How to Choose the Right Thermal Insulation for Your Application

Thermal protective sleeving is frequently used to provide proper thermal protection to wiring and cabling in a variety of applications including Battery Protection, Aerospace / Defense, Automotive, RAIL, Commercial Vehicles, Heavy Equipment / Industrial, and Electronics / Machinery. Selecting the right sleeving for your application is critical to ensuring safety and extending the useful life of your wire or cabling.

So what specifications are most important to consider when choosing a thermal insulation product? Let’s get into it.

Protection Type

There are several types of thermal insulation products available and depending on your application, one is likely to be best suited for the job.

Radiant

This type of thermal insulation reflects heat from nearby heat sources. It’s typically used in automotive, heavy duty trucks, heavy equipment, off-road and aviation applications.

Convective

This type of thermal insulation provides protection against heat transferred from air or fluid. It’s typically used in engine compartment applications, wire harnesses, brake lines and fuel lines.

Thermal Containment

This type of thermal insulation is used to keep heat contained within a system. It’s typically used on exhaust systems.

Flame Protection

This type of thermal insulation provides a protective barrier against molten splash and welding sparks. It’s typically used on busbars, hydraulic hoses, and steel cables.

Dialectic Resistance

This type of thermal insulation is used to protect electrical components It’s typically used in EV applications to insulate busbars.

Many thermal insulation sleeving options offer two or more or these types of protection in the same product so you can choose the protection combination that is the best choice for your specific application requirements.

Temperature Rating

Thermal protective sleeving is available with temperature ratings from as low as 150°C up to +2000°C. You want to be sure to select the product that is rated to handle the environment where you will be installing it. Check the manufacturer component specifications to determine max temperatures or conduct your own temperature measurements of the components in operation with an infrared thermometer.

Alternatively, you can rely on industry standards to help you determine a temperature rating for your application.

Certifications

In addition to temperature rating and type of thermal protection, you’ll also need to consider industry specific requirements and certifications.

For instance, Therm-L-Wrap™ and Therm-L-Wrap™ 66 are both rated to provide operating temperature protection up to +200°C (+392°F) and both provide radiant and convective heat protection. However, only Therm-L-Wrap™ 66 provides Flammability / Smoke Density / Toxicity protection to meet FAR Part 25.853 standards. So, it can be used on an aircraft or in defense applications.

Therm L Wrap does not meet that standard so it can not be used in aerospace or defense applications but it can be used on anything else, like an engine compartment of a car, motorcycle, dune buggy, etc.

Material

Thermal insulation products are available in a variety of materials and material combinations that can improve the overall protection the sleeving offers. Products made from basalt yarns, for example, offer a high degree of thermal protection while also maintaining extreme flexibility. Silicone or rubber coated fiberglass provides thermal protection via the fiberglass layer but adds in resistance to chemicals, abrasion, and puncture with the outer layer. An outer layer of Aluminum can be used on top of a fiberglass base to withstand convective heat soaks up to 200ºC and simultaneously protect critical components from radiant or reflected heat.

Count on the Experts at Titan Electronics

No matter the application you need thermal protection for, you can count on the experts at Titan Electronics to guide you to the best product for your specific requirements. We stock industry-leading options from Systems Protection including the Therm-L-Wrap™, Fyrejacket®, and ROUNDIT® families of products and more. Reach out to our product specialists today at (866)956-8323 or complete our contact form and we’ll reach out to you.

About The Author

Joe Wigginton is a seasoned Sales Manager with a rich background in the aerospace and defense industries. With over 20 years of experience in the cable and cable protection sector, Joe initially served as a manufacturers' representative for 5 years before taking the entrepreneurial route. For the past 15 years, he has successfully owned and operated a business dedicated to supporting customers with top-quality products and solutions.

Beyond his professional achievements, Joe has traveled extensively worldwide to forge meaningful relationships and source the best products to meet our customers' needs. His global perspective and commitment to excellence make him a valuable asset to our team and clients alike.