Abstract: The present invention relates to a muffler facia assembly including a muffler with at least one thermoplastic shell formed into a facia assembly on a motor vehicle. The facia may be any suitable body part of a motor vehicle, such as a bumper, a rocker panel, an air dam, a spoiler, a sideboard or a body module. An assembly in accordance with the present invention includes structural members to provide crash management features to increase the strength and impact resistance. In accordance with the present invention, the long fiber thermoplastic material and moldings may also be combined with over-molding of preforms of unidirectional or woven inlays, which provide local structural performance. The use of such preforms is particularly suited to use in the manufacture of high temperature, structural articles such as bumper muffler combinations.

Abstract: A muffler assembly includes a housing defining at least one internal chamber. The housing is constructed from a composite material made from a thermoplastic resin and a reinforcing element. The reinforcing element is selected from a group of reinforcing materials consisting of glass fibers, aramid fibers, polyamide fibers, carbon fibers, graphite fibers, mineral fibers, ceramic fibers, carbon nanotubes, nano fillers, mineral fillers, ceramic fillers and combinations thereof. A pipe is received in the housing. The pipe includes at least one opening providing acoustic communication between an internal passage in the pipe and the chamber in the housing. An acoustic attenuating material is received in that chamber.

Abstract: The present invention relates to a muffler facia assembly including a muffler with at least one thermoplastic shell formed into a facia assembly on a motor vehicle. The facia may be any suitable body part of a motor vehicle, such as a bumper, a rocker panel, an air damn, a spoiler, a sideboard or a body module. An assembly in accordance with the present invention includes structural members to provide crash management features to increase the strength and impact resistance. In accordance with the present invention, the long fiber thermoplastic material and moldings may also be combined with over-molding of preforms of unidirectional or woven inlays, which provide local structural performance. The use of such preforms is particularly suited to use in the manufacture of high temperature, structural articles such as bumper muffler combinations.