Abstract: A parcel shelf for a vehicle includes a tray disposed between a trunk area and a cabin area of the vehicle and a soundproofing partition extending laterally between two distal portions of the tray such that the tray is partitioned into a forward region and a rearward region. The forward region includes openings and each of these openings is sealed to limit passage of sound from the trunk area into the cabin area through the forward region. The soundproofing partition is configured such that the sound from the trunk area reaching the rearward region is redirected along an extended sound pathway before entering the cabin area. A resulting sound level entering the cabin area is reduced below a defined threshold level.

Abstract: A method and system for constructing an architectural component from a three-dimensional form, the system including a movable support table for supporting and moving a three-dimensional form, a multi-task robotic arm having a base end configured for controlled movement along a path proximate the support table and a distal end configured to extend, translate, and/or rotate relative to the base and to include an end effector for applying successive layers of material onto a form on the support table, optionally, a linear rail to which said base is attached, and a computer processor for controlling a sequence of movements of the support table, the base, and the distal end of said multi-task robotic arm, and for controlling application of material to the three-diniensional form to form an architectural component of a predetermined shape and dimension.

Abstract: A method of analyzing wind turbine noise is provided. The method comprises acquiring noise data representing noise produced by a wind turbine and acquiring data from a plurality of vibration sensors positioned at different locations about the wind turbine. The method further comprises identifying a region of interest in the noise data, the region of interest being a candidate for containing tonal noise generated by the wind turbine, and identifying a vibration sensor, the data for which correlates with the noise data in the region of interest. The method further comprises determining a threshold vibration level for the identified vibration sensor, the threshold being based on the vibration level detected by the identified vibration sensor in the region of interest, and determining when the vibration level detected by the identified vibration sensor exceeds the determined threshold.

Abstract: A small mobile space includes a top plate, a bottom plate, and wall modules between the top plate and the bottom plate and is connected in sequence. The top plate, the bottom plate and the wall modules jointly define an accommodating space. A door assembly is arranged on at least one of the wall modules. A joint between every two adjacent wall modules, a joint between each wall module and the top plate, as well as a joint between the bottom plate and each of wall modules are clamped respectively by using a concave-convex structure. An air inlet module is arranged in the top plate and includes an air inlet channel, and a sound absorption component in the air inlet channel. An air inlet of the air inlet channel is communicated to the outside. An air outlet of the air inlet channel is communicated with the accommodating space.

Abstract: A golf car includes a frame including main frames and cross members, an undercover that includes a front cover and a rear cover and is supported by the frame, and an engine room including an underside defined by the undercover. The front cover includes a rear end region provided with pawls. The rear cover includes a front end region provided with pawls. All of the pawls are engaged with the cross member. The front cover is fixed to the cross member and the main frames with fasteners, and the rear cover includes a rear end region fixed to the main frames with fasteners. The front cover and the rear cover include water drainage holes.

Abstract: Disclosed is a waterproof sound-transmitting sheet, which includes a waterproof layer of a nonporous material and a support layer of a porous material, and maintains waterproof performance and sound transmission performance at a water pressure of about 10 atm. The disclosed waterproof sound-transmitting sheet includes a waterproof layer formed of a film shape of a nonporous material, a first adhesive layer having one surface adhered to one surface of the waterproof layer, and a support layer formed of a film shape of a porous material, and having one surface adhered to the other surface of the adhesive layer; and the support layer can be composed of metal mesh or nonwoven fabric.

Abstract: According to an aspect, the present embodiments may be associated with a heat shield including a sealing member. In an embodiment, the sealing member is positioned along at least a portion of a partially hemmed edge and retained thereby. Thus, the heat shield is capable of providing insulative and/or sealing properties when used, specifically thermal, vibrational and/or acoustical shielding, as well as limiting fluid flow across the edge of the heat shield.

Abstract: A baffle, for directing air within a compressor head, includes a first leg extending along a first direction, positioned proximate to a first valve of the compressor head, and a second leg extending along the first direction and substantially parallel to the first leg, positioned proximate to a second valve of the compressor head. A first portion of air from a first side of the first leg is communicated to a second side of the first leg beyond an end of the first leg. An aperture in the first leg communicates a second portion of the air from the first side of the first leg to the second side of the first leg. A turbulence and/or pressure fluctuation proximate the first valve is reduced by communicating the second portion of the air from the first side to the second side of the first leg.

