Abstract: A fuel tank having an integrally molded heat shield. An insulating material is secured to one surface of a pad made from foamed high density polyethylene (PE). The heat shield is placed within a blow-molding apparatus. A hot pliable HDPE parison is extruded adjacent a second surface of the pad. The parison contacts the second surface and causes the second surface to heat and partially melt. The parison is urged against the pad. HDPE material from the pad and parison intermingle and fuse. Pressure from the blow molding process aids in intermingling the molten surfaces together to form a strong integral attachment.

Abstract: A polymeric container having a permeation retardant laminate welded to a surface of the container. The laminate comprises a polymeric carrier film and a permeation retardant coating applied to the carrier film. The carrier film welds to the container material to form an integral composite structure. The container may be produced by a method wherein a heated polymeric material is extruded within a mold. Laminate is dispensed adjacent hot polymeric material. The hot polymeric material softens the polymeric film carrier causing the two to weld together.

Abstract: An automotive exhaust manifold is fabricated from stainless steel sheet metal of thin dense gauge, and provided with an outer coating of less dense stainless steel or other suitable material spray bonded to it to provide an irregular surface of non-uniform cross-section with a large surface area to damp the transmission of sound waves from the manifold.

Abstract: This invention is directed to a composite pipe comprising three layers adjacent to one another. It consists of a thin-walled metallic inner liner, a thermally insulating ceramic material layer, and an outer casing of a non-metallic material. The composite pipe is useful in automotive applications such as exhaust gas systems to reduce the thermal energy transfer from the exhaust pipe along the length of the pipe, reduce sound transmission, hinder corrosion and reduce weight.

Abstract: An engine component assembly is disclosed having a bi-material wrist pin which secures a piston rotatably to an associated connecting rod. The bi-material wrist pin includes a cylindrical ceramic core. Surrounding the cylindrical core is a tubular shell which fixedly secures the core in relation to the shell. The shell rotatably cooperates with the piston and is fixed in relation to the connecting rod.

Abstract: A fiber reinforced article having an integrally molded heat shield is produced using a liquid resin injection molding technique. One or more layers of heat shielding material are placed adjacent a preform. The preform contains a non-porous inner core and a porous fibrous mat exterior surface. The core is either a foam core, blow-molded core or a metal reinforced core. The heat shielding material is at least partially porous and includes a heat insulating material and/or a heat reflecting material. The heat shield also contains a layer of nonporous insulating material designed to prevent liquid resin from passing therethrough. The preform and heat shielding material are placed in a mold and resin is injected into the mold to impregnate the fibrous mat and partially impregnate the heat shielding material so that the heat shielding material is integrally molded to the product.

Abstract: A molded article comprising a molded body and one or more llayers of heat shielding material attached to the molded body and a method of making same. The heat shielding material is placed on localized areas of the molded articles which are exposed to elevated temperatures. The molded article may be a fiber reinforced plastic (FRP) which comprises a fibrous material containing a resin or alternatively, the molded article may be a thermoplastic material with or without reinforcement.

Abstract: An EGR valve assembly for use in an EGR valve body having a chamber with an inlet and outlet, comprising: (a) a stemmed reciprocable valve controlling flow into said chamber, the stem of said valve being constituted of an iron-based core material (i.e., 300 seeries stainless steel) impregnated at its outer surface with an ingredient (i.e., electroless nickel, ion implanted or chemically deposited nitrides, and electrolytic chromium) that is compatible in sliding contact with ceramic and provides said stem with a hardness at room temperature of at least 60 R.sub.c and a lubricating oxidized passivation layer at a temperatures in excess of 600.degree. C., and (b) a ceramic-based bushing (SiC, Si.sub.3 N.sub.4, Al.sub.2 O.sub.3, ceramic/metal composite) for sealingly guiding the reciprocal movement of said stem.