Pad including heat sink and thermal insulation area

• US 5,800,905 A
• Filed: 09/19/1995
• Issued: 09/01/1998
• Est. Priority Date: 01/22/1990
• Status: Expired due to Term

• Current Assignee: Sevex North America Incorporated
• Original Assignee: ATD Corporation (American Tire Distributors Incorporated)
• Inventors: Sheridan, William M., Ragland, Raymond E.
• Primary Examiner(s): Foelak, Morton
• Application Number:
  US08/530,094
• Time in Patent Office: 1,078 Days
• Field of Search: 428/593, 428/594, 428/603, 428/604, 428/600, 428/601, 428/583, 428/582, 428/577, 428/133, 428/138, 428/164, 428/166, 428/172, 428/157, 428/457, 428/544, 428/571, 428/606, 428/607, 428/615, 52/792, 52/796, 52/797, 52/798, 52/809, 296/39.3, 138/DIG. 10, 156/219, 156/222, 156/251
• US Class Current: 428/157
• CPC Class Codes: B32B 15/00 Layered products comprising a layer of metal
• CPC Class Codes: B32B 15/01 all layers being exclusively metallic making layered metal workpieces by pressure cladding B23K20/22; making coatings with a metallic material characterised by its composition C23C30/00
• CPC Class Codes: B32B 2305/024 Honeycomb
• CPC Class Codes: B32B 2307/304 Insulating
• CPC Class Codes: B32B 3/12 characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
• CPC Class Codes: B32B 3/28 characterised by a layer comprising a deformed thin sheet , i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled B32B29/08 takes precedence
• CPC Class Codes: F16L 59/08 Means for preventing radiation, e.g. with metal foil
• CPC Class Codes: F17C 2203/014 Suspension means
• CPC Class Codes: F28D 2021/0029 Heat sinks
• CPC Class Codes: F28F 2275/025 by using adhesives
• CPC Class Codes: Y10T 156/1039 Surface deformation only of sandwich or lamina [e.g., embossed panels]
• CPC Class Codes: Y10T 156/1044 of parallel stacked sheets only
• CPC Class Codes: Y10T 156/1054 and simultaneously bonding [e.g., cut-seaming]
• CPC Class Codes: Y10T 428/12 All metal or with adjacent metals
• CPC Class Codes: Y10T 428/12188 having marginal feature for indexing or weakened portion for severing
• CPC Class Codes: Y10T 428/12347 Plural layers discontinuously bonded [e.g., spot-weld, mechanical fastener, etc.]
• CPC Class Codes: Y10T 428/12389 having variation in thickness
• CPC Class Codes: Y10T 428/1241 Nonplanar uniform thickness or nonlinear uniform diameter [e.g., L-shape]
• CPC Class Codes: Y10T 428/12431 Foil or filament smaller than 6 mils
• CPC Class Codes: Y10T 428/12438 Composite
• CPC Class Codes: Y10T 428/12493 : Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
• CPC Class Codes: Y10T 428/24289 : Embedded or interlocked
• CPC Class Codes: Y10T 428/24298 : Noncircular aperture [e.g., slit, diamond, rectangular, etc.]
• CPC Class Codes: Y10T 428/24488 : Differential nonuniformity at margin
• CPC Class Codes: Y10T 428/24545 : Containing metal or metal compound
• CPC Class Codes: Y10T 428/24562 : Interlaminar spaces
• CPC Class Codes: Y10T 428/24612 : Composite web or sheet
• CPC Class Codes: Y10T 428/31678 : Of metal

Abstract

A pad including thermal insulation and heat sink areas. The pad includes a plurality of layers of metal foil forming a stack with the layers arranged one above the other, the stack including at least one heat sink area and at least one insulating area adjacent to the heat sink area, the layers providing better heat conduction in the vertical direction at the heat sink area than at the insulating area. At least one of the layers includes a plurality of embossments therein separating the one layer from an adjacent one of the layers in the insulating area. The pad can include a single insulating area surrounded by a heat sink area and a black coating can be provided on selected portions of the layers to improve heat radiating characteristics of the pad. For instance, the heat sink area can be coated with the black coating to radiate heat away from the pad at a desired location. The pad is particularly useful in shielding a heat sensitive component on one side of the pad from a heat source on the other side of the pad. The pad can be covered with a prescored and/or embossed metal sheet coated on one or both sides with adhesive. The sheet can also be used by itself for fixturing. The sheet can be secured to an object by heating to cause the adhesive to adhere to the object. The prescoring can be perforations in the sheet and the embossments can be in a diamond shaped cross-hatching configuration.

