The present disclosure relates to a method of molding a motor vehicle part, the motor vehicle part being made from thermosetting plastic material and including at least one metal insert having a shape allowing it to extend substantially through the entire thickness of the motor vehicle part, the method being characterized in that it includes the following steps placing the metal insert and the thermosetting plastic material in a mold, and molding the motor vehicle part comprising the overmolded metal insert, the metal insert being deformed at least at one mechanical weakening zone by closing the mold for molding the motor vehicle part.

A lightweight and simplified vehicle door assembly is provided with four main components, an upper frame positioned about the window, an inner frame structure, an outer body panel, and a composite reinforcement component. The composite reinforcement component provides an all-in-one solution for a side impact cross beam, as well as an upper door reinforcement, a front door pillar reinforcement, and a rear door pillar reinforcement. The composite reinforcement component acts to reinforce the overall door structure, offers resistance to a side impact that limits the intrusion into the passenger compartment, and offers resistance to a frontal impact by maintaining the spacing between the vehicle A and B pillars (for a front door) and pillar C and D for a back door. A coupe vehicle door in which there is no window frame may be reinforced with the composite reinforcement component. The composite reinforcement component may have continuous or chopped fibers.

A vehicle door module includes a unitary frame and areas circumscribed by the unitary frame wherein the circumscribed areas are filled with a material comprising a closed cell polymeric foam. The vehicle door module can be made by overmolding or compression molding.

A curved panel part includes: a curved panel made of metal; and a reinforcement joined to the curved panel and made of a plurality of FRP layers including continuous fibers, in which each of the plurality of FRP layers has a single fiber direction, at least one layer out of the plurality of FRP layers has a fiber direction different from that of another layer, in the plurality of FRP layers, a proportion of layers having an angular difference in the fiber direction of 30° or more is 15% or more of all of the layers, and when calculating, by defining a maximum principal curvature direction of the curved panel as a 0° direction and a direction orthogonal to the 0° direction as a 90° direction, each of a 0° direction component and a 90° direction component regarding the fiber direction of each FRP layer of the reinforcement joined to the curved panel, by using a trigonometric function, an expression (1) is satisfied.

An interfacing element of a lock zone of a door of a motor vehicle. The interfacing element comprises: includes a support made of plastic material, intended to be attached to a lining of the door, the lining being made of plastic material and a reinforcing plate of the lock zone onto which a lock is intended to be fastened, the plate being integrated to the support by overmolding. The support is made of a material having a Young's modulus lower than that of the plastic material of the lining of the door, and a coefficient of elongation at break greater than that of the plastic material of the lining of the door. A sub-assembly of motor vehicle includes a lining of tailgate and an interfacing element fastened onto an outer face of the lining.

A vehicle door according to an exemplary embodiment enhances coupling strength through structural coupling by molding a window frame of a door module assembled between a door trim and the door panel with a separate aluminum injection product, and insert-injection molding a coupling portion of the window frame to a module body, and a groove is formed along the coupling portion of the window frame coupled to the module body to easily distinguish respective parts and serve to carry out sealing in injection molding.

A door assembly for a vehicle is provided. The door assembly includes an inner panel and an outer panel which are joined together to define a central space therebetween. The central space has a front which faces towards the front of a vehicle and a back which faces towards a back of the vehicle. Both the inner and outer panels are made of aluminum, and at least one reinforcement beam made of steel is disposed in the central space between the aluminum inner and outer panels to provide the door assembly with increased impact resistance.

A composite sheet metal component for an automobile comprises an inner metal sheet, an outer metal sheet and an intermediate polymer sheet arranged between the inner and the outer metal sheet. The intermediate polymer sheet comprises a semiconductor device and the outer metal sheet comprises at least one functional area.

An impact absorbing structure for a vehicle wherein the impact absorbing structure includes a metal beam and a resin crash pad installed on a side of the metal beam where an external impact is received, the resin crash pad is installed within a range in a longitudinal direction of the metal beam, the range including a site including a longitudinal direction center of the metal beam and receives the external impact, the resin crash pad is composed of a thermoplastic resin composition, and the thermoplastic resin composition constituting the resin crash pad has a flexural modulus if 1 to 20 GPa as measured using an ISO test piece obtained by injection molding, a bending test is performed in accordance with ISO 178 at a strain rate of 2 mm/min in an atmosphere at a temperature of 23° C. and a humidity of 50% to measure the flexural modulus.

A panel structure includes: a panel made of metal; and a reinforcement joined to the panel and made of a plurality of FRP layers including continuous fibers, in which each of the plurality of FRP layers has a single fiber direction, at least one layer out of the plurality of FRP layers has a fiber direction different from that of another layer, in the plurality of FRP layers, a proportion of layers having an angular difference in the fiber direction of 30° or more is 15% or more of all of the layers, and when calculating, by defining a long side direction being a long direction of a long edge of the panel as a 90° direction and a direction orthogonal to the 90° direction as a 0° direction, each of a 90° direction component and a 0° direction component regarding the fiber direction of each FRP layer of the reinforcement joined to the panel, by using a trigonometric function, an expression (1) is satisfied.