Method of molding an article with integral heat shield

Abstract

A fiber reinforced article having an integrally molded heat shield is produced using a liquid resin injection molding technique. One or more layers of heat shielding material are placed adjacent a preform. The preform contains a non-porous inner core and a porous fibrous mat exterior surface. The core is either a foam core, blow-molded core or a metal reinforced core. The heat shielding material is at least partially porous and includes a heat insulating material and/or a heat reflecting material. The heat shield also contains a layer of nonporous insulating material designed to prevent liquid resin from passing therethrough. The preform and heat shielding material are placed in a mold and resin is injected into the mold to impregnate the fibrous mat and partially impregnate the heat shielding material so that the heat shielding material is integrally molded to the product.

Dependencies are inferred from the claim text.