Abstract: An underbody panel assembly and related method of manufacture is provided. The underbody panel assembly includes an underbody panel coupled to a thermal shield including a plurality of expansion joints. The expansion joints are adapted to accommodate a lengthening or shortening of the thermal shield in response to a corresponding lengthening or shortening of the underbody panel. The related method includes providing an underbody panel, providing a thermal shield including a plurality of expansion joints, and joining the thermal shield to the underbody panel at intervals. The thermal shield can be joined to the underbody panel using a plurality of welds, with each weld being proximate a separate expansion joint. The resulting underbody panel assembly can withstand repeated heating and cooling cycles along a vehicle exhaust, muffler or catalytic converter, while also reducing aerodynamic drag at high vehicle speeds, contributing to an overall increase in vehicle fuel efficiency.

Abstract: A thermoforming apparatus having a mold with an internal vacuum chamber and a quench for cooling a thermoplastic sheet while it remains on the mold. Because the quench cools the sheet, conventional cooling lines are eliminated from the mold. A preferred process of using the thermoforming apparatus includes drawing a heated sheet over the mold, creating a partial vacuum in the vacuum chamber of the mold to maintain the sheet on the mold and quenching the sheet on the mold in a quenching tank. A preferred process of manufacturing a mold with an interior vacuum chamber includes forming an impression of the mold in a casting media, suspending a vacuum line or vacuum cabinet within the impression and pouring molten material around the vacuum line or vacuum cabinet to form the mold at least partially surrounding the vacuum line or vacuum cabinet. Vacuum holes are drilled through the mold from the mold face to the vacuum chamber.

Abstract: A thermoforming apparatus having a mold with an internal vacuum chamber and a quench for cooling a thermoplastic sheet while it remains on the mold. Because the quench cools the sheet, conventional cooling lines are eliminated from the mold. One method of using the thermoforming apparatus includes pushing a heated sheet towards the mold with a plug assist, drawing the heated sheet over the mold, creating a partial vacuum in the vacuum chamber of the mold to maintain the sheet on the mold and quenching the sheet on the mold in a quenching tank by moving the quenching tank to the mold.

Abstract: A thermoforming apparatus having a mold with an internal vacuum chamber and a quench for cooling a thermoplastic sheet while it remains on the mold. Because the quench cools the sheet, conventional cooling lines are eliminated from the mold. A preferred process of using the thermoforming apparatus includes drawing a heated sheet over the mold, creating a partial vacuum in the vacuum chamber of the mold to maintain the sheet on the mold and quenching the sheet on the mold in a quenching tank. A preferred process of manufacturing a mold with an interior vacuum chamber includes forming an impression of the mold in a casting media, suspending a vacuum line or vacuum cabinet within the impression and pouring molten material around the vacuum line or vacuum cabinet to form the mold at least partially surrounding the vacuum line or vacuum cabinet. Vacuum holes are drilled through the mold from the mold face to the vacuum chamber.