System and method for overmolding union nut into panel assembly

Abstract

A panel assembly for an automotive component has a panel. The panel includes a panel body having a first side and a second side formed on a side opposite the first side, and an inner wall extending between the first side and the second side to define an aperture extending at least partially through the panel body, the inner wall including a channel formed therein. The panel assembly also has a union nut including an inner portion having a plurality of teeth cooperating to define a fastener opening and a flange surrounding the inner portion. The flange is received within a channel formed in an inner wall of the body.

Description

[0001] Introduction

[0002] The information provided in this section is for the purpose of generally presenting the context of the present disclosure. The work of the presently named inventors, to the extent described in this section, and aspects of the description that may not otherwise be considered prior art at the time of filing, are neither expressly nor implicitly admitted to be prior art against the present disclosure. Technical Field

[0003] The present disclosure generally relates to an injection molded panel disposed on an automotive component of a vehicle and includes a system and method for embedding a palnut within the panel. Background Art

[0004] Palnuts are incorporated into the design of many vehicle components, and these palnuts provide a means for attaching bolts or other fasteners to the vehicle components as needed to facilitate the vehicle manufacturing process. For example, palnuts can be incorporated into the acoustic covers of engines, transmissions, drive units, or a large number of other vehicle components, and the acoustic cover is one of many components of various vehicle components. Continuing with this example, when the acoustic cover is installed on a vehicle component during vehicle assembly, a bolt is passed through the palnut and tightened to mechanically connect the acoustic cover to the remainder of the vehicle component.

[0005] During the manufacturing process of vehicle components and corresponding panels, adhesives can be used to attach palnuts to the panels or vehicle components. However, during transportation or assembly, adhesively attached palnuts may become detached from the panels or vehicle components. This results in vehicle assembly delays due to the need to reattach the palnuts to the panels or vehicle components or the need to obtain entirely new palnuts to replace the lost ones. Summary of the Invention

[0006] One aspect of the present disclosure provides a panel assembly for an automotive component. The panel assembly includes a panel. The panel includes a panel body having a first side and a second side formed on a side opposite the first side. The panel further includes an inner wall extending between the first side and the second side. The inner wall defines an aperture that at least partially extends through the panel body. The inner wall includes a channel formed therein. The panel assembly further includes a palnut. The palnut includes an inner portion having a plurality of teeth that cooperate to define a fastener opening. The palnut further includes a flange surrounding the inner portion. The flange is received within the channel formed in the inner wall of the body.

[0007] Embodiments of the present disclosure may include one or more of the following optional features. In some examples, the palnut is a PV type palnut.

[0008] In some embodiments, the flange defines a flange width that extends radially outward from the inner portion to the outer peripheral edge, and the flange width is variable along the perimeter of the union nut.

[0009] In some configurations, the plurality of teeth are arranged in a hexagonal orientation and define the fastener opening.

[0010] In some other examples, the union nut is one of a triangular union nut or a rectangular union nut.

[0011] In some other embodiments, the orifice of the panel body has a hexagonal cross-sectional shape.

[0012] In some other configurations, the flange of the union nut extends into the panel body a first distance at a first position of the union nut and a different second distance at a second position of the union nut.

[0013] Another aspect of the present disclosure provides a panel assembly system for an automotive component. The system includes a die assembly. The die assembly includes an ejector die. The ejector die includes a surface, a plateau disposed on the surface, a center post disposed on the plateau, and an orientation post disposed on the plateau and offset from the center post. The die assembly also includes a cover die. The system also includes a union nut. The union nut includes an inner portion having a plurality of teeth that cooperate to define a fastener opening. The union nut also includes a flange surrounding the inner portion. The center post is received in the fastener opening, and the orientation post is received between adjacent teeth of the plurality of teeth.

[0014] Embodiments of this aspect of the present disclosure may include one or more of the following optional features. In some examples, the ejector die and the cover die cooperate to form a cavity.

[0015] In some embodiments, the union nut is a PV type union nut.

