DuraLite High Performance Structural Core advanced foams are manufactured in varied densities for composite applications as substrates for sandwich composites and composite insulation boards. DuraLite is designed to address all the top concerns of composite designers namely:
DuraLite can achieve high bending strength-to-weight ratios and resistance to deformation (axial/flexural/torsional) when combined with laminate substrates such as carbon, metal, fibre/glass, or poly (carbonate/vinyl/ethylene/etc.).
DuraLite & DuraLite HT are quite unique since, as closed-cell thermoset rigid foam cores, they offer performance effective from at cryogenic temperatures up through 177°C while offering impressive thermal insulation characteristics not available in alternative structural foam cores. DuraLite densities range from 32–96 Kg / M3 and are available with:
High-volume,
Quick-turnaround
Sheets,
blocks, or fabricated shapes typically much larger and diverse than alternatives.
Precise dimensional tolerance.
A wide range of core densities, strengths and flexible dimensions are available for both DuraLite and DuraLite HT foam core products. Additionally, down-stream cutting and fabrication capabilities utilizing CAD and CNC equipment that can achieve unmatched flexibility in producing sheets, tapers, routed edges, or virtually any shape are available. Extremely tight dimensional tolerances can be maintained to meet the most demanding composite engineering specifications.
DuraLite
DuraLite is Defex’s Structural foam core product specifically designed for use within composite structures. DuraLite rigid foam is a material ideal for composite panel applications using substrates such as metal, fibre-resin, or composites that are laid over the DuraLite foam. Applications include structural composites that require an insulation value as well as a rigidity, dimensional stability, water resistance, and long-term performance. DuraLite is produced in the form of foam bun stock with the ability to custom size the bun, which we then cut into custom thicknesses, widths, and Lengths or Special Cut shapes to very high tolerances. Defex can utilize a variety of CAD-based cutting and shaping equipment, controlled by highly trained technicians to fabricate customized single or mass-produced shapes and special parts.
Defex high-volume production and fabrication abilities plus extensive inventory ensure quick, on-time deliveries at high capacity.
Common Applications:
Aerospace/aircraft
Marine (ship, boat, platforms)
Transportation (truck, rail)
Construction (building, architectural)
Wind/bioenergy
Light-weight DuraLite at 32 Kg per Cubic Meter density has an excellent compressive strength at 174 KPa achieving strength to weight ratios higher than alternative structural core products. Improved flexibility characteristics can also be achieved in applications where it may be an important property. DuraLite is also available in higher densities of 40, 48, 64, and 96 Kg / CuM, each with increasingly improved strength profiles. DuraLite can be used in foam core applications from -183 to +149°C. DuraLite HT is useful in higher temperature applications up to 177°C continuous, and 190°C intermittent.
Our proprietary production process utilizes hydrocarbon blowing agents creating a portfolio of DuraLite products with an extremely low Global Warming Potential (GWP).
THERMAL EFFICIENCIES
DuraLite has higher thermal efficiency than competing foam cores, which can offer benefits sometimes not considered. For instance, DuraLite based composite panels used in transportation containers will require less additional insulation. Similarly, composite panels using DuraLite on, for example transportation containers, ships, and boats, may offer warmer, or cooler, environments than would be otherwise be achieved with other composite cores - while offering comparable or superior strength characteristics. WATER
ABSORPTION/VAPOR TRANSMISSION
Water absorption within foam cores can compromise physical properties. DuraLite’s excellent resistance to water absorption (0.5%) as measured in accordance with Test Method ASTM C272 helps ensure long-term performance. In the unlikely event of a failure of the outer laminates, DuraLite offers an additional layer of protection. Note that water absorption for different foam cores is often measured by different ASTM Test Methods, making comparisons challenging. For instance, DuraLite’s WA of 0.5% was based on C272’s 24 hour period of immersion; comparable foam cores can be measured from as little as a 2 hour immersion period.
For optimum performance and longevity, some composite foam core systems must be designed for additionally controlling condensation. This requires a combination of thermal control and water vapour permeability. No other foam core offers DuraLite’s combination of high thermal efficiency and low permeability.
ADDITIONAL APPLICATIONS
Composite panels with substrates e.g. metal, fibre/resin, poly/plastic, or composites laid-overEPS cores)
Cores for Structural Insulated Panels (SIPS)
Laminated panels / Sandwich panels
Transportation/vehicle walls and floors
Customized form moulds for concrete arches and other shapes in building applications
Special Cuts for customized applications
PU / PET / Recycled PET / PVC / Other sandwich cores
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