Molded article having a rigid support and a rigid hollow member

A method of preparing a molded article comprising a molded rigid hollow thermoplastic member fixedly attached to a rigid support, said method comprising:

• (I) placing said rigid support in a mold, said rigid support having a plurality of perforations having edges, a first surface and a second surface;
• and
• (II) blow molding a thermoplastic parison precursor of said rigid hollow member against the first surface of said rigid support;
• wherein a portion of the thermoplastic material of said thermoplastic parison extends through at least some of said perforations of said rigid support, the edges of said perforations being embedded in the plastic material extending therethrough, thereby attaching fixedly said rigid hollow member to said rigid support.

A molded article comprising:

• (a) a rigid support having a first surface, a second surface and a plurality of perforations having edges;
• and
• (b) a molded rigid member of thermoplastic material, at least a portion of said rigid member being in abutting relationship with the first surface of said rigid support, said rigid member having a hollow interior,
• wherein said article is prepared by a process comprising blow molding a thermoplastic parison precursor of said rigid member (b) onto the first surface of said rigid support (a), a portion of the thermoplastic material of said thermoplastic parison extends through at least some of said perforations of said rigid support (a), the edges of said perforations being embedded in the plastic material extending therethrough, thereby fixedly attaching said rigid member (b) to said rigid support (a), and
• further wherein said rigid support (a) has a plurality of anchoring extensions extending into said rigid hollow member (b), each of said anchoring extensions having walls, an interior chamber and at least one wall perforation in said walls, each wall perforation having edges, a portion of said rigid hollow member (b) extends through at least some of said wall perforations into said chamber, the edges of said wall perforations being embedded in the plastic material extending therethrough, thereby fixedly attaching said rigid hollow member (b) to said rigid support (a).

A molded article comprising:

• (a) a rigid support having a first surface, a second surface and a plurality of perforations having edges;
• and
• (b) a molded rigid member of thermoplastic material, at least a portion of said rigid member being in abutting relationship with the first surface of said rigid support, said rigid member having a hollow interior, said rigid hollow member being an air duct,
• wherein said article is prepared by a process comprising blow molding a thermoplastic parison precursor of said rigid member (b) onto the first surface of said rigid support (a), a portion of the thermoplastic material of said thermoplastic parison extends through at least some of said perforations of said rigid support (a), the edges of said perforations being embedded in the plastic material extending therethrough, thereby fixedly attaching said rigid member (b) to said rigid support (a), and
• further wherein said molded article is an automotive cross car beam.