[0016] In some configurations, the flange defines a flange width that extends radially outward from the inner portion to the outer peripheral edge, and the flange width is variable along the perimeter of the union nut.

[0017] In some other examples, the plurality of teeth are arranged in a hexagonal orientation and define the fastener opening.

[0018] In some other embodiments, the fastener opening is sized to receive the center post, and the space between the plurality of teeth is sized to receive the orientation post.

[0019] In some other configurations, the union nut is one of a triangular union nut or a rectangular union nut.

[0020] Another aspect of the present disclosure provides a method of manufacturing a panel for an automotive component. The method includes securing a union nut to an ejector die. The union nut includes an inner portion having a plurality of teeth that cooperate to define a fastener opening. The union nut also includes a flange surrounding the inner portion. The method further includes mating a cover die with the ejector die to form a cavity, injecting liquid plastic into the cavity through an injection port provided in the ejector die to form a panel body that at least partially encapsulates the flange of the union nut, allowing the liquid plastic to cure and solidify within the cavity for a period of time to obtain a panel, and removing the ejector die and the cover die from the panel.

[0021] Embodiments of this aspect of the present disclosure may include one or more of the following optional features. In some examples, the inner portion of the union nut is outside the cavity.

[0022] In some embodiments, the flange defines a flange width that extends radially outward from the inner portion to an outer peripheral edge, and the flange width is variable along the perimeter of the union nut.

[0023] In some configurations, the flange of the union nut is within the cavity.

[0024] In some other examples, the ejector die includes a platform and a central post extending from the platform, and the method further includes arranging the union nut on the platform, wherein the central post is received within the fastener opening.

[0025] In some other embodiments, the ejector die further includes an orientation post extending from the platform and offset from the central post, and the method further includes arranging the union nut on the platform, wherein the orientation post is received between adjacent teeth of the plurality of teeth. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The drawings described herein are for illustrative purposes only for the selected configurations and are not intended to limit the scope of the present disclosure.

[0027] Figure 1 is a perspective view of an automotive component including a panel assembly located on the automotive component, the panel assembly including a panel and a union nut mounted within the panel body;

[0028] Figure 2 is a partially enlarged perspective view of the panel assembly with the union nut mounted within the panel body;

[0029] Figure 3 is along Figure 2 a cross-sectional view of the panel assembly including the union nut mounted within the panel body taken along line 3-3;

[0030] Figure 4 is an exploded view of an example of a panel component system that includes a union nut, a panel, and a mold assembly for forming Figure 1 the panel component, the mold assembly including a cover mold and an ejection mold;

[0031] Figure 5 is a partially enlarged perspective view of the ejection mold for molding Figure 1 the panel;

[0032] Figure 6 is Figure 5 a partially enlarged perspective view of the ejection mold of

[0033] Figure 7 is Figure 4 a partial cross-sectional view of the mold assembly of

[0034] Figure 8 showing the union nut and the cover mold spaced apart from the ejection mold; Figure 4 is

[0035] Figure 9 a partial cross-sectional view of the mold assembly of Figure 4 showing the cover mold mating with the ejection mold to form a cavity;

[0036] Figure 10 is an exploded view of another example of a mold assembly for forming a panel component in accordance with the principles of the present disclosure;

[0037] Figure 11 is an exploded view of another example of a mold assembly for forming a panel component in accordance with the principles of the present disclosure; and

[0038] Figure 12 is an exploded view of another example of a mold assembly for forming a panel component in accordance with the principles of the present disclosure.

[0039] In all the drawings, corresponding reference numerals represent corresponding parts. Detailed Description

[0040] Example configurations will now be described more fully with reference to the drawings. The example configurations are provided so that this disclosure will be thorough and will fully convey the scope of the disclosure to those of ordinary skill in the art. Specific details, such as examples of specific components, devices, and methods, are set forth to provide a thorough understanding of the configurations of the present disclosure. It will be apparent to those of ordinary skill in the art that the example configurations may be embodied in many different forms and that specific details and example configurations should not be construed as limiting the scope of the present disclosure.

