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.

A vehicle door enables introduction of a plastic resin through penetration holes formed in the reinforcement bracket that is inserted into the window frame portion in injection molding of the door module assembled between the door trip and the door panel to improve structural bonding force and at the same time assure structural rigidity by forming various ribs and bosses to thereby prevent separation of the reinforcement bracket due to torsion, and particularly, prevents deformation by strengthening bending strength by filling a plastic resin in a space formed between ribs in a portion where structural strength is required.

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.

A method of assembling at least two types of vehicles with different powertrain requirements on the same assembly line is provided. The method includes assembling a first structural body component for a first vehicle type including a first powertrain requirement. The first structural body component comprises a first structural core surrounded by a first fiber reinforced material having a first thickness. The first structural body component has a first external geometry. The method includes assembling a second structural body component for a second vehicle type that has a second powertrain requirement different from the first powertrain requirement. The second structural body component comprises a second structural core surrounded by a second fiber reinforced material having a second thickness different from the first thickness. The second structural body component has a second external geometry that is the same in shape and dimension as the first external geometry.

A vehicle bodywork panel is formed by an outer wall supported by a structural lining. The structural lining is produced by molding a plastic or composite material. The structural lining may include stiffeners arranged to provide said bodywork panel with a given amount of mechanical strength. One or more added connection elements connect separate