Abstract: A method of forming a structural oil pan via lost core molding is disclosed. The structural oil pan comprises a bracket portion configured for mounting to the vehicle, a pan portion integrated with the bracket portion and defining an oil reservoir, and a structural section formed via lost core molding and defining a cavity. The method comprises the step of lost core molding by forming a metal core, molding the bracket portion and/or the pan portion about the metal core, and removing the metal core to form the structural section in at least one of the bracket portion and the pan portion. The method also includes co-molding the bracket portion and the pan portion together to form the structural oil pan.

Abstract: A structural oil pan for a vehicle is formed from polymeric material, The structural oil pan includes a bracket portion configured for mounting to the vehicle, and a pan portion integrated with the bracket portion and defining an oil reservoir. The structural oil pan also includes a structural section defining a cavity within at least one of the bracket portion and the pan portion for reducing vibration.

Abstract: A frictional weld joint couples first and second body portions of an article together. The frictional weld joint comprises a first bead extending from the first body portion of the article and a second bead extending from the second body portion of the article. The second bead has an interior stem and an exterior stem space from the interior stem defining a cavity therebetween. The first and second beads are placed in contact with each other with the centerline of the second bead offset from the centerline of the first bead. A force is applied to either the first or second body portions to generate friction between the first and second beads to plastically displace the first and second beads. The force is removed for fusing the first and second beads together to couple together the first and the second body portions of the article.

Abstract: A method of forming a structural oil pan via lost core molding is disclosed. The structural oil pan comprises a bracket portion configured for mounting to the vehicle, a pan portion integrated with the bracket portion and defining an oil reservoir, and a structural section formed via lost core molding and defining a cavity. The method comprises the step of lost core molding by forming a metal core, molding the bracket portion and/or the pan portion about the metal core, and removing the metal core to form the structural section in at least one of the bracket portion and the pan portion. The method also includes co-molding the bracket portion and the pan portion together to form the structural oil pan.

Abstract: A structural oil pan for a vehicle is formed from polymeric material, The structural oil pan includes a bracket portion configured for mounting to the vehicle, and a pan portion integrated with the bracket portion and defining an oil reservoir. The structural oil pan also includes a structural section defining a cavity within at least one of the bracket portion and the pan portion for reducing vibration.

Abstract: A frictional weld joint couples first and second body portions of an article together. The frictional weld joint comprises a first bead extending from the first body portion of the article and a second bead extending from the second body portion of the article. The second bead has an interior stem and an exterior stem space from the interior stem defining a cavity therebetween. The first and second beads are placed in contact with each other with the centerline of the second bead offset from the centerline of the first bead. A force is applied to either the first or second body portions to generate friction between the first and second beads to plastically displace the first and second beads. The force is removed for fusing the first and second beads together to couple together the first and the second body portions of the article.

Abstract: An article manufactured from a polymer filled with fibers includes a plurality of ribs orientated and configured in a unique manner to improve resistance to an impact from an object. The ribs extend from a planar portion of the article. A fillet interconnects the ribs and the planar portion and includes a fillet radius of at least 0.75 mm. The fibers of the polymer are aligned within the article parallel to a flow of the polymer when injected into a mold during a molding process. The ribs are oriented in a pattern relative to the aligned fibers to maximize the impact resistance of the article.