This disclosure details vehicle assemblies that are made up of a plurality of loose layered build components. One or more of the loose layered build components may include locating features for locating and supporting the component relative to other components of the assembly while still permitting movement of the component or one of the other components in at least one direction during the assembly process.

This disclosure details overmolded vehicle sheet metal structures that included integrated attachments for achieving part integration. An exemplary sheet metal structure includes a sheet metal panel, a reinforcing structure molded on the sheet metal panel, and an integrally molded attachment structure formed within the reinforcing structure. In some embodiments, the integrally molded attachment structure may include a nut, a bracket, or both. An additional vehicle component may be attached to the sheet metal panel via the integrally molded attachment structure. The sheet metal structure may be formed in a single shot injection molding process.

The present disclosure relates to a hybrid material panel assembly for a vehicle. The panel assembly includes a panel and a plurality of mounting flanges integrally formed with the panel. The panel is formed of a first material having a first coefficient of thermal expansion. The plurality of mounting flanges are formed of a second material having a second coefficient of thermal expansion, where each of the plurality of mounting flanges include a mounting area that defines a mounting surface and at least one mounting hole. The first coefficient of thermal expansion is greater than the second coefficient of thermal expansion.

An apparatus, according to an exemplary aspect of the present disclosure includes, among other things, a body-in-white member having an inboard side and an outboard side, a reinforcing structure molded on the inboard side, and an energy absorbing structure molded on the outboard side. A method according to an exemplary aspect of the present disclosure includes, among other things, providing a body-in-white member having an inboard side and an outboard side, molding a reinforcing structure on the inboard side, and molding an energy absorbing structure on the outboard side.

A method produces a fiber-reinforced body component for a motor vehicle. The body component has at least one opening, in particular one door opening or one window opening. The method includes at least the following steps: providing the body component; applying a reinforcing element made of fiber composite material having reinforcing fibers embedded in a matrix, in order to stiffen the body component, the matrix being in an uncured state, and the reinforcing element being applied to an opening frame of the opening, which opening frame is formed by the body component.

A chassis component for a motor vehicle has a core module with at least one first load-conducting element, at least one second load-conducting element and at least one load transfer element connecting the at least one first load-conducting element and the at least one second load-conducting element, and an insert molding. A method for producing the chassis component first of all produces the core module by joining the at least one first load-conducting element and the at least one load transfer element and also the at least one load transfer element and the at least one second load-conducting element, and then overmolds the produced core module.

The present invention relates to a hybrid cowl cross bar manufactured through an improved method of performing an insert injection molding without applying hydraulic pressure to the inside of a metal pipe during injection molding in order to simplify a manufacturing process of a hybrid cowl cross bar and to secure rigidity of the cowl cross bar. According to an aspect of the present invention, a reinforcing material is inserted into a metal pipe that is a material of a cowl cross bar. The metal pipe may be made of a material such as aluminum, magnesium, or steel, like a conventional cowl cross bar. The reinforcing material may be manufactured by extruding a synthetic resin or a composite material (for example, PP+GF50%). A rib may be formed inside the reinforcing material to increase a capability to resist injection pressure when the metal pipe is insert-injected and to secure rigidity.

A motor vehicle front end having a structural component that has a first structural element for absorbing mechanical forces. The first structural element surrounds a spatial region, at least in part, such that a cavity is formed in the interior of the first structural element. The first structural element has a surface region that defines said cavity. The structural component has at least one second structural element which is connected to the first structural element. For the purpose of mechanical reinforcement of the first structural element, the structural component has at least one reinforcing element. The reinforcing element supports a portion of the surface region. The first structural element is composed of at least two separate structural element parts.

A hybrid structure includes a frame member with at least three walls, forming a channel having a convex portion where two walls meet. A concave deformation is present in at least one convex portion, wherein the concave deformation extends into the channel and has open ends forming an opening through the convex portion. A plastic reinforcement member is present in the channel, wherein a portion of the reinforcement member extends into the opening and on the concave deformation.

A B-pillar for a motor vehicle body extends along a longitudinal axis, and comprises an upper metal portion for connecting the B-pillar to a roof area of the motor vehicle body and a lower metal portion for connecting the B-pillar to a sill area of the motor vehicle body; and a fiber composite component comprising fibers and a plastic matrix, the upper metal portion comprising an upper region for force introduction, and the lower metal portion comprising a lower region for force introduction being axially spaced from the upper region for force introduction, the upper region for force introduction and the lower region for force introduction being embedded into the fiber composite component.