Claims

1. A pad including at least one compressed portion forming a heat sink area and at least one thermal insulating area, comprising:

a plurality of interior layers of metal foil between a top layer and a bottom layer of metal foil forming a stack wherein said layers are arranged one above another in said at least one compressed portion forming the heat sink area and in said at least one thermal insulating area, at least one of said layers including plurality of embossments therein separating said at least one of said layers from an adjacent one of said layers in said at least one insulating area so as to provide a gap therebetween, the layers being secured together by securing means at said at least one compressed portion of the stack, one of the layers in said at least one insulating area being adjacent to and not metallurgically bonded to another one of the layers in said at least one insulating area.

2. The pad of claim 1, wherein said pad includes shapability means in the form of perforations in the pad for providing shapability to the pad.

3. The pad of claim 2, wherein said perforations extend completely through said pad.

4. The pad of claim 1, wherein said pad includes shapability means in the form of at least one indentation in the pad for providing shapability to the pad.

5. The pad of claim 4, wherein the at least one indentation is provided at least along said at least one thermal insulating area of the pad.

6. The pad of claim 1, wherein the compressed portion of the stack is a heat sink area wherein the layers provide better heat conduction through the pad than at the insulating area.

7. The pad of claim 2, wherein the shapability means comprises at least one row of perforations in the pad.

8. The pad of claim 4, wherein the shapability means comprises at least one row of indentations in the pad.

14. The pad of claim 1 wherein the top layer of metal foil is about 2 mils (0.002 in.) in thickness.

15. The pad of claim 1 wherein the bottom layer of metal foil is about 2 mils (0.002 in.) in thickness.

16. The pad of claim 1 wherein the interior layers of metal foil are each about 0.8 mils (0.0008 in.) in thickness.

17. The pad of claim 1 comprising three interior layers and wherein the overall thickness of said at least one thermal insulating area is about 5 mm.

18. The pad of claim 1 further comprising a frame for supporting at least one compressed portion of the stack.

19. The pad of claim 1 further comprising a pan for supporting at least one compressed portion of the stack.

20. The pad of claim 19 wherein the pan has a thickness of about 20 mils (0.02 in.).

21. The pad of claim 19 wherein the top layer extends over the edges of the pan to hold the pad in a recess in the pan.

22. The pad of claim 1 wherein the top layer extends over the outer edges of the interior and bottom layers and beneath the bottom layer and is secured beneath the bottom layer.

23. The pad of claim 1 wherein the at least one thermal insulating area provides a reduction in temperature to about 50°

C. on a side of the pad facing away from a heat source when the heat source is at a temperature of about 250°

C.

24. The pad of claim 1 wherein the at least one thermal insulating area provides a temperature differential of 200°

C. between a surface of the pad facing a heat source and an opposite surface of the pad and the at least one compressed portion provides a temperature differential of about 25°

C. between the surface of the pad facing the heat source and the opposite surface of the pad.

25. The pad of claim 1 wherein said securing means comprises interengaging the layers with each other.

9. A pad, including at least one compressed area forming a heat sink area and at least one thermal insulating area, comprising:

a plurality of interior layers of metal foil arranged one above another in said compressed area forming said heat sink area and in said thermal insulating area between a top layer and a bottom layer of metal foil, at least two of said layers being separated in said insulating area so as to provide a gap therebetween, one of said layers in said insulating area being adjacent to and not metallurgically bonded to another one of said layers in said insulating area, and said layers being secured together by securing means in said compressed area.

