Insulation blankets have generally been considered a somewhat mundane, but necessary part of many engine applications. The concept was simple; part of the engine was hot, the manufacturer didn't want somebody leaning on it and getting burned, so a blanket was put over the hot spot.
The marine market probably was a leader, given the presence of hot engines in cramped quarters that still required mechanics and operators to have access to all the nooks and crannies. There were also operational considerations in on- and off-highway equipment, such as an engine hot spot being exposed to engine or hydraulic fluids or a dirty operating environment and the resulting risk of fire.
As a result, engine insulation blankets have been an accepted component in almost types of engines and equipment for many years. In on-highway, off-highway, stationary or marine uses, you usually find an insulation blanket or cover somewhere on the engine.
But now, in an emissions-regulated environment where heat and noise are significant design problem as well as an operational concern, insulation blankets are moving from safety-only towards potentially adding value in terms of engine performance, fuel economy, possibly emissions and even noise reduction.
Some of this has developed out of the aerospace and industrial gas turbine markets where insulation blankets also have a long history and are seen more as an engineered product than an add-on piece and are credited with improvements in fuel economy and performance.
"In most uses, insulation blankets are typically brought into the picture when there's a problem," said David Buckett, vice president and general manager, Thermal Structures Inc. Thermal Structures, Corona, Calif., has been a supplier to the aerospace markets, "It's the foundation of our business," he said.
Thermal Structures' history in the diesel engine markets dates from manufacturing insulation blankets for the transit market, specifically manifold, exhaust and turbocharger blankets for buses, as well as for electrical power generation packages. Today the company is seeing increasing interest from a broader range of diesel, natural gas and gasoline engine and equipment markets.
"Blankets are usually an afterthought," Buckett said. "Typically an engine system is developed and installed in the equipment, and then something happens. Maybe it's in the engine compartment where the components can't easily be modified or changed. Maybe the turbo is too close to something, or maybe another component is not reacting well to the ambient heat.
"An insulation blanket or cover is the usual solution," Buckett said. "And this is only going to increase as exhaust emissions regulations tighten and engines run hotter. The problem is we don't get involved until it's too late, after it's become a problem, when it could have been done be as an engineered solution.
"That's the approach we're taking to the industrial markets, as we did with aerospace, of providing solutions to both heat and acoustical problems with engine-powered equipment," he said.
Thermal Structures offers a range of custom-designed metal foil and fabric insulation systems, nonmetallic fire shields, silicone seals, composite insulation systems and metal heat shields.
Applications include external thermal blankets, internal engine insulation, ducting insulation, exhaust system insulation and turbocharger covers. Where Thermal Structures differs somewhat is that it also supplies firewall insulation and is very active in noise reduction, with sound suppression products such as insulated ducting systems, interior noise reduction components and wall and ceiling panels. Thus, Buckett said, the company is in the somewhat unique position of being able to address noise or heat concerns.
"We're focusing our resources in engineering and product development at providing solutions for both heat and noise," Buckett said. He outlined a number of recent projects where Thermal Structures has done a complete thermal profile of the engine system as well as looking at the vibration involved and the operating environment of the equipment before selecting the materials. He added that the company has also recently worked with a number of diesel aftertreatment manufacturers in engineering both sound and heat products into those developing systems.
Thermal Structures has nearly 250 materials, mostly ceramic-based in its system. Outer covers are mostly 300 series stainless, with an increasing interest in both Inconel for higher temperature applications and aluminum for lower temperature uses.
"Sometimes there is a preconceived notion that the metal cover is the blanket," Buckett said. "The real key is the insulation under the metal cover. The idea, if we're in the loop early enough, is to select the right materials and develop a noise or heat blanket for the specific application."
Thermal Structures is a completely captive manufacturing operation with facilities in California and New Mexico totaling over 140,000 sq.ft. The main plant in Corona, west of Los Angeles, has been specifically designed for a wide range of materials and product lines.
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