Lightweight Thermal Shield

摘要

A method of making a lightweight thermal shield that includes obtaining a mold having a shaped support screen with a molding surface configured to allow the passage of air and moisture therethrough, and with the mold being adapted for drawing a vacuum from behind the support screen. The method also includes applying a wet insulation material onto the molding surface of the support screen and drawing a vacuum to withdraw moisture through the support screen and consolidate a layer of insulation material on top the molding surface. The method further includes removing the consolidated layer of insulation material from off the molding surface, installing the consolidated layer of insulation material into an outer shell layer, and drying the consolidated layer of insulation material within the outer shell layer to form a lightweight core insulation layer.

主权项

1. A thermal shield for inhibiting a transfer of heat between components on a vehicle, the thermal shield comprising:
an outer shell layer having an outer surface, an inner surface, a thickness between the inner surface and the outer surface, and at least one curved portion extending out-of-plane to form a shape in three-dimensions; and a core insulation layer coupled to the inner surface and substantially conforming to the shape of the outer shell layer, the core insulation layer being formed from at least one layer of dried fibrous insulation material having a thickness greater than about ten times the thickness of the outer shell layer.