ElroTherm™ shielding systems.
Thermal and acoustic management for the entire vehicle.
Experience mobility – Drive the future.
The ElringKlinger Group.
Whether it is a matter of improving the combustion engine or developing e-mobility, ElringKlinger
is one of just a few automotive suppliers with the necessary expertise to provide customized product
solutions and engineering services for the drive technologies of the future. We are a development
partner and series supplier to almost all vehicle and engine manufacturers around the globe. At the
same time, we are channeling our innovative strengths into shaping eco-friendly mobility of the
future.
CONTENTS
04
The ElringKlinger Group
07
ElroTherm™ shielding systems
08
New challenges
12
ElroTherm™ Light
13
ElroTherm™ D and PF
14
ElroTherm™ Acoustic
15
ElroTherm™ ML and SL
16
ElroTherm™ Flex
17
Shielding systems with additional functions
18
Nine ElroTherm™ systems
20
Engineering
23
Expertise
03
ElringKlinger worldwide.
North America
C ANADA
Leamington
USA
Plymouth
Buford
Austin
South America
ME XICO
BR A ZIL
Toluca
Piracicaba
Cylinder-head
gaskets
04
Specialty gaskets
Plastic oil suction
modules
Plastic oil pans
Topographic housing
modules
Underbody shielding
parts
Engine shielding
parts
Europe
GERMANY
G R E AT B R I TA I N
S PA I N
Dettingen/Erms
Langenzenn
Runkel
Geretsried-Gelting
Thale
Bietigheim-Bissingen
Heidenheim
Idstein
Rottenburg am Neckar
Magdeburg
Lenningen
Redcar
Gateshead
Reus
I TA LY
FR ANCE
Nantiat
Chamborêt
Poissy
Settimo Torinese
Milan
HUNGARY
Kecskemét-Kádafalva
SWITZERL AND
Sevelen
Elsau
ROMANIA
NETHERL ANDS
TURKEY
Enschede
Bursa
Timisoara
Asia
PR CHINA
Changchun
Suzhou
Qingdao
S O U T H KO R E A
Changwon
Seoul
J A PA N
Tokyo
Saitama
Africa A F R I K A
INDIA
Ranjangaon
SOUTH AFRIC A
Johannesburg
INDONESIA
Karawang
THAIL AND
Bangkok
Transmission control
plates
Exhaust gas
purification systems
Components for
lithium-ion batteries
Bipolar plates for
fuel cells
PTFE components
Engine development
services
Tooling technology
05
06
ElroTherm™shielding systems.
Protective shields against heat and noise.
The areas of a vehicle that develop high temperatures call for an
effective thermal shielding solution. In addition, noise protection standards are becoming more and more demanding. In its
capacity as technology leader and major supplier of shielding
parts, ElringKlinger always has the right solution to meet any
challenge within these areas. We develop sophisticated shielding solutions designed to help bring vehicles in line with increasingly stringent legal requirements worldwide.
ElringKlinger has established a global presence, with local production facilities in all key automobile markets. International
quality and manufacturing standards guarantee best-in-class
technology and products. Our local presence – and thus the geographical proximity to our customers – facilitates short channels
of communication, which in turn provides perfect conditions for
project management. Numerous locations have resources in application development, while research and basic development
take place at our technological center of excellence in Germany,
thus safeguarding our corporate know-how.
Shielding system for underbody
Fully recyclable, micro-perforated
underbody shielding
Underbody shielding with multi-layer
insulation packing
Shielding system for underbody,
1.50 m long
07
New challenges.
Intelligent solutions.
The management of temperatures in modern vehicles is becoming increasingly complex. Tightly packed components, engine
encapsulation, minimal cooling air flows, catalytic converter
technology and exhaust gas turbochargers result in high temperatures in the engine compartment, across the exhaust system
and within the area of the underbody. At the same time, there
are a growing number of temperature-sensitive components
that have to be protected from heat. The demands on shielding technology have been increasing along with the number of
applications. Thermal and acoustic shielding systems help engine and exhaust systems to function safely and reliably. In the
process, they also contribute to enhanced driving comfort and
environmental protection.
08
09
Engine encapsulation
Direct shielding for oxidation
catalytic converter
Catalytic converter encapsulation with
ElroTherm™ D
Intelligent temperature management is playing an increasingly
crucial role in modern motor vehicles. Heat-sensitive components have to be protected, but at the same time, the exhaust
gas temperature must be prevented from decreasing too sharply. This is because optimum exhaust gas aftertreatment that
guarantees complete removal or neutralizing of the pollutants
in the exhaust gases depends on having a reaction temperature
that is as high as possible. In addition, this also cuts cold start
phases and the engine reaches its optimum operating temperature sooner, saving fuel and reducing emissions.