10. The pad of claim 9, wherein said compressed area forming said heat sink area provides better heat conduction in the transverse direction than said insulating area and is located to dissipate heat from the pad.

11. The pad of claim 9, wherein medial lines through each layer of said at least two separated layers are substantially parallel.

12. The pad of claim 9 wherein said pad includes shapability means in the form of at least one indentation in the pad for providing shapability to the pad.

13. The pad of claim 9 wherein said pad includes shapability means in the form of perforations in the pad for providing shapability to the pad.

26. The pad of claim 9 wherein at least two of said interior layers being separated in said insulating area so as to provide a gap therebetween.

27. The pad of claim 9 wherein the top layer of metal foil is about 2 mils (0.002 in.) in thickness.

28. The pad of claim 9 wherein the bottom layer of metal foil is about 2 mils (0.002 in.) in thickness.

29. The pad of claim 9 wherein the interior layers of metal foil are each about 0.8 mils (0.0008 in.) in thickness.

30. The pad of claim 9 comprising three interior layers and wherein the overall thickness of said at least one thermal insulating area is about 5 mm.

31. The pad of claim 9 further comprising a frame for supporting at least one compressed portion of the stack.

32. The pad of claim 9 further comprising a pan for supporting at least one compressed portion of the stack.

33. The pad of claim 32 wherein the pan has a thickness of about 20 mils (0.02 in.).

34. The pad of claim 32 wherein the top layer extends over the edges of the pan to hold the pad in a recess in the pan.

35. The pad of claim 9 wherein the top layer extends over the outer edges of the interior and bottom layers and beneath the bottom layer and is secured beneath the bottom layer.

36. The pad of claim 9 wherein the at least one thermal insulating area provides a reduction in temperature to about 50°

C. on a side of the pad facing away from a heat source when the heat source is at a temperature of about 250°

C.

37. The pad of claim 9 wherein the at least one thermal insulating area provides a temperature differential of 200°

C. between a surface of the pad facing a heat source and an opposite surface of the pad and the at least one compressed portion provides a temperature differential of about 25°

C. between the surface of the pad facing the heat source and the opposite surface of the pad.

38. The pad of claim 9 wherein said securing means comprises interengaging the layers with each other.

39. A method of making a pad having at least one compressed area forming a heat sink area and at least one thermal insulating area, comprising:

assembling a plurality of interior layers of metal foil arranged one above another between a top layer and a bottom layer of metal foil to form a stack of metal foil layers, at least two of said layers being separated so as to provide a gap therebetween to form said insulating area;

compressing at least a portion of said stack to form said compressed heat sink area adjacent to said insulating area; and

securing said layers together in said compressed area.

40. The pad of claim 39 wherein the at least two of said layers being separated comprise at least two of said interior layers.

41. The method of claim 39 further comprising securing said layers together by interengaging the layers with each other in said compressed area.

42. The method of claim 39 further comprising cutting the stack to provide a compressed area between an insulating area and an outer edge of the stack.

43. The method of claim 41 further comprising cutting the stack to provide a compressed area between an insulating area and an outer edge of the stack.

44. The method of claim 39 wherein the compressing and securing steps are performed simultaneously.

45. The method of claim 41 wherein the steps of compressing and interengaging the layers are performed simultaneously.

46. The method of claim 42 wherein the cutting, compressing and securing steps are performed simultaneously.

47. The method of claim 43 wherein the cutting, compressing and interengaging the layers are performed simultaneously.

48. The method of claim 39 wherein said securing step comprises forming a plurality of openings extending in said vertical direction through said layers in said heat sink area by passing a punch through said layers, said punch including a plurality of spaced-apart projections, each of which forms a respective one of said openings and said compressing and securing steps being simultaneously performed with a composite tool comprising a compressible material which performs said compressing step and said punch which performs said securing step, the compressible material and the punch being mounted together in side-by-side relationship.

49. The method claim 39 further comprising a step of cutting said stack such that said heat sink are lies between said insulating area and an outer edge of sad stack, said cutting step being performed simultaneously with said compressing and securing steps.

