Overmolded Magnesium

Abstract

A method of manufacturing an assembly, including a structural member and an appearance feature formed therealong, is provided utilizing first and second molds. The method includes the steps of: injecting magnesium into the first mold to form the structural member; removing the structural member from the first mold; placing the structural member in the second mold; and injecting thermoplastic material into the second mold to overmold the appearance feature along a portion of the structural member.

1 . A method of manufacturing an assembly, including a structural member and an appearance feature formed therealong, utilizing first and second molds, the method comprising the steps of:
 injecting magnesium into the first mold to form the structural member;   removing the structural member from the first mold;   placing the structural member in the second mold; and   injecting thermoplastic material into the second mold to overmold the appearance feature along a portion of the structural member.   
     
     
         2 . A method as set forth in  claim 1  wherein the step of injecting thermoplastic material into the second mold to overmold the appearance feature along a portion of the structural member includes forming a cover for the structural member. 
     
     
         3 . A method of manufacturing a running board assembly, including a platform, a mounting bracket, and an appearance feature, via first and second molds, the method comprising the steps of:
 injecting magnesium into the first mold to form the platform;   removing the platfoim from the first mold;   attaching the mounting bracket to the platform;   placing the platform and the mounting bracket attached thereto in the second mold; and   injecting thermoplastic material into the second mold to overmold the appearance feature along at least one of the platform and mounting bracket.   
     
     
         4 . A method as set forth in  claim 3  wherein the step of attaching the mounting bracket to the platform occurs at the same time as the step of injecting magnesium into the first mold to form the platform such that the platform and the mounting bracket are formed as one piece. 
     
     
         5 . A method as set forth in  claim 3  wherein the step of attaching the mounting bracket to the platform occurs subsequent to the step of injecting magnesium into the first mold to form the platform. 
     
     
         6 . A method as set forth in  claim 3  wherein the step of injecting thermoplastic material into the second mold to overmold the appearance feature along at least one of the platform and mounting bracket includes forming a cover for the platform. 
     
     
         7 . A method as set forth in  claim 3  wherein the step of injecting thermoplastic material into the second mold to overmold the appearance feature along at least one of the platform and mounting bracket includes forming a shield along a portion of at least one of the platform and the mounting bracket. 
     
     
         8 . A method as set forth in  claim 3  wherein the step of injecting thermoplastic material into the second mold to overmold the appearance feature along at least one of the platform and mounting bracket includes forming a step mat including a plurality of spaced apart tread portions along the platform. 
     
     
         9 . A running board assembly for a motor vehicle, said running board assembly comprising:
 a structural member including a platform formed from injection molded magnesium and adapted to be mounted to the motor vehicle, said platform having a stepping surface and extending between opposing ends;   an appearance feature injection molded onto said platform.   
     
     
         10 . A running board assembly as set forth in  claim 9  including a mounting bracket fixedly secured to said platform and directly mountable to the motor vehicle. 
     
     
         11 . A running board assembly as set forth in  claim 9  wherein said appearance feature is a step tread disposed along said stepping surface of said platform. 
     
     
         12 . A running board assembly as set forth in  claim 9  wherein said appearance feature is a cover formed along said stepping surface of said platform. 
     
     
         13 . A running board assembly as set forth in  claim 9  wherein said appearance feature is an end cap formed along each opposing end of said platform. 
     
     
         14 . A running board assembly as set forth in  claim 9  wherein said appearance feature is a shield formed along at least one of said platform and said mounting bracket.