EMBOSSED THERMAL SHIELD AND METHODS OF CONSTRUCTION AND INSTALLATION
A hand wrappable heat shield and method of construction thereof has outer and inner layers of metal embossed with peaks and valleys. An intermediate layer of insulation material is sandwiched between the outer and inner layers of metal. The peaks embossed in the outer layer are offset relative to the peaks embossed in the inner layer.
1 . A heat shield, comprising:
an outer layer of hand wrappable metal material having an embossed pattern of undulating peaks and valleys;
an intermediate layer of insulation material; and
an inner layer of hand wrappable metal material, said intermediate layer being sandwiched between said outer layer and said inner layer and said inner layer having an embossed pattern of undulating peaks and valleys, said peaks of said outer layer being offset from said peaks of said inner layer.
2 . The heat shield of claim 1 wherein said peaks of said outer layer are aligned opposite said valleys of said inner layer.
3 . The heat shield of claim 1 wherein said outer layer is between about 0.006-0.020″ thick and said inner layer is between about 0.001-0.002″ thick.
4 . The heat shield of claim 1 wherein said inner layer has a plurality of openings.
5 . The heat shield of claim 4 wherein said openings extend through said valleys of said inner layer.
6 . The heat shield of claim 4 wherein tangs of said inner layer metal material extend from said openings into said intermediate layer.
7 . The heat shield of claim 1 wherein said outer layer has adjacent rows of said peaks and valleys staggered relative to one another.
8 . The heat shield of claim 7 wherein every other one of said rows has aligned peaks and valleys.
9 . The heat shield of claim 1 wherein said intermediate layer is a non-woven material.
10 . A method of constructing a heat shield, comprising:
providing a first layer of metal material;
providing a second layer of metal material;
providing a layer of insulation material;
sandwiching said layer of insulation material between the first and second layers; and
embossing a pattern of peaks and valleys in the first and second layers of material with the peaks in the first layer being embossed in offset relation to the peaks in the second layer.
11 . The method of claim 10 further including laminating the first and second layers to the insulation material by bonding the insulation material to the first and second layers.
12 . The method of claim 10 further including providing the first layer as an outer layer having a thickness between about 0.006-0.020″ and the second layer as an inner layer with a thickness between about 0.001-0.002″.
13 . The method of claim 12 further including forming a plurality of openings in the inner layer.
14 . The method of claim 13 further including penetrating the insulation material with tangs of the inner layer metal material.
15 . The method of claim 13 further including forming the openings during the embossing step.
16 . The method of claim 11 further including performing the laminating step prior to the embossing step.
17 . The method of claim 16 further including cutting a predetermined shape from the bonded layers.
18 . The method of claim 10 further including constructing the heat shield to be hand-wrappable.