DE19825813C2 - Flexible, corrugated, multi-layer metal foil shields and process for their manufacture - Google Patents

Description

The present invention relates to multilayer metal foils Line and sheet metal structures that act as heat and sound shielding or insulation or insulation suitable are.

Multi-layer metal foil insulation or insulation elements have been used for many years, such as in U.S. Patent No. 1934174. Such metal foils insulation or insulating elements have typically been used for High temperature applications as reflective heat insulation used. For these applications they are Metal foil layers embossed or with beads or humps provided in order to maintain a distance between the layers ten, and the stacked layers are in one Containers or protected in a rigid cover arranges to prevent the metal foil stack in ir against a section, causing the Thermal insulation value of the stack would be reduced.

U.S. Patent No. 5011743 describes that by a multilayer metal foil insulation an improved lei Stability can be obtained as thermal insulation can if part of the multilayer metal foil structure is compressed to a heat sink area generate by the heat from the insulation sections of the stack collected and abge from the thermal insulation is leading. Such multilayer metal foil thermal insulation Mungen are embossed from a stack or with Humped metal foil layers are formed, with Ab cuts of the stack are compressed to form the ge desired heat sink areas. The locations are attached to each other or tacked together to prevent the layers from separating. According to the US Patent No. 5011743 manufactured insulating and are sound absorbing elements, typically in the Heat sink areas compressed and are in cut a desired pattern. Such thermal insulation Mende multilayer metal foil elements show for many Applications usually do not have sufficient structure stability or firmness to be used alone or separately use. For many applications, the heat Insulating metal foil elements typically on one Bracket structural element or attached to a pan, to get a composite end product that then as a heat-insulating or sound-absorbing element can be used. The bracket elements are typi usually metal pans, pressed metal parts or stampings pieces or metal castings. Such composite Insulating elements are typically, for example usually used for thermal insulation in motor vehicles puts.

It is an object of the present invention multilayer metal foil insulation or insulation structure be to sit on, flexible and for thermal insulation and Soundproofing is suitable.

The flexible, corrugated, multilayer Me Tall foil structure has a stack of metal foil layers that are formed in waves that cross one another Extend stacks of metal foil layers, with all layers the same wave pattern and waveform point because the entire stack is curled or the layers individually or separately corrugated and then nested or interlocking to form a sta to form pel. A section of the waves of the stack from Me Tall foil layers are pressed together, so the layers fold up so that they overlap and mutually block.

The multilayer, corrugated, interlocked structure obtained is flexible because of the multilayer, corrugated, blocked structure along the ridges of the waves, where these are not too are compressed and folded, and along the vertical between the waves where the wave crests meet are pressed and folded so that the layers are mutually closed block, is flexible. Depending on the thickness of the Layers, the number of layers and the degree of compression the mutually interlocked layers are the together pressed sections of the waves together with the non-compressed sections of the blocked Flexible structure.

The flexible, corrugated, multilayer according to the invention Metal foil structures have at least three metals lay on, of which at least two layers of metal foils with a thickness of 0.15 mm (0.006 inches) or less are. It is generally preferred that the invention flexible, corrugated, multilayer structures at least three layers of metal foil and more typically preferred have five or more layers of metal foil. Preferably the metal foil layers have a thickness of 0.12 mm (0.005 inches) or less with the thickness of the metal foils especially for the inner layers of flexible, corrugated th, multi-layer metal foil structure preferably Is 0.05 mm (0.002). In addition to the metal foil layers NEN outer sheet metal layers on or on both sides of the flexible, corrugated, multi-layer structure be provided. Such metal layers have a thickness from more than 0.15 mm (0.006 inches) to about 1.27 mm (0.050 inch). The thickness of the optional external Outer sheet metal layer is chosen so that it in the same Chen shape and wavy in the same pattern can be detected like the other layers (either individually or separately and nested or interlocking or simultaneously as part of the stack) and as part of the inventions integral multi-layer metal foil structure according to the invention engaging with the other layers by blocking can be brought. Preferably the outer metal sheet thickness between about 0.20 mm (0.008 inches) and about 0.76 mm (0.030 inches). A preferred out management form of a flexible, corrugated according to the invention The multi-layer metal foil structure is complete made of metal foils, each 0.15 mm thick (0.006 inches) or less, with no stronger outer Layers are provided.

