Flexible corrugated multilayer metal foil shields and method of making

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.

We claim  
     
         1 . A flexible multilayer metal foil structure comprising: 
 at least two layers of metal sheets wherein the layers are metal foil each having a thickness of 0.006 in. (0.15 mm) or less; wherein 
 the two layers of metal sheets are corrugated and nested together in a stack; and  
 a portion of the corrugations of the stack is compressed to form interlocking folds of the layers.  
   
     
     
         2 . A flexible multilayer metal foil structure of    claim 1    further comprising a third metal sheet corrugated, nested and interlocked with the two metal foil sheets.  
     
     
         3 . A flexible multilayer metal foil structure according to    claim 1    wherein the corrugations are compressed in creases across the corrugations, whereby the structure is flexible by bending of the corrugated stack at the creases.  
     
     
         4 . A flexible multilayer metal foil structure according to    claim 1    comprising spacers to provide gaps between the layers.  
     
     
         5 . A method of making a flexible multilayer metal foil structure comprising: 
 forming a stack of at least two layers of metal sheets wherein the layers are metal foil each having a thickness of 0.006 in. (0.15 mm) or less;    forming corrugations across the stack of metal sheets whereby the corrugations in the layers are nested in the stack; and    compressing a portion of the corrugations in the stack of metal sheets to form folds and interlock the layers together.    
     
     
         6 . A method according to    claim 5    wherein the stack comprises a third metal sheet.  
     
     
         7 . A method according to    claim 5    further comprising forming creases across the corrugations to provide flexibility of the structure by bending at the creases.  
     
     
         8 . A method according to    claim 6    further comprising forming creases across the corrugations to provide flexibility of the structure by bending at the creases.  
     
     
         9 . A method according to    claim 6    wherein the stack comprises spacers to provide gaps between the layers.  
     
     
         10 . A method of making a flexible multilayer metal foil structure comprising; 
 providing individual corrugated metal sheets;    forming a nested stack of said corrugated metal sheets where the stack comprises at least three layers of metal sheets wherein at least two of the layers are metal foil each having a thickness of 0.006 in. (0.15 mm) or less; and    compressing a portion of the corrugations in the stack of metal sheets to form interlocking folds of the layers.    
     
     
         11 . A method according to    claim 10    further comprising forming creases across the corrugations to provide flexibility of the structure by bending at the creases.  
     
     
         12 . A flexible multilayer metal sheet structure comprising: 
 at least two layers of metal sheets each having a thickness greater than 0.006 in. (0.15 mm); wherein 
 the two layers of metal sheets are corrugated together in nested corrugations and a portion of the corrugations are compressed to form interlocking folds of the layers.  
   
     
     
         13 . A flexible multilayer metal sheet structure according to    claim 12    further comprising a third metal sheet corrugated, nested and interlocked with the two metal foil sheets.  
     
     
         14 . A flexible multilayer metal sheet structure according to    claim 12    comprising spacers to provide gaps between the layers.  
     
     
         15 . A method of making a flexible multilayer metal sheet structure comprising: 
 forming a stack of at least two layers of metal sheets each having a thickness of greater than 0.006 in. (0.15 mm);    forming corrugations across the stack of metal sheets whereby the corrugations in the layers are nested in the stack; and    compressing a portion of the corrugations in the stack of metal sheets to form interlocking folds of the layers.    
     
     
         16 . A method according to    claim 15    wherein the stack comprises a third metal sheet.  
     
     
         17 . A method according to    claim 15    further comprising forming creases across the corrugations to provide flexibility of the structure by bending at the creases.  
     
     
         18 . A method of making a flexible multilayer metal sheet structure comprising; 
 providing individual corrugated metal sheets;    forming a nested stack of said corrugated metal sheets where the stack comprises at least two layers of metal sheets each having a thickness of greater than 0.006 in. (0.15 mm); and    compressing a portion of the corrugations in the stack of metal sheets to fold the layers in the corrugations into interlocking engagement.    
     
     
         19 . A method according to    claim 18    wherein the stack comprises a third metal sheet.  
     
     
         20 . A method according to    claim 18    further comprising forming creases across the corrugations to provide flexibility of the structure by bending at the creases.