Abstract: A method for forming an overmolded component, includes arranging a first mold part and a second part with at least part of a first mold cavity defined by the first mold part and the second mold part, providing material to form a substrate into the first mold cavity, providing an overmold cavity that is defined at least in part by the substrate, one or both of the first mold part and second mold part, and a seal that engages the substrate and also engages one or both of the first mold part and the second mold part, and providing material for an overmolded layer in the overmold cavity. The overmold layer may be formed from a material having low viscosity and the seal inhibits or prevents overflow of the overmold material to reduce or eliminate formation of flash at parting or junction lines in the molding process.

Abstract: A liftgate 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 and wherein a 3-dimensional reinforcement plate is connected between the pair of separate reinforcements. Preferably the 3-dimensional reinforcement plate is connected to three reinforcements.

Abstract: A process for edge sealing during an overmolding of a polyurethane on a substrate part comprising the steps of: A. Providing an injection mold cavity including a first side platen forming mold and a second side mating part forming platen; B. Molding a substrate part formed between the first side platen and the second side mating part forming platen; C. Providing a second overmold cavity for overmolding a polyurethane or other covering over the substrate part; and D. Providing a seal at the flashing edge of the second overmold cavity and overmolding the polyurethane or other covering over the substrate part such that there is substantially no flashing material where the seal is located.

Abstract: A vehicle closure structure (such as a liftgate door, trunk door, frunk door, vehicle hood or the like); which requires a mechanical reinforcement of an area (such as a door latch, hinge, lift cylinder, spoiler attachment or the like). The closure has at least one thermoplastic or thermoset boss which is extending through an orifice in a support member which is ultrasonically mushroom welded for securing the support member to the vehicle closure structure.

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 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 vehicle panel arrangement having an inner panel having strategically positioned load point areas. Each of these load point areas includes a local reinforcement which is connected securely to the outer surface of the inner panel. The arrangement further includes bulkheads extending from the outside surface of the inner panel and a continuous reinforcement in contact with at least two locations on a vehicle body structure. The combination of the local reinforcements, bulkheads and continuous reinforcement ensures that when external forces are applied to the vehicle panel arrangement, the forces are efficiently distributed across the vehicle panel arrangement and to the vehicle body structure through the continuous reinforcement.

Abstract: A liftgate 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 and wherein a 3-dimensional reinforcement plate is connected between the pair of separate reinforcements. Preferably the 3-dimensional reinforcement plate is connected to three reinforcements.

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 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 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 vehicle closure panel including a molded inner panel for resting on a vehicle body mounted shuffle bumper. The molded inner panel has a molded in shuffle bumper interface providing a solid interference stop with a shuffle bumper when the vehicle closure panel is in a closed position.

Abstract: A reinforced lift gate panel arrangement that includes a lift gate panel formed of fiber filled polymer material. The lift gate panel has a structural side with a connection surface region. The arrangement further includes at least one reinforcement bracket with a panel contact side and a tool contact side with at least one aperture formed through the reinforcement bracket that extends from the panel contact side to the tool contact side. There is at least one mechanical lock formed between the lift gate panel and the reinforcement bracket. The mechanical lock is formed by a portion of the fiber filled polymer material curing in the at least one aperture of the reinforcement bracket.

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: A reinforcement attachment arrangement for a thermoplastic liftgate having a liftgate inner panel with an outer surface area defining a plurality of reinforcement areas. Each reinforcement area has at least one receiving portion and at least one connection member extending from the outer surface area of the liftgate inner panel. Connected to each reinforcement area is a reinforcement connected to each respective one of the plurality of reinforcement areas. Each reinforcement includes at least one engagement tab for engaging the at least one receiving portion formed on the respective reinforcement area. The reinforcement includes apertures that align with the connection member formed on the outside surface of the liftgate inner panel, to hold the reinforcement onto the outer surface of the liftgate inner panel. The arrangement further includes a liftgate exterior panel connected to the liftgate inner panel and covering the reinforcement areas and each reinforcement.

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.