Magna International Inc.

Decoma International Corporation

Rudolpf A Schrempf

Bradford D Armstrong

Steven S Grgac

Martin McLeod

Alireza Ebrahimi

A novel method and set of structures for performing resistive implant welding of two plastic components to form an assembly. A first one of the components to be welded includes a channel structure which receives the resistive implant and maintains it in a desired position until the welding operation is performed. The second component to be welded includes a complementary structure including a land which is sized to engage the channel structure and captive resistive implant on the first component. The two components are pre-weld positioned with the land in the channel structure and the positioned components are then placed in a press which exerts a pre-selected pressure on the interface between the channel and the land. Next, a pre-selected electric current is passed through the resistive implant to heat it and to bring the plastic material of the channel structure and the land to their molten points, where they intermingle through the resistive implant. The electrical current is removed and the weld is allowed to cool to its finished state and the welded assembly is removed from the press.

Resistive implant welding for assemblies of plastic components

A tailgate assembly for a motor vehicle includes an outer panel, an integrally formed inner structural panel, and at least one reinforcing panel. The inner structural panel is coupled to the outer panel and includes a support surface facing the outer panel. The inner structural panel also includes spaced apart upper and lower walls extending laterally along the support surface, a pair of end walls extending between the upper and lower walls, and a plurality of ribs spaced apart and disposed between the upper and lower walls. The plurality of ribs also extends laterally between the end walls. The reinforcing panel is disposed between the outer and inner structural panels. The reinforcing panel is secured to the integrally formed inner structural panel between a portion of the plurality of ribs to add rigidity to the tailgate assembly.

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Brampton, Canada

Rudolpf A Schrempf