically designed for use in the rigorous environment associated with data recording systems (such as flight, rail and voyage data recorder systems) and the events, which surround them. As a result, there are additional proprietary components added to the standard Excelblok® formulation, which increase the chances of survival and retrieval of stored data.
Among these additional components are both an endothermic compound component (which absorbs a portion of the heat energy as it passes through the material and helps further delay the time to steady-state), and a proprietary coating (which also helps further dull the initial effects of high temperature heat on the material, and which expands slightly under the presence of high heat to fill fissures or fractures that may form in the insulation due to impact or stress).
The Excelblok® Data Recorder material is supplied standard in 18”x36” sizes (to thicknesses up to 3”), but is most commonly pressed into data recorder armors or housings before being shipped back to the OEM.
DynaGuard® Board Microporous Insulation-
DynaGuard Board™ microporous insulation systems are industrial and commercial grade materials for use in applications where the lowest thermal conductivity and highest strength, compression resistance and thermal performance are of the greatest importance. They are processed as a highly compacted form of microporous core materials and are supplied in uniformally distributed pieces. All DynaGuard Board™ materials are supplied standard in individually shrink-wrapped pieces for moisture resistance and dust control, and may be easily butt-jointed together in large or small surface-area applications where they will be used in conjunction with castables, standard cements, or moldable materials.
DynaGuard Board™ microporous insulation systems are supplied standard 18”x24”, in thicknesses of 1/2” to 1-1/2”, and in densities ranging from 18# (standard) to 22# and 25# (high density).
DynaGuard Board™ microporous insulation systems are used in incinerators, kilns, ovens, molten metal backup linings for melters, bakes and ladles, glass tank foreharths, and boilers, as well as a variety of automotive and marine applications.
DynaGuard™ Panel Microporous Insulation-
DynaGuard PanelDynaGuard Panel™ microporous insulation systems are industrial and commercial grade materials for use in applications where the lowest thermal conductivity and highest strength, compression resistance and thermal performance are of the greatest importance. They are processed as a highly compacted form of microporous core materials and are encased in a high temperature textile shell (see photo) in order to increase material uniformity, strength, and handleability, as well as decrease the overall cost of the part.
DynaGuard Panel™ microporous insulation systems are supplied standard 24”x36”, in thicknesses of 1/2” to 1-1/2”, and at 17# density.
DynaGuard Panel™ microporous insulation systems are typically used in commercial appliances, night storage heaters, most of the applications where DynaGuard Board( is used, and often in various types of fuel cells and alternative energy systems.
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