High level temperature-management in the exhaust tract with WDS®


WDS® Flexible Contour

The automotive industry is permanently looking for possibilities to offer to its customers more engine power, driving pleasure, comfort and space. In Contrary to this the legislator is asking for vehicles with less fuel consumption and lower emissions.
All that is asked to be realized without a significant increase of weight and the dimensions of the engine- resp. exhaust system.

Due to the limited available space, the increasing use of plastics and the constantly rising temperatures at the exhaust tract and the engine compartment an effective temperature management becomes more and more important.

In the engine compartment temperatures of more than 200°C are not unusual and considerably affect the function of important parts, like for example battery, starter, electronic motor management and -control as well as components of the air conditioning system.
The use of heat shields creates an increased effort for the construction, increases the part variety, repair sensitivity and not least the cost.

WDS® in manifolds and catalytic convertersIn the exhaust tract, temperatures of up to 900°C represent a genuine challenge for most insulating materials. Ideally, these temperatures should not be lost in the system and should arrive as fast as possible at the catalytic converter, in order to make a fast light off possible. Apart from the pure thermal resistance also a high thermal insulation in this temperature range is necessary.

WDS® in comparison

While some conventional insulation like e.g. silica fibers, textile glass fibers, mineral wool or ceramic fiber mats withstand the very high temperatures at the exhaust tract, the insulation properties are 3- to 4-times worse compared to WDS® Flexible.

No comparable product offers better thermal insulation properties in the relevant temperature range than WDS® Flexible.

Therefore clearly slimmer insulations can be realized with WDS®. Already an insulation thickness of 3 – 4 mm substantially reduces the surface temperature of the parts and temperature management to the CAT or DPF (diesel particle filter) is effectively stabilized.
Beside the thermal properties, WDS® Flexible also slightly improves the acoustic characteristics in double-wall systems and thus offers a further benefit.

Application of WDS®

WDS® Flexible Contour between 2 half shell

Porextherms WDS® - products for the automotive industry offer the ideal solution for a highly effective thermal insulation of exhaust systems in the area of manifolds, entry- and exit-cones of catalytic converters (CAT) as well as for diesel particle filters (DPF).

Further applications in the area of fuel cells, latent heat storage and bearing mats for catalytic converters are intensively under development.

Particularly for these applications, Porextherm offers the products WDS® Flexible Kontur and WDS® Flexible Design.
In most cases, the microporous insulation is integrated positive locked into the gap between two half shells. The insulation completely follows the three-dimensional form of the shells. Thus almost all geometrical forms can be represented.
WDS® Flexible is supplied with different coatings that guarantee a trouble-free installation and welding of the parts. The coating dissolves completely during process.

The advantages at a glance

  • 3-4 times better insulation than conventional product for exhaust systems
  • reduces surface temperature dramatically
  • reduces the insulation thicknesses and thus the thickness and/or size of the construction
  • high pressure resistance, therefore forming integrated in a sandwich system possible
  • high weight savings
  • vibration resistant
  • not flammable
  • improves the acoustic characteristics
  • reduces the design cost
  • reduces part variety – e.g. no heat shield necessary
  • almost all forms can be realized individually
  • simple and clean handling and processing
  • environment-friendly
  • recyclable


WDS® Flexible Contour
WDS® Flexible Design
WDS® Flexible Design-AL