The following discussion provides a brief overview and history of thermal packaging solutions, alternatives and limitations.

There have been several different materials traditionally used for thermal packaging systems. The most basic and inexpensive is a polystyrene cooler with an R-value of about 1-2. The next best approach is to use blown foam, typically polyethylene or polyurethane. The R-value here may reach as high as 5-7 per inch, with most applications requiring a 2"-3" nominal wall of foam.

Currently, these traditional solutions represent the largest volume of containers sold for thermal packaging applications. Using these solutions, customers are forced to compromise through the use of voluminous amounts of coolant, oversized boxes, as well as expedited shipments. Even with these compromises, the percentage of rejected product is extremely significant.

Another alternative developed in the last decade, is called Vacuum Insulation Panel (VIP) Technology. The core material for early VIP's has been a quasi-open celled polystyrene, marketed by Dow Chemical called Instill. These VIP's were advertised as an R-25, but independent tests have shown that this was an optimistic value. However, VIP Technology is significantly more efficient than traditional foams.

Since its inception, Dow Chemical faced significant quality and consistency issues with Instill. They struggled to service a market that they were instrumental in developing. In 2004, after more than a decade of sustained losses, Dow decided to stop producing Instill, leaving a tremendous void in the market for VIP Solutions.

As a result of Dow's efforts, there is an extensive demand for VIP Solutions worldwide. Active markets exist in Europe and Asia, with an accelerating demand in North America. The next generation of VIP Technology to fill the void is base on an advanced material known as an Aerogel.

Although Aerogels have been under development for almost 70 years, they have been extremely expensive to produce. Today, there are several suppliers of Aerogel based VIP's. However, until the recent development of AEROBLACK®, a patented Aerogel, VIP supplier could not offer a core material in a monolithic form. 

Utilizing AEROBLACK® as the core material, Therm-Max™ Panels provide the most advanced VIP Solution available: R-40 at 1" thick. Foamcore Inc., manufacturer of Therm-Max™ Panels, is currently the only licensed manufacturer and distributor of AEROBLACK®.