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Machine translation
1. (WO2017191610) REPLACEMENT OF METAL STAMPINGS WITH A MESH COMPONENT IN PLASTIC METAL HYBRID PART DESIGNS
Note: Text based on automatic Optical Character Recognition processes. Please use the PDF version for legal matters

CLAIMS

What is claimed is:

1 . A plastic / mesh hybrid assembly for a vehicle, comprising:

at least one insert molded mesh component located on at least one layer of the assembly in at least one predetermined area to provide increased stiffness, and

a thermoplastic overmold mechanically interlocked with the mesh of the insert molded mesh component,

wherein the insert molded mesh component mechanically interlocked with the plastic overmold adds stiffness and impact properties in the predetermined areas with increased performance criteria.

2. The plastic / mesh hybrid assembly of claim 1 , wherein the assembly includes a crossmember, and the insert molded mesh component is located in the crossmember.

3. The plastic / mesh hybrid assembly of claim 2, wherein the insert molded mesh component eliminates use of metal stampings in the crossmember.

4. The plastic / mesh hybrid assembly of claim 1 , wherein the insert molded mesh component is located in at least one predetermined area to add incremental stiffness over sections of the assembly without metal stampings to meet predetermined load requirements.

5. The plastic / mesh hybrid assembly of claim 1 , wherein the assembly is a grille opening reinforcement including a crossmember and a pair of upper and lower rail members.

6. The plastic / mesh hybrid assembly of claim 1 , wherein the assembly is selected from the group consisting of a front support crossmember, headlamp mounting crossmember, and grille opening reinforcement.

7. The plastic / mesh hybrid assembly of claim 1 , further comprising at least one attachment point on the overmold for connecting at least one secondary component.

8. The plastic / mesh hybrid assembly of claim 1 , wherein the at least one insert molded mesh component is positioned on an outer layer of the thermoplastic overmold.

9. The plastic / mesh hybrid assembly of claim 1 , wherein the at least one insert molded mesh component is positioned in an inner layer of the thermoplastic overmold.

10. The plastic / mesh hybrid assembly of claim 1 , wherein each of the insert molded mesh components are loaded directly into a mold of a tool, wherein the insert molded mesh components and thermoplastic overmold mechanically interlock in-mesh during molding.

1 1 . The plastic / mesh hybrid assembly of claim 1 , wherein the mesh component is steel.

12. The plastic / mesh hybrid assembly of claim 1 , wherein the mesh component is plastic.

13. The plastic / mesh hybrid assembly of claim 1 , wherein the mesh component has a mesh spacing of about grade 4 to 20 openings per inch.

14. The plastic / mesh hybrid assembly of claim 1 , wherein the mesh component has an off count mesh spacing.

15. The plastic / mesh hybrid assembly of claim 1 , wherein the mesh component is selected from the group consisting of plain weave, lock crimp, intermediate crimp and twill weave.

16. The plastic / mesh hybrid assembly of claim 1 , wherein the mesh component is a welded mesh.

17. The plastic / mesh hybrid assembly of claim 1 , wherein the mesh component has mesh that is coated.

18. The plastic / mesh hybrid assembly of claim 1 , wherein the mesh component has a three dimensional geometry.

19. A plastic / metal composite assembly for a vehicle, comprising:

at least one insert molded mesh component positioned on an outer layer and/or inner layer of the assembly; and

at least one plastic composite overmold, wherein the insert molded mesh component and plastic composite overmold mechanically interlock within mesh spacing during molding providing increased stiffness and impact properties.

20. A method for making a plastic / metal composite assembly for a vehicle, comprising:

providing a thermoplastic material;

providing at least one insert molded mesh component of predetermined geometry;

providing a mold;

loading the at least one insert molded mesh component into the mold, wherein the mesh conforms to the injection mold shape without requiring a pre-form operation; injecting the thermoplastic material into the mold forming an overmold, wherein the mesh and thermoplastic material mechanically interlock during molding providing increased properties in the assembly.