Thermal insulation materials for heavy equipment provide protection against high temperatures that can cause engines to overheat, automotive fluids to evaporate, batteries and electronics to fail, and operators to become fatigued. They can be used individually or combined with other types of thermal or acoustic insulation and applied to surfaces with pressure-sensitive adhesive (PSA) tape.
Elasto Proxy distributes sheets and rolls of insulating materials, but we also transform stock materials into finished products. Heavy equipment manufacturers who buy our ready-to-install solutions save time on their assembly lines. They can also save money by buying all the rubber that they need from a single source that has access to over 200 material manufacturers.
Keep reading to learn about thermal insulation materials, or contact us for an insulation sample kit.
Thermal Insulation Basics and Material Specifications
Heat doesn’t stay still. It moves from hotter objects to colder ones. In diesel-powered heavy equipment, heat flows from the engine block to other parts of the engine bay. Without thermal insulation on the firewall, heat can also move into the cabin. In electric vehicles (EVs), heat flows from the battery, especially during heavy charging or rapid acceleration.
R-Value
The R-value of thermal insulation measures its resistance to heat flow. R-values are expressed in per unit thickness, and higher R-values indicate greater thermal resistance. For example, let’s say a thermal insulation material has an R-value of 3.5 per inch. If you install 4 inches of this material, the total R-value is 14 because 3.5 x 4 = R-14.
Thickness
Whether it’s measured in inches (in) or millimeters (mm), thickness is about more than just resistance to heat flow. If you’re filling a gap in the engine bay, you need a thermal insulation material that will fill the gap completely while avoiding compression set, permanent deformation that occurs when a material is compressed for a specific period under a certain temperature and load.
Tensile Strength
Tensile strength is the maximum amount of stress a material can withstand before breaking when pulled or stretched. In heavy equipment, thermal insulation materials with higher tensile strength are less likely to deform because of vibrations, pressure, or movement. The greater structural integrity of these materials also prevents the formation of gaps that could affect insulation performance.
Density
Lower-density materials provide greater thermal insulation. That’s because they contain more air, which has a relatively high thermal resistance and a relatively low thermal conductivity (TC), a measure of the ability to transfer heat. In basic terms, the less dense a material is, the better it insulates by trapping air – a poor conductor of heat.
Temperature Range and Fire Resistance
The temperature range of thermal insulation is the range of temperatures where a material will work optimally and without significant degradation or loss of properties. Essentially, it’s the range between the lowest and highest usable temperatures. Not all high-temperature materials are fire resistant, however, so make sure to compare your flammability requirements to a material’s properties.
Types of Thermal Insulation Materials
Elasto Proxy can distribute and fabricate these types of thermal insulation materials
- Foam Rubber
- Metal Foils
- Metallized Fabrics and Fibers
- Composite Materials
Foam Rubber Materials
Foam rubber materials for thermal insulation include these options.
- Polyurethane (PUR) has excellent thermal resistance.
- Polyisocyanurate (PIR) resists heat and has greater fire resistance than PUR.
- Extruded polystyrene (XPS) resists heat, moisture, and over-compression.
- Expanded polystyrene (EPS) is both lightweight and cost-effective.
- Phenolic combines good heat resistance with excellent fire resistance.
- Melamine is flame retardant and resists high temperatures.
These cellular materials are supplied as closed-cell foams that contain tiny pockets of trapped air. Practically speaking, this air helps reduce heat transfers. Yet air still transfers some amount of heat – and possibly too much for engine or cabin electronics to handle, or for heavy equipment operators to tolerate.
That’s why engineers choose foam rubber materials with higher and more predictable R-value than air. The R-values of air are highly variable, and the amount of air space, the air temperature, and the amount of moisture in the air are all factors.
Metal Foils, Metallized Fabrics and Fibers, and Composite Materials
Metals are a good choice for thermal insulation because they can withstand high temperatures and reflect heat. For heavy equipment, thin metal foils can be combined with other materials to form heat shields. Thermal insulation that’s made with aluminum foil can also be applied elsewhere, such as with engine or muffler baffles.
Thin metal foils won’t reflect as much heat as thick metal plates, but foils are cost-effective and can be combined with other materials for a complete thermal management solution. For example, an aluminum foil that’s laminated to a foam rubber can create a product that withstands high temperatures, reflects heat, and is a poor conductor of thermal energy.
Metallized fabrics and fibers are also used for thermal insulation. For example, aluminized fiberglass cloth is used with engine exhaust covers. Metallized fibers are made of polymers, a group of materials that includes rubbers, and are coated with metal. To support application-specific requirements, you can select metallized fabrics and fibers in various densities and thickness.
Thermal insulation is also made of fiberglass, a type of composite material with a matrix-like structure. Within this matrix, glass fibers are embedded in a resin such as polyester, epoxy, or viny ester. This resin holds the fibers together and, depending on its chemistry, can withstand high heat and even fire. Because glass is a poor conductor of heat, the glass fibers provide thermal insulation.
Ask Elasto Proxy for Thermal Insulation Materials
Elasto Proxy supplies the thermal insulation materials that heavy equipment manufacturers need. We also offer ready-to-install products for thermal management, and custom solutions for application-specific challenges. We can store your materials or finished goods in our warehouses, and Elasto Proxy can kit and package your parts in assembly order.
Ready to learn more? Talk to our team.
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