frame of a tank

Thermal Acoustic Insulation for Military Vehicles

This case study explains how Elasto Proxy applied its expertise in technical design, compound selection, and custom fabrication to replace the thermal and acoustic

Insulation in the engine bays of military vehicles.

When a manufacturer of military vehicles isn’t satisfied with a product design, more than just the bottom line is at stake. For coalition forces in Iraq and Afghanistan, armored fighting vehicles provide mission-critical force protection. Most military observers focus on features like the steel plating and the guns, but this type of vehicle won’t deploy anywhere without a big diesel engine under the hood.

In military vehicles such as armored personnel carriers, diesel engines run hot and loud. Without engine bay insulation, this heat and noise could put both the power plant and military personnel at risk. Thermal-acoustic insulation must also meet flame, smoke, and toxicity (FST) standards. In addition, engine bay insulation must withstand vehicle wash-downs and exposure to detergents and other cleaning chemicals.

Technical Design

Espace de travail

As the manufacturer of military vehicles explained to Elasto Proxy, power washing had become especially problematic. The engine bay insulation, a regular polyurethane foam with a heat-resistant Mylar facing, proved unsuitable for hose downs.

The defense manufacturer wanted to replace this thermal-acoustic insulation, but still needed to meet all of its other application requirements.

That’s when Elasto Proxy’s technical design team applied its expertise in building “insulation sandwiches” from thermal and acoustic materials.

By using foams, fillers or barrier materials, and adhesives, Elasto Proxy can design custom insulation that dissipates heat, quiets noise, and even dampen vibrations. The specialty insulation we can design is ideal for engine bays, but that’s not where our expertise ends. From compound selection to custom fabrication and beyond, Elasto Proxy strengthens the defense supply chain.

Compound Selection

During compound selection, technical buyers and product designers may be challenged by the many different choices for insulating materials.

For example, do you need ether, ester, polyurethane, Triamid, or silicone foam? If so, which grade or type will meet your requirements? With insulation sandwiches, which type of adhesive meets FST requirements and can handle exposure to cleaning chemicals?

In the case of the defense industry manufacturer, Elasto Proxy researched the available materials and recommended a high-temperature silicone foam with acoustical properties. The laminated facing material that we selected was specialized, and resisted engine-cleaning chemicals.

Armed with expert technical design and compound selection, the vehicle manufacturer’s mission now became custom fabrication.

Custom Fabrication

Initially, the military vehicle manufacturer just wanted some sample parts. That’s where Elasto Proxy’s water jet capabilities saved time and money.

Unlike die cutting, water jet cutting doesn’t require metal dies or expensive setup charges. This makes water jet cutting ideal for parts prototyping and low-to-medium volume parts manufacturing.

Water jet cutting is great for rubber and plastic, but also works well with thermal and acoustic foams. The high pressure heads in our water jet machine enable Elasto Proxy’s skilled production personnel to cut multiple sheets or parts at the same time.

Our custom fabrication expertise also extends to adhesive bonding. From insulation sandwiches to taped gaskets, Elasto Proxy supplies sealing and insulation solutions that stick.

Military Experience and Manufacturing Expertise

For over 25 years, Elasto Proxy has supplied North American defense contractors with low-to-medium volume quantities of high-quality rubber and plastic parts. Our first customer, Atlantic Defense Industries, deployed our sealing solutions on the boom hoist for a ten-ton military truck. Since then, Elasto Proxy has won numerous defense-related contracts for projects in Canada and the United States.

As a registered member of Canada’s Controlled Goods Program (CGP), Elasto Proxy meets all requirements for record keeping, training programs, security briefings, and inspections. The Controlled Goods Certificate (CGC) that Elasto Proxy holds demonstrates our commitment to the defense industry, and we work closely with leading trade groups such as the Canadian Association of Defense and Security (CADSI).

Today, Elasto Proxy is a global company with offices and warehouses in Canada and the United States. Our headquarters in Boisbriand, Quebec is also our production facility, a place where highly-skilled personnel combine traditional pride in craftsmanship with state-of-the-art technologies. Facilities in Newmarket, Ontario and Simpsonville, South Carolina strengthen our position in the defense supply chain.

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