Front end module

• US 6,955,393 B2
• Filed: 12/19/2003
• Issued: 10/18/2005
• Est. Priority Date: 12/19/2002
• Status: Expired due to Fees

• Current Assignee: Sabic Innovative Plastics IP BV (Government of Saudi Arabia), Vari-Form
• Original Assignee: Carlisle Engineered Products, Inc., General Electric Company, Vari-Form
• Inventors: Goral, Thomas M., Kowal, Eric, Klanges, Jerry, Gaida, Dennis, Panter, Keith R., Staargaard, James E., Nardone, Terry E., Butterfield, Larry D., Brown, Mitch, Longhouse, Blair
• Primary Examiner(s): Engle, Patricia L.
• Application Number:
  US10/741,095
• Publication Number:
  US 20040160088A1
• Time in Patent Office: 669 Days
• Field of Search: 296/193.09, 296/203.02, 296/193.01, 296/193.04, 296/193.1, 296/901.01, 180/68.4
• US Class Current: 296/193.1
• CPC Class Codes: B29C 2045/14327 anchoring by forcing the material to pass through a hole in the article
• CPC Class Codes: B29C 45/1418 the inserts being deformed or preformed, e.g. by the injection pressure
• CPC Class Codes: B29C 45/14344 Moulding in or through a hole in the article, e.g. outsert moulding
• CPC Class Codes: B29L 2031/30 Vehicles, e.g. ships or aircraft, or body parts thereof vanes or blades B29L2031/08, air bags B29L2022/027
• CPC Class Codes: B29L 2031/3002 Superstructures characterized by combining metal and plastics, i.e. hybrid parts
• CPC Class Codes: B62D 25/084 Radiator supports
• CPC Class Codes: B62D 29/001 characterised by combining metal and synthetic material
• CPC Class Codes: B62D 29/004 the metal being over-moulded by the synthetic material, e.g. in a mould

Abstract

A front end module including a plastic component connected to a metallic substrate. The metallic substrate can be formed by hydroforming and shaped into a substantially unitary member. The plastic component is then molded about the metallic substrate and simultaneously forms connections thereto at discrete locations along the length of the metallic substrate.

Claims

1. A front end module, comprising:

a continuous and unitary metallic component having at least one opening formed therein; and

a plastic component disposed about at east a portion of the metallic component, wherein a first portion of the plastic material extends through the at least one opening and a second portion of the plastic material extends about an external surface of the metallic component so as to connect the plastic component to the metallic component;

wherein the metallic component includes a horizontal portion and two spaced and opposed vertical portions extending therefrom.

2. The invention according to claim 1, wherein the metallic component is formed by hydroforming.

3. The invention according to claim 1, wherein the metallic component is a contoured unitary member.

4. The invention according to claim 1, wherein the metallic component comprises a closed cross section.

5. The invention according to claim 1, wherein the metallic component includes a plurality of openings formed therein.

6. The invention according to claim 1, wherein the plastic component includes at least one opening formed therein.

7. The invention according to claim 1, wherein the plastic component includes a plurality of openings formed therein.

8. The invention according to claim 1, wherein the plastic component includes at least one attachment hole formed therein.

9. The invention according to claim 1, wherein the plastic component includes at least one reinforcement member formed on a surface thereof.

10. A front end module, comprising:

a contoured continuous and unitary metallic component having at least one opening formed therein, wherein the metallic component includes a horizontal portion and two spaced and opposed vertical portions extending therefrom; and

a plastic component disposed about at least a portion of the metallic component, wherein a first portion of the plastic material extends through the at least one opening and a second portion of the plastic material extends about and envelopes an external surface of the metallic component so as to connect the plastic component to the metallic component.

11. The invention according to claim 10, wherein the metallic component is formed by hydroforming.

12. The invention according to claim 10, wherein the metallic component comprises a closed cross section.

13. The invention according to claim 10, wherein the metallic component includes a plurality of openings formed therein.

14. The invention according to claim 10, wherein the plastic component includes at least one opening formed therein.

15. The invention according to claim 10, wherein the plastic component includes a plurality of openings formed therein.

16. The invention according to claim 10, wherein the plastic component includes at least one attachment hole formed therein.

17. The invention according to claim 10, wherein the plastic component includes at least one reinforcement member formed on a surface thereof.