Hybrid composite structure and process for forming utilizing high pressure die cast components with structural plastic overmold

Abstract

A process, article and assembly for joining a plurality of individual castings into a hybrid composite, including providing a plurality of individual castings and arranging the castings in an arrayed fashion, transporting the arranged castings into an injection molding machine, and injecting a plasticized material between and around the castings for forming a single hybrid structure. Additional steps include the castings being provided as aluminum castings. The step of injecting a plasticized material further includes utilizing a High Pressure Die Casting (HPDC) technology with thermoplastic injection molding or over-molding techniques to form the single hybrid structure. The single hybrid structure further includes forming any of a vehicle frame, chassis or underbody. Alternatively, the step of forming a single hybrid structure can include forming an EV battery tray.

Dependencies are inferred from the claim text.