[0041] The terms used herein are for the purpose of describing particular exemplary configurations only and are not intended to be limiting. As used herein, the singular articles "a", "an" and "the" may also be intended to include the plural forms unless the context clearly dictates otherwise. The terms "comprises", "comprising", "including" and "having" are inclusive and thus specify the presence of stated features, steps, operations, elements and / or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components and / or groups thereof. The method steps, processes and operations described herein should not be construed as necessarily requiring them to be performed in the particular order discussed or illustrated unless specifically identified as an order of performance. Additional or alternative steps may be employed.

[0042] When an element or layer is referred to as "on", "engaged to", "connected to", "attached to" or "coupled to" another element or layer, it can be directly on, engaged, connected, attached or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as "directly on", "directly engaged to", "directly connected to", "directly attached to" or "directly coupled to" another element or layer, intervening elements or layers may not be present. Other words used to describe the relationship between elements should be interpreted in a like manner (e.g., "between" versus "directly between", "adjacent" versus "directly adjacent", etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0043] The terms "first", "second", "third", etc. may be used herein to describe various elements, components, regions, layers and / or portions. These elements, components, regions, layers and / or portions are not to be limited by these terms. These terms may be used only to distinguish one element, component, region, layer or portion from another. Unless the context clearly indicates otherwise, terms such as "first", "second" and other numerical terms do not imply an order or sequence. Thus, a first element, component, region, layer or portion discussed below may be termed a second element, component, region, layer or portion without departing from the teachings of the exemplary configuration.

[0044] Reference Figure 1 , there is provided an exemplary automotive component 12 that will be included in the construction of a vehicle 10. While Figure 1The automotive component 12 shown in is an engine, but it will be understood that the automotive component 12 can be anything that can be included in the general makeup of the vehicle 10, including but not limited to an engine, a transmission, or a drive unit. The automotive component 12 includes a panel assembly 14 attached to the automotive component 12. The panel assembly 14 can be used to cover a portion of the automotive component 12, to fasten together the parts of the automotive component 12, or to provide shielding for the automotive component 12, as well as other uses applicable to a particular application.

[0045] Referring Figure 1 and Figure 2 , the panel assembly 14 includes a panel 100 and a panel body 102. The panel body 102 includes a first side 104 and a second side 106 formed on the opposite side of the first side 104. In Figure 2 the example shown, the first side 104 is the outer portion of the panel body 102 relative to the automotive component 12. However, it is not necessary or required that the first side 104 face the outside of the automotive component 12. The panel body 102 includes an aperture 110 that extends from the first side 104 through the panel body 102 to the second side 106. As shown, the aperture 110 is defined by an inner wall 108 that extends between the first side 104 and the second side 106. The inner wall 108 is continuous and defines a hexagonal cross-section of the aperture 110.

[0046] Still referring Figure 1 , a PV type union nut 200 is disposed within the aperture 110 of the panel 100. The union nut 200 has a material different from that of the panel 100. For example, the union nut 200 can include a metallic material, while the panel 100 can include a plastic or polymeric material. The union nut 200 includes an inner portion 202 that includes a plurality of teeth 204. When assembled to the panel 100, the teeth 204 are fully received within the aperture 110. The teeth 204 cooperate to define a fastener opening 206 at the center of the inner portion 202 of the union nut 200. The fastener opening 206 is the location where a fastening device such as a bolt can be inserted, whereby the teeth 204 engage the fastening device to secure the fastening device in place by interacting with the threads of the fastening device. To facilitate this interaction between the teeth 204 and the fastening device, the teeth 204 must be able to bend independently of one another to accommodate the helical threads of the fastening device.

