Integrated structural member for a vehicle and method of making

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

a structural member;

a first beam component secured to the structural member by a molding process, the first beam component being molded from a first amount of thermoplastic material, wherein the configuration of the first beam component is defined by the molding process;

a second beam component secured directly and only to the first beam component by a vibration weld, the second beam component being separately molded from a second amount of thermoplastic material, the second beam component having a configuration different from the first beam component, and the system further comprising a first bracket and a second bracket attached to the structural member, the first bracket and second bracket being configured to secure the structural member to a portion of the vehicle and the first bracket and the second bracket each have an opening the opening on the first bracket and second bracket being configured to receive a locating pin for positioning the structural member in a desired position when the first beam component is secured to the structural member.

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

a structural member;

a first beam component secured to the structural member by a molding process, the first beam component being molded from a first amount of thermoplastic material wherein the configuration of the first beam component is defined by the molding process;

a second beam component secured directly and only to the first beam component by a vibration weld, the second beam component being separately molded from a second amount of thermoplastic material, the second beam component having a configuration different from the first beam component, wherein the structural member includes a first structural member and a second structural member secured together, the first structural member and second structural member being formed from steel, and the first structural member being configured to have higher mechanical properties than the second structural member.

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

a structural member;

a first beam component secured to the structural member by a molding process, the first beam component being molded from a first amount of thermoplastic material wherein the configuration of the first beam component is defined b the molding process;

a second beam component secured directly and only to the first beam component by a vibration weld, the second beam component being separately molded from a second amount of thermoplastic material, the second beam component having configuration different from the first beam component, wherein the first beam component includes a housing portion configured to define a portion of an airbag module and the housing portion further comprises at least one of the following: a plurality of ribs; a continuous fiber prepeg fabric; a stamped metal bracket; extruded metal bracket; or a combination thereof for reinforcing a localized area of the housing portion.

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

a structural member;

a first beam component secured to the structural member by a molding process, the first beam component being molded from a first amount of thermoplastic material, wherein the configuration of the first beam component is defined by the molding process;

a second beam component secured directly and only to the first beam component by a vibration weld, the second beam component being separately molded from a second amount of thermoplastic material, the second beam component having a configuration different from the first beam component, wherein the first beam component includes a housing portion configured to define a portion of an airbag module and the structural system further comprises an inflator bracket secured to the housing portion, the inflator bracket being secured to the structural member by a fastener that passes through the structural member and also secures an energy absorbing bracket to the structural member.

5. The integrated structural system as in claim 1 , wherein the second beam component defines a plurality of fluid pathways for a heating ventilating and air-conditioning system and the integrated structural system comprises a plurality of mounting surfaces created on the structural member.

6. The integrated structural system as in claim 1 , wherein the structural member includes a first structural member and a second structural member secured together, the first structural member and second structural member being formed from steel, and the first structural member being configured to have higher mechanical properties than the second structural member.

7. The integrated structural system as in claim 3 , further comprising a first bracket and a second bracket attached to the structural member, the first bracket and second bracket being configured to secure the structural member to a portion of the vehicle and the first bracket and the second bracket each have an opening the opening on the first bracket and second bracket being configured to receive a locating pin for positioning the structural member in a desired position when the first beam component is secured to the structural member.

8. The integrated structural system as in claim 7 , wherein the structural member includes a first structural member and a second structural member secured together, the first structural member and second structural member being formed from steel, and the first structural member being configured to have higher mechanical properties than the second structural member.

9. The integrated structural system as in claim 3 , wherein the structural member includes a first structural member and a second structural member secured together, the first structural member and second structural member being formed from steel, and the first structural member being configured to have higher mechanical properties than the second structural member.

10. The integrated structural system as in claim 4 , further comprising a first bracket and a second bracket attached to the structural member, the first bracket and second bracket being configured to secure the structural member to a portion of the vehicle and the first bracket and the second bracket each have an opening the opening on the first bracket and second bracket being configured to receive a locating pin for positioning the structural member in a desired position when the first beam component is secured to the structural member.

11. The integrated structural system as in claim 10 , wherein the structural member includes a first structural member and a second structural member secured together, the first structural member and second structural member being formed from steel, and the first structural member being configured to have higher mechanical properties than the second structural member.

12. The integrated structural system as in claim 4 , wherein the structural member includes a first structural member and a second structural member secured together, the first structural member and second structural member being formed from steel, and the first structural member being configured to have higher mechanical properties than the second structural member.

13. The integrated structural system as in claim 2 , wherein the second beam component defines a plurality of fluid pathways for a heating ventilating and air-conditioning system and the integrated structural system comprises a plurality of mounting surfaces created on the structural member.

14. The integrated structural system as in claim 3 , wherein the second beam component defines a plurality of fluid pathways for a heating ventilating and air-conditioning system and the integrated structural system comprises a plurality of mounting surfaces created on the structural member.

15. The integrated structural system as in claim 4 , wherein the second beam component defines a plurality of fluid pathways for a heating ventilating and air-conditioning system and the integrated structural system comprises a plurality of mounting surfaces created on the structural member.