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Blueshift (Spencer, Mass., U.S.) introduces  (FTBs), a portfolio of ultra-thin, lightweight and flexible flame and thermal material solutions that can withstand exposure up to 1200°C for 30 minutes. The company’s family of thermal protection systems (TPS) can be “can be applied to various surfaces, including carbon fiber composites,” according to the company. AeroZero FTB in particular is especially applicable for composite applications in the aerospace and defense industries, including eVTOLS.

With the continuing global adoption of electric vehicles (EVs) and aerospace electrification, Blueshift’s latest addition to its AeroZero family is ideal for a wide range of applications and industries that may experience extreme temperature fluctuations — from EVs and aerospace markets to marine and rail.

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For example, within the field of EVs, FTBs are primarily used as a safety barrier material aimed at preventing the transfer of extreme heat or fire that can result in mechanical damage of battery cells and exposure to high temperatures or discharge events. Blueshift’s AeroZero FTBs can withstand exposure up to 1200°C for 30 minutes while maintaining a cold-side temperature below 300°C. This means they may either be used as safety features in preventing uncontrolled fire, for example, due to an aircraft engine fire, or protecting surfaces from direct exposure to flame such as during a rocket takeoff or helping to mitigate the risk of a battery thermal runaway event.

Outperforming traditional mica, silica or polyurethane foams, AeroZero FTBs are up to 80% lighter, with a thickness range of 0.32-1.77 mm — significantly thinner than conventional barriers (3-10 mm). Alongside this, their ease-of-use and flexibility is a key factor in their application; with their “peel-and-stick” pressure sensitive adhesives (PSA) backing that simplifies installation on irregular surfaces, labor time and cost can be reduced.

“Traditional thermal insulators have often been based on polymeric foams or ceramic blankets that can suffer from drawbacks due to their added weight, thickness, toxic off-gassing, lack of flexibility and processing issues,” says Tim Burbey, Blueshift president. “Available across multiple ranges, we look to incorporate as many vehicles and industries as possible, so everyone can overcome their unique thermal challenges.”

The AeroZero FTBs family includes, AZ-FTB 100 for up to 500°C applications; AZ-FTB 101 for up to 800°C; and AZ-FTB 300 for maximum protection up to 1200°C. These advanced FTBs are ideal for protection in EV battery modules, and aerospace components that see indirect and direct exposure to flames.