All-terrain vehicles (ATVs) are built to handle rugged terrain and the most demanding environments while maintaining high performance. However, these harsh conditions can create tough challenges for engineers to address as they look for ways to meet rider needs and improve overall performance.
Extreme heat, constant vibrations, heavy impacts, and excessive noise are among the challenges that could impact the vehicle and the rider.
Still, manufacturers have a line of defense against these conditions that can be applied throughout their ATV designs. Rubber components, silicone hoses, and custom molded foam solutions can improve overall vehicle performance and rider comfort by enhancing thermal management, shock absorption, and acoustical control.
By addressing these issues in the engine, exhaust system, and even the handgrips, ATV manufacturers can ensure their vehicles can withstand challenging demands in any environment, keeping the rider safe and in control. We’ll explore ways molded rubber and foams can mitigate these challenges to improve performance and meet riders’ needs.
What Are the Critical Needs that Every ATV Manufacturer Must Meet?
ATVs are generally used for recreational applications, allowing riders to explore and tackle off-road areas often inaccessible by traditional vehicles. These powerful vehicles feature advanced suspension systems and engines with enough torque to handle heavy obstacles. They are built with reinforced frames and have higher ground clearance than other vehicles to overcome treacherous trails.
These features have been improved incrementally as engineers discover new ways and materials to offset common risks. However, significant challenges can still affect performance, longevity, and safety.
Nearly 100,000 accidents happen yearly due to rider error, hazardous environmental conditions, and equipment failure. If engineers reduce risk by minimizing the effects of heat, shocks, and excessive noise, they can improve safety while enhancing vehicle performance and longevity. When we discuss the impact molded rubber and foams can have on ATV design, we want to look at the following questions:
- How can manufacturers keep the engine running cool, quiet, and efficiently?
- Which solutions help protect critical components from heat, vibrations, and debris, minimizing wear and tear?
- How might additional insulation enhance shock absorption and reduce noise to deliver a smooth and enjoyable off-road experience for the rider?
We’ll examine how molded rubber and foams can solve these issues and ensure better performance, longevity, and safety.
Silicon Hoses and Molded Rubber Components
Thermal Management
Excessive heat from the engine, exhaust systems, and other heat-generating parts can damage components, reducing performance and overall efficiency. However, molded rubber hoses and components made from silicone, ethylene-propylene-diene monomer (EPDM), and other materials can bring the heat down in difficult environments where more energy is needed and generated.
High-performance silicone hoses can handle high-temperature fluids up to 510°F to ensure greater flexibility for engine cooling without cracking or leaking. Molded rubber components from EPDM and other synthetic heat-resistant rubbers can regulate the temperature in various air and fluid transmission applications. EPDM is frequently molded into gaskets and seals to minimize thermal damage and ensure fluid containment.
Vibration Control and Acoustical Absorption
Molded rubber can also absorb mechanical shock and isolate vibrations from the engine and suspension to improve performance and longevity. Vibrations from riding uneven terrain can make it difficult for the rider to maintain control, causing significant fatigue.
Molded rubber gaskets, bushings, and mounts insulate and reduce stress on the engine’s surrounding systems and reduce any airborne noise. By isolating vibrations and insulating various engine and suspension parts, molded rubber components can minimize and block excess noise to ensure quieter, calmer operation and a safer riding experience.
Molded Foam Solutions
Thermal Management
Custom molded foam solutions can support thermal management by insulating critical engine components and sensitive electronics impacted by internal heat while providing an added layer of protection against rough terrain and harsh environmental conditions. Our POLYFORM® Molded Foam offers custom-designed thermal barriers to prevent overheating and other energy management challenges for ATV manufacturers.
Polyurethane is relatively lightweight and durable, offering significant resistance and low thermal conductivity to reduce heat transfer. Our step-by-step process can determine the proper compartments and exact fit to enhance temperature control, optimize airflow, and improve reliability. While flat cut foam may also be applicable, molded foam ensures precise shaping and less assembly time in the manufacturing process.
Vibration Absorption and Acoustical Control
Molded foams can be used in seating and overmolding for handgrips to dampen jolts from uneven terrain, reducing rider fatigue and injury. Polyurethane is particularly effective at absorbing impact and dissipating energy safely. Overmolding is also frequently used for acoustical control to eliminate noise from vibrating components and prevent them from impacting the rider.
Our custom molded solutions can also be found as insulation in wall panels and various compartments to minimize wear and tear and limit mechanical and airborne noise for a quieter and safer riding experience. By eliminating these distracting and dangerous variables, riders are less likely to make a mistake that could damage the vehicle or themselves.
Our PMP Division develops our POLYFORM® Molded Foam and 3-D Molded Foam products. We have different formulations of molded polyurethane foam to ensure the right fit for your ATV systems.
Find the Right Custom Solution for ATV Performance and More
Polymer Technologies can handle the most formidable challenges regarding customization and advanced materials for ATVs. We have molded rubber and foam solutions that will mitigate thermal, vibration, and acoustical issues that impact performance, longevity, and safety.
Let’s explore ways our custom solutions can help your engineering team go bold and think forward to address your most significant ATV design challenges.