Abstract: A method of preparing a molded cross vehicle beam which includes a hollow blow molded thermoplastic rigid member that is integrally attached to a rigid support, e.g., a U-shaped metal plate, and at least one attachment element, is described. The rigid support (12) has a first surface, a second surface and a plurality of perforations having edges. The attachment element(s) (81, 84) have a first surface, a second surface and a plurality of perforations having edges. The attachment element provides a means of attaching the molded cross vehicle beam to a separate structure (e.g., the A-pillars of an automobile). A thermoplastic parison precursor of the hollow rigid thermoplastic member (15) is blow molded against the first surfaces of the rigid support (12) and the attachment element (81, 84).

Abstract: A tubular assembly that includes a plug (45) residing within at least a portion of each of a first tube (12) and a second tube (30), is described. Each of the first and second tubes have perforations (21 and 39) that are separately aligned with cavities (51) in the exterior surface (48) of the plug (45). Plastic material (54) is molded separately through the perforations (21 and 39) of the first and second tubes (12 and 30) and at least partially fills the cavities (51) of the plug (45). The edges (24) of the perforations (21) of the first tube (12), and the edges (42) of the perforations (39) of the second tube (30) are embedded in the plastic material (54) extending therethrough, thereby fixedly attaching the first and second tubes to the plug therein.

Abstract: A tubular assembly which includes a first (or outer) tube (12), a second tube (21) is described. A portion of the second tube (21) resides within the first tube (12). The first tube (12) has a plurality of perforations (15) having edges (18), and the exterior surface (32) of the second tube (21) has a plurality of indentations (24), at least some of which are aligned with the perforations (15) in the first tube (12). Alternatively, or in addition thereto, the interior surface (35) of the first tube (12) has a plurality of indentations (59), at least some of which are aligned with a plurality of perforations (47) having edges (50) in the second tube (21). The tubular assembly is prepared by molding plastic material (e.g., thermoplastic material) through at least some of the perforations (e.g., in the first tube) into and at least partially filling the indentations aligned therewith (e.g., in the exterior surface of the second tube).

Abstract: A tubular assembly that includes a plug (45) residing within at least a portion of each of a first tube (12) and a second tube (30), is described. Each of the first and second tubes have perforations (21 and 39) that are separately aligned with cavities (51) in the exterior surface (48) of the plug (45). Plastic material (54) is molded separately through the perforations (21 and 39) of the first and second tubes (12 and 30) and at least partially fills the cavities (51) of the plug (45). The edges (24) of the perforations (21) of the first tube (12), and the edges (42) of the perforations (39) of the second tube (30) are embedded in the plastic material (54) extending therethrough, thereby fixedly attaching the first and second tubes to the plug therein.

Abstract: A tubular assembly which includes a first (or outer) tube (12), a second (or inner) tube (21) and a plug (42) within the second tube (21) is described. The plug (42) resides within at least a portion of the second tube (21), which itself resides within a portion of the first tube (12). The first (12) and second (21) tubes each have perforations (15, 24), at least some of which are aligned. The plug (42) has cavities (45) in its exterior surface (48), at least some of which are aligned with the aligned perforations (36). Plastic material (e.g., thermoplastic material) is molded through aligned perforations (36) and at least partially fills aligned cavities (45). The edges (39) of aligned perforations (36) are embedded in the plastic material (53) molded therethrough. The plastic material (53) extending through aligned perforations (36), into cavities (45) and embedding perforation edges (39) therein, serves to fixedly attach the first tube (12), second tube (21) and plug (42) together.

Abstract: A molded cross vehicle beam which includes a hollow blow molded thermoplastic rigid member that is integrally attached to a rigid support, e.g., a U-shaped metal plate, and at least one attachment element, is described. The rigid support (12) has a first surface, a second surface and a plurality of perforations having edges. The attachment element(s) (81, 84) have a first surface, a second surface and a plurality of perforations having edges. The attachment element provides a manner of attaching the molded cross vehicle beam to a separate structure (e.g., the A-pillars of an automobile). A thermoplastic parison precursor of the hollow rigid thermoplastic member (15) is blow molded against the first surfaces of the rigid support (12) and the attachment element (81, 84).