Patent ID: 7125466

Claim:
A method of preparing a molded cross vehicle beam comprising a rigid molded hollow thermoplastic member fixedly attached to a rigid support and at least one attachment element, said method comprising: (I) placing said rigid support and said attachment element in a mold, said rigid support having a plurality of perforations having edges, a first surface and a second surface, and said attachment element having a plurality of perforations having edges, a first surface and a second surface; and (II) blow molding a thermoplastic parison precursor of said rigid hollow member against the first surface of said rigid support and the first surface of said attachment element; wherein a portion of the thermoplastic material of said thermoplastic parison extends through at least some of said perforations of said rigid support and said attachment element, the edges of said perforations being embedded in the plastic material extending therethrough, thereby attaching fixedly said rigid hollow member to said rigid support and to said attachment element.