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.

Abstract: Gasket stock is disclosed having a rectangular metal core that is readily bendable in one direction and a deformable rubberized jacket coextruded with and encasing the metal core. A method of fabricating the gasket stock through a coextrusion process is disclosed. A method also is disclosed for forming a press-in-place gasket with the method including obtaining bendable gasket stock, incrementally advancing the gasket stock to predetermined positions in a bender, and bending the gasket stock at the predetermined positions along its length to form a desired shape of the press-in-place gasket. The bender is controlled by a computer to form the shape of the gasket according to a CAD or other electronic file. Finally, a method of supplying press-in-place gaskets and accommodating design changes of such gaskets is disclosed.

Abstract: A method of making a gasket having a high temperature coating that includes obtaining a substrate formed from a metallic material and having the shape of a gasket, applying a nanoparticle suspension over the outer surfaces of the substrate, and heating the substrate to a first elevated temperature to form an undercoat layer of a self-protective oxide coating. The method also includes applying a liquid comprising boron nitride over the undercoat layer and drying the boron nitride liquid at a second elevated temperature to form an overcoat layer.

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.