# US 6,293,615 B1 · Injection molded thermoplastic integrated front end reinforcement and method of making same > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 6,293,615 B1 - Document ID: US6293615B1 - Status: Granted - Kind: B1 - Application number: 09/732,691 - Filed: 2000-12-08 - Granted: 2001-09-25 - Earliest claimed: 2000-05-24 - Assignees: Patent Holding Company - Inventors: Sassan Tarahomi - Web page: https://patentgrep.com/patent/US6293615B1 ## CPC - B62D 29/041: {Understructures} - B62D 25/084: {Radiator supports} - C25D 13/12: characterised by the article coated - Y10T 29/49622: Vehicular structural member making - Y10T 29/49888: Subsequently coating - Y10T 29/49984: and casting - 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) - C25D: PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## 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. ## Claims ### Claim 1 A vehicle body front end pre-assembly comprising: a frame; an injection molded integrated front end module secured to the frame and extending transversely across a portion of the vehicle at the front end thereof, said integrated front end module having a plurality of fastener receptacles integrally molded as part of the integrated front end module and a plurality of reinforcement ribs integrally molded as part of the integrated front end module; a plurality of unpainted body panels secured to some of the fastener receptacles of the integrated front end module; and the frame, injection molded integrated front end module, body panels and brackets having a hot dipped electro-coating applied thereto. ### Claim 2 (depends on 1) The vehicle body front end pre-assembly of claim 1 further comprising a paint coating applied thereto that is baked in an oven. ### Claim 3 (depends on 1) The vehicle body front end pre-assembly of claim 1 wherein the integrated front end module is formed from a glass fiber and mineral fiber filled thermoplastic polymer. ### Claim 4 (depends on 1) The vehicle body front end pre-assembly of claim 1 wherein the integrated front end module is formed from polyethylene terephthalate. ### Claim 5 (depends on 1) The vehicle body front end pre-assembly of claim 1 wherein the integrated front end module is a grill opening reinforcement panel to which plurality of light receptacles each being attached to at least one of the brackets and a grill being attached to a plurality of the brackets. ### Claim 6 (depends on 1) The vehicle body front end preassembly of claim 1 further comprising a plurality of brackets secured to some other of the fastener receptacles of the integrated front end module.