Importance

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Abstract

An improved rocker panel on side sill construction includes a substantially planar horizontal top portion, a side portion with a substantially convex show surface and a substantially concave hidden surface opposite the show surface, and a clip house mounting structure disposed on the hidden surface. The improvement consists of joining the clip house to the rocker panel or side sill at the juncture formed between the top show surface and side show surface of the part. Preferably, this joint comprises at least one hollow channel surrounded by a reinforcing rib connecting to the hidden surface proximate the juncture of the top portion with the side portion and connecting the clip house mounting structure to this rib. The channel and reinforcing rib may run substantially longitudinally the length of the rocker panel. The channel and reinforcing rib inhibiting sagging in the top portion of the part between adjacent clip house mounting structures. The rocker panel or side sill may be made by gas-assisted injection molding wherein a mold including a mold cavity having the desired final shape, including one or more channel cavities, is provided. A predetermined amount of thermoplastic material is then injected into the mold cavity. Gas is injected into the one or more channel cavities at a predetermined pressure. The thermoplastic material is then allowed to set while the gas pressure is maintained.

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First Claim