Abstract: A sheet flipping device includes a receiving member for receiving a sheet, a flipping volume being the volume which in operation is defined by the flipping movement of the sheet, and a flipping element for flipping the sheet around an axis of rotation within the flipping volume onto the receiving member. The sheet flipping device further includes an air vortex ring generator having an air vortex ring exit nozzle defining a translational direction of a generated air vortex ring when the generated vortex ring is in operation generated from the air vortex ring exit nozzle. The air vortex ring generator is mounted such that in operation the sheet is urged onto the receiving member by the air vortex ring during the flipping motion of the sheet through the flipping volume. A sheet stacking device and a printing apparatus include the sheet flipping device.

Abstract: A thrust reverser of a turbofan engine has a translating structure and a blocker door device capable of diverting a bypass flowpath for reversing propulsion direction. The translating structure moves axially between a forward position and a rearward position and thereby drives a compound motion of a blocker door of the blocker door device that moves between respective stowed and deployed states. A passive linkage of the blocker door device is orientated between a stationary structure and the blocker door and may be utilized in combination with an extendable linkage that may be orientated between the blocker door and the stationary structure.

Abstract: Provided is a substrate treating apparatus. The substrate treating apparatus includes a chamber, a support member disposed within the chamber to support a substrate, and an exhaust member for exhausting a gas within an inner space of the chamber to the outside of the chamber. A trap space for collecting fumes contained in the gas is defined in the exhaust member.

Abstract: Non-woven mat including basalt and amorphous refractory ceramic fibers, bio-soluble ceramic fibers, and/or heat-treated silica fibers. Embodiments of the non-woven mat surprisingly have a Resiliency Value after three thermal cycles from 25° C. to 700° C./400° C. of the Real Condition Fixture Test at least 1.1 times greater than the Resiliency Value of a comparable non-woven mat consisting of any individual type of fibers of the non-woven mat. The non-woven mats are useful, for example, in pollution control devices and other thermal insulation applications.

Abstract: Methods and devices are disclosed for a gaseous liquid to audibly deform the shape of a closed container. One embodiment includes pushing inward to depress a plurality of deformations integral with an exterior of the plastic container having a bottom, a top, the exterior, and an interior, wherein the top is at least partially opened. Further, the method includes sealing, subsequent to the depressing, the top to close the plastic container. Further still, the method includes pushing outward, subsequent to the sealing, by carbonation from a carbonated liquid contained within the interior, on the plurality of deformations. Yet further, the method includes deforming, by the pushing outward, at least two of the plurality of deformations to displaced positions. The method also includes creating two or more sounds and/or movement by the deforming.

Abstract: A wind absorbing and deflecting device attached to the leading strap on a cycling helmet to reduce wind noise while ambient sound passes through to the inner ear so that the user's hearing in not impaired. The device is located in front of the user's ear and against the temple. It is fabricated from faux fur with a pile length of approximately ½ inch and/or soft fleece with a thickness of ¼ to ½ inches. While cycling, the device deflects oncoming wind while the soft fleece and/or faux fur absorbs variable wind gusts and turbulence. The direct wind flow over the ear and particularly over the ear canal is significantly reduced so there is less air pressure variation and less wind noise.

Abstract: A wheel assembly for a vehicle and a method of manufacturing the wheel assembly for the vehicle are disclosed. The wheel assembly includes a rim and a tire. The tire includes a distal wall, a first side wall and a second side wall, with the first and second side walls extending from the distal wall and each of the side walls attached to the rim such that the distal wall is spaced from the rim to define an interior cavity between the tire and the rim. The wheel assembly also includes a resonator defining a hole such that the resonator presents an inner wall defining a boundary of the hole. The hole cooperates with the interior cavity. The resonator includes an insert mounted to the inner wall. The insert defines an aperture in fluid communication with the interior cavity for attenuating sound produced inside the interior cavity.

Abstract: Methods and devices are disclosed for a gaseous liquid to audibly deform the shape of a closed container. One embodiment includes pushing inward to depress a plurality of deformations integral with an exterior of the plastic container having a bottom, a top, the exterior, and an interior, wherein the top is at least partially opened. Further, the method includes sealing, subsequent to the depressing, the top to close the plastic container. Further still, the method includes pushing outward, subsequent to the sealing, by carbonation from a carbonated liquid contained within the interior, on the plurality of deformations. Yet further, the method includes deforming, by the pushing outward, at least two of the plurality of deformations to displaced positions. The method also includes creating two or more sounds and/or movement by the deforming.

