Basf Aktiengesellschaft

Honeywell International Inc.

Alliedsignal Inc.

Val A Kagan

Chul S Lee

Thomas J Krolick

Peter K Han

Emile N Homsi

A frictionally welded, filled thermoplastic article is strengthened by restricting lateral flow of molten material out of the gap between the workpieces, so that a molten pool of substantial depth is maintained from the beginning of melting to the onset of solidification. The restriction to lateral flow of material is provided by dams (projections) of essentially rectangular cross-section at each lateral edge of one of the workpieces, while the other workpiece has a substantially flat mating surface.

Frictionally welded thermoplastic articles having improved strength

A co-injection molded air intake manifold shell comprises an inner and outer skin layer separated by a sound absorbing or sound insulation core. Each skin layer is composed of a polyamide resin which, optionally, contains glass fiber reinforcement and high specific gravity fillers such as barium sulfate or tungsten. The sound insulating core is composed of a high density material having a foam structure, such as a polyamide resin. Skin layers are provided with a plurality of pockets to permit distribution of localized lumped masses at predetermined locations tailored to increase noise transmission losses. A single layer air intake manifold shell having non-uniform thickness is also provided. The thickness of the single layer air intake manifold shell is larger over preselected noise sources of larger amplitude to maximize noise attenuation for a nominal air intake manifold shell thickness.

Engine noise barrier

Two polygon shaped articles having walls of different thicknesses are mated and welded together. Specimens cut from this composite part are used to evaluate the performance of welded joints with the influence of design, processing conditions such as welding, molding, and the like, and material composition. The evaluation advantageously provides an accurate predictor for linear vibration, orbital vibration, hot plate, hot gas, hot gas extrusion and infrared welding at a variety of bead thicknesses.

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Morris Plains, NJ, United States of America

Val A Kagan