Automotive

Aerogel insulations help Light Vehicle Manufacturers run Hotter and Harder

As light vehicle manufacturers strive to deliver the power, acceleration and cabin space that customers thrive, without significantly increasing the size of the engine or drive train, engine temperatures have continued to climb, raising the requirements for under hood, under carriage and cabin heat shielding and thermal management.

On some platforms, heat given off by the engine is now in the range of 200-225°C, which is near or beyond the limit of existing materials used to shield or insulate under hood components from excessive thermal loads. Temperatures at this level, and surprisingly significantly below, can have an adverse impact on the operating performance and life of vital parts such as batteries, starters, electronic engine management controls and sensors and climatic system components. Spark plug boots must also be improved or shielded, and excess engine heat can also raise the temperature of intake air for combustion, lowering efficiency and power output.

The increased demand for power and cabin space have also conspired to place sophisticated cabin electronics at risk of thermal exposure through the firewall, and raised the temperature of catalytic converters and other exhaust components, which can be transmitted through the floor pan.

While some existing insulations such as glass filled foams, fibers and metals can tolerate these higher temperatures, they have a relatively low capacity for shielding and insulation, which means that in order to continue to provide effective thermal management, insulation thickness would need to be increased. Since additional insulation and shielding space in the areas that need it most is not available, an alternative means to provide effective heat shielding and insulation is needed.

Our thin, lightweight flexible aerogel blankets have between two to four times more thermal resistance than existing insulations, making them well suited for these purposes and enabling vehicle manufacturers to increase effective shielding and thermal insulation by a factor of between two and four, without giving up more valuable space to insulation.

We presently provide two product classifications with respect to continuous use temperature; Spaceloft™, which can be used continuously up to 200°C/390°F; and Pyrogel^®; which can be put into continuous service at temperatures up to 650°C/1200°F. Within each class of product there are several different types with respect to thickness and IR opacification.

In addition to superior thermal performance, our aerogel insulations also possess moderate acoustical capabilities as well. These are most useful in space constrained areas where improvement in acoustics are desired, but there is little or no space available to increase the amount of sound deadening or insulating materials.

For example, automotive convertible tops are migrating quickly towards headliner systems in response to retractable hard tops, and consumer demand for a quieter cabin with a convertible top that has a more finished look. Acoustics can be improved through the headliner material itself, or even further by placing insulation between the headliner and the top. Aerogels are ideal here as they represent equivalent acoustical performance but at 25-75% lower thickness.

For a general overview, please review the Product Selection Guide. For specific details on specific products, you can also click on the Product Data Sheets in the Literature Center.