Abstract: Disclosed herein is a waterproof sound-transmitting sheet having high sound transfer efficiency and excellent water proofing performance and a method of producing same. The waterproof sound-transmitting sheet includes: a film-shaped sound-transmitting layer made of a first polymer material; and a webbed pigment layer formed on at least one side of the sound-transmitting layer and made of a second polymer material containing a pigment having a predetermined color, wherein the second polymer material has a melting point higher than that of the first polymer material.

Abstract: Disclosed herein is a waterproof sound-transmitting sheet, the thickness of which can easily be adjusted and which has a high sound transmitting efficiency and excellent waterproofness, and a method for producing same. The waterproof sound-transmitting sheet, which is attached to a sound hole of a case, includes: a support layer made of a film-shaped porous material and formed in the case; and a waterproofing layer formed on one side of the support layer in the shape of a porous nanoweb in which fine fiber strands are crosswisely layered and exposed to the outside of the case.

Abstract: An apparatus is disclosed for an improved acoustic panel comprising a sound absorbing member defined by a first and second face surface and a peripheral edge for absorbing sound from a sound source. A sound blocking member is defined by a first and second face surface and a peripheral edge for blocking the transmission of sound through the sound reducing panel. A first fire retardant spacing material is interposed between and affixed to the second face surface of the sound absorbing material and the first face surface of the sound blocking material. A second fire retardant spacing material having a first and a second face surface and a peripheral edge with the first face surface of the second spacing material is affixed to the second face surface of the sound blocking material. A fire retardant coating is affixed to the second face surface of the second spacing material.

Abstract: A combination acoustic and flash suppression system and method for use with a weapon that fires a bullet. A noise suppressor module or section of the system is adapted to be connected to a distal end of a barrel of the weapon, and a flash suppressor module or section of the system is adapted to be connected to the outlet end of the noise suppressor module, so that the downstream position of the flash suppressor module relative to the noise suppressor module helps to disrupt a Mach disk from forming at a downstream location from the discharge port when a bullet fired from the barrel exits from the discharge port so as to suppress both flash and noise.

Abstract: A muffler is equipped with a catalytic converter and is compact and capable of stably supporting the catalytic converter disposed in a muffler box with a single partition. The muffler box is formed by joining outer peripheral ends of three parts which are first and second box halves with open surfaces thereof abutting each other and a partition interposed between the first and second box halves. A first silencing chamber communicating with an exhaust inlet pipe is defined between the first box half and the partition and a second silencing chamber communicating with a tailpipe is defined between the second box half and the partition. A pair of supporting bosses protruding toward the first and second silencing chambers, respectively, are formed in the partition, and the supporting bosses support a holding tube of the catalytic converter communicating between the first and second silencing chambers.

Abstract: A muffler is capable of stably supporting the catalytic converter in a muffler box with a pair of partitions. The muffler box includes first and second box halves joined together with open surfaces thereof abutting each other, and first and second partition plates interposed between the first and second box halves and overlapping each other to separate inside of the muffler box into first and second silencing chambers and define a third silencing chamber between the first and second partition plates, one end opening of a cylindrical holding tube housing and holding the catalytic converter is connected to the exhaust inlet pipe, the pair of partition plates support the holding tube in such a way as to wrap an outer peripheral surface thereof, and another end opening of the holding tube is communicated with the exhaust outlet pipe through the first, second, and third silencing chambers in this order.

Abstract: An exhaust system for an internal combustion engine having a first exhaust tract assigned to a first group of cylinders of the internal combustion engine, and a second exhaust tract assigned to a second group of cylinders of the internal combustion engine, the first exhaust tract and the second exhaust tract being coupled to one another by a connecting line. A common bypass line branches off from the connecting line coupling the exhaust tracts.

