Abstract: The present invention comprises a method of attaching plastic to a metal substrate and a part made by the method. A hydroformed metal section having top and bottom openings is provided. A plastic component is molded about the metal component and through the bottom opening. The plastic component includes a flange on one side thereof to secure the plastic component with the metal component.

Abstract: The present invention comprises a method of attaching plastic to a metal substrate and a part made by the method. A hydroformed metal section having top and bottom openings is provided. A plastic component is molded about the metal component and through the bottom opening. The plastic component includes a flange on one side thereof to secure the plastic component with the metal component.

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.

Abstract: The present invention comprises a method of attaching plastic to a metal substrate and a part made by the method. A hydroformed metal section having top and bottom openings is provided. A plastic component is molded about the metal component and through the bottom opening. The plastic component includes a flange on one side thereof to secure the plastic component with the metal component.

Abstract: The present invention is directed to a plastic double-walled structural panel suitable for use as a door or tailgate for a motor vehicle. The structural panel includes a plastic outer panel, a plastic inner panel, and a substantially plastic support structure. Generally, the plastic outer panel has one or more outer attachment points that correspond to one or more inner attachment points in the inner panel. In a preferred embodiment of the invention, the support structure is comprised of plastic and is formed integrally with the inner or outer panel, e.g., as integral trusses. Integrally-formed or non-integrally-formed connectors may be included for connecting attachment points of the inner panel and attachment points of the outer panel. The invention further includes a method for manufacturing and assembling a substantially plastic double-walled structural panel that is suitable for use in connection with motor vehicles.

Abstract: An inventive air duct includes a blow molded tubular body of a first material having at least one annular open end, the open end terminating at a radially outwardly extending lip. A cuff of a second material is molded to the main body such that at least a portion of the lip is embedded within the cuff. Before molding the cuff, a portion of the main body adjacent the open end is pre-formed to remove any seams created during blow molding and to provide improved dimensional stability. Thus, leak pathways are minimized. The improved dimensional stability in combination with the use of an outwardly extending lip, a portion of which is embedded within the cuff, helps promote a strong seal between the cuff and the main body.

Abstract: An improved end tank-to-header joint is disclosed. An end tank is formed with a flange portion that has at least one groove therein. A gasket having a predetermined cross-sectional shape is provided with at least one tongue portion that is adapted to engage the groove in an interference fit, thereby integrating the gasket with the end tank. A header is crimped to form a channel. The channel has a shape the corresponds to the shape of the gasket, such that the gasket is fully seated within the channel. A distal end of the header is then crimped around the flange of the end tank to ensure a fluid-tight seal at the joint.