# US 2015/0145286 A1 · Hinge pillar assembly having an inner retainer panel, and method of manufacturing the same > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2015/0145286 A1 - Document ID: US20150145286A1 - Status: Published application - Kind: A1 - Application number: 14/092,368 - Filed: 2013-11-27 - Published: 2015-05-28 - Earliest claimed: 2013-11-27 - Assignees: GM Global Technology Operations LLC - Applicants: GM Global Technology Operations LLC - Inventors: Robert N. Saje; Martin G. Foulkes; William P. Ciaramitaro; Jack E. Brown; Michael W. Davenport; Keith J. Saari - Web page: https://patentgrep.com/patent/US20150145286A1 ## CPC - B22D 17/2236: {Equipment for loosening or ejecting castings from dies (for plastics B29C45/40)} - B22D 17/00: Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure - B22D 25/02: by its peculiarity of shape; of works of art {(cylinders, pistons B22D15/02)} - B62D 25/02: Side panels {(B62D33/046 takes precedence; sideboards for open load compartments B62D33/023)} - B62D 25/04: Door pillars {; windshield pillars} - B62D 29/002: {a foamable synthetic material or metal being added in situ (shaping of substances in a plastic state by foaming, in general B29C44/00)} - Y10T 29/49002: Electrical device making - Y10T 29/49622: Vehicular structural member making - B22D: CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES (shaping of plastics or substances in a plastic state B29C; metallurgical processing, selection of substances to be added to metal C21, C22) - B62D: MOTOR VEHICLES; TRAILERS (steering, or guiding on a desired track, of agricultural machines or implements A01B69/00; wheels, castors, axles, increasing wheel adhesion B60B; vehicle tyres, tyre inflation or tyre changing B60C; connections between vehicles of a train or the like B60D; vehicles for use on rail and road, amphibious or convertible vehicles B60F; suspension arrangements B60G; heating, cooling, ventilating or other air treating devices B60H; windows, windscreens, non-fixed roofs, doors or similar devices, protective coverings for vehicles not in use B60J; propulsion plant arrangements, auxiliary drives, transmissions, controls, instrumentation or dashboards B60K; electric equipment or propulsion of electrically-propelled vehicles B60L; power supply for electrically-propelled vehicles B60M; passenger accommodation not otherwise provided for B60N; adaptations for load transportation or to carry special loads or objects B60P; arrangement of signalling or lighting devices, the mounting or supporting thereof or circuits therefor, for vehicles in general B60Q; vehicles, vehicle fittings or vehicle parts not otherwise provided for B60R; servicing, cleaning, repairing, supporting, lifting, or manoeuvring, not otherwise provided for, B60S; brake arrangements, brake control systems or parts thereof B60T; air-cushion vehicles B60V; motor-cycles, accessories therefor B62J, B62K; testing of vehicles G01M) - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A hinge pillar assembly includes a hinge pillar panel that is cast from a die casting process, and that defines an interior surface. An acoustic foam layer is disposed adjacent the interior surface of the hinge pillar panel. An inner retainer panel is attached to the hinge pillar panel. The inner retainer panel secures the acoustic foam layer between the inner retainer panel and the hinge pillar panel. The hinge pillar assembly is cast to define a cored boss that is used to retain the hinge pillar panel within an upper ejector half of a die set during the casting process. A fastener is disposed in the threaded engagement with the cored boss to attach the inner retainer panel to the hinge pillar panel. A vehicle component may be attached to the inner retainer panel. ## Claims ### Claim 1 A method of manufacturing a hinge pillar assembly for a vehicle, the method comprising: casting a hinge pillar panel with a high pressure direct casting process including a die set having an upper ejector die half disposed vertically above a lower non-ejector die half, to define a casting interlock feature disposed on an interior surface of the hinge pillar panel wherein the interlock feature includes a cored boss; positioning an acoustic foam layer about the casting interlock feature such that the casting interlock feature positions the acoustic foam layer relative to the hinge pillar panel; and attaching an inner retainer panel to the hinge pillar panel by fastening the inner retainer panel to the hinge pillar panel with a fastener, with the acoustic foam layer disposed between the interior surface of the hinge pillar panel and the inner retainer panel. ### Claim 2 (depends on 1) The method as set forth in claim 1 further comprising forming the acoustic foam layer to conform to and mate with the interior surface of the hinge pillar panel. ### Claim 3 (canceled) ### Claim 4 (canceled) ### Claim 5 (depends on 1) The method as set forth in claim 1 wherein fastening the inner retainer panel to the hinge pillar panel includes inserting a fastener through an aperture of the inner retainer panel and into grasping engagement with the cored boss of the hinge pillar panel. ### Claim 6 (depends on 5) The method as set forth in claim 5 wherein inserting the fastener into grasping engagement with the cored boss of the hinge pillar panel is further defined as inserting the fastener into threaded engagement with the cored boss of the hinge pillar panel. ### Claim 7 (depends on 1) The method as set forth in claim 1 further comprising attaching a component to the inner retainer panel. ### Claim 8 (depends on 7) The method as set forth in claim 7 wherein the component includes one of an electrical module, an electrical connector, a wiring harness, or a trim piece. ### Claim 9 (depends on 7) The method as set forth in claim 7 wherein attaching the component to the inner retainer panel includes fastening the component to the inner retainer panel with a fastener that attaches the inner retainer panel to the hinge pillar panel. ### Claim 10 (canceled) ### Claim 11 (depends on 1) The method as set forth in claim 1 further comprising retaining the hinge pillar panel on the upper ejector die half of the die set with the cored boss. ### Claim 12 (depends on 11) The method as set forth in claim 11 wherein casting the hinge pillar panel to define the cored boss includes forming the cored boss to include a draft angle operable to retain the cast hinge pillar panel within the upper ejector die half of the die set. ### Claim 13 A hinge pillar assembly for attachment to a support structure of a vehicle, the hinge pillar assembly comprising: a hinge pillar panel cast from a die casting process, including a high pressure direct casting process, and defining an interior surface; an acoustic foam layer disposed adjacent the interior surface of the hinge pillar panel; and an inner retainer panel attached to the hinge pillar panel and securing the acoustic foam layer between the inner retainer panel and the hinge pillar panel. ### Claim 14 (depends on 13) The hinge pillar assembly as set forth in claim 13 wherein the hinge pillar panel includes a cored boss having a draft angle operable to retain the hinge pillar panel within an upper ejector die half of a die set. ### Claim 15 (depends on 14) The hinge pillar assembly as set forth in claim 14 further comprising a fastener in threaded engagement with the cored boss to attach the inner retainer panel to the hinge pillar panel. ### Claim 16 (depends on 14) The hinge pillar assembly as set forth in claim 14 wherein the acoustic foam layer conforms with and mates to the interior surface of the hinge pillar panel. ### Claim 17 (depends on 16) The hinge pillar assembly as set forth in claim 16 further comprising a component attached to and supported by the inner retainer panel. ### Claim 18 (depends on 13) The hinge pillar assembly as set forth in claim 13 wherein the hinge pillar panel includes at least one rib disposed on the interior surface thereof. ### Claim 19 (canceled) ### Claim 20 (depends on 13) The hinge pillar assembly as set forth in claim 13 wherein the inner retainer panel is a polymer.