One or more of the individual layers of metal foil that Are part of the multilayer structure according to the invention, can embossed or with humps or other Ab Stand elements to show distances and intermediate to provide spaces between the layers. Although some the hump or gaps during training the waves of the multilayer stack in the areas in which the waves are compressed to the folds to form, through which the layers are mutually blocked that can be reduced and some can be completely eliminated NEN, the remaining gaps or spaces between the layers in different sections of the multi layer common wave structure for many applications the heat-insulating and sound-absorbing properties ten advantageous. Without humps or other spacers, through which the layers are kept spaced the metal foil layers, however, in themselves a few twos spaces and distances between the layers formed by folds or other deformations which during the formation of the waves in the multilayer Metal foil structure occur. Except spacers in Form of humps or folds in the layers themselves, can separate spacers can be used to Zwi to provide space between the layers, as with  for example compressible pieces of film or Ma material or non-compressible materials, so long by the presence of such spacing elements the compression and folding of the waves on the desired positions in the structure for mutual ver blocking the layers and preventing separation of the Layers when the multi-layer metal foil structure for your intended use is not disturbed or be is influenced.

The flexible, multi-layer, wavy according to the invention metal foil structures are when waves cross across the Layer stacks are formed, rigid or stable or against there are at least one bend in one direction however flexible in the other direction because the stack ent long the wave crests and / or valleys are flexible. By this flexibility of the multi-layer corrugated structure can this as a heat-insulating and sound-absorbing element for profile shapes, especially for curved flat surfaces chen, e.g. B. for pipes can be used. The invent multi-layer, corrugated structures according to the invention however also adapted to any shape or in any any shape can be formed by the multilayer Structure bent in one direction along the waves and by bending, folding or kinking the ridges or be curved to the structure in the other direction to shape across the waves. In addition, the Ab the waves were laterally enlarged by pulling them apart eats or can be reduced by compressing the Shape of the multi-layer corrugated metal foil structure support and desired three-dimensional form to train men. For example, an insulation or insulation lierelement be formed in a desired shape, by forming the waves in the stack of metal foil layers det, the stack including an operation to Pull apart or compress the waves in late direction (along the level of the layers) as required nis for the shaping and then the waves at the desired places vertically compressed to fold the waves and the layers to each other block.

In an alternative embodiment, the invented corrugated, multilayer metal foil structure in accordance with the other direction can be made flexible by training that of kinks across the waves through together push or compress, causing the kinks deep enough pressed into the waves to allow the multilayer structure along these creases and flexible is fit. In the formation of such kinks, whereby the corrugated, multilayer metal foils according to the invention additional flexibility is provided by the compression process in which the kinks are formed the function is provided, the wavy Lay in the same way to fold and to each other block like the vertical described above Press the waves together to block each other layers and to prevent separation of the layers This folding and blocking of the layers by training that of the kinks can be in addition to or instead of the above mentioned first operation to compress the Waves to fold and block the layers be carried out. These kinks can be any Wide, from a razor-sharp kink to a wide flattened strip across the waves, and depending on the flexibility and the ge wanted heat-insulating or sound-absorbing egg properties of the end product any desired Have direction across the waves.

The present invention provides a method for Manufacture of a flexible, corrugated metal foil structure provided, initially a stack of metal foils is being prepared. Each layer of metal foil can optionally be one embossed or humped, folded or ge kinking or curling (for example, waves with one compared to the main shafts of the multi-layer Product of very small period and height who trained den) or may have other spacers to Gaps or distances between the layers to bil the. The stack of metal foils is then called integral Structure shaped in waves, what is coming from using conventional metal corrugation processes and devices can be executed. After the waves in the multilayer are stacked, a portion of the waves squeezed to fold the layers over each other, whereby the layers are mutually blocked. By the blocking of the layers becomes a separation of the layers prevents while the flexibility of the multi-layer ge corrugated metal foil stacks by bending along the wel lenberge and valleys or channels along the wave structure is maintained. The section of the waves that go together is printed to fold the layers and each other to block can ge for a particular product desired portion of the waves to be, however is sufficient to separate the layers during the Prevent handling and use. Example wise it is preferred in many applications that the Edges of the corrugated stack are compressed where through the metal foil layers around the circumference or along at least one edge of the multilayer corrugated metal foil stacks are folded and mutually interlocked. In Ab dependence on the end use of the multilayer Metal foil structure can be used in other configurations be nice. For example, it can be advantageous to hold one section of the waves in a strip parallel to the Compress edge of the multilayer structure where through the layers in an inner section of the corrugated multilayer metal foil structure folded and mutually be blocked and the edge portions of the wave structure remain in the non-compressed state. Al Alternatively, it can be periodic or alternate waves along all or most of it the length of each wave to compress where compressed by a certain proportion of the waves is to fold the layers together and to each other block up while other waves over their entire Length in the uncompressed state.

