Injection molded thermoplastic integrated front end reinforcement and method of making same

Abstract

A vehicle body front end preassembly and method of making a vehicle front end assembly is disclosed. The vehicle body front end preassembly includes a frame to which an integrated front end module formed by an injection molding process is secured. The integrated front end module extends transversely across the vehicle and is provided with a plurality of fastener receptacles that are integrally molded as part of the integrated front end module. A plurality of reinforcement ribs are integrally molded as part of the integrated front end module. Unpainted body panels are secured to some of the fastener receptacles. The frame, injection molded integrated front end module, and body panels are then hot dipped in an electro-coating bath. According to the method of the present invention, the integrated front end module is injection molded to include integrally molded fastener receptacle and integrally molded reinforcement ribs that are injection molded from a fiber reinforced thermoplastic polymer. A partially assembled vehicle body is provided that has partially unattached body panels that are secured to the frame. Unattached body panels are secured to the integrated front end module. The preassembly is then immersed in an electro-coat bath, painted and then baked in a paint oven.

Dependencies are inferred from the claim text.