A back door attached to a rear of a vehicle body includes an inner panel, an outer panel facing the inner panel, a first reinforcing member laid on an outer side of the vehicle body and fixed to the inner panel together with a hinge, and a second reinforcing member including a porous portion and arranged to fill a first space between the first reinforcing member and the outer panel on an outer side in a width direction of the vehicle body from a hinge support that supports the hinge to overlap at least a part of a glass upper edge of a back window glass.

A back door that reduces noise in a vehicle interior by suppressing vibration of an outer panel while reducing the weight and costs includes an outer panel and an inner panel. The inner panel includes a horizontal frame part, vertical frame parts, merging parts, and connecting parts. The connecting part extends only from one end part on an opening part side in a width direction of the horizontal frame part, the connecting part extends only from one end part on an opening part side in the width direction of the vertical frame part, and the connecting part extends only from one end part on an opening part side in the width direction of the vertical frame part. The connecting parts are respectively connected to the outer panel. The merging parts are formed with higher torsional rigidity than the horizontal frame part and the vertical frame parts.

A back door structure of a vehicle capable of reducing noise in a vehicle interior by suppressing vibration of an outer panel while reducing the weight and costs includes an outer panel and an inner panel. The inner panel includes a horizontal frame part, side-direction frame parts, and connecting parts. The horizontal frame part and each of the side-direction frame parts are mutually connected. The connecting part extends only from one end part on an opening part side in a vertical width direction of the horizontal frame part, the connecting part extends only from one end part on an opening part side in the vertical width direction of the side-direction frame part, and the connecting part extends only from one end part on an opening part side in the vertical width direction of the side-direction frame part. The connecting parts are respectively connected to the outer panel.

A composite liftgate including an inner panel construction having strengthening channel structure in combination with a ribbing. Structural steel reinforcements are bonded to the inner panel where additional strength is needed. Where the extra structure is needed, a minimum amount of steel is used and the structural reinforcement is bonded in place using adhesive. A plurality of access doors are provided that are removable for easier maintenance and repair.

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.

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.

An impact absorbing reinforcement member for a liftgate of a vehicle includes a body having a first end and second end opposite the first end, the body including a center reinforcement member, a first outboard reinforcement member extending from the center reinforcement member to the first end and including a first plurality of curved segments, and a second outboard reinforcement member extending from the center reinforcement member to the second end and including a second plurality of curved segments. The first and second pluralities of curved segments laterally extend when the liftgate is subjected to an impact force.

A disclosed system includes a liftgate housing; a tab of the liftgate housing moveable to an acute angle relative to a first portion of the liftgate housing; a tab aperture disposed in the tab; a first wall and a second wall attached to the liftgate housing, where the first wall, the second wall, and the tab form a barrier to prevent debris from entering into the housing; a camera, where at least a portion of the camera is disposed through the tab aperture, and where movement of the tab relative to the first portion of the liftgate housing adjusts the field of view of the camera.

A composite liftgate including an inner panel construction having strengthening channel structure in combination with a ribbing. Structural steel reinforcements are bonded to the inner panel where additional strength is needed. Where the extra structure is needed, a minimum amount of steel is used and the structural reinforcement is bonded in place using adhesive. A plurality of access doors are provided that are removable for easier maintenance and repair.

A sensor unit manufacturing method includes: a core metal insertion process of inserting a core metal member having a length dimension smaller than a length dimension of a core metal accommodation portion into a predetermined location (a section of a curving portion) extending along a longitudinal direction of the core metal accommodation portion; and a bending process of bending the section (the section of the curving portion) of a fixation base portion, into which the core metal member is inserted, following a curved shape of a sensor bracket.