By sheathing engines with ElroTherm™ shielding systems, it
is possible to meet these two heat management requirements.
Thanks to a cleverly devised material combination and a design
tailored to the application, ElroTherm™ engine encapsulations
represent an efficient and reliable solution to thermal management. Moreover, they make a significant contribution to environmentally friendly and fuel-efficient driving. Other benefits of
engine encapsulation are that noise is reduced and acoustics
systematically controlled.
10
Lightweight construction
Highly efficient underbody shielding
in ElroTherm™ Light 600
Lightweight underbody shielding with
optimized material thickness
Acoustics
Acoustically effective exhaust
manifold shielding
Underbody shielding with highly
effective absorber system
Opting for specific materials can reduce the weight of compo-
Modern exhaust systems and vehicle underbodies increasingly
nents. This makes cars lighter and more fuel-efficient. Lower
call for combined systems that not only protect from heat but
fuel consumption also means fewer emissions. In addition, the
also absorb noise.
manufacturing processes consume less raw materials.
For example, ElringKlinger shielding components ElroTherm™
In ElroTherm Light and ElroTherm D, ElringKlinger is offering
Acoustic and ElroTherm™ D for exhaust manifolds and turbo-
highly efficient lightweight solutions for all applications, even
chargers. These models reduce heat loss and therefore ensure
where very high temperatures are involved. This is made possible
that the high temperatures at which the catalytic converter
by innovative composite materials.
works best are reached as quickly as possible in the exhaust
™
™
gas zone. At the same time, they protect heat-sensitive parts in
One key area of focus in ElringKlinger’s development efforts is
the vicinity from excessive heat exposure and absorb the noise
lightweight design for exhaust gas systems, underbodies and
generated by the vibrations of add-on components. The result:
engine-level protection systems. Through its specific use of thin,
the vehicle is quieter.
low-density materials, ElringKlinger is making an active contribution to conserving resources and protecting the environment.
Incidentally, these combined systems are of course just as durable in the long term as all other ElringKlinger shielding systems.
11
ElroTherm™ Light
E L R O T H E R M ™ L I G H T 11 0 0
ELROTHERM™ LIGHT 60 0
PROPERTIES
PROPERTIES
▪
▪
▪
▪
▪
▪
▪
▪
Average thermal shielding effect of 93%
Materials joined by flanging the edges
Weight reduction through use of particularly thin materials
Use of stainless steel allows protection against extremely
high temperatures
Excellent thermal insulation
Very high emissivity
Lightweight construction
100% recyclable without prior treatment
MAT E R I A L ST R U CTU RE
MATERIAL STRUCTURE
ElroTherm™ Light 1100
Multi-layer system in minimal material thicknesses
ElroTherm™ Light 600
Insulating layer, multi-layer, with specialty foils
INTERMEDIATE LAYER MADE
OF INSULATING MATERIAL
FLANGING
FOIL THICKNESS
0,02 - 0,05 mm
COVER MATERIAL MADE OF METAL
(PREFERABLY STAINLESS STEEL)
THICKNESS 0.1 – 0.2 MM
12
COVER MATERIAL MADE OF METAL
(PREFERABLY ALUMINUM)
Thickness 0.1 – 0.5 mm
MAX. 8 LAYERS
Composite thickness:
6,8 - 9 mm
A P P L I C AT I O N S
A P P L I C AT I O N S
High-temperature applications and applications requiring
weight reduction due to dynamic characteristics.
Ideal for demanding use in underbody or large visible areas
in the wider engine environment.
W O R K I N G T E M P E R AT U R E
W O R K I N G T E M P E R AT U R E
Maximum 1100 °C
Maximum 600 °C
ElroTherm™ D und PF
E L ROT H E R M ™ D
ELROTHERM ™ PF
PROPERTIES
PROPERTIES
▪ Average thermal shielding effect of 93%
▪ Extremely light, highly efficient thermal protection
▪ Silicate nonwoven allows direct contact with surface of
components to be protected
▪ Optimum acoustic absorption regarding components
exposed to high temperatures
▪ Very good thermal insulation
▪ Lightweight construction and excellent formability
▪ Specific material pre-treatment results in high damping
values
▪ Especially suitable for small- and medium-volume
production
MAT E R I A L ST R U CTU RE
MATERIAL STRUCTURE
ElroTherm™ D (D = Direct shielding)
ElroTherm™ PF (PF = Proform)
ELROTHERM™ SILICATE
FIBER MATERIAL
Composite thickness:
3 - 25 mm
COVER MATERIAL MADE OF METAL:
Thickness: 0,1 - 0,5 mm
METALLIC
REFLECTION LAYER
INTERMEDIATE LAYER
IN INSULATING MATERIAL
A P P L I C AT I O N S
A P P L I C AT I O N S
For demanding fields of application with regard to thermal
and acoustic management, as well as in areas in which system temperatures have to be maintained at a constant level.