The shape of the waves can be varied by experts depending on the desired properties of the structure be chosen. For example, the waves can be sinusoidal mig, square, rectangular, semicircular or in one other suitable shape. The size that Height, width and spacing of the waves can be the same moderate and regular or uneven and irregular be as long as the waves are designed so that if the selected section of the selected waves together is pressed, the layers when compressing the Slightly kinking waves and easily blocking each other ken. Similarly, the shape of the folds in which the Layers deformed and by which the layers mutually deform be blocked, depending on the blocking egg properties selected and trained for the Flexible, corrugated, multilayered manufactured according to the invention Metal foil end product are desired.

The flexible, multilayer metal foils according to the invention Line structures are used for numerous purposes suitable, but they are preferred for thermal insulation and sound absorption, especially in motor vehicles  turns.

The flexible, multilayer metal foils according to the invention Line structures can be used as thermal insulation materials are used, but they are preferred for heating insulation for distributing and dissipating heat from Heat point sources or overheated places are used. Due to the high lateral conductivity of the several Metallages can heat from an overheated area or from other places of the flexible, multi-layer metal foil lien structure efficiently derived laterally to a position where the heat is absorbed or absorbed by the environment the environment can be delivered and where the tempe temperature is lower than in the area of the overheated area. It it is expected that heat in the ge according to the invention corrugated, multi-layer metal structure suitable and fast is derived along the shortest route that runs along the length of the wave channels or valleys.

Across the wave channels, i. H. along or over the Wave peaks and valleys, heat is conducted more slowly. Heat will also come along the paths faster tet squeezed by those mentioned before areas and formed by the buckling areas, in which the wave peaks and valleys flattened considerably are. These properties allow the invention corrugated, multi-layer, heat-insulating metal foil structure doors are slightly constructed and overheated areas are slightly insulated be by placing the heat laterally along the waves in ge wanted and given directions and then headed is derived. Similarly, the flexible, multi-layer metal foil structures due to the vibration and sound absorbing or damping the properties of the corrugated multilayer metal foils structure can be used as sound absorbing elements. It is obvious to experts that it is for acoustic applications may be suitable, other material layers between to arrange the corrugated metal layers.

Materials such as plastic films, adhesive fabrics, fiber materials and other materials used to the sound absorbing properties the corrugated multilayer metal foil structure to verbes although some of these other materials are for some Applications as thermal insulation or heat protection may not be suitable.

The corrugated, multilayer metal foils according to the invention The line structure has two advantages for different applications the structure as thermal insulation and sound insulation fung or insulation. First, through through the wave structure obtained flexibility the fiction moderate flexible, corrugated, multilayer metal foil structure for desired applications can be positioned appropriately. As can be seen from those described above Longitudinal kinks or folds across the waves an additional flexibility, or by preforming of the corrugated stack of layers of metal foil before the La mutually blocked, it is possible that the structures according to the invention can be used, if different forms of a thermal insulation or sound-absorbing element are required. The second Advantage of a corrugated, multi-layer according to the invention Metal foil structure consists in the surprisingly high ver tical strength and in the load capacity or in the load absorbance of the flexi manufactured according to the invention Blen, corrugated, multi-layer metal foil structure. After which the selected sections of the waves merged were pressed to fold the layers and close each other block, know the non-compressed Ab cuts of the shafts absorb and point vertical loads the uncompressed sections of the shafts one Compression resistance that is greater than one for Me would expect tall foils. Because of this load-bearing capacity or Load-bearing properties are those according to the invention flexible, corrugated, multi-layer metal foil structures particularly suitable as thermal insulation and silencer fung under the carpet of the passenger compartment of vehicles. The corrugated, multi-layer metal foils according to the invention Line structures can be found between the floor pan of an Au tomobils and the passenger compartment carpet are arranged, to heat from overheated areas under the floor pan, such as from a catalyst or an off puff or exhaust system, to absorb and discharge, and Noises, e.g. B. road noise to absorb or to dampen. By the waveform of the invention multilayer metal foil structures becomes a sufficient Grain pressure or crushing resistance under the Carpet provided to allow the waited Metal foil structure their waveform and their thermal insulation sound and sound absorbing properties in normal Use if maintained by occupants on the Carpet kick, vertical loads on the corrugated multilayer metal foil structures are exercised.

Those skilled in the art can see that the inventive flexible, corrugated, multi-layer metal structures made of Me sheet metal with a thickness of more than 0.15 mm (0.006 inch) and without using metal foil layers with a 0.15 mm (0.006 inch) or less in thickness know that. Such flexible, wavy, multilayered me Tall sheet structures are made in the same way like multilayer metal foil structures and can be suitable to be one for certain end-uses additional strength or stability and an additional Obtain vibration resistance.

