Hybrid material vehicle panel and methods of making the same
The present disclosure relates to a hybrid material panel assembly for a vehicle. The panel assembly includes a panel and a plurality of mounting flanges integrally formed with the panel. The panel is formed of a first material having a first coefficient of thermal expansion. The plurality of mounting flanges are formed of a second material having a second coefficient of thermal expansion, where each of the plurality of mounting flanges include a mounting area that defines a mounting surface and at least one mounting hole. The first coefficient of thermal expansion is greater than the second coefficient of thermal expansion.
1. A panel assembly comprising:
a panel formed of a first material having a first coefficient of thermal expansion; and
a plurality of mounting flanges integrally formed with the panel, the plurality of mounting flanges formed of a second material having a second coefficient of thermal expansion that is lower than the first coefficient of thermal expansion, and each of the plurality of mounting flanges including a mounting area that defines a mounting surface and at least one mounting hole.
2. The panel assembly of claim 1 , wherein the plurality of mounting flanges includes a first mount having a flange integrally formed with the panel.
3. The panel assembly of claim 2 , wherein the flange includes a first aperture that receives a first coupling flange of the panel.
4. The panel assembly of claim 3 , wherein the mounting area comprises a second aperture that receives a second coupling flange of the panel.
5. The panel assembly of claim 3 , wherein the panel further comprises a cavity, the flange of the first mount extending into the cavity.
6. The panel assembly of claim 2 , further comprising:
a bump guard integrally formed with the first mount about a perimeter of the mounting area, the bump guard being contiguous with the panel; and
a panel strip extending over the mounting surface and contiguous with the bump guard and the panel.
7. The panel assembly of claim 1 , wherein the first material is a polymeric material and the second material is a metal or metal alloy.
8. The panel assembly of claim 1 , wherein the panel further comprises:
a fender portion having an arc shape configured to accommodate a wheel of a vehicle; and
an upper portion disposed above the fender portion and coupled with at least one of the plurality of mounting flanges.
9. The panel assembly of claim 8 , wherein the plurality of mounting flanges includes an upper mounting flange, a lower mounting flange, and a fore mounting flange.
10. A front quarter panel assembly for a vehicle, the front quarter panel assembly comprising:
a panel formed of a first material having a first coefficient of thermal expansion;
a first mount positioned at a top portion of the panel and integrally formed with the panel, the first mount formed of a second material having a second coefficient of thermal expansion;
wherein the first coefficient of thermal expansion is greater than the second coefficient of thermal expansion.
11. The front quarter panel assembly of claim 10 , wherein the first mount comprises a flange and a mounting area, the flange received by a cavity of the panel.
12. The front quarter panel assembly of claim 11 , wherein the panel further includes a first coupling flange extending through a first aperture of the flange.
13. The front quarter panel assembly of claim 12 , wherein the panel further includes a second coupling flange extending through a second aperture of the mounting area.
14. The front quarter panel assembly of claim 11 , further comprising a bump guard extending about a perimeter of the mounting area, the bump guard contiguous with the panel and integrally formed with the first mount.
15. The front quarter panel assembly of claim 10 , wherein:
the first material is a polymeric material;
the second material is one of a metal or metal alloy; and
the panel is overmolded with the first mount.
16. The front quarter panel assembly of claim 10 , further comprising a second mount formed of a third material different from the first material and different from the second material, the second mount overmolded with the panel.
17. A method of forming a panel assembly, the method comprising:
forming a first mount from a first material having a first coefficient of thermal expansion;
preparing the first mount to receive a panel; and
forming the panel such that the panel is integrally formed with the first mount, the panel formed from a second material having a second coefficient of thermal expansion;
wherein the second coefficient of thermal expansion is greater than the first coefficient of thermal expansion.
18. The method of claim 17 , wherein the first mount comprises:
a flange defining a first aperture; and
a mounting area defining a second aperture;
wherein the step of forming the panel further comprises integrally forming the panel with the first mount by extending a portion of the panel through both the first aperture and the second aperture.
19. The method of claim 17 , further comprising:
forming a second mount from a third material different from both the first material and the second material, the third material having a third coefficient of thermal expansion less than the first coefficient of thermal expansion; and
coupling the second mount with the panel via overmolding.
20. The method of claim 17 , wherein:
the first material is a metal or metal alloy;
the second material is a polymeric material; and
the step of forming the panel further includes injection molding the panel such that the first mount is overmolded with the panel.