Gm Global Technolgoy Operations, Inc.

Mark A Cunningham

Gary F Altman

Blair E Carlson

Robert T Szymanski

A welded assembly characterized by improved structural integrity includes a first component disposed along a first plane. The first component includes first and second substantially parallel surfaces, and also includes a channel arranged on the first surface. The welded assembly also includes a second component disposed along a second plane, wherein the second component includes a leading edge. The leading edge of the second component is inserted into the channel of the first component such that an interface is formed between the first and second components. A weld generated on the second surface joins the first component with the second component at the interface such that the assembly is formed. The subject weld may be a friction-stir type of a weld. The subject welded assembly may be a vehicle bumper support. A method of forming such a welded assembly is also disclosed.

Structural integrity welded assembly

A two-staged or sequential reaction injection molding (RIM) method of manufacturing a glass fiber mat reinforced plastic part having at least one appearance surface in which a high viscosity RIM material and a low viscosity RIM material are sequentially injected into a mold cavity containing at least one reinforcing member of a glass fiber mat.

Method of manufacturing a plastic motor vehicle door

A vehicle door includes an outer panel and an inner panel of molded synthetic resin construction. The inner panel has a structural lower portion concealed beneath the outer panel and an upper portion integral with the lower portion and defining a window frame surrounding a window opening. A tubular reinforcement member of generally inverted U shape is embedded in the upper portion of the inner panel and has leg portions extending downwardly from the upper portion and embedded in the structural lower portion so that the structural lower portion connects the leg portions of the upper portion. The tubular member is a continuous hollow tube formed to have varying cross sectional shape along the continuous length to fit within the shape of the window frame. The synthetic resin of the upper portion is a reinforced reaction injection molded material providing a finished surface for painting and the synthetic resin of the lower portion is a structural reaction injection molded material providing relatively high strength and having a glass fiber mat embedded therein to span between the legs of the tubular member and facilitate bonding between the resin materials of the upper and lower portions.

Growing community of inventors

Mason, MI, United States of America

Mark A Cunningham