Fig. 1 shows a perspective view of a multilayer metal foil stack in which waves are formed;

Fig. 2 shows a partial perspective view of an edge portion of the stack of corrugated metal foils to illustrate how the waves are compressed, whereby the layers fold and block each other;

Fig. 3 shows a cross-sectional view of another form of folds and another pasture for mutual Ver blocking the layers by compressing the waves;

Fig. 4 shows an illustration of additional kinks in the waves in order to impart flexibility to the structure in the longitudinal direction across the waves and in the lateral direction along the waves;

Fig. 5 shows a perspective view of a suitable for the isolation of pipelines, diagonally embossed or buckled multi-layer metal foil strips; and

Fig. 6 shows the use of the corrugated multi-layer metal foil structures according to the invention for a vehicle.

The invention provides methods for manufacturing of sheet metal corrugations or corrugated sheets used to novel flexible, corrugated, multi-layer metal foil and To produce sheet metal structures. Conventional procedure ren for forming metal corrugations, such as see the method described in U.S. Patent No. 3,966,646 to Noakes et al. and No. 4,810,588 to Bullock et al. described ver can drive to form waves in the inventions use multi-layer metal foil structures according to the invention be det. While U.S. Patent No. 4,810,588 to Bul lock et al. not nested or not nested gripping corrugated metal foil layers, the in U.S. Patent No. 3,966,646 to Noakes et al. described Methods and other known methods of formation the waves in the multilayer metal according to the invention  foil structures are used. In practice the present ing invention is preferred that first a stack with a desired number of layers of metal foils and Sheet metal is provided, with the layers humps or other spacers to form intermediate clear or have gaps between the layers can.

The stack of metal foils is then an integral structure corrugated to ripple in all layers of the stack at the same time to train. The corrugated stack of metal foils is removed in selected wavebands or sections presses to cause the layers in the stack to separate fold over and block each other when the waves in the selected areas essentially be squeezed flat. That through the present The product obtained by the invention is a multi-layer metal foil line structure in which all layers are compressed in these th wave sections folded together and mutually be blocked, whereby the entire structure together is kept, and the multi-layer metal foil structure remains due to their flexibility or pliability in the he high and / or deep areas of the waves or in the Wave crests and / or wave valleys flexible.

In an alternative method of making it Structures according to the invention can be individual metal foils layers and sheet metal layers individually or separately corrugated, then stacked on top of each other and then as a stack corrugated individual layers nested or in one another be comprehensively arranged. The waves can be a right irregular or irregular shape, period, etc. as long as each of the layers is essentially in the other Intervening layers to allow the stack to curl the layers can be folded and the layers mutually can be blocked.

The stack of interlocking corrugated sheet metal layers can then be compressed into shaft sections to fold the layers and block each other and the multilayer metal foil structure according to the invention to form doors.

One or more individual layers can be embossed or be humped or otherwise turned on presses or provided with depressions, with folds or Ripples (in a direction in which the layers not interlocking, or in one regarding the be neighboring position different patterns) may be curled or otherwise contoured or structured or profiled, to spaces and distances between the layers receive. If metal foils such embossing or hump or have spacer elements to close spaces will usually form part of the hump or ab stand elements during the corrugation process to stop form the corrugated multilayer Me according to the invention tall film structure eliminated or at least reduced. In addition, if shaft sections in the multilayer preformed stacks are compressed to form the Laying folds and blocking each other's humps or other spacers in this merged pressed areas significantly or completely eliminated However, it can be beneficial for many applications be to provide such humps or spacers, to form gaps between the layers because through spaces between the layers in the corrugated Areas that are not squeezed and mutually are blocked, generally the insulating and sound-absorbing or insulating properties of the flexible, corrugated, multi-layer metal according to the invention film structures are improved.