50. The method claim 49 wherein said cutting, compressing and securing steps are simultaneously performed with a composite tool comprising a compressible material for comprising a compressible material for compressing said layers, a punch for securing said layers by forming at least one opening therein and a cutter for cutting said layers, said compressible material being mounted between said cutter and said punch, said compressible material contacting said stack before said cutter and said punch contact said stack during said simultaneous cutting, compressing and securing steps, said compressible material being compressed to a predetermined amount and compressing said stack in said heat sink area when said cutter cuts said stack and said punch punches said at least one opening.

51. A pad including thermal insulation and heat sink areas, comprising:

a plurality of layers (2) of metal foil forming a stack (3) wherein said layers (2) are arranged one above another in a vertical direction, said stack (3) including at least one heat sink area (4) and at least one thermal insulation area (5) adjacent to said heat sink area (4), at least one of said layers (2) being separated from an adjacent one of said layers (2) in said insulating area (5) so as to provide gaps therebetween wherein at least one of said layers (2) in said insulating area (5) is in point contact with another one of said layers and is not metallurgically bonded to another one of said layers in said insulating area (5);

wherein said heat sink area (4) comprises a compressed portion of the stack whereby each layer (2) is in flat contact with an adjacent layer in the heat sink area (4) and the heat sink area (4) is located to dissipate heat from the pad.

52. The pad of claim 51 wherein a heat sink area is located at the outer periphery of the pad.

53. The pad of claim 51 wherein a heat sink area is located between the insulating area and the edge of the stack.

54. The pad of claim 51 wherein the pad is about 5 mm in thickness.

55. The pad of claim 51 wherein at least one of said layers (2) of metal foil is 0.05 mm or 0.02 mm in thickness.

56. The pad of claim 51 wherein said layers (2) in the heat sink area (4) being secured together by securing means (7).

57. The pad of claim 56, wherein said securing means (7) comprises stapling layers (2).

58. The pad of claim 56 wherein the securing means (7) comprises crimping the layers (2).

59. The pad of claim 56 wherein the securing means (7) comprises mechanical bonding of the layers (2).

60. The pad of claim 59 wherein the mechanical bonding of the layers (2) comprises interengaging the layers with each other.

61. The pad of claim 56 wherein the securing means (7) comprises metallurgical bonding of the layers (2).

62. The pad of claim 56 wherein the securing means (7) comprises an adhesive between the layers (2).

63. A pad of claims 51 comprising:

means (100) for providing shapability to the pad.

64. The pad of claim 63, wherein said shapability means comprises at least one row of perforations (100) in said pad.

65. The pad of claim 64, wherein the perforations (100) extend completely through said pad.

66. The pad of claim 63 wherein said shapability means comprises a pattern of indentations in an outer one of said layers of said pad.

67. The pad of claims 51 wherein at least one of said layers (2) comprises a black surface on at least part of at least one side of said layer.

68. A method of making a heat insulating pad having insulating and heat sink areas, comprising:

a step of assembling a plurality of layers (2) of metal foil in a stack wherein said layers are arranged one above another in a vertical direction, at least two of said layers being in point contact with each other and separated from each other by gaps between said layers (2) in the insulating area (5); and

a step of compressing a portion of said stack such that heat sink (4) is formed adjacent to insulating areas (5) therein with said layers being in flat contact with each other in said heat sink area (4).

69. The method of claim 68 wherein the step of compressing is performed with a tool (T₂) comprising a compressible material (13).

70. The method of claim 68 further comprising the step of securing the layers (2) together in the heat sink area (4).

71. The method of claim 70 wherein the compressing and securing steps are performed simultaneously.

72. The method of claims 68 further comprising cutting the stack.

73. The method of claim 72 wherein the cutting, compressing and securing steps are performed simultaneously.

74. The method of claim 72 wherein the steps of compressing, securing and cutting are performed with a tool (T₂) comprising a cutter (14) mounted on a holder (15) in side-by-side relationship with compressible material (13) and comprising a punch (12) mounted in side-by-side relationship with said compressible material (13).

75. The method of claims 68 further comprising the step of applying a black coating to at least a portion of at least one side of at least one of said layers (2).