For applications requiring complex molded components
with reduced material thicknesses as well as components
requiring a high-quality appearance due to their visibility
when installed.
W O R K I N G T E M P E R AT U R E
W O R K I N G T E M P E R AT U R E
Maximum 1100 °C
Maximum 1100 °C
13
ElroTherm™ Acoustic
E L R O T H E R M ™ A C O U S T I C 11 0 0
ELROTHER M™ ACOUS TIC 6 0 0
PROPERTIES
PROPERTIES
ML (multi-layer) structure with a highly heat resistant and
acoustically highly effective inner layer.
ML (multi-layer) structure with a carrier plate and highly
effective absorber system.
▪
▪
▪
▪
▪ Combines good thermal insulation with highly efficient
acoustic shielding
▪ A micro-perforated aluminum foil protects the absorber
▪ No ingress of dirt and moisture
▪ Choice of absorber material depending on thermal
requirements, e.g. ElroTherm™ F (Foam) or ElroTherm™
Average thermal shielding effect of 93%
Very good sound absorption
High damping of structure-borne noise
Thermal protection function at high temperatures
V (Vlies = German for nonwovens)
MAT E R I A L ST R U CTU RE
MATERIAL STRUCTURE
ElroTherm™ Acoustic 1100
Multi-layer, with specially perforated inner layer
ElroTherm™ Acoustic 600
Multi-layer, with highly effective absorber
COVER MATERIAL MADE
OF PERFORATED METAL
(PREFERABLY STAINLESS
STEEL)
Thickness: 0,2 - 0,8 mm
14
COVER FOIL
Thickness:
0,05 mm
COVER MATERIAL
MADE OF DIMPLED
METAL
Thickness: 0,3 - 0,8 mm
ELOTHERM ™ -SILICATE
FIBER MATERIAL
Composite thickness:
3 - 25 mm
HOLE-PUNCHED (Ø 4 MM),
DIMPLED CARRIER PLATE
Thickness: 0,3 - 1,0 mm
MICRO-PERFORATED
MEMBRANE FOIL
Thickness: 0,05 mm
ABSORBER
A P P L I C AT I O N S
A P P L I C AT I O N S
For stringent requirements relating to heat and noise
management, specially developed for the area around the
engine.
Highly efficient acoustic management with excellent temperature shielding.
W O R K I N G T E M P E R AT U R E
W O R K I N G T E M P E R AT U R E
Maximum 1100 °C
Maximum 600 °C
ElroTherm™ ML und SL
E L ROT H E R M ™ M L
ELROTHERM ™ S L
PROPERTIES
PROPERTIES
▪ Average thermal shielding effect of 93%
▪ Materials joined by flanging the edges
▪ Combines high drawability in manufacture with good
thermal and acoustic insulating properties
▪ Average thermal shielding effect of 85%
▪ Low manufacturing cost
▪ Special dimpled structure of material minimizes risk of
structure-borne noise generation and increases component stiffness, i.e. weight reduction potential through
material savings
▪ With safety edge
M AT E R I A L S T R U C T U R E
M AT E R I A L S T R U C T U R E
ElroTherm™ ML
(multi layer = mehrlagig)
ElroTherm™ SL
(single-layer)
FLANGING
INTERMEDIATE LAYER MADE OF
INSULATING MATERIAL
COVER MATERIAL MADE
OF METAL
Thickness: 0,3 - 0,8 mm
SAFETY EDGE
SINGLE-LAYER
METAL
Thickness: 0,3 - 0,8 mm
A P P L I C AT I O N S
A P P L I C AT I O N S
This material combination can be used for a wide range of
applications.
Primarily used in areas where there is little need for thermal
shielding and in low-temperature applications such as the
underbody.