The invention is explained in more detail below with reference to the drawings. Fig. 1 shows a stack 10 of metal foil layers 1, which are wavy as a stack of sheet metal layers, in order to produce shafts 2 in the lateral direction across the sheet stack. One or more of the sheets can optionally have preformed embossments or bosses 7 therein in order to obtain preferred gaps or distances between the sheet layers 1 . The waves can be designed and selected to have any shape, e.g. B. a sinusoidal shape, a semicircular shape, a quadratic shape, a rectangular shape, etc., which is advantageous to provide suitable waves that can be compressed to fold the metal sheets according to the invention and to block each other. Similarly, the height of the shafts and the period or distance between the shafts can be selected by those skilled in the art depending on the desired properties of the final product and depending on the economics and equipment available to form the shafts in the stack. The waves can be formed in the sheet metal stack by conventional metal corrugation methods and devices, such as described in the aforementioned U.S. Patent No. 3,966,646. It will also be appreciated by those skilled in the art that each sheet layer can be corrugated individually or separately and the corrugated sheet layers can then be stacked on top of one another and nested or interlocking to produce the stack of corrugated metal sheets useful in the present invention. Similarly, a stack of metal foils, such as four metal foil layers, each 0.051 mm (0.002 inch) thick, can be formed, and this metal foil stack can be corrugated. From a single cover plate with a thickness of, for example, 0.254 mm (0.010 inches) can be corrugated individually or separately, whereupon the corrugated cover plate is arranged on the stack of corrugated metal foils and can be brought into engagement therewith in order to be suitable for producing the structures according to the invention to form corrugated metal foil stacks. In addition, in the corrugated, multi-layer metal foil and sheet metal structures according to the invention, not all layers in the structure have to be arranged interlocking. To interlock the layers by compressing stacks of corrugated layers, the layers must interlock at these points, however, it may be desirable to provide portions or areas of the structure where the corrugations of the layers do not interlock. Such a configuration of the product according to the invention can be advantageous if an additional overall height for insulation or insulation values or for other purposes is desired.

Fig. 2 shows a partial perspective view of the Randab section of the corrugated stack of sheet metal shown in Fig. 1 to illustrate how the layers are folded by compressing the shafts 2 and mutually interlocked. In this illustration, the waves in an edge region 5 are compressed in sections 26 into an omega (Ω) shape, as a result of which the layers are folded together and mutually blocked. Other folds can be formed, e.g. B. a T, an L or a mushroom shape. This method of compressing the corrugated layers may, if desired, be carried out along the edge portion of the stack, as shown, or in an inner portion of the stack, or in both portions, to provide sufficient interlocking of the layers and separation of the layers to prevent while using the final product. Fig. 2 shows the remaining in the corrugated areas, optionally provided hump 7 , through which a separation of the layers is obtained, and the flattened hump 7 a in the area 5 , where the waves are compressed. Fig. 2 ver also interpreting the properties of the inventive light SEN multilayer metal foil structure. The flexibility of the structure is obtained by the multi-layer corrugated, interlocking structure which is flexible in the transverse and longitudinal directions, such as along the valleys 24 between the waves 2 and in the wave crests 23 of the waves 2 due to the transition between the wave crests, and the flattened areas 26 of the shafts are also somewhat flexible when the structure is bent.

Fig. 3 shows in a cross-sectional view another form of folding and interlocking of the layers by compressing a shaft section. The wel len of the multilayer stack structure are pressed together to obtain flattened areas 36 in which the layers are folded and mutually interlocked. Wave valley regions 34 remain between the compressed portions of the corrugations and the non-compressed portions to provide flexibility to the corrugated end structure with interlocked layers. Although two examples have been presented, other forms of pleating and interlocking of the layers to make the integral structure of the present invention will be apparent to those skilled in the art.

Fig. 4 shows a further embodiment of the OF INVENTION to the invention flexible, corrugated, multi-layer structure, wherein parallel shafts 42 extending transversely pel via the Lagensta are pressed together in the edge regions 46 and ge by extending in the longitudinal direction kinks 44 bends through which, together with the waves 42 , it is possible that the multi-layer structure can bend along the kinks 44 or along the valleys between waves to give the corrugated, multi-layer metal foil structure according to the invention an additional formability. The kinks 44 may extend across the shafts at any angle for the flexibility and formability desired for the product. The kinks 44 may also be formed by the corrugated stack formed as shown in FIG. 1 a second time, but at an angle of 90 ° (or any other angle) with respect to the first pass through the corrugator, the same (or one other) wel through device. If the same corrugation device is used for the second pass and the second pass is performed at an angle of 90 °, the kinks 44 will be spaced apart by the same amount as the valleys 34 . It will be apparent to those skilled in the art, with reference to the description of the present invention, that changes in spacing and angles can be made for the second corrugation pass and optionally for a third etc. corrugation pass at different angles and / or spacings, ie, wave periods.

Fig. 5 shows further embodiments of the present invention, the shafts 52 are formed at a right or egg nem oblique angle across the width of the metal sheet stack and the waves are too sammengedrückt in edge regions 56 to the positions blocking each other to ver.

The oblique or angled configurations of the corrugated, interlocked, multilayered metal foil structure according to the invention can be repeatedly (in the right-angle embodiment in the embodiment) or spiral (in the oblique-angle embodiment) wound around a hot, a cold or a low-temperature line 58 , whereby the multilayer stack structure bends at the recesses or ridges of the corrugations of the structure to enable the multilayer structure according to the invention to be wound around a conduit, the corrugations 52 being arranged parallel to the pipe axis.

