Abstract: Apparatus for manufacturing multi-layer metal feedstock material for stamping shaped parts eliminates the need for rolls of metal at the stamping site. Multilayer metal feedstock material is assembled from multiple rolls of metal stock, then folded in a zig zag fashion, or “Z-fold” configuration, whereby the multilayer metal assembly is stacked vertically, usually on conventional pallets, for ease of moving with a forklift or otherwise. The multilayer metal z-fold stack of material is then transported to a parts stamping operation where the material is used as it unfolds as a continuous feed to machines to produce shaped multilayer metal parts. This invention is most useful in making multilayer metal foil z-fold feedstock material and using the z-fold material as continuous feed to processes for making shaped multilayer metal foil parts. The layers may have non-metal layers of material, such as fiber, between the metal layers or on the outside of the metal layers.

Abstract: Apparatus for manufacturing multi-layer metal feedstock material for stamping shaped parts eliminates the need for rolls of metal at the stamping site. Multilayer metal feedstock material is assembled from multiple rolls of metal stock, then folded in a zig zag fashion, or “Z-fold” configuration, whereby the multilayer metal assembly is stacked vertically, usually on conventional pallets, for ease of moving with a forklift or otherwise. The multilayer metal z-fold stack of material is then transported to a parts stamping operation where the material is used as it unfolds as a continuous feed to machines to produce shaped multilayer metal parts. This invention is most useful in making multilayer metal foil z-fold feedstock material and using the z-fold material as continuous feed to processes for making shaped multilayer metal foil parts. The layers may have non-metal layers of material, such as fiber, between the metal layers or on the outside of the metal layers.

Abstract: A flexible multilayer metal structure includes using multiple layers interlocked to form folds holding the layers together. These folds can extend into non-edge portions of the multilayer structure so that the multilayer structure defines air gaps that aid in producing a heat-shielding effect.

Abstract: A rigid structural foil and a method for forming a rigid structural foil is provided. The structural foil includes at least two layers of metal sheets, valley areas and spacers. The metal sheet layers include metal foil having a thickness of 0.006 in. The valley areas are disposed between compressed and uncompressed portions of the structural foil formed during compression of portions of the structural foil. In addition to the valley areas, the structural foil includes spacers. The spacers within the metal sheet layers provide spacing between portions of the metal layers such that the structural foil functions as both a heat shield and an acoustic shield.

Abstract: Multilayer metal foil pads or panels for heat or sound insulation or shielding comprising two or more corrugated metal foil or metal sheet layers wherein a flat metal foil or metal sheet layer is positioned between each pair of corrugated layers. The corrugated layers and/or the flat layers may be embossed, patterned or textured to enhance performance of the pad or panel. A preferred pad or panel comprises an embossed, patterned or textured flat exterior layer adapted for contacting the surface to be insulated or shielded to provide air space between the pad or panel and the surface and to separate the first corrugated layer from the surface. Methods are provided for making the pads and panels, which are useful in automotive applications, food cooking devices and other uses.

Abstract: A flexible multilayer metal structure includes using multiple layers interlocked to form folds holding the layers together. These folds can extend into non-edge portions of the multilayer structure so that the multilayer structure defines air gaps that aid in producing a heat-shielding effect.

Abstract: A forge/swage formed three dimensional multilayer metal foil shield having areas therein where the layers are in a spaced apart relationship, areas therein where the layers are tensioned or stretched, and areas therein where the layers are compressed and interlocked together by folding, rolling, wrinkling, curling, coiling, crimping and the like. The multilayer metal foil shield is formed by forge/swage shaping in an appropriate mold apparatus a preform of a stack of metal foil layers having gaps between the layers. The gaps are provided by embossments in the layers or by spacers between the layers. The forge formed multilayer metal foil shields have utility as heat shields and acoustic shields, particularly on vehicles. The forge formed multilayer metal foil shields are mounted on automobile underbody areas, such as the bottom of the floor pan of the passenger compartment, to provide heat and sound insulation. Other automotive uses include fire wall, exhaust tunnel, motor mount and exhaust down pipe.