[0047] Now referring Figure 3, the inner wall 108 includes a passage 112 formed within the panel body 102. The passage 112 is disposed between a first side 104 and a second side 106 of the panel body 102. In this example, the second side 106 is the inward-facing interior portion of the panel body 102 toward the automotive component 12. The union nut 200 includes a flange 208 that extends radially outward from an inner portion 202. It will be appreciated that when the fastening device is inserted into the fastener opening 206, the teeth 204 of the union nut 200 can be biased upward or downward from the flange 208 to accommodate the threaded and curved nature of the teeth 204. The flange 208 is received by the passage 112 to rigidly secure the union nut 200 in its position within the orifice 110. The flange 208 surrounds the inner portion 202 of the union nut 200 and extends radially outward from the inner portion 202 to an outer peripheral edge 210 that defines a perimeter 212 of the union nut 200.

[0048] Now referring Figure 4 , an exemplary mold assembly 30 for forming the panel assembly 14 includes an ejector die 300 and a cover die 312. The mold assembly 30 is a component of the panel assembly system 16, which also includes the union nut 200 and the panel 100. Referring Figure 5 and Figure 6 , a detailed view of the ejector die 300 is shown. The ejector die 300 includes a cavity surface 302 and a platform 304 that projects from the cavity surface 302. Additionally, an injection port 310 is also disposed within the cavity surface 302 of the ejector die 300, and the injection port 310 facilitates the introduction and flow of molten plastic or resin material. A center post 306 and alignment posts 308 are disposed on the platform 304, and the alignment posts 308 are offset from the center post 306. The center post 306 is sized to match the size of the fastener opening 206 of the union nut 200, such that when the union nut 200 is placed on the ejector die 300, the center post 306 is allowed to extend through the fastener opening 206. The alignment posts 308 are sized to match the space allocated between adjacent teeth in the teeth 204 of the union nut 200. The center post 306 ensures that the union nut 200 is placed in the necessary position to facilitate the desired results of the injection molding process, while the alignment posts 308 secure the union nut 200 to the correct orientation on the ejector die 300.

[0049] The combined nut 200 has a flange width W208 that varies along the perimeter 212. In this example, the inner portion 202 of the combined nut 200 is defined by a hexagonal shape, with a plurality of teeth 204 arranged in a hexagonal orientation, and the perimeter 212 is a circular perimeter. Due to the combination of two different shapes in the design of the combined nut 200, the flange width W208 is variable. Continuing with the example of the hexagonal combined nut 200, the flange width W208 is maximum at the central base of one of the teeth 204, referred to as the first position 214, and the flange width W208 is minimum at the position between a pair of teeth 204, referred to as the second position 216. The flange width W208 will gradually increase from the second position 216 around the perimeter 212 until it reaches the first position 214, at which point the flange width W208 decreases in the direction towards the subsequent second position 216. This pattern of the varying flange width W208 will repeat around the perimeter 212 of the combined nut 200.

[0050] As described above, referring again to Figures 3 to 6 , the flange 208 extends into the panel body 102, facilitated by the channel 112 provided in the inner wall 108. It can be understood that the distance by which the flange 208 extends into the panel body 102 corresponds to the flange width W208 and can be non-uniform around the perimeter 212 of the combined nut 200. The channel 112 only admits the flange 208, leaving the inner portion 202 exposed within the orifice 110 of the panel 100. Since the inner portion 202 of the combined nut 200 is defined by a hexagonal shape and the perimeter 212 is circular, the variable flange width W208 determines the distance by which the flange 208 extends into the panel body 102. For example, the distance between the first position 214 and the perimeter 212 is the first distance D214, and the distance between the second position 216 and the perimeter 212 is the second distance D216. Based on the shape of the combined nut 200 in this example, the first distance D214 is greater than the second distance D216, which means that the flange 208 will extend into the panel body 102 a greater distance at the first position 214 compared to the distance by which the flange 208 extends into the panel body 102 at the second position 216. The non-uniformity in the amount by which the flange 208 extends into the panel body 102 around the perimeter 212 of the combined nut 200 mechanically locks the combined nut into its orientation, thereby disabling the ability of the combined nut 200 to rotate when the flange 208 is received within the channel 112.

