Shaped multilayer metal foil shield structures and method of making

Abstract

A forge/swage formed three dimensional multilayer metal foil shield having areas therein where the layers are in a spaced apart relationship, areas therein where the layers are tensioned or stretched, and areas therein where the layers are compressed and interlocked together by folding, rolling, wrinkling, curling, coiling, crimping and the like. The multilayer metal foil shield is formed by forge/swage shaping in an appropriate mold apparatus a preform of a stack of metal foil layers having gaps between the layers. The gaps are provided by embossments in the layers or by spacers between the layers. The forge formed multilayer metal foil shields have utility as heat shields and acoustic shields, particularly on vehicles. The forge formed multilayer metal foil shields are mounted on automobile underbody areas, such as the bottom of the floor pan of the passenger compartment, to provide heat and sound insulation. Other automotive uses include fire wall, exhaust tunnel, motor mount and exhaust down pipe. The three dimensional shields include multilayer metal sheet formed structures. Intermediate beaded or rolled edge multilayer metal preforms are made for transport to the final three dimensional stamping operation.

Dependencies are inferred from the claim text.