Patent ID: 7234763

Claim:
A method of forming an instrument panel assembly for an automotive vehicle, comprising: providing a first cross-vehicle structure configured for extending in a cross-vehicle direction relative to the vehicle, the first structure being formed of a first material wherein the first material is a plastic and wherein the first structure includes a flange extending along a side of the first structure and forming a distal edge extending in the cross-vehicle directions; providing a second cross-vehicle structure also configured for extending in the cross-vehicle directions, the second cross-vehicle structure being formed of a second material wherein the second material is a plastic and wherein the second structure includes a flange extending along a side of the second structure and forming a distal edge extending in the cross-vehicle directions; joining the first structure to the second structure including vibration or ultrasonic welding the flange of the first structure to the flange of the second structure such that the distal edges of the first and second structures cooperatively form a distal edge of instrument panel assembly; wherein the first and second cross-vehicle structures cooperatively form an HVAC duct of the instrument panel assembly; wherein the flange of the first structure and the flange of the second structure extend cross-vehicle and extend along a substantial portion of the sides of the first and second structures; and wherein the flange of the first structure and the flange of the second structure extend away from the duct.