[0051] Now referring to Figures 6 - 9, when the union nut 200 is placed on the ejector die 300, with the central post 306 extending through the fastener opening 206 and the orientation post 308 extending through the space between the teeth 204, the union nut 200 rests on the platform 304. The platform 304 has a perimeter shaped to match the inner portion 202 of the union nut 200. This allows the entire flange 208 to extend beyond the boundaries of the platform 304 while keeping the entire inner portion 202 positioned on the platform 304. Since the platform 304 is provided on the cavity surface 302 of the ejector die 300, a space is created between the flange 208 and the cavity surface 302 when the union nut is mounted on the ejector die 300.

[0052] The cover die 312 can be used in combination with the ejector die 300 to form a cavity 314 when mated together. The cover die 312 is shaped to accommodate the central post 306, the orientation post 308, and the union nut 200. The cavity 314 encapsulates the flange 208 of the union nut 200 while sealing and separating the inner portion 202 from the cavity 314 due to the shape of the platform 304 matching the shape of the inner portion 202. The positioning of the injection port 310 in the ejector die 300 allows the injection port 310 to be received within the boundaries of the cavity 314. When the cavity 314 is filled with liquid plastic via injection molding, the panel 100 is produced after the curing process occurs.

[0053] Now refer to Figures 10 to 12 , alternative examples of the mold assemblies 30a - 30c are provided, including a portion of the panel assembly system 16. In these examples, the shapes and configurations of the union nuts 200, 200b - 200c, the ejector dies 300a - 300c, the cover dies 312a - 312c, the panel assemblies 14a - 14c, and the panels 100a - 100c can be modified while maintaining the same concepts described above with respect to the mold assembly 30 and the panel 100. Additionally, changes to the mold assemblies 30a - 30c may require corresponding changes to the shapes and configurations of the orientation posts 308a - 308c, the central posts 306a - 306c, the platforms 304a - 304c, the cavity surfaces 302a - 302c, the plate bodies 102a - 102c, the first sides 104a - 104c, the second sides 106a - 106c, the inner walls 108a - 108c, the orifices 110a - 110c, and the channels 112a - 112c. Although the exemplary mold assembly 30 and panel 100 include a union nut 200 with an inner portion 202 having a hexagonal shape (coinciding with the hexagonal orifice 110), a hexagonal platform 304, and a matching cover die 312 configuration, a mold assembly 30a can also be used that includes a platform 304a having a hexagonal shape with inwardly tapered arcuate edges, as Figure 10As shown. When the panel 100a is formed via injection molding, the shapes of the platform 304a and the mating cover mold 312a define the resulting shape of the orifice 110a, since the platform 304a and the cover mold 312a define the limiting shape of the cavity 314a. The union nut 200 having an interior portion 202 shaped as a regular hexagon will still fit within the modified "tapered" hexagon design. In this example, the arcuate or concave sides of the platform 304a result in an inner wall 108a having a plurality of concave sections that define a generally hexagonal orifice 110a. Thus, these convex sides of the inner wall 108 provide increased engagement along the first position 214 of the flange 208.

[0054] Reference Figure 11 and 12 provide additional examples of mold assemblies 30b, 30c in accordance with the principles of the present disclosure. In these examples, the shapes of the orifices 110b, 110c can be triangular or rectangular, corresponding to the shapes of the mating platforms 304b, 304c and cover molds 312b, 312c. In these examples, in cases where the shapes of the orifices 110b, 110c are more significantly modified, the union nuts 200b, 200c must also be selected to correspond to the triangular and rectangular shapes, respectively. The design of the union nuts 200b, 200c implies that the interior portions 202b, 202c, teeth 204b, 204c, fastener openings 206b, 206c, flanges 208b, 208c, outer perimeters 210b, 210c and perimeters 212b, 212c may need to change shape and configuration. Similarly, the same concepts described above can be applied to a variety of configurations while achieving the same result, each configuration being capable of accommodating the specific nature and application of the automotive component 12.

