Abstract: A liftgate assembly having finished show surfaces, and process of manufacturing same. The liftgate assembly includes local reinforcements that are overmolded to first reinforcements, and the first reinforcements are infrared welding to a first panel. Second and third reinforcements are also infrared welded to the first panel. To infrared weld the respective reinforcements to the first panel in predetermined locations with respect to the first panel, nesting structures are provided to hold the respective reinforcements and first panel. At least one infrared heating fixture heats various predetermined surfaces on the reinforcements and first panel, and the parts are then pressed together for joining the predetermined surfaces of the respective parts together. The process is repeated, if needed, until all of the reinforcements are infrared welded to the first panel. Outer panels are bonded to the second and third reinforcements.

Abstract: A liftgate structure having a structural inner panel with an outside surface and an inner surface having a lower perimeter surface area extending across substantially the entire width of the structural inner panel. The structural inner panel includes a wiper motor housing recess formed on the inner surface. A plurality of brackets are connected to the outside surface of the structural inner panel, where each of the brackets has at least one friendly hole. The liftgate structure further includes a tether having 2 ends each having at least one over molded retainer for connecting the tether to a wiper motor housing positioned within the wiper motor housing recess of the structural inner panel. Additionally the tether is positioned through each of the at least one friendly holes of the plurality of brackets.

Abstract: A liftgate integrating bulkhead reinforcements into an inner panel and/or outer panel of the liftgate or closure creating an efficient design that adds mold-in reinforcement structure and eliminates the need to add steel or plastic parts to meet performance requirements.

Abstract: A three-dimensional overmolding and process for manufacturing same. The three-dimensional overmolding has a three-dimensional structure with overmolding, which gives significant performance benefits. Assembly and joining of reinforcements is done before the overmolding or in the injection molding tool. The three-dimensional overmolding meets predetermined structural requirements without requiring secondary operations and at a lower mass and cost. The structural benefits are due to the three dimensional shape in combination with the benefit of the overmolding process.

Abstract: A liftgate having an overmolded hinge point comprising a metal reinforcement overmolded with a polymer and having a compression limiter portion molded in. The compression limiter portion including a tubular portion for receiving a fastener encapsulated during overmolding and having overmolded gusset ribs extending therefrom during the overmolding process.

Abstract: Metal rib overmolding joining including creating geometrical features in reinforcements for interconnecting a three-dimensional metal reinforcement to a metal base plate of an overmolding part in order to transfer load forces. Interlocked reinforcement is pre-assembled or assembled in an injection molding tool. Geometric features are positioned and joined creating a connection geometry that is overmolded. The joints created between the metal reinforcements are done without a welding process.

Abstract: A liftgate (28) formed with a thermoplastic which is overmolded around preselected reinforcements at stress points, such as a corner area, which includes a pair of separate reinforcement plates (14,18) and wherein a 3-dimensional reinforcement plate (12) is connected between the pair of separate reinforcements (14,18). Preferably the 3-dimensional reinforcement plate is connected to three reinforcements.

Abstract: A liftgate structure having a structural inner panel with an outside surface and an inner surface having a lower perimeter surface area extending across substantially the entire width of the structural inner panel. The structural inner panel includes a wiper motor housing recess formed on the inner surface. A plurality of brackets are connected to the outside surface of the structural inner panel, where each of the brackets has at least one friendly hole. The liftgate structure further includes a tether having 2 ends each having at least one over molded retainer for connecting the tether to a wiper motor housing positioned within the wiper motor housing recess of the structural inner panel. Additionally the tether is positioned through each of the at least one friendly holes of the plurality of brackets.

Abstract: An exterior body panel assembly having a Class A painted surface, mold-in color or non-Class A surface, and process of infrared welding components of the assembly. Panels of the assembly are placed on a nesting structure and the inside half of the structures are brought together with the other for a fit check. Panels are separated and an infrared heating fixture then heats the various areas to be heated on the panels. The areas on the panels are heated depending on the thicknesses of the parts at each area and surface geometries to be welded. The parts are immediately clamped back together under pressure for joining and cooling of the joined surfaces in the clamped arrangement.

Abstract: A liftgate assembly having finished show surfaces, and process of manufacturing same. The liftgate assembly includes local reinforcements that are overmolded to first reinforcements, and the first reinforcements are infrared welding to a first panel. Second and third reinforcements are also infrared welded to the first panel. To infrared weld the respective reinforcements to the first panel in predetermined locations with respect to the first panel, nesting structures are provided to hold the respective reinforcements and first panel. At least one infrared heating fixture heats various predetermined surfaces on the reinforcements and first panel, and the parts are then pressed together for joining the predetermined surfaces of the respective parts together. The process is repeated, if needed, until all of the reinforcements are infrared welded to the first panel. Outer panels are bonded to the second and third reinforcements.

Abstract: An exterior body panel assembly having a Class A painted surface, mold-in color or non-Class A surface, and process of infrared welding components of the assembly. Panels of the assembly are placed on a nesting structure and the inside half of the structures are brought together with the other for a fit check. Panels are separated and an infrared heating fixture then heats the various areas to be heated on the panels. The areas on the panels are heated depending on the thicknesses of the parts at each area and surface geometries to be welded. The parts are immediately clamped back together under pressure for joining and cooling of the joined surfaces in the clamped arrangement.

Abstract: An exterior body panel assembly having a Class A painted surface, mold-in color or non-Class A surface, and process of infrared welding components of the assembly. Panels of the assembly are placed on a nesting structure and the inside half of the structures are brought together with the other for a fit check. Panels are separated and an infrared heating fixture then heats the various areas to be heated on the panels. The areas on the panels are heated depending on the thicknesses of the parts at each area and surface geometries to be welded. The parts are immediately clamped back together under pressure for joining and cooling of the joined surfaces in the clamped arrangement.

Abstract: An exterior body panel assembly having a Class A painted surface, mold-in color or non-Class A surface, and process of infrared welding components of the assembly. Panels of the assembly are placed on a nesting structure and the inside half of the structures are brought together with the other for a fit check. Panels are separated and an infrared heating fixture then heats the various areas to be heated on the panels. The areas on the panels are heated depending on the thicknesses of the parts at each area and surface geometries to be welded. The parts are immediately clamped back together under pressure for joining and cooling of the joined surfaces in the clamped arrangement.

Abstract: The invention provides a motor vehicle bumper comprising: a shield presenting a first impact zone situated substantially at the same height as the knee of an adult pedestrian and, immediately below said first zone, a second impact zone situated substantially at the height as the tibia of an adult pedestrian; a beam placed behind the shield substantially at the same height as the knee of an adult pedestrian, in register with and at a certain distance from the shield; and interposed between the beam and the shield, at least one block made of a compressible material, the block having a front end disposed beside the shield and a rear end disposed beside the beam, and having a cross-section that increases from its front end towards its rear end. The front end of the block is disposed in register with the second impact zone of the shield.

Abstract: The invention provides a motor vehicle bumper comprising: