Abstract: Disclosed is a injection molded composite wheel, including a thermoplastic polyamide composition consisting essentially of (A) 20 to 70 weight percent of at least one polyamide resin including at least one repeat unit selected from the group consisting of the formulas —C(O)(CH2)10C(O)NH(CH2)nNH—??(I), —C(O)(CH2)12C(O)NH(CH2)nNH—??(II), —C(O)(CH2)14C(O)NH(CH2)nNH—??(III), and —C(O)(CH2)16C(O)NH(CH2)nNH—??(IV); wherein n is an integer selected from 4, 6, and 10, and with the proviso that when the polyamide resin has repeat units of formula (I), at least one other repeat unit of formula (II)-(IV) is also present in at least 30 mol % content; (B) 20 to 65 weight percent of one or more fiber reinforcing agents, and (C) 0 to 20 weight percent of one or more polymer impact modifiers.

Abstract: Disclosed is a muffler assembly including: a) polymeric housing having an interior surface and at least one opening for at least one inlet and one outlet exhaust pipe; b) at least one metal inlet exhaust pipe and at least one metal outlet exhaust pipe positioned within the openings to provide housing-exhaust pipe interfaces; c) a thermal insulating material coating the interior surface of the polymeric housing and extending through the housing-exhaust pipe interfaces; wherein the thermal insulating material seals the muffler assembly at the housing-exhaust pipe interfaces; and wherein the muffler assembly has a leak rate of 105 Liters/minute or less at 4.5 psig pressure. An optional muffler assembly has body mounting adapters attached to the inlet and outlet exhaust pipes and positioned within the openings to provide housing-body mounting adapter interfaces. Also disclosed are processes for manufacturing the muffler assemblies.

Abstract: A muffler assembly including one or more exhaust pipe(s), a polymeric housing carried by at least one of the exhaust pipe(s); a thermal insulating layer lining the housing interior surface and extending between the housing and exhaust pipe at the housing-exhaust pipe interface; wherein the thermal insulating layer includes a nonwoven fabric; wherein when the fabric is exposed to heat, the fabric increases in thickness to seal the muffler assembly at the housing-exhaust pipe interface and provides thermal insulation to the polymeric housing.

Abstract: Disclosed is a injection molded composite wheel, including a thermoplastic polyamide composition consisting essentially of (A) 20 to 70 weight percent of at least one polyamide resin including at least one repeat unit selected from the group consisting of the formulas —C(O)(CH2)10C(O)NH(CH2)nNH—??(I), —C(O)(CH2)12C(O)NH(CH2)nNH—??(II), —C(O)(CH2)14C(O)NH(CH2)nNH—??(III), and —C(O)(CH2)16C(O)NH(CH2)nNH—??(IV); wherein n is an integer selected from 4, 6, and 10, and with the proviso that when the polyamide resin has repeat units of formula (I), at least one other repeat unit of formula (II)-(IV) is also present in at least 30 mol % content; (B) 20 to 65 weight percent of one or more fiber reinforcing agents, and (C) 0 to 20 weight percent of one or more polymer impact modifiers.

Abstract: Disclosed is a muffler assembly including: a) polymeric housing having an interior surface and at least one opening for at least one inlet and one outlet exhaust pipe; b) at least one metal inlet exhaust pipe and at least one metal outlet exhaust pipe positioned within the openings to provide housing-exhaust pipe interfaces; c) a thermal insulating material coating the interior surface of the polymeric housing and extending through the housing-exhaust pipe interfaces; wherein the thermal insulating material seals the muffler assembly at the housing-exhaust pipe interfaces; and wherein the muffler assembly has a leak rate of 105 Liters/minute or less at 4.5 psig pressure. An optional muffler assembly has body mounting adapters attached to the inlet and outlet exhaust pipes and positioned within the openings to provide housing-body mounting adapter interfaces. Also disclosed are processes for manufacturing the muffler assemblies.

Abstract: A muffler assembly including one or more exhaust pipe(s), one or more mounting adapter(s) attached to the one or more exhaust pipe(s), a polymeric housing carried by one or more mounting adapter(s), a thermal insulating layer lining the housing interior surface and extending between the housing and one or more mounting adapter(s) at the housing-mounting adapter interface(s); wherein the thermal insulating layer includes a nonwoven fabric; wherein when the fabric is exposed to heat, the fabric increases in thickness to seal the muffler assembly at the housing-exhaust pipe interface and provides thermal insulation to the polymeric housing.

Abstract: A muffler assembly including one or more exhaust pipe(s), a polymeric housing carried by at least one of the exhaust pipe(s); a thermal insulating layer lining the housing interior surface and extending between the housing and exhaust pipe at the housing-exhaust pipe interface; wherein the thermal insulating layer includes a nonwoven fabric; wherein when the fabric is exposed to heat, the fabric increases in thickness to seal the muffler assembly at the housing-exhaust pipe interface and provides thermal insulation to the polymeric housing.

Abstract: Disclosed is a muffler (1, 21, 41) integrated with a catalytic converter bed (9, 32, 52) including a polymeric muffler body (2, 22, 42), an inlet pipe (3, 23, 43) in flow communication with engine exhaust, said inlet pipe connected to a first body mounting adapter (5, 25, 45) so as to hold the inlet pipe a heat insulating distance from said polymeric muffler body, said inlet pipe in flow communication with an inlet of said catalytic converter bed (9, 32, 52), and a perforated exhaust pipe (4, 34, 44) in flow communication with an outlet of the catalytic converter bed, said perforated exhaust pipe mounted on a second body mounting adapter (6, 26, 56) so as to hold the perforated exhaust pipe a heat insulating distance from the polymeric muffler body; said inlet pipe and said perforated exhaust pipe holding said catalytic converter bed a heat insulating distance from the polymeric muffler body, said first body mounting adapter, polymeric muffler body, and second body mounting adapter forming a sealed internal c

Abstract: Disclosed is a injection molded composite wheel, including a polyamide composition including (A) about 20 to about 70 weight percent of at least one polyamide resin, (B) about 30 to about 65 weight percent of one or more fiber reinforcing agents wherein the fiber has an average length of 0.1 to 0.9 mm; and (C) 0 to about 20 weight percent of one or more polymer impact modifiers; wherein 4 mm test bars prepared from the polyamide composition have an average tensile modulus greater than or equal to about 9 GPa, and an elongation at break of at least 4%.

Abstract: Disclosed is a muffler (1, 21, 41) integrated with a catalytic converter bed (9, 32, 52) including a polymeric muffler body (2, 22, 42), an inlet pipe (3, 23, 43) in flow communication with engine exhaust, said inlet pipe connected to a first body mounting adapter (5, 25, 45) so as to hold the inlet pipe a heat insulating distance from said polymeric muffler body, said inlet pipe in flow communication with an inlet of said catalytic converter bed (9, 32, 52), and a perforated exhaust pipe (4, 34, 44) in flow communication with an outlet of the catalytic converter bed, said perforated exhaust pipe mounted on a second body mounting adapter (6, 26, 56) so as to hold the perforated exhaust pipe a heat insulating distance from the polymeric muffler body; said inlet pipe and said perforated exhaust pipe holding said catalytic converter bed a heat insulating distance from the polymeric muffler body, said first body mounting adapter, polymeric muffler body, and second body mounting adapter forming a sealed internal c

Abstract: Disclosed is a process for making muffler systems wherein the muffler polymeric bodies have a cross section that is constant over the length of the muffler polymeric body. The muffler systems are inexpensive to make and install.

Abstract: Mufflers having polymeric bodies that are protected from being overheated from the exhaust pipe by having an air gap between the exhaust pipe and the polymeric body are disclosed. Also disclosed is a process for making muffler systems wherein the muffler polymeric bodies have a cross section that is constant over the length of the muffler polymeric body. The muffler systems are inexpensive to make and install.