SOLUTIONS - Eagle

Elevate The Driving Experience

Battery Box Fillers

Energy Absorber

Engine Cover

Hose Insulator

Injector Cover

Pump Cover

Transmission Cover

Drive Unit Insulator

AC Compressor Insulator

HVAC Duct Insulator

Center Console

Hood Insulators

NVH
COMFORT
SAFETY
WATER
THERMAL
AESTHETICS
LIGHTWEIGHTING

NVH

Applications: Our polyurethane foam is expertly designed to reduce noise and vibration within automotive systems. By covering loud components, our foam absorbs radiated sound, helping to create a quieter cabin and improve overall vehicle comfort. From engines to HVAC systems, our solutions enhance acoustic performance.

Case Study: ACEC Cover

Challenge: An air conditioning electrical compressor was producing a speed-based broadband noise that required high-performance noise absorption. The existing design was significantly underperforming, leading to excessive cabin and pass-by noise.

Solution: Eagle Industries stepped in to redesign the compressor cover, enhancing noise absorption without increasing costs. We optimized the part by designing it for maximum coverage, reducing potential leak paths. The foam density was carefully selected to target key frequencies where noise was most problematic.

Outcome: The newly designed cover achieved a 10 dB SPL reduction at critical frequencies, significantly outperforming the previous design across all frequency ranges, resulting in a quieter and more comfortable vehicle cabin.

COMFORT

Applications: We use our foam technology to enhance comfort in vehicle interiors. Ideal for center consoles and armrests, our foam provides the perfect balance of cushioning and durability. These applications improve the driving experience by ensuring superior softness and support, creating a more comfortable environment for passengers.

SAFETY

Applications: In the realm of safety, our foam solutions play a critical role in energy absorption during crashes. Commonly used in areas like door bolsters, our polyurethane foam is engineered to mitigate impact forces, helping protect passengers by dissipating crash energy efficiently.

Case Study: Door Bolster

WATER

Applications: Our foam solutions provide an effective means of shedding water from critical areas in vehicles. By guiding water away from sensitive electrical components, such as the top of the engine, our foam helps prevent water intrusion, safeguarding vital systems from potential damage.

Case Study: Engine Cover

THERMAL

Applications: Polyurethane foam offers superior thermal insulation, making it ideal for managing heat within various automotive systems. Our foam is used to insulate components, helping to control temperatures and enhance performance in applications where thermal regulation is essential.

Case Study: HVAC Duct Cover

Challenge: Heat radiating from HVAC ducts running through the center console was causing the cup holders and storage compartments to become uncomfortably hot. With the issue identified late in vehicle development, there was very limited space to implement a solution.

Solution: Eagle Industries developed a cast polyurethane foam system specifically designed to minimize heat transfer through the duct walls. This compact solution fit within the constrained package space while effectively insulating the center console components.

Outcome: The polyurethane foam system reduced the overall temperature of the cup holders and storage area by 20°F, ensuring a more comfortable and user-friendly experience for passengers without compromising the vehicle’s design constraints.

AESTHETICS

Applications: Our foam can be processed to achieve a Class A surface, making it a versatile solution for aesthetic enhancements. One prime example is engine covers, where our foam not only provides functionality but also meets the high visual standards required for exposed vehicle components.

LIGHTWEIGHTING

Applications: In pursuit of lighter vehicles and improved fuel efficiency, our foam serves as a lightweight alternative to solid, high-density components. This foam technology reduces overall weight without compromising strength or performance, helping manufacturers meet stringent weight reduction targets.

Case Study: Battery Box Fillers

Challenge: Non-modular electric vehicle batteries require high-density potting material to cover the cells and prevent moisture contamination. However, the potting material is both heavy and costly, impacting overall vehicle weight and production expenses.

Solution: Eagle Industries identified a specialized foam system that could be used to create offset fillers within the battery box, specifically in areas where potting material wasn’t necessary. By strategically placing foam fillers, the overall volume of potting material required was significantly reduced.

Outcome: This solution effectively decreased both the weight and cost of the battery system, contributing to improved vehicle efficiency without compromising the protective qualities of the potting material.