Structural hybrid attachment system and method

1. An integrated structural system for a vehicle, comprising:

a molded duct system configured to guide airflow, said molded duct system having a first section having a first flange portion and a second section having a second flange portion, said molded duct system configured to operably attach a vehicle component thereto; and

a metal structure, said metal structure integrated with said molded duct system by a means for integrating said metal structure with said molded duct system forming an integrated structural load path assembly, said integrated structural load path assembly being configured as a load bearing area to distribute a load of said vehicle component operably attached thereto over said integrated structural load path assembly, wherein said means for integrating said metal structure with said molded duct system includes joining said first flange portion and said second flange portion by one of;

sonic welding,

heat staking,

insert molding, and

gluing.

2. The integrated structural system of claim 1 , wherein said integrated structural load path assembly is a cross car structural beam having a vehicle HVAC air duct assembly.

3. The integrated structural system of claim 1 , wherein said vehicle component is one of:

a steering column; and

an HVAC assembly.

4. The system integrated structural of claim 1 , wherein said metal structure is at least one of:

a metal tube; and

a metal frame member.

5. The integrated structural system of claim 1 , wherein said metal structure is fabricated by one of stamping, bending, hydroforming, extruding and casting.

6. The integrated structural system of claim 1 , wherein said metal structure includes one of steel, aluminum, and magnesium.

7. The integrated structural system of claim 2 , wherein said metal structure extends a length of said cross car beam structure.

8. The integrated structural system of claim 7 , wherein said metal structure includes brackets at opposing ends thereof for mounting said integrated structural load path assembly to the vehicle.

9. The integrated structural system of claim 1 , wherein when said means for integrating said metal structure with said molded duct system includes insert molding, said insert molding includes at least one of:

compression molding; and

injection molding.

10. The integrated structural system of claim 9 , wherein said compression molding includes extrusion deposition compression molding (EDCM).

11. The integrated structural system of claim 1 , wherein said means for integration further includes a protrusion extending from at least one of said first section and said second section toward said metal structure encased therebetween.

12. The integrated structural system of claim 11 , wherein said protrusion extends into one of a cavity and an aperture configured in said metal structure.

13. The integrated structural system of claim 12 , wherein said protrusion extends to an opposing section of said molded duct system.

14. The integrated structural system of claim 1 , wherein said metal structure includes a portion extending therefrom configured to receive a mechanical fastener extending through one of said first and second flange portions.

15. The integrated structural system of claim 1 , wherein said molded duct assembly is configured to provide air to an internal compartment of the vehicle.

16. The integrated structural system of claim 1 , wherein said first and second sections of said molded duct assembly is composed of a plastic.

17. The integrated structural system of claim 1 , wherein said first and second sections form a one-piece structure, wherein said first and second sections define portions of said one-piece structure integrated with said metal structure.