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.