Plastic double-walled structural panel

A plastic double-walled structural panel suitable for a vehicle, comprising:

• an outer panel comprised of plastic and having a top portion, first and second longitudinal ends, an outer appearance surface, an inner surface, and one or more outer attachment points;
• an inner panel comprised of plastic and having first and second longitudinal ends, an inner appearance surface, a support structure formed integrally with the inner panel, and inner attachment points corresponding to one or more outer attachment points of the outer panel;
• a hardware bracket connected to the inner panel;
• and
• at least one connector for connecting at least one inner attachment point of the inner panel and at least one corresponding outer attachment point of the outer panel.

A method for forming a plastic double-walled structural panel suitable for a vehicle, comprising:

• molding a plastic outer panel having a top portion, first and second longitudinal ends, an outer appearance surface, an inner surface, and one or more outer attachment points;
• molding a plastic inner panel having first and second longitudinal ends, an inner appearance surface, a support structure, and one or more inner attachment points corresponding to one or more outer attachment points of the outer panel;
• and
• connecting one or more inner attachment points of the inner panel and one or more outer attachment points of the outer panel.

A method for forming a plastic double-walled structural panel suitable for a vehicle, comprising:

• molding a plastic outer panel having a top portion, first and second longitudinal ends, an outer appearance surface, an inner surface, a support structure, and one or more outer attachment points;
• molding a plastic inner panel having first and second longitudinal ends, an inner appearance surface, and one or more inner attachment points corresponding to one or more outer attachment points of the outer panel;
• and
• connecting one or more inner attachment points of the inner panel and one or more outer attachment points of the outer panel.

A method for forming a plastic double-walled structural panel suitable for a vehicle, comprising:

• molding a plastic outer panel having a top portion, first and second longitudinal ends, an outer appearance surface, an inner surface, and one or more outer attachment points;
• molding a plastic inner panel having first and second longitudinal ends, an inner appearance surface, and one or more inner attachment points corresponding to one or more outer attachment points of the outer panel;
• molding a separate plastic support structure;
• positioning the support structure between the inner and outer panels;
• and
• connecting at least one inner attachment point of the inner panel and at least one outer attachment point of the outer panel.