Thermamax, Inc.

Many components in the engine compartment and exhaust line are interconnected to make up a complete system – generally using metallic V-Band Clamps of some description. Even an otherwise perfectly insulated system can have gaps at these interfaces, allowing unwanted and uncontrolled heat loss into the engine compartment. Apart from the temperature loss, there is also a risk that heat-sensitive components in the surrounding space may be damaged by the radiated heat.

From the thermal viewpoint often the weak point in an otherwise finely-tuned exhaust system: compensators, hoses, and bellows. They eliminate the various axial and lateral forces between components within the exhaust system and can be found on nearly every engine. The challenge is to close these last gaps in the thermal system with flexible and high-performance elements. The fully-enclosed and insulated metallic compensators from Thermamax fulfil this function, can be integrated within the overall system, and can reduce temperature-loss in a sensitive system.

The Tmax-Blankets are removable multi-component shells made from stainless steel foil, which effectively protect the intermediate insulation material against all kinds of damaging effects. The inner and outer shells of the Tmax-Blankets are formed using the latest stamping and forming tools in such a way so that they perfectly fit the contours of the object to be insulated as if made to measure. The materials and the strengths of the insulating inserts are specially developed according to the respective technical requirements in the Thermamax works. Intrinsic oscillation is virtually non-existent due to the low weight of this insulation variant. Extractions, hollows or additional fastening elements are possible at any location of the insulation necessary, meaning that Tmax-Blankets are multi-functional and can be used for any of your machines.

You know: Temperature-sensitive components are often situated in close proximity to plants which heat up in motors and machines. You need special heat protection in order to guarantee the functionality of these components. Protect all your temperature-sensitive components effectively and thus ensure their continued functionality whilst increasing their service life and reliability using Tmax-Heatshield. They can be used for a variety of purposes and protect sensitive parts located at the most inaccessible places. The multi-layered design made from thin stainless steel foil andor stainless steel sheets with alternately layered heat insulation material guarantees a high mechanical stability and enables the construction of very complex forms. The integration of stiff fastening elements as well as extractions, hollows or additional fastening elements is possible at any location necessary without problems.

Tmax-SKELTEC is a further development of the extremely successful Tmax-Integral Insulation. The Skeltec structure is integrated into the micromacro-structured stainless steel sheet and assuming the same material thickness, gives the outer shell an increased stiffness up to 150% higher. In practice this gives several clear advantages: A very high stiffness and resistance to stone-impact and other external forces acting on the component. Weight saving due to a reduction in material thickness up to 50%. The type and configuration of this additional Skeltec-structure will be detailed during the design stage based on the actual requirements

With Tmax-NIROTEX Thermamax is able to deliver a further approach to the insulation of exhaust systems. Depending on the requirement and the application this metallic-based insulation system can replace shields or soft wraps for example. Tmax-NIROTEX combines an improved thermal and acoustic protection with significantly reduced life-cycle costs. Tmax-NIROTEX is based on a media-resistant metallic but flexible outer and inner layer sandwiching an insulating material. Due to the flexible installation the Tmax-NIROTEX system differs from other metallic-based solutions in having zero tooling costs. Development times are minimal. That makes this particular technology the ideal solution for pilot production or volumes up to ca. 10000 units. Tmax-NIROTEX can be delivered in volume and fitted easily at Customer’s works.

Tmax-3D fibre-formed components exhibit different thicknesses and contours in different positions. This means they can fit the component even better than a 2D fibre-formed component.

Tmax-Insulation fabrics insulation mats are removable multi-component insulation shells made from technical textiles with integrated insulating material. The individual layers of the Tmax-insulation fabrics insulation mats are produced with a suitable cutting tool and subsequently sewn together. State-of-the-art materials are used with or without coating according to the individual technical requirements. The insulating thickness depends on the design specifications as well as the required insulation capacity. Extractions are possible at any location of the insulation.

Working with complex machinery can conceal enormous risks for the operator. For this reason the Classification Societies and Trade Associations have imposed strict guidelines to protect man and machine in the workplace. Tmax-Insulation Coverings are torsionally rigid, vibration-resistant, and can be easily fitted and removed as supported modules. They are infinitely adjustable and provide an effective protection for both operators and machinery – in accordance with applicable guidelines and standards. Tmax-Insulation Coverings are produced using the very latest metalworking machines – e.g. 2D3D laser cutting machines, CNC bending presses and CNC rotary machines. The materials employed and their properties are matched to the individual machines and the engines to be treated.

Fibrous insulating material can easily get soaked in wet conditions or during engine washing. The result is a delayed light-off performance as the system loses useful heat in drying the fibre. Fuel consumption and emissions are therefore especially high during this phase. The durability of the insulation system is also adversely affected due to the salt, dirt deposits and water accumulating in the fibre. Particularly affected are insulation systems positioned under the vehicle e.g. around the DPF-, SCR-Modules, silencers or thermo-acoustic insulations. This latter type are defined by a perforated outer shell and therefore easily damaged and prone to lose their effectiveness. Tmax-DryTec. The first high-temperature insulation that also protects against water ingress. Tmax-DryTec protects fibrous insulating material against water ingress giving it increased performance and longer life. Simpler compliance with future emission standards, lower fuel consumption, and an easier installation. Tmax-DryTec can be employed on all fibres used by Thermamax. Extended durability and improved insulation performance The effects of water spray mean that various salts, dirt and dust particles can reach the insulation. The so-called hydrophobic fibre material rejects the water and prevents deposits forming. The fibre stays clean, extending its durability and ensuring the maximum insulating efficiency. An additional benefit is the avoidance of expensive, close-tolerance welding that would otherwise be required in manufacturing the insulation system. Lower Emissions and Fuel Consumption Thanks to the shorter warm-up period the light-off performance is better. Future emission standards are met more easily and fuel consumption is lower. That’s how we keep out the water...