Dual-Layer AeroZero® Polyimide Aerogel Graphite Thermal Protection Film with Silicone PSA DualZero TPS GR 201
DualZero TPS GR 201 is a dual-layer AeroZero® polyimide aerogel thermal protection film construction with an external graphite film and a silicone pressure-sensitive adhesive (PSA) bonding layer, with an overall thickness of 483 µm (19.0 mil) and a density of 0.65 g/cm³. It carries a UL94 V-0 flammability rating with a decomposition temperature (10 wt% loss, TGA) of 410°C (770°F) and a thermal conductivity of 0.045 W/m·K at 25°C. Adhesive strength exceeds 380 N/m (2.1 lbf/in) on aluminum foil, enabling permanent bonding to metal, composite, and polymer substrates.
Key Properties
- Thermal Conductivity (25°C): 0.045 W/m·K
- Decomposition Temp (10 wt% loss, TGA): 410°C (770°F)
- UL Flammability Rating: V-0 (UL94 V-0)
- Adhesive Strength (180° peel, AZ film on 2 mil Al foil): >380 N/m (2.1 Lbf/in)
- Tensile Strength: 6.7 MPa (0.9 ksi)
- Thickness: 483 µm (19.0 mil)
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- Specifications
- Applications
- General Info
- FAQs
Physical & Mechanical Properties
| Property | Value | Test Method |
| Thickness, µm (mil) | 483 (19.0) | ASTM D374 |
| Tensile Strength, MPa (ksi) | 6.7 (0.9) | ASTM D882 |
| Young’s Modulus, MPa (ksi) | 460 (66.7) | ASTM D882 |
| Tensile Elongation at Break, % | 6.7 | ASTM D882 |
| Density, g/cm³ | 0.65 | ASTM D202 |
Thermal Properties
| Property | Value | Test Method |
| Thermal Conductivity (25°C), W/m·K | 0.045 | ASTM C518 |
| IR Emissivity (Graphite Surface) | 0.29 | ASTM E408 |
| Specific Heat Capacity (25°C), J/g·°C | 1.03 | ASTM C1784 |
| Glass Transition Temp (AZ Tg, DMA), °C (°F) | 305 (580) | ASTM E1640 |
| Decomposition Temp (10 wt% loss, TGA), °C (°F) | 410 (770) | ASTM 2550 |
Adhesion Properties
| Property | Value | Test Method |
| Adhesive Strength — AZ Side: 180° peel/3 day-RT dwell time, AZ film on 50.8 micron (2 mil) Al foil, N/m (Lbf/in) | >380 (2.1) | ASTM D3330 |
| Adhesive Type | Silicone | — |
Flame & Fire Performance
| Property | Value | Test Method |
| UL Flammability Rating | V-0 | UL94 V-0 |
Compliance
- UL94 V-0 — Compliant
- Thermal barrier and protection systems for aerospace structures
- Thermal insulation for defense platform applications
- Heat protection for electronic components
- Adhesive-bonded thermal barriers on metal substrates such as stainless steel and aluminum
- Adhesive-bonded thermal barriers on composite and polymer substrates such as carbon fiber, polyimide, polyether ketone, polyurethane, and polyester
Common industries: Aerospace, Defense, Electronics.
DualZero TPS GR 201 is a dual-layer thermal protection film construction built from two 165 micron (6.5 mil) AeroZero® polyimide aerogel layers joined with an external graphite film and bonded using a silicone pressure-sensitive adhesive (PSA) layer. The overall construction measures 483 µm (19.0 mil) in thickness with a density of 0.65 g/cm³, forming an ultra-thin, lightweight thermal protection system (TPS) intended for applications where space and weight are constrained. Its primary advantage is combining high heat resistance with flame retardance in a thin, adhesive-backed film format that bonds directly to a substrate for permanent thermal protection.
Thermally, the construction offers a thermal conductivity of 0.045 W/m·K at 25°C, a specific heat capacity of 1.03 J/g·°C, and an IR emissivity of 0.29 on the graphite surface, supporting its function as both a thermal insulator and heat spreader. The AeroZero® layers exhibit a glass transition temperature (AZ Tg, DMA) of 305°C (580°F) and a decomposition temperature (10 wt% loss, TGA) of 410°C (770°F), consistent with a stated high heat resistance greater than 1000°F (538°C). The silicone PSA is protected by a release layer that is peeled off before application, and the adhesive bonds to substrates including stainless steel, aluminum, glass, carbon fiber, and polymer substrates such as polyimides, polyether ketones, polyurethanes, and polyesters, with adhesive strength greater than 380 N/m (2.1 lbf/in) on aluminum foil by 180° peel.
DualZero TPS GR 201 is flame retardant and carries a UL94 V-0 flammability rating, supporting its use in aerospace and defense thermal barrier applications where fire safety is a design requirement. Compliant with UL94 V-0.
What differentiates DualZero TPS GR 201 from other thermal protection film constructions?
DualZero TPS GR 201 combines two AeroZero® polyimide aerogel layers with an external graphite film and an integrated silicone pressure-sensitive adhesive into a single 483 µm (19.0 mil) construction. This pairs a UL94 V-0 flame rating and a decomposition temperature of 410°C (770°F) with a built-in PSA bonding layer, allowing the material to be applied directly to a substrate for permanent thermal protection without a separate bonding step.
Why is decomposition temperature critical for a thermal protection film like DualZero TPS GR 201?
Decomposition temperature defines the upper thermal limit at which the AeroZero® aerogel layers begin to break down and lose their insulating and protective function. DualZero TPS GR 201 is rated to a decomposition temperature (10 wt% loss, TGA) of 410°C (770°F) and a glass transition temperature (AZ Tg, DMA) of 305°C (580°F), with a stated high heat resistance greater than 1000°F (538°C), allowing it to maintain thermal protection performance in the extreme-temperature environments typical of aerospace and defense thermal barrier applications.
What is the temperature range for DualZero TPS GR 201?
The manufacturer's TDS does not specify a discrete operating temperature range. It lists a stated high heat resistance greater than 1000°F (538°C), a glass transition temperature (AZ Tg, DMA) of 305°C (580°F), and a decomposition temperature (10 wt% loss, TGA) of 410°C (770°F).
Is DualZero TPS GR 201 suitable for flame-rated environments?
Yes. DualZero TPS GR 201 carries a UL94 V-0 flammability rating, the only compliance standard specified on the manufacturer's TDS, supporting its use in aerospace and defense thermal barrier and protection system applications where flame retardance is required.
How should DualZero TPS GR 201 be specified?
Specify grade (DualZero TPS GR 201), thickness, adhesive type, target bond substrate, compliance requirements, dimensional tolerances, and finished format.