[0055] In operation, the panel assembly 14 requires a means to fasten to the remainder of the automotive component 12 or, possibly, to attach parts of the automotive component 12 together, depending on the specific application. Integrating the union nut 200 within the panel assembly 14 satisfies this requirement, and this integration can be facilitated by the injection molding process available for manufacturing the panel 100. The panel assembly system 16 includes the necessary elements required to facilitate this process. Again, reference Figure 5 and Figure 6, the union nut 200 is placed on the ejector die 300. The central post 306 extends through the fastener opening 206, and the orientation post 308 extends through the space between the teeth 204. In this example, remembering that various shapes can be used to achieve the same result, the orientation post 308 aligns the hexagonal shape of the inner portion 202 with the matching hexagonal shape of the platform 304. During the injection molding process, the platform 304 defines the shape of the inner wall 108 and the shape of the orifice 110. Aligning the shape of the platform 304 with the shape of the inner portion 202 of the union nut 200 positions the entire inner portion 202 within the orifice 110, which allows the teeth 204 to bend and accommodate the threads of a fastener (such as a bolt). Additionally, the orientation post 308 prevents the union nut 200 from rotating during the injection molding process. In this example, a rotating union nut 200 during injection molding would prevent the injection molding process from occurring successfully because the rotation action would prevent the inner wall 108 and the orifice 110 from forming a hexagonal shape that matches the shape of the inner portion 202 of the union nut 200. If the shapes of the inner wall 108 and the orifice 110 do not match the shape of the inner portion 202, the union nut 200 will not be mechanically locked within the panel body 102, creating the possibility that the union nut 200 will rotate when attempting to install a mechanical fastener in the fastener opening 206. Compared to the desired result of the union nut 200 being mechanically locked within the panel body 102 and not being able to rotate, this would make installing a mechanical fastener in the fastener opening 206 more challenging.

[0056] Referring again to Figures 7 to 9 , once the union nut 200 is in the correct position on the ejector die 300, the cover die 312 is installed over the union nut 200, mates with the ejector die 300, and forms a cavity 314. Only the flange 208 extends within the boundaries of the cavity 314, sealing the entire inner portion 202 outside the boundaries of the cavity 314 and allowing the inner portion 202 to be unaffected by the injection molding process. When the ejector die 300 mates with the cover die 312, with the union nut 200 encapsulated between the ejector die 300 and the cover die 312, the injection molding process is ready to begin. Liquid plastic or resin is injected into the cavity 314 via the injection port 310 until the entire cavity 314 is filled with liquid plastic. Once the plastic has cured and solidified over a period of time, the ejector die 300 and the cover die 312 are removed, resulting in the production of the panel 100. Because the flange 208 is contained within the boundaries of the cavity 314, the flange 208 creates a channel 112 that is provided in the inner wall 108 of the panel 100. Additionally, the shape of the platform 304 and the shape of the cover die 312 define the final shape of the inner wall 108 and the shape of the orifice 110.

[0057] Referring again to Figure 2 and Figure 3Once the injection molding process is complete and the liquid plastic has cured and solidified, the panel assembly 14 is formed. The flange 208 is embedded within the panel body 102, extending a variable flange width W208 into the panel body 102 via the channel 112. The inner portion 202 of the union nut 200 is clear of and remote from the panel body 102 and is fully contained within the boundaries of the aperture 110. Because the flange 208 is molded into the panel body 102, the union nut 200 cannot fall out of or be removed from the panel 100. Additionally, in this example, due to the hexagonal shape of the inner portion 202 of the union nut 200 that matches the hexagonal shape of the inner wall 108, in combination with the teeth 204 that are slightly offset upward or downward from the flange 208, the union nut 200 cannot rotate when in the described position. This allows the panel assembly 14 to be bolted to its particular automotive component 12 application via a fastener passing through the fastener opening 206 without risk of the union nut 200 falling out of or rotating within the panel 100. Additionally, the panel assembly 14 can be shipped from its manufacturing location to a vehicle assembly plant without risk of the union nut 200 being removed from or falling out of the panel assembly 14.

