Lightweight integral corrosion-resistant front-end structure for a vehicle

1. A lightweight integral corrosion-resistant front-end structure for a vehicle, comprising:

a one-piece composite structure formed from a polymer-composite and defining at least one of a washer fluid reservoir, a tray, and an arcuate wheel housing;

a metal insert incorporated within said one-piece composite structure and isolated from corrosive substances;

said metal insert having a pair of opposing ends with at least one of a radiator support member and a hood pivot member; and

a series of washers offsetting said metal insert from a radiator support frame and a hood so as to eliminate a galvanic potential and prevent corrosion of said metal insert;

said series of washers attached to said one-piece metal insert by said one-piece composite structure.

2. The lightweight integral corrosion-resistant front-end structure recited in claim 1 wherein said one-piece composite structure is formed from a material selected from the group consisting of glass, graphite, and carbon.

3. The lightweight integral corrosion-resistant front-end structure recited in claim 1 wherein each of said washers is formed from aluminum.

4. The lightweight integral corrosion-resistant front-end structure recited in claim 1 wherein each of said washers has a first annular flange, a second annular flange, and an annular groove therebetween.

5. The lightweight integral corrosion-resistant front-end structure recited in claim 4 wherein said second annular flange is sandwiched between a portion of said one-piece composite structure and said metal insert.

6. The lightweight integral corrosion-resistant front-end structure recited in claim 5 wherein said annular groove receives said portion of said one-piece composite structure.

7. The lightweight integral corrosion-resistant front-end structure recited in claim 1 wherein said metal insert is a frame supporting said one-piece composite structure and including a series of reinforcing ribs.

8. A front-end assembly for a vehicle, comprising:

said lightweight integral corrosion-resistant front-end structure recited in claim 1 ;

a hood pivotally attached to said hood pivot member;

a radiator support frame attached to said radiator support member; and

a body-side structure attached to said lightweight integral corrosion-resistant front-end structure.

9. The front-end assembly recited in claim 8 wherein said one-piece composite structure is formed from a material selected from the group consisting of glass, graphite, and carbon.

10. The lightweight integral corrosion-resistant front-end structure recited in claim 8 wherein each of said washers is formed from aluminum.

11. The front-end assembly recited in claim 8 wherein each of said washers has a first annular flange, a second annular flange, and an annular groove therebetween.

12. The front-end assembly recited in claim 11 wherein said second annular flange is sandwiched between a portion of said one-piece composite structure and said metal insert.

13. The front-end assembly recited in claim 12 wherein said annular groove receives said portion of said one-piece composite structure.

14. The front-end assembly recited in claim 11 wherein said first annular flange is sandwiched between said one-piece composite structure and one of said radiator support frame, said hood, and said body-side structure.

15. The front-end assembly recited in claim 8 wherein said metal insert is a frame supporting said one-piece composite structure and including a series of reinforcing ribs.

16. A lightweight integral corrosion-resistant front-end structure for a vehicle, comprising:

a one-piece composite structure defining at least one of a washer fluid reservoir, a tray, and an arcuate wheel housing;

a one-piece metal insert incorporated within said one-piece composite structure and isolated from corrosive substances;

said one-piece metal insert having a pair of opposing ends with at least one of a radiator support member and a hood pivot member; and

a series of washers offsetting said one-piece metal insert from a radiator support frame and a hood so as to eliminate a galvanic potential and prevent corrosion of said one-piece metal insert;

said series of washers attached to said one-piece metal insert by said one-piece composite structure.

17. The lightweight integral corrosion-resistant front-end structure recited in claim 14 wherein said one-piece metal insert is a frame having a perimeter surface supporting said one-piece composite structure.

18. The lightweight integral corrosion-resistant front-end structure recited in claim 16 wherein said frame has rear end portion and a front end portion, with said front end portion having a C-shaped lateral cross-section adapted for use in one of a right-hand vehicle structure and a left-hand vehicle structure.

19. A lightweight integral corrosion-resistant front-end structure for a vehicle, comprising:

a one-piece composite structure defining at least one of a washer fluid reservoir, a tray, and an arcuate wheel housing;

a metal insert incorporated within said one-piece composite structure;

said metal insert formed from a material selected from the group consisting of magnesium and aluminum;

said one-piece metal insert having a pair of opposing ends with at least one of a radiator support member and a hood pivot member; and

a series of washers offsetting said metal insert from a radiator support frame and a hood so as to eliminate a galvanic potential and prevent corrosion of said metal insert;

said series of washers comprised of aluminum;

said series of washers attached to said one-piece metal insert by said one-piece structure.

20. The lightweight integral corrosion-resistant front-end structure recited in claim 19 wherein said one-piece metal insert is a frame having a perimeter surface supporting said one-piece composite structure.