Abstract: Method and arrangement for reducing the effects of a sonic boom created by an aerospace vehicle when the vehicle is flown at supersonic speed. The method includes providing the aerospace vehicle with a first spike extending from the nose thereof substantially in the direction of normal flight of the aerospace vehicle, the first spike having a second section aft of a first section that is aft of a leading end portion, the first and second sections having a second transition region there between and each of the sections having different cross-sectional areas, the leading end portion of the first spike tapering toward a predetermined cross-section with a first transition region between the predetermined cross-section and the first section. The first transition region is configured so as to reduce the coalescence of shock waves produced by the first spike during normal supersonic flight of the aerospace vehicle.

Abstract: An internal combustion engine having an engine body and an acoustic and thermal cover assembly are provided. The engine body includes an exhaust gas recirculation (EGR) pipe extending therefrom and the acoustic and thermal cover assembly is positioned adjacent to the engine body. The acoustic and thermal cover assembly includes a first section and a second section extending along the engine body. The assembly further includes an acoustic and thermal shield extending along the first section, a plastic shell extending along the second section, the acoustic and thermal shield and plastic shell forming a cover, and an insulating layer positioned between the cover and the engine body.

Abstract: A muffler assembly for a vehicle includes a housing at least partially defining an internal cavity and having an inlet and an outlet. The muffler assembly includes an outlet pipe that has an inlet end open to the internal cavity and an outlet end open at the outlet of the housing. A siphon tube is in the internal cavity and has an inlet opening adjacent an inner surface of the housing and an outlet opening in fluid communication with the outlet pipe between the inlet end and the outlet end of the outlet pipe. The siphon tube is configured to remove condensate from the internal cavity when a predetermined pressure differential is established between the inlet opening and the outlet opening.

Abstract: A portable media player sound deflecting assembly includes a panel that has a front side, a back side, a first edge, a second edge, a bottom edge and an upper edge. A first lateral flange is attached to the first edge. The first lateral flange has a first side abutting the front side. The first lateral flange is angled forward of the front side such that an obtuse angle is formed with the front side and the first lateral edge. The first lateral edge deflects sound from a personal sound emitting apparatus forward of the panel when the personal sound emitting apparatus is positioned on the front side.

Abstract: A construction machine capable of effectively reducing noise which would intrude into a cab, without deterioration in ride quality, comfort and air-conditioning efficiency in the cab is provided. The construction machine includes a lower propelling body, an upper slewing body including an upper frame, a cab including a floor plate and installed on the upper frame, and a cab noise reduction device. The cab noise reduction device includes: the floor plate; an under-cab member including a cab deck supporting the cab and provided under the cab to define a closed-form under-cab space whose periphery is substantially closed, in cooperation with the floor plate; and a resonator reducing noise in the under-cab space by a resonance effect.

Abstract: A device for reducing booming noise in a motor vehicle has a wind deflector (3) having openings. The device furthermore has an air source (1), which is arranged in the motor vehicle and connected to the wind deflector. The air provided by the air source can be channeled to the wind deflector and released through the openings (4) thereof.

Abstract: A method and apparatus for controlling noise. An apparatus may comprise a structure configured to be positioned at an opening for a channel. The channel may be formed at least partially within a fastener. The structure may be configured to change a movement of air within the channel to reduce noise generated by the movement of air within the channel.

Abstract: An exhaust system includes first and second exhaust components with an inter-pipe that fluidly connects an outlet of the first exhaust component to an inlet of the second exhaust component. A passive valve is mounted within the inter-pipe. The second exhaust component defines an internal cavity that is at least partially packed with a high frequency absorption material and cooperates with the passive valve to effectively attenuate low and high frequency noise.

Abstract: A panel assembly for use in any number of different applications, including a variety of vehicle applications, that reduces noise or vibrations, provides thermal insulation, and/or improves structural integrity. According to an exemplary embodiment, the panel assembly includes a main panel made from a metal, one or more sound damping patches also made from a metal, and an adhesive layer that joins the patches to the main panel in a constrained layer construction. The sound damping patches may include one or more forming features, which are designed to improve the formability of the panel assembly without significantly impairing its sound damping characteristics. There are different types of forming features, including internal forming features (e.g., openings, holes, slits, slots, etc.) located within the interior of the patch and external forming features (e.g., projections, fingers, recesses, waveforms, etc.) located along the perimeter of the patch.

