Polymeric engine hood assembly, vehicle front end module, vehicles comprising the same and methods of making the same

A method of making a polymeric engine hood assembly for use in a vehicle, comprising:

• applying heat to a first polymeric sheet;
• applying heat to a second polymeric sheet;
• stacking the first polymeric sheet and the second polymeric sheet
• placing the stacked sheets between a first mold half and a second mold half;
• closing the first mold half and second mold half;
• applying vacuum to the space between the first polymeric sheet and the first mold half and between the second polymeric sheet and the second mold half, wherein the first polymeric sheet forms an exterior panel and wherein the second polymeric sheet forms a reinforcing structure including a body comprising a reinforcing structure first surface and a reinforcing structure second surface, wherein the reinforcing structure includes alternating ridges and flanges extending across the reinforcing structure in the y direction forming corrugations, wherein the corrugations extend at least partially transversely across the body of the reinforcing structure, wherein indentations are disposed in the corrugations on the reinforcing structure;
• and
• attaching the exterior panel to a fender skin at a junction surface, wherein the reinforcing structure includes a connecting ridge extending transversely across the reinforcing structure located between indentations, wherein the connecting ridge is configured to accept the junction surface of the exterior panel and the fender skin, wherein the reinforcing structure is adjacent to and extends along a portion of an exterior panel engine facing surface and along a portion of a fender skin engine facing surface.

A polymeric engine hood assembly for use in a vehicle, comprising:

• an exterior panel having an exterior panel engine facing surface and an exterior panel outermost surface, wherein the exterior panel extends in an x direction;
• a fender skin adjacent to a portion of the exterior panel engine facing surface at a junction surface, wherein the fender skin has a fender skin engine facing surface and a fender skin outermost surface, wherein a portion of the fender skin extends in the x direction and wherein a portion of the fender skin extends in a y direction;
• and
• a reinforcing structure including a body comprising a reinforcing structure first surface and a reinforcing structure second surface, wherein the reinforcing structure attaches to and extends along a portion of an exterior panel engine facing surface and along a portion of a fender skin engine facing surface, wherein the reinforcing structure includes a ridge and groove extending transversely in the y direction forming a corrugation;
• wherein ribs are disposed laterally across a portion of the exterior panel engine facing surface and wherein ribs are disposed longitudinally across a portion of the fender skin engine facing surface;
• wherein the reinforcing structure includes a connecting ridge extending transversely across the reinforcing structure located between ribs, wherein the connecting ridge is configured to accept the junction surface of the exterior panel and the fender skin;
• wherein a channel is formed in air cavities located between the ridge on the reinforcing structure and the engine facing surfaces of the exterior panel or the fender skin.