Abstract: A thermal barrier material for use in shielding components of a vehicle from hot exhaust surfaces includes 35 to 53% of a plurality of clays by weight and a remainder including magnesium silicate, alumina trihydrate, alumino-borosilicate glass, rock wool, basalt fiber, acrylamide copolymer coagulant, acrylic latex, fatty alcohol alkoxylate, or anionic polyacrylamide. A sample of the thermal barrier material, when exposed to a temperature of 400° Celsius, produces smoke having a density less than 5 g/cm3 as measured according to the ISO 5659-2:2006(E) standard.

Abstract: According to some embodiments, a multi-layer gasket with a non-compressible core, formed of any material that is relatively rigid and incompressible and can serve as a carrier for a gasket, and compressible layers, formed of any flowable or compressible sealing material with appropriate rheology for a particular sealing application, in the form of edge or surface coatings, is presented.

Abstract: A thermal barrier material is disclosed for applications such as heat shields in automobiles and other vehicles. The thermal barrier material is made on a Fordenier paper making machine from a slurry that is very low in organic compounds that can cause smoke and odor when exposed to high temperatures. A first thermal barrier material is disclosed that can withstand up to 650° C. and a second thermal barrier material is disclosed that can withstand up to 1000° C. In each case, the barrier material withstands it max temperature specification while producing extremely low quantities of smoke and extremely low levels of offensive odors. Prior art thermal barrier materials with similar temperature specifications on the other hand produce many times the smoke and offensive odors at the same temperatures and do so for a far longer time.

Abstract: According to some embodiments, a multi-layer gasket with a non-compressible core, formed of any material that is relatively rigid and incompressible and can serve as a carrier for a gasket, and compressible layers, formed of any flowable or compressible sealing material with appropriate rheology for a particular sealing application, in the form of edge or surface coatings, is presented.

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.