Abstract: An assembly for managing heat and noise generated by an engine comprises a dash panel, an acoustic absorbing layer, a scrim, and a heat reflective coating. The acoustic absorbing layer comprises a plurality of fibers secure in a resin, where the acoustic absorbing layer is positioned proximate to the dash panel. The scrim is positioned proximate to the acoustic absorbing layer. The heat reflective coating comprises a polymer material and heat reflecting additives dispersed in the polymer material. The heat reflective coating is applied to the scrim as a solution of the polymer material and heat reflecting additives.

Abstract: A monolithically fabricated sound absorbing structural precast concrete noise barrier panel comprising a sound absorbing layer of specialized raw materials. The raw materials include wood particles as well as granulated rubber.

Abstract: The invention relates to a foam part (1), in particular for suspended arrangement in a room, for example for use as a sound absorber (2), with an acoustic region of the foam part which has an outer contour being illuminated by a lighting element (11), further with the lighting element (11) being mounted on the foam part (1) and being disposed within the outer contour of the foam part (1). In particular, the invention also relates to a foam part (1) which is fixed, as a sound absorber (2), in a suspended manner to a room ceiling (3) or room wall, a lighting element (11) which is mounted on the sound absorber (2) and illuminates a subregion of the foam part (1), being provided in said foam part.

Abstract: The composite sound-absorbing device of the present invention includes a perforated board having a number of first pores thereon, a back board and side boards, the perforated board, back board and side boards forming a closed cavity, wherein: at least one or more of the resonant cavities being located within the closed cavity; at least one or more of second pores being located on the resonant cavities; at least one of the second pores being connected with the closed cavity; the resonant cavity having a volume of V=10 mm3 ?1×1010 mm3, having a thickness of 0.05 mm-10 mm, the second pores having an aperture of d?=0.05-100 mm, with a perforation rate ??=0.01%-30%. The present invention is beneficial to improve the effect of sound-absorbing and expand the frequency band of sound-absorbing.

Abstract: A method of forming a monolithically fabricated sound absorbing structural precast concrete noise barrier panel comprising a sound absorbing layer of specialized raw materials. The method includes providing a sound absorbing layer that is a blended mixture of an aggregate, granulated rubber, chemically treated wood particles, cement, pozzolans, water, air entraining admixture, and water reducing mixture; placing the sound absorptive layer ingredients in a form mold; compressing the ingredients to a preset density; backing the compressed ingredients with reinforced structural concrete; and curing the backed and compressed ingredients.

Abstract: A monolithically fabricated sound absorbing structural precast concrete noise barrier panel comprising a sound absorbing layer of specialized raw materials. The raw materials include wood particles as well as granulated rubber.

Abstract: A silencer cover adapts to a heat expansion of a silencer even when, for example, the silencer cover has a large size and is attached to the silencer over an area from the front to the rear. A silencer cover is provided for a silencer connected to a downstream end of an exhaust pipe of an engine. The silencer cover is fixed to a fixing support provided to the silencer. The silencer is heat-expanded with the fixing support part fixed as a base. The fixing support part is provided at a front end portion, in a vehicle front-rear direction, of the silencer. With a tail pipe constituting a rear end portion of the silencer, the rear end portion of the silencer is provided with a slide structure in which the silencer cover is slidably supported.

Abstract: An apparatus of the present disclosure enhances the audio/visual experience of a portable digital device, and comprises a lens positioning slot, a lens storage compartment, a passive audio amplifier, a receiving station.

Abstract: An acoustically resistive protective cover assembly for an opening in a casing is provided, the casing separates an enclosed space from the ambient space and has an exposed face oriented toward the ambient space and an internal face oriented toward the internal space. The cover assembly comprises an acoustically resistive porous material disposed upon the exposed face of the case and an acoustically resistive water repellant material disposed upon the internal face of the case.

Abstract: A device for reducing booming noise in a motor vehicle has a wind deflector (3) having openings. The device furthermore has an air source (1), which is arranged in the motor vehicle and connected to the wind deflector. The air provided by the air source can be channeled to the wind deflector and released through the openings (4) thereof.

Abstract: The present invention relates to a photovoltaic soundproof wall having a plurality of soundproof members each formed by surrounding the edge portions of two transparent sheets with a main frame and a plurality of posts adapted to mount the plurality of soundproof members therebetween, the photovoltaic soundproof wall including: a subframe disposed inside the main frame; a motor disposed inside the subframe for rotating a drive shaft rotatably mounted inside the subframe; a power transmission unit adapted to transmit the rotary force of the motor; a plurality of slats spaced apart from each other vertically between the two transparent sheets in such a manner as to be moved collectively by the power transmitted from the power transmission unit; and a plurality of solar cells attached to the top surface of each of the plurality of slats.