[0058] Referring again to Figures 10 to 12 this operation can be performed in the same manner as described, where after the injection molding process takes place, the union nut 200, the ejector die 300, the cover die 312, and the resulting panel 100 are modified in shape and design. The varying designs can be configured to different applications and space requirements within the particular automotive component 12.

[0059] Numerous embodiments have been described. However, it should be understood that various modifications can be made without departing from the spirit and scope of the disclosure. Accordingly, other embodiments are within the scope of the appended claims.

[0060] The foregoing description has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. The individual elements or features of a particular construction are generally not limited to that particular construction but, where applicable, are interchangeable and can be used in a selected construction even if not specifically shown or described. It can also vary in many ways. Such variations should not be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Claims

1. A panel assembly for an automobile component, the panel assembly comprising: a panel including a panel body having a first side and a second side formed on a side opposite the first side, and an inner wall extending between the first side and the second side to define an aperture extending at least partially through the panel body, the inner wall including a channel formed therein; as well as A union nut includes an inner portion having a plurality of teeth that cooperate to define a fastener opening, and a flange surrounding the inner portion, the flange being received in a channel formed in an inner wall of the body.

2. The panel assembly according to claim 1, wherein the union nut is a PV type union nut.

3. The panel assembly of claim 1, wherein the flange defines a flange width extending radially outward from the inner portion to an outer peripheral edge, the flange width being variable along a periphery of the union nut.

4. The panel assembly of claim 1, wherein the plurality of teeth are arranged in a hexagonal orientation and define the fastener opening.

5. The panel assembly according to claim 1, wherein the union nut is one of a triangular union nut or a rectangular union nut.

6. The panel assembly of claim 1, wherein the aperture of the panel body has a hexagonal cross-sectional shape.

7. The panel assembly of claim 1, wherein the flange of the union nut extends into the panel body a first distance at a first position of the union nut and extends into the panel body a different second distance at a second position of the union nut.

8. A panel assembly system for an automotive component, the system comprising: A mold assembly, the mold assembly comprising: an ejector mold comprising a surface, a platform disposed on the surface, a central column disposed on the platform, and an orientation column disposed on the platform and offset from the central column, and a cover mold, wherein the cover mold and the ejector mold form a cavity when mated together; and A union nut comprising an inner portion having (i) a plurality of teeth that cooperate to define a fastener opening, wherein the fastener opening is sized to receive the center column and the spaces between the plurality of teeth are sized to receive the orientation column, and (ii) a flange surrounding the inner portion, wherein the center column is received in the fastener opening and the orientation column is received between adjacent teeth of the plurality of teeth, wherein the union nut is a PV-type union nut, wherein the flange defines a flange width extending radially outward from the inner portion to an outer peripheral edge, the flange width being variable along the periphery of the union nut.

9. The system of claim 8, wherein the union nut is one of a triangular union nut, a hexagonal union nut, or a rectangular union nut.

10. A method of manufacturing a panel assembly for an automotive component, the method comprising: securing a union nut to an ejector mold, the union nut comprising an inner portion having a plurality of teeth that cooperate to define a fastener opening, and a flange surrounding the inner portion, wherein the flange defines a flange width extending radially outward from the inner portion to an outer peripheral edge, the flange width being variable along a perimeter of the union nut, wherein the ejector mold comprises a platform, a center post extending from the platform, and an orientation post extending from the platform and offset from the center post; placing the union nut on the platform with the center post received within the fastener opening and the orientation posts received between adjacent ones of the teeth; Matching the cover mold with the ejector mold to form a cavity, wherein the inner portion of the union nut is outside the cavity and the flange of the union nut is inside the cavity; injecting liquid plastic into the cavity via an injection port provided in the ejection mold to form a panel body at least partially enclosing the flange of the union nut; allowing the liquid plastic to cure and solidify within the cavity over a period of time to produce a panel; as well as The ejector mold and the cover mold are removed from the panel.

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