FIG. 6 shows a schematic illustration of the use of an insulating or insulating or damping element shown in FIG. 4 in the floor group or underbody section of a vehicle 60 . The insulating element 41 can be brought by mechanical fastening or by gluing to the underside of the passenger compartment tub or to the floor 61 . An insulating or insulating element, e.g. B. the insulating or insulating element shown in Fig. 4, as well as any desired shape of corrugated multi-layer Me tallfoliendämm- or insulating elements can be designed and adapted according to the Invention so that it to any desired section of the underbody of a vehicle or the fire wall or another area of the engine compartment, etc., of a vehicle. The insulation or insulating elements produced according to the invention are advantageously fastened to the vehicle sections by adhesive or another mechanical fastening in order to obtain an integral body or chassis part because the efficient, lightweight, recyclable, insulating or insulating elements according to the invention are constructed in this way iert can be that a desired combination of thermal insulation and soundproofing can be achieved at any point of the vehicle. The direct fastening by mechanical fasteners or by gluing the multilayer metal foil insulation or insulation elements according to the invention to the desired areas and components of a vehicle is achieved by the flexibility of the corrugated, multilayer metal foil insulation or insulation elements and parts produced according to the invention.

The compression of the wave structure for folding and mutually blocking the layers can be carried out appropriately by experts. According to a preferred method and a preferred device for compressing the shafts, a compression tool is used, such as an elastic element, e.g. B. a rubber or plastic element through which the waves can be compressed to fold the waves into an "Ω-", "T-", "L-" or in a mushroom shape or in another shape and the layers to block each other. An advantage of a rubber pressure element is that the shafts are compressed sufficiently to fold and block the layers, but the compressed areas remain somewhat more flexible than when the areas were compressed under greater pressure. Alternatively, metal, plastic, wood or other pressure elements can be used to compress the waves and fold and block the metal foil layers of the stack. As explained above with reference to FIG. 4, the longitudinal creases that can be formed across the shafts by squeezing to give the multilayer structure increased flexibility, similarly using a suitable method and a suitable pressure element or ei ner suitable corrugation device are formed. Those skilled in the art will recognize that the pressure element, depending on the type of compression and in the ball of the longitudinal kinks formed across the shafts, depending on the desired flexibility of the end product, may be a flat element, a V-shaped element or a blade-shaped element can.

The shaft sections that were printed together to fold the layers and block each other, can at any point or anywhere  be ordered, e.g. B. at the edge of the multilayer structure or in an inner section of the multilayer metal foils structure. It will be apparent to those skilled in the art that with reference to the present description for a specific product structure according to the invention any combination or Configuration of the compressed areas formed can be used to fold and fold the layers appropriately block. The edge section of the multilayer structure can possibly in the corrugated non-compressed State left open, and inner sections of the Waves can be squeezed around the layers blocking each other. Alternatively, the margin cut, except that it is compressed, also folded, rolled, crimped, tipped or in any Mu be shaped. A folded or curled or crimped edge is suitable for some applications a section for assembling components or Provide components because of the multi-layer structure for example, is attached to the underbody of a vehicle. Therefore, it is obvious that the layers are for end use purpose, except that the waves are compressed, to fold the layers and block each other, too by other methods, e.g. B. by brackets, clamps or bolted to other components can.

It is obvious to experts which materials for the corrugated stack structures according to the invention are suitable such as aluminum, stainless steel, copper fer, corresponding metal foils and metal sheets, art fabric-coated metal foils and sheets, metal laminates, Alloys of these and other metals and metallic Materials that are plastically and permanently deformable. In addition to metal, between two or more of the metal can film layers of the multilayer structure according to the invention other materials can be arranged. For example, NEN between the metal foil layers plastic films, adhesive layers of material, sprayable plastics, coatings etc. be arranged, especially for acoustic applications applications in which additional sound attenuation wishes. The thickness of the different me used tall and other layers depends on the end use purpose. It is preferred that the multilayer structure be primary from metal foils with a thickness of 0.152 mm (0.006 inch) or less, and it is particularly preferred that at least in a five-layer structure, for example the three inner layers of thin metal foils with a thickness of, for example, 0.051 mm (0.002 inches). It is common desired that the outer layers be made exclusively of Foil formed structure thicker or stronger metal fo lines with a thickness of 0.127 mm or 0.152 mm (0.005 inch or 0.006 inch). Similarly, if the outer layers are supposed to serve as protective layers, these me sheet metal with a thickness of 0.254 mm (0.010 inch) up to 1.27 mm (0.050 inches). In this regard, it is also conceivable that the flexible, corrugated, multilayer according to the invention metal structures a non-foil Structure is made entirely of sheet metal that are thicker than metal foils, i.e. H. from metal sheets with egg Thickness greater than 0.152 mm (0.006 inches). Invention appropriate flexible, corrugated, multi-layer metal structures For example, five layers of 0.254 mm (0.010 inches) thick metal sheets are made.