Abstract: Multilayer metal foil pads or panels for heat or sound insulation or shielding comprising two or more corrugated metal foil or metal sheet layers wherein a flat metal foil or metal sheet layer is positioned between each pair of corrugated layers. The corrugated layers and/or the flat layers may be embossed, patterned or textured to enhance performance of the pad or panel. A preferred pad or panel comprises an embossed, patterned or textured flat exterior layer adapted for contacting the surface to be insulated or shielded to provide air space between the pad or panel and the surface and to separate the first corrugated layer from the surface. Methods are provided for making the pads and panels, which are useful in automotive applications, food cooking devices and other uses.

Abstract: Multilayer metal foil pads or panels for heat or sound insulation or shielding comprising two or more corrugated metal foil or metal sheet layers wherein a flat metal foil or metal sheet layer is positioned between each pair of corrugated layers. The corrugated layers and/or the flat layers may be embossed, patterned or textured to enhance performance of the pad or panel. A preferred pad or panel comprises an embossed, patterned or textured flat exterior layer adapted for contacting the surface to be insulated or shielded to provide air space between the pad or panel and the surface and to separate the first corrugated layer from the surface. Methods are provided for making the pads and panels, which are useful in automotive applications, food cooking devices and other uses.

Abstract: A forge/swage formed three dimensional multilayer metal foil shield having areas therein where the layers are in a spaced apart relationship, areas therein where the layers are tensioned or stretched, and areas therein where the layers are compressed and interlocked together by folding, rolling, wrinkling, curling, coiling, crimping and the like. The multilayer metal foil shield is formed by forge/swage shaping in an appropriate mold apparatus a preform of a stack of metal foil layers having gaps between the layers. The gaps are provided by embossments in the layers or by spacers between the layers. The forge formed multilayer metal foil shields have utility as heat shields and acoustic shields, particularly on vehicles. The forge formed multilayer metal foil shields are mounted on automobile underbody areas, such as the bottom of the floor pan of the passenger compartment, to provide heat and sound insulation. Other automotive uses include fire wall, exhaust tunnel, motor mount and exhaust down pipe.

Abstract: A flexible multilayer metal structure includes using multiple layers interlocked to form folds holding the layers together. These folds can extend into non-edge portions of the multilayer structure so that the multilayer structure defines air gaps that aid in producing a heat-shielding effect.

Abstract: A flexible multilayer metal structure includes using multiple layers interlocked to form folds holding the layers together. These folds can extend into non-edge portions of the multilayer structure so that the multilayer structure defines air gaps that aid in producing a heat-shielding effect.

Abstract: A forge/swage formed three dimensional multilayer metal foil shield having areas therein where the layers are in a spaced apart relationship, areas therein where the layers are tensioned or stretched, and areas therein where the layers are compressed and interlocked together by folding, rolling, wrinkling, curling, coiling, crimping and the like. The multilayer metal foil shield is formed by forge/swage shaping in an appropriate mold apparatus a preform of a stack of metal foil layers having gaps between the layers. The gaps are provided by embossments in the layers or may be provided by spacers between the layers. The forge formed multilayer metal foil shields have utility as heat shields and acoustic shields, particularly on vehicles. The forge formed multilayer metal foil shields are mounted on automobile underbody areas, such as the bottom of the floor pan of the passenger compartment, to provide heat and sound insulation.

Abstract: A flexible corrugated multilayer metal foil structure comprising a stack of metal foil layers which are formed in corrugations extending across a stack of the metal foil layers, wherein all of the layers have the same corrugated pattern and shape as a result of the stack being shaped in corrugations or the layers being separately shaped in corrugations then nested into a stack. A portion of the corrugations of the stack of metal foil layers can be compressed to fold the layers together whereby the layers are interlocked together in overlapping relationship.

Abstract: An outdoor cooking device which reduces heat transfer between the inner and outer surfaces of the device. The base includes a food cooking surface and a grate for supporting a heat source such as charcoal briquettes. The cover is supported on the base and encloses an open space facing the cooking surface. A multilayer heat insulating composite is provided on an inside surface of the cover and/or the base. The composite includes at least two layers of metal foil and at least one of the layers has a plurality of projections in point contact with an adjacent layer of the metal foil so as to provide a plurality of air spaces therebetween.