Hinge pillar assembly having an inner retainer panel, and method of manufacturing the same

1. A method of manufacturing a hinge pillar assembly for a vehicle, the method comprising:

casting a hinge pillar panel with a high pressure direct casting process including a die set having an upper ejector die half disposed vertically above a lower non-ejector die half, to define a casting interlock feature disposed on an interior surface of the hinge pillar panel, wherein the interlock feature includes a cored boss;

positioning an acoustic foam layer about the casting interlock feature such that the casting interlock feature positions the acoustic foam layer relative to the hinge pillar panel; and

attaching an inner retainer panel to the hinge pillar panel by fastening the inner retainer panel to the hinge pillar panel with a fastener, with the acoustic foam layer disposed between the interior surface of the hinge pillar panel and the inner retainer panel.

2. The method as set forth in claim 1 further comprising forming the acoustic foam layer to conform to and mate with the interior surface of the hinge pillar panel.

3. The method as set forth in claim 1 wherein fastening the inner retainer panel to the hinge pillar panel includes inserting a fastener through an aperture of the inner retainer panel and into grasping engagement with the cored boss of the hinge pillar panel.

4. The method as set forth in claim 3 wherein inserting the fastener into grasping engagement with the cored boss of the hinge pillar panel is further defined as inserting the fastener into threaded engagement with the cored boss of the hinge pillar panel.

5. The method as set forth in claim 1 further comprising attaching a component to the inner retainer panel.

6. The method as set forth in claim 5 wherein the component includes one of an electrical module, an electrical connector, a wiring harness, or a trim piece.

7. The method as set forth in claim 5 wherein attaching the component to the inner retainer panel includes fastening the component to the inner retainer panel with a fastener that attaches the inner retainer panel to the hinge pillar panel.

8. The method as set forth in claim 1 further comprising retaining the hinge pillar panel on the upper ejector die half of the die set with the cored boss.

9. The method as set forth in claim 8 wherein casting the hinge pillar panel to define the cored boss includes forming the cored boss to include a draft angle operable to retain the cast hinge pillar panel within the upper ejector die half of the die set.

10. A hinge pillar assembly for attachment to a support structure of a vehicle, the hinge pillar assembly comprising:

a hinge pillar panel cast from a die casting process, including a high pressure direct casting process, and defining an interior surface;

an acoustic foam layer disposed adjacent the interior surface of the hinge pillar panel; and

an inner retainer panel attached to the hinge pillar panel and securing the acoustic foam layer between the inner retainer panel and the hinge pillar panel.

11. The hinge pillar assembly as set forth in claim 10 wherein the hinge pillar panel includes a cored boss having a draft angle operable to retain the hinge pillar panel within an upper ejector die half of a die set.

12. The hinge pillar assembly as set forth in claim 11 further comprising a fastener in threaded engagement with the cored boss to attach the inner retainer panel to the hinge pillar panel.

13. The hinge pillar assembly as set forth in claim 11 wherein the acoustic foam layer conforms with and mates to the interior surface of the hinge pillar panel.

14. The hinge pillar assembly as set forth in claim 13 further comprising a component attached to and supported by the inner retainer panel.

15. The hinge pillar assembly as set forth in claim 10 wherein the hinge pillar panel includes at least one rib disposed on the interior surface thereof.

16. The hinge pillar assembly as set forth in claim 10 wherein the inner retainer panel is a polymer.