Abstract: A panel assembly for use in any number of different applications, including a variety of vehicle applications, that reduces noise or vibrations, provides thermal insulation, and/or improves structural integrity. According to an exemplary embodiment, the panel assembly includes a main panel made from a metal, one or more sound damping patches also made from a metal, and an adhesive layer that joins the patches to the main panel in a constrained layer construction. The sound damping patches may include one or more forming features, which are designed to improve the formability of the panel assembly without significantly impairing its sound damping characteristics. There are different types of forming features, including internal forming features (e.g., openings, holes, slits, slots, etc.) located within the interior of the patch and external forming features (e.g., projections, fingers, recesses, waveforms, etc.) located along the perimeter of the patch.

Abstract: An ultrasonic sensor includes a substantially cylindrical case including a bottom portion and a side wall portion and a plurality of members disposed within the case. A reinforcement having a substantially ring shape is fitted on a thick section in the case at a location that is not in contact with an inner surface of a thin section of the side wall portion. A piezoelectric element is attached to an inner bottom surface of the case. An elastic member is fitted on the reinforcement so as to cover a substantially ring-shaped opening region of the reinforcement. A gap between the elastic member and an inner circumferential surface of the case is filled with a first filler. The terminal holding member is placed on the elastic member. A surrounding region of the terminal holding member is filled with a second filler.

Abstract: A system and method for reducing the noise of an airfoil is provided. The airfoil includes a main portion including a leading edge and a trailing edge. The airfoil further comprises a noise attenuator coupled to the main portion and disposed proximate to at least a portion of the trailing edge. The noise attenuator has a chord length in the range of about 0.5 to about 5 times a trailing edge thickness and is fixed relative to the trailing edge. The airfoil can be a rotating blade deployed on a wind turbine. The airfoil can also be deployed on an aircraft as a fixed wing.

Abstract: The present invention provides an assembly of a tire and a rim, which assembly has on the tire inner cavity side thereof a sound absorbing member capable of effectively suppressing cavity resonance and reducing road noise, while suppressing increase in weight of the tire and increase in volume of the sound absorbing member. In this assembly of a tire and a rim, the sound absorbing member is mounted on the inner cavity side of the tire as a sound absorbing layer for suppressing cavity resonance inside the tire. The sound absorbing member is unwoven cloth made of plural fibers, and the average distance d between fibers constituting the unwoven cloth is within the range of 0.50? to 4.00?.

Abstract: Disclosed is a muffler (1, 21, 41) integrated with a catalytic converter bed (9, 32, 52) including a polymeric muffler body (2, 22, 42), an inlet pipe (3, 23, 43) in flow communication with engine exhaust, said inlet pipe connected to a first body mounting adapter (5, 25, 45) so as to hold the inlet pipe a heat insulating distance from said polymeric muffler body, said inlet pipe in flow communication with an inlet of said catalytic converter bed (9, 32, 52), and a perforated exhaust pipe (4, 34, 44) in flow communication with an outlet of the catalytic converter bed, said perforated exhaust pipe mounted on a second body mounting adapter (6, 26, 56) so as to hold the perforated exhaust pipe a heat insulating distance from the polymeric muffler body; said inlet pipe and said perforated exhaust pipe holding said catalytic converter bed a heat insulating distance from the polymeric muffler body, said first body mounting adapter, polymeric muffler body, and second body mounting adapter forming a sealed internal c

Abstract: A construction machine capable of effectively reducing noise which would intrude into a cab, without deterioration in ride quality, comfort and air-conditioning efficiency in the cab is provided. The construction machine includes a lower propelling body, an upper slewing body including an upper frame, a cab including a floor plate and installed on the upper frame, and a cab noise reduction device. The cab noise reduction device includes: the floor plate; an under-cab member including a cab deck supporting the cab and provided under the cab to define a closed-form under-cab space whose periphery is substantially closed, in cooperation with the floor plate; and a resonator reducing noise in the under-cab space by a resonance effect.

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.