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Application Analysis: Employing Microporous Insulation to Reduce the Overall Weight of Necessary Insulation for a Formula 1 Race Vehicle
Formula 1
Proposition:
A Formula One (F1) racing team is looking to decrease the overall weight of their vehicle from 1,165.5 lbs to as close to 1,163 lbs as possible (making their total vehicle weight + 158 lb driver as close to the 1,322 lb minimum as possible). Given, therefore, that the total initial weight for the vehicle is 1,165.5 lbs, and that the desired end weight for the vehicle is 1,163 lbs, a reduction of 1% of the total body weight is required. In order to accomplish this goal, the team has decided to first evaluate their current insulation for the exhaust systems of the vehicle, and wishes to determine if (or how substantial) gains can be made to work toward their goal of overall weight reduction in this area. The team currently utilizes the following types of insulation in the following capacities on their vehicle:
• 4 Piece exhaust manifold heat shield manufactured from 2” thick, 8# density aluminized cloth encapsulated ceramic fiber blanket (5 SF of materials total).
• Various Pipe and Hose wraps/heat shields manufactured from 1/2” thick 13# density aluminized cloth backed ceramic fiber paper (3 SF of material total).
• Currently, the exhaust manifold’s “hot face” temperature is 1,272°F (688°C), and the various pipes and hoses insulated by the ceramic fiber paper operate at mean temperatures of approximately 500°F (260°C).
Primary Goals:
• Reduce the weight of the insulation system by 25%, providing a 1% overall reduction in weight for the vehicle.
• Any weight reductions should not compromise the cold face temperature of the insulation system more than +5°F.
• Any additional space savings made by reducing the thickness of the insulation would be beneficial as well.
Proposals:
By substituting a .75” thickness HyperDyne™ Flexible 16# microporous insulation for the 2” thick ceramic fiber blanket being used on the exhaust manifold, and a .25” thickness of HyperDyne™ Flexible 16# microporous insulation for the 1/2” thick ceramic fiber paper, the overall weight of the insulation system can be reduced to meet the team’s set goals.
Analysis & Comparison:
Exhaust Manifold Insulation
Exhaust and Manifold Insulation chart
Results:
• The HyperDyne™ microporous material reduces the overall weight of the insulation system from a total of 8 #’s to 6 #’s, thus creating a 25% reduction in overall insulation weight for the exhaust manifold system.
• The HyperDyne™ microporous materials produce a cold face consistent to or better than the current ceramic fiber blanket system.
• Utilizing a .75” thickness of HyperDyne™ Flexible 16# microporous insulation provides a 37% reduction in overall insulation thickness over the current 2” 8# material.
Pipe and Hose Installation
Pipe and Hose Installation
Results
The HyperDyne™ microporous material reduces the overall weight of the insulation system from a total of 1.62 #’s to just under 1 #, thus creating a 40% reduction in overall insulation weight for the pipes and hoses.
• The HyperDyne™ microporous materials produce a cold face consistent to or within the stated tolerances of the current system.
• Utilizing a .25” thickness of HyperDyne™ Flexible 16# microporous insulation provides a 50% reduction in overall insulation thickness over the current .5” 13# material.
Summary:
By combining the results of the two comparisons listed above, it can be easily proven that using HyperDyne™ microporous insulation in place of the current insulation systems yields a total weight savings of approximately 2.63 #’s (27% savings) for the insulation systems, and a 1% overall weight reduction for the Formula 1 vehicle operated by the team.
Conclusion:
ThermoDyne’s HyperDyne™ microporous insulation systems are the best solution to the problems associated with the Formula 1 team’s weight challenge. For more information about how ThermoDyne’s HyperDyne™ materials may be of use in your particular race or high performance automotive application, please contact ThermoDyne’s team of Application Engineers toll-free at: 866.741.5458.
Assumptions:
- Calculations assume ambient air temperature to be = 80°F, with natural convection, and using planar geometry consistent with a wall structure.
- Calculations and information provided are for comparison purposes only, and are not intended for design specifications as individual scenarios for material use may vary.
- Calculations assume steady state during points of comparison and analysis.
• Graphic courtesy of Racing One (http://www.Racingone.com)
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