The number of layers and the thickness of each layer will by experts depending on the desired fle flexibility that is suitable for the corrugated, flexible end product vertical strength, lateral heat transfer load capacity, the requirements for silencers fung etc. selected. The thickness of the different metal film layers varies from 0.020 mm to 0.1542 mm (0.0008 to 0.006 inches), with a metal foil thickness of 0.0051 mm and 0.127 mm (0.002 inch and 0.005 inch) for many applications is preferred.

If thicker or thicker sheets are used, and especially for the top sheets or the outside Fenders, the sheet metal thickness can be more than 0.152 mm to about 1.27 mm (0.006 inches to about 0.05 inches) amount, the preferred thickness being upper or outer Sheet layers from 0.254 mm (0.010 inches) to about 0.762 mm (0.030 inch) or about 1.27 mm (0.050 inch). Some Examples of combinations of the number of layers and the thickness of layers used to manufacture the Invention moderate flexible, corrugated, multi-layer metal foil structure The following are used: (in milli-inches, 1 milli- Inch = 0.001 inch) 10/2/2/2/5; 5/2/2/2/5, 8/2/2/2/4, 10/2/2/10, 5/2/2, 5 / 0.8 / 0.8 / 5 and 10/2 / 0.8 / 0.8 / 2/5. Examples of not Sheet metal structures formed from foils are. 10/8/8/8, 30/10/10/10/30, 8/8/8 and 50/8/8/10. The for the present The most expedient materials are aluminum nium and stainless steel, however, for experts it is evident that other suitable materials ver can be used, such as copper, tin, galvanized sheet, brass, etc. Professionals can use suitable Combinations of materials and metal foils and me sheet thicknesses for certain applications, certain Forming processes and form configurations and the be agreed to easily select the metals used. The Ge velvet thickness of the insulating or insulating element or part is not only dependent on the number of layers, the thickness the layers and the spaces between the layers, but also of the malleability and adaptability of the Preform or the profile preform to the suitably shaped and manufacture finished end product. The thickness is between 0.254 mm (0.010 inches) and 6.35 mm (0.25 inches) or more.

It is also for professionals referring to the previous one Description can be seen that the insulation or Iso lierelemente and parts according to the invention without use of metal foils, d. H. using Metallble with a thickness of more than 0.152 mm (0.006 inch) can be produced. Examples of such structures are 10/7/10, 20/10/10/10, 30/8/8/8 and the like, the Layers are selected so that using the Methods for making multiple la described herein metal sheet preforms suitable formability and adaptability is obtained.

The total thickness of the corrugated, multilayer metal foil or sheet metal structures can appropriately selected by experts to meet the ge desired requirements for thermal insulation and To meet sound insulation. For example, with a typical under-carpet application a structure of layers with a thickness of 10/2/2/5/5 mils with wave heights used by a total vertical thickness from about 3 mm to about 4 mm from the base to the top the waves are preserved.

As described above, the flexible, corrugated, multi-layer metal foil and sheet metal structures according to the invention are suitable for heat insulation and dissipation or dissipation and for sound absorption. For these applications, the structures according to the invention can be produced in any desired shape and in any configuration for any desired purpose. For example, this structure can be constructed and adapted for use on hot exhaust pipes or exhaust pipes, if they are wound as shown in Fig. 5, they can be produced as large-sized moldings that conform to the shape of the underside of a floor pan of a passenger compartment Vehicle adapts, or can be Herge so that they adapt to the shape of a vehicle fire wall. For these applications, the structures according to the invention serve both as insulation or insulation and to laterally dissipate heat from overheated points to cooler areas where they can be absorbed or dissipated by the environment in the vicinity of the multilayer metal structures according to the invention. The flexible, corrugated, multilayer metal foil structures according to the invention can, as described above, be arranged under the passenger compartment carpet of a vehicle to remove the heat from the areas where the floor pan of the passenger compartment can be heated by the exhaust or exhaust gas and catalyst system to distribute and to derive. Such applications can equally provide sound absorption. The attachment of the flexible, corrugated, multi-layer metal structures according to the invention is obvious to those skilled in the art, normally mechanical fastenings, eg. B. clamps, bolts, screws and similar elements who used the. Fastening by adhesives, such as mastic coatings, etc. is a preferred method for arranging the structures according to the invention on various vehicle or motor vehicle parts, in particular for attaching the structures according to the invention to underbody structures, in particular on the underside of the floor pan of a passenger compartment. The corrugated, multilayer metal foil and metal sheet structures according to the invention can also on or between other materials, for. As metal, fabric, plastic, etc., are laminated if desired for certain applications and operating conditions. For example, the corrugated, multi-layer structures according to the invention can have a smooth metal foil or sheet metal layer or an embossed or provided with buc, non-corrugated metal foil or sheet metal layer on one or both sides of the structures, which by adhesive or by mechanical fastening is attached in order to obtain a desired structural strength or desired insulation or insulation properties. It will be apparent to those skilled in the art that the structures of the invention are equally useful for non-vehicle or non-automotive purposes, such as furnace linings, etc. For various acoustic end uses, it may be desirable to have perforations in one or more layers of the structure train to improve the sound and vibration damping ability of the structure. Such perforations can be formed in conjunction with buckles, for example perforations can be formed in the positions of the humps in metal foils. Such perforations can also be formed in rows along the upper webs of the waves in some or all layers of the structure. For those skilled in the art, changes in the methods for producing the structures according to the invention and in the end use can be seen under reference to the description of the present invention.