W O R K I N G T E M P E R AT U R E
W O R K I N G T E M P E R AT U R E
Maximum 1100 °C
Maximum 1100 °C
15
ElroTherm™ Flex
ElroTherm™ UB
ELROTHERM™ FLE X
ELROTHERM™ UB
PROPERTIES
PROPERTIES
▪ Average thermal shielding effect of 92%
▪ Fiberglass mat with vacuum-metalized coating allows
direct contact with component surface
▪ Optimum offsetting of positional variations
▪ Direct protection of temperature-sensitive components
such as cables
▪ Modular design allows system to be used in
other engine models
▪ High level of rigidity and stability
▪ Long service life
▪ Easy to install and remove
▪ Maintenance-friendly design
▪ No molding tools necessary
M AT E R I A L S T R U C T U R E
MATERIAL STRUCTURE
ElroTherm™ Flex
Multi-layer, with fiberglass mat
ElroTherm™ UB (UB = UniBox)
Multi-layer, with nonwoven
INTERMEDIATE FLEECE
LAYER
Gauge: 3 - 20 mm
Seal: 130 - 200 kg/m 3
METALLIC
REFLECTIVE LAYER
FIBERGLASS MAT
EXTERNAL MATERIAL
PRIMARILY STAINLESS STEEL
(1.4301)
Gauge: 1.5 mm
INTERNAL CASING
PRIMARILY STAINLESS STEEL
(1.4301)
Gauge: 0.5 mm
A P P L I C AT I O N S
A P P L I C AT I O N S
For perfect shielding directly on the component to be protected. Also as extra protection or in combination with other
ElroTherm™ products.
Meets highly exacting requirements for durability,
ruggedness and temperature management, specially
developed for complete encapsulation of units on large
engines (e.g. marine diesel engines).
W O R K I N G T E M P E R AT U R E
Maximum 480 °C
W O R K I N G T E M P E R AT U R E
Maximum 1100°C
16
WELDED CLEAT
Extras included.
Shielding systems with additional functions.
A growing trend in modern vehicle and engine development is
THE ADVAN TAGES
to combine various individual components and functions into
one unit, the aim being to make the best possible use of the lim-
▪ Integration of separate components into one system
ited space available due to the tight packaging of engine com-
▪ Reduced development times and costs due to simultaneous
ponents. ElringKlinger offers innovative shielding systems that
engineering of all components
integrate numerous add-on functions. For example, they can
▪ Simplified logistics due to smaller number of add-on parts
incorporate gaskets, cable clips and fastening and connecting
▪ Shorter assembly time
elements to create compact functional units.
▪ Good cost efficiency
▪ 100% function and quality controls
Shielding component with integrated
fasteners for an air cooler module
Turbocharger shielding with
integrated gasket
Spare wheel shielding with
integrated bracket
Catalytic converter shielding against
engine block with integrated gasket
Shielding with integrated
anti-vibration elements
Shielding with integrated
cable conduit
17
Nine ElroTherm™ systems.
Always a matching solution.
The ElroTherm™ product range now includes nine system variants in different material combinations. These form the basis
for custom-engineered shielding solutions for the entire vehicle.
The model used will depend on the specific requirements for
heat and noise protection and on the design, while materials
and shape are always optimally tailored to the respective application location.
Comparison of ElroTherm™ shielding systems
Temperature
shielding
Noise
reduction
Weight
reduction
Durability
Recyclability
Cost efficiency
+ + +
+ +
+ + +
+ + +
+ +
+
+
+ +
+ + +
+ + +
+ + +
+ + +
+ + +
+ + +
+ + +
+ +
+
+
E L ROT HERM ™ P F
+ + +
+ +
+
+ +
+ +
+
E L ROT HERM ™ ACO U STI C 1100
+ + +
+ + +
+
+ + +
+
+
+ +
+ + +
+ +
+ +
+ +
+ +
+ + +
+ +
+ +
+
+ +
+ +
E L ROT HERM ™ SL
+
+
+
+ +
+ + +
+ + +
E L ROT HERM ™ FLEX
+
+ +
+ +
+ +
+
+
E LROT HE RM ™ LIGHT 1100
E L ROT HERM ™ LIGHT 600
E L ROT HERM
™
E L ROT HERM
™
ACO U STI C 600
E L ROT HERM
™
ML
+ + + very good
18
D
+ + good
+ adequate
ElroTherm™ Light 1100
ElroTherm™ Light 600
ElroTherm™ D
ElroTherm™ PF
ElroTherm™ Acoustic 1100
ElroTherm™ Acoustic 600
ElroTherm™ ML
ElroTherm™ SL
ElroTherm™ Flex
19
Engineering.
Thinking ahead.
