Abstract: A manufacturing process (100) for forming a product, such as a thermal shield (20), in a web (102) of material. The thermal shield includes a first plate (22) and a second plate (24) joined to one another at a seam (28). The manufacturing process includes engaging an upper member (128) containing second plate with the web, which contains the first plate. Registration structures (112, 130) are provided to the upper member and web for keeping the upper member in proper registration with the web during formation of the seam. After the seam has been at least partially formed, the thermal shield is separated from the web.

Abstract: A method of making thermal shield (20) having a first plate (22) and a second plate (24) with an interior chamber (26) positioned in between. The method includes a seam (40) extending around the periphery of the thermal shield which prevents the ingress of fluid into the interior chamber. The seam is formed to include portions (60 and 72) that extend at least partially, and preferably completely, around the outer surface (56) of a shoulder (54) of the seam. The method may be used to form a seam (40) that is capable of sealing a pressure differential between the interior chamber and the regions surrounding the thermal shield of up to about 40 psi.

Abstract: A method of making thermal shield (20) having a first plate (22) and a second plate (24) with an interior chamber (26) positioned in between. The method includes a seam (40) extending around the periphery of the thermal shield which prevents the ingress of fluid into the interior chamber. The seam is formed to include portions (60 and 72) that extend at least partially, and preferably completely, around the outer surface (56) of a shoulder (54) of the seam. The method may be used to form a seam (40) that is capable of sealing a pressure differential between the interior chamber and the regions surrounding the thermal shield of up to about 40 psi.