Claims (20)

1. Flexible, multi-layer metal foil structure with:
at least two layers of metal foil each 0.15 mm (0.006 inch) or less in thickness;
in which
the two metal foil layers are corrugated and arranged in a stack-like manner; and
a portion of the shafts of the stack is compressed to form interlocking folds of the layers. 2. Structure according to claim 1, further comprising a third corrugated metal layer, which in the two Metallfolienla arranged engagingly and with the two metal layers of film are mutually blocked. 3. Structure according to claim 1, wherein the waves together are pressed to kinks across the waves train, which makes the structure by bending the corrugated stack is flexible at the kinks. 4. Structure according to claim 1 with spacers to provide gaps between the meet. 5. A method for producing a flexible, multi-layer metal foil structure with the steps:
Forming a stack of at least two layers of metal foil each 0.15 mm (0.006 inch) or less in thickness;
Forming waves across the stack of metal foils, the waves being interdigitated in the layers in the stack; and
Squeezing a portion of the shafts in the stack of metal foils to form folds and block the layers together. 6. The method of claim 5, wherein the stack is a has third metal layer. 7. The method according to claim 5 or 6, further comprising Step to form kinks across the world len, the waves compressed and the La mutually interlocked to the structure to give flexibility by bending the kinks. 8. The method according to claim 5 or 6, further comprising Step of forming a second wave structure across the first wave structure, the waves to be squeezed to each other's layers to block. 9. The method of claim 6, wherein the stack Ab stand elements for providing space between the layers. 10. A method for producing a flexible, multilayer metal foil structure comprising the steps:
Provision of individual corrugated metal layers:
Forming a stack by nesting the corrugated metal layers together, the stack comprising at least three metal layers and at least two of the metal layers being metal foils each 0.15 mm (0.006 inches) or less thick; and
Compressing a portion of the shafts of the metal layer stack to form interlocking folds of the layers. 11. The method of claim 10, further comprising Step to form kinks across the world len to the structure by bending at the kinks Fle to give flexibility. 12. Flexible, multi-layer metal sheet structure, with min at least two layers of sheet metal with a thickness each greater than 0.15 mm (0.006 inch); being the two metal sheet layers a common waves have structure and arranged interlocking are and a section of the waves compressed is to bil mutually interlocked folds of the layers the. 13. The structure of claim 12, further comprising a third corrugated sheet metal layer that with the two metal interleaved sheet metal layers arranged and ver is blocked. 14. Structure according to claim 12 with spacer elements  to provide gaps between the locations. 15. A method for producing a flexible, multilayer sheet metal structure comprising the steps:
Forming a stack of at least two layers of sheet metal each greater than 0.15 mm (0.006 inches) thick;
Forming waves across the metal sheet stack, the waves in the layers in the stack being arranged in one another; and
Compress a portion of the corrugations in the sheet metal stack to form interlocked folds of the layers. 16. The method of claim 15, wherein the stack has a third sheet metal layer. 17. The method of claim 15, further comprising Step to form kinks across the world len to the structure by bending at the kinks Fle to give flexibility. 18. A method of manufacturing a flexible, multi-layer sheet metal structure comprising the steps:
Providing individual corrugated metal sheets;
Forming a stack of interlocking corrugated metal sheets, the stack comprising at least two layers of metal sheets each greater than 0.15 mm (0.006 inches) thick; and
Compressing a portion of the shafts in the sheet metal stack to fold the layers in the shafts so that they interlock. 19. The method of claim 18, wherein the stack has a third sheet metal layer. 20. The method of claim 18, further comprising Step to form kinks across the world len to the structure by bending at the kinks Fle to give flexibility.