Lightweight thermal shield

Abstract

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.

What is claimed is: 
     
       1. A thermal shield for inhibiting a transfer of heat between components on a vehicle, the thermal shield comprising:
 an outer shell layer formed from a solid and impermeable material having an outer surface, an inner surface, a thickness between the inner surface and the outer surface, and at least one curved portion, the outer shell layer defining a shape in three-dimensions; 
 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, wherein 
 the core insulation layer further comprises a first layer of dried fibrous insulation material and a second layer of dried fibrous insulation material different from the first layer. 
 
     
     
       2. The thermal shield of  claim 1 , wherein the core insulation layer has a thickness greater than or about twenty times the thickness of the outer shell layer. 
     
     
       3. The thermal shield of  claim 1 , wherein the outer shell layer comprises aluminized steel. 
     
     
       4. The thermal shield of  claim 1 , wherein the outer shell layer has a thickness ranging from about 0.010 inches to about 0.018 inches. 
     
     
       5. The thermal shield of  claim 1 , wherein the core insulation layer provides a majority portion of the overall structural strength and stiffness of the thermal shield. 
     
     
       6. The thermal shield of  claim 1 , wherein the dried fibrous insulation material further comprises 1401 millboard. 
     
     
       7. The thermal shield of  claim 1 , wherein the core insulation layer further comprises a first layer of dried fibrous insulation material is formed from silica fibers and a the second layer of dried fibrous insulation material formed from fiberglass fibers. 
     
     
       8. The thermal shield of  claim 1 , further comprising an inner shell layer formed from a solid and impermeable material coupled to a perimeter of the outer shell layer and covering an opposite surface of the core insulation layer. 
     
     
       9. The thermal shield of  claim 8 , further comprising a gap in the core insulation layer between the outer shell layer and the inner shell layer. 
     
     
       10. The thermal shield of  claim 9 , wherein the gap is filled with a thermal insert further comprising metallic foil. 
     
     
       11. The thermal shield of  claim 1 , further comprising a scrim liner overlying an opposite surface of the core insulation layer and adapted to contact a hot component. 
     
     
       12. The thermal shield of  claim 1 , further comprising a thermal standoff extending through an opposite surface of the core insulation layer and adapted to contact a hot component. 
     
     
       13. A thermal shield for inhibiting a transfer of heat between components on a vehicle, the thermal shield comprising:
 a outer shell layer formed from a solid and impermeable material having a first surface, a second surface a perimeter, and at least one curved portion, the outer shell layer forming a shape in three-dimensions; 
 an insulation layer contacting the first surface and substantially conforming to the shape of the outer shell layer, the insulation layer being formed from at least one layer of dried fibrous insulation material; 
 an inner shell layer formed from a solid and impermeable material coupled to the perimeter of the outer shell layer and covering an opposite surface of the insulation layer; 
 wherein the insulation layer further comprises a first layer of dried fibrous insulation material formed from silica fibers and a second layer of dried fibrous insulation material formed from fiberglass fibers. 
 
     
     
       14. A thermal shield comprising:
 an outer shell layer having an outer surface, an inner surface, and a thickness between the inner surface and the outer surface, the outer shell layer defining a shape in three-dimensions;   a dried core insulation layer secured to the inner surface and substantially conforming to the shape of the outer shell layer, the core insulation layer comprising:   a fibrous insulation material formed from a slurry shaped to conform to the shape of the outer shell layer and having a thickness greater than the thickness of the outer shell layer.   
     
     
       15. The thermal shield of claim 14, wherein
 the slurry comprises inorganic fibers, fillers, and binders,   the slurry is vacuumed such that the inorganic fibers, fillers and binders are deposited onto at least one of the inner surface and the outer surface of the outer shell layer to form the core insulation layer, and   the core insulation layer is dried such that it bonds to at least one of the inner surface and the outer surface of the outer shell layer.   
     
     
       16. The thermal shield of claim 14, wherein the pre-formed core insulation layer comprises at least one of rock wool silica, and mineral wool. 
     
     
       17. The thermal shield of claim 14, further comprising:
 an inner shell layer,   wherein the pre formed core insulation layer comprises: an upper surface; and a lower surface opposite the upper surface,   wherein the upper surface is secured to the inner surface of the outer shell layer, and the lower surface is secured to the inner shell layer.   
     
     
       18. The thermal shield of claim 17, wherein a perimeter edge of the outer shell layer is coupled to a perimeter edge of the inner shell layer. 
     
     
       19. The thermal shield of claim 17, wherein at least one of the inner shell layer and the outer shell layer, in combination with the preformed core insulation layer, forms abarrier that is impermeable to liquids. 
     
     
       20. The thermal shield of claim 17, wherein each of the outer shell layer and the inner shell layer comprise a metallic material, the metallic material comprising a mesh and a thin sheet of metal. 
     
     
       21. The thermal shield of claim 14, wherein the outer shell layer comprises a solid material.