Development cycles are getting shorter and shorter, while the
challenges are greater than ever before. Nowadays, increasingly
complex scenarios call for an all-embracing approach. This is
why ElringKlinger places particular emphasis on short lines of
communication and integrated processes. Within this context,
our focus is on pooling our company’s decades of experience at
a center of excellence for thermal and acoustic shielding technology.
Cutting-edge development tools allow us to create integrated
system solutions precisely matched to a specific set of requirements from a technical, economic and ecological viewpoint.
From design to testing, and from prototype to production
launch, our specialists are committed to developing new technologies and innovative product solutions for future generations
of vehicle – in close consultation with our customers around
the globe. By collaborating with the central R&D services of the
ElringKlinger Group, we are able to create synergy and benefit
from a wealth of technological expertise and interdisciplinary
know-how.
20
FEM
Acoustic simulation
Thermal shielding components undergo their first stress test
Even before the prototype manufacturing stage, we take ac-
in the very early phase of their development. We even test
count of all conditions that might occur in the finished shield-
the first design layout for its everyday suitability and use
ing system and its environment, for example by simulating
the Finite Element Method (FEM) and computer software to
resonance frequencies and their modes. Further simulations
simulate the subsequent application and identify where the
and calculations supply information about the acoustic behav-
component is subject to particular stresses. This then gives
ior, sound pressure distribution and expected sound power of
an approximate indication of where and how to provide rein-
the shielding system.
forcement in the design under given conditions, the aim being
to achieve the greatest possible component stiffness. Based
In support of these procedures, specialist optimization soft-
on these results, we optimize the shape, surface topology and
ware is used for the purpose of determining the components’
connections and then transpose them to a CAD model.
topography.
21
Air flow and temperature
simulation
Metal-forming simulation
The shielding part achieves good thermal insulation by re-
Forward-thinking engineering is an absolute must for stream-
flecting as much heat as possible and letting through as little
lined manufacturing at consistent quality levels. Before ap-
heat as possible. Within this context, the choice and applica-
proving the part for production, therefore, we optimize all
tion of suitable materials are of major importance. However,
manufacturing steps with the help of simulations. Nothing
even more crucial with regard to the insulating effect are the
that might potentially affect the project execution and subse-
thermal dynamics of the entire system, as the air flows of heat
quent launch of serial production is left to chance, including
source and shielding parts have a mutual impact. It is impor-
specific optimization of the costs of tools for mass production.
tant to understand this interaction and incorporate it into the
design.
Our development engineers simulate the air flows of all components at every stage in the development of the shielding
system. Using Ansys simulation software, they can investigate the air flow in detail, simulate the temperatures to which
the individual parts are likely to be exposed and thus tailor
and design the shielding parts to match the specific circumstances.
22
Expertise.
For the entire system.
For ElringKlinger, supplier performance means offering reliable solutions from a single source. From
development, production and pre-assembly of add-ons to automated function and quality control
and just-in-sequence delivery of ready-to-install shielding systems to our customers’ assembly lines.
We produce ElroTherm™ shielding systems in state-of-the-art assembly cells and manufacturing
centers – fast, cost-efficiently and in premium quality. Fully automated press lines and twenty robotassisted processes facilitate particularly efficient manufacturing in small and large volumes, with
camera systems performing online quality checks during production.
We have ISO/TS 16949, ISO 14001 and ISO 9001 certified production facilities at numerous locations
around the globe, allowing us to cater for customer requirements directly at local level. The advantages: clear chains of responsibility, speed, flexibility, top quality and all-round service. Worldwide.
W W W. E L R I N G K L I N G E R . C O M
HOCHBURG.NET
ElringKlinger AG
Max-Eyth-Straße 2
72581 Dettingen/Erms, Germany
Phone +49 7123 724-0
Fax +49 7123 724-9006
E-mail [email protected]
SHIELDING TECHNOLOGY DIVISION
ElringKlinger AG
Langenzenn Plant
Nürnberger Straße 2
90579 Langenzenn, Germany
ElringKlinger Abschirmtechnik (Schweiz) AG
Phone +49 9101 606-111
Fax +49 9101 606-114
E-mail [email protected]
Phone +41 81 750 12-10
Fax +41 81 750 12-25
E-mail [email protected]
www.elringklinger.com
www.elringklinger.ch
09/11
Schildstraße 20
9475 Sevelen, Switzerland
The information provided in this brochure is the result of technological analyses and may be subject to changes depending on the design of the system. We reserve the right to make technical changes and
improvements. The information is not binding and does not represent warranted characteristics. We do not recognize any claims for compensation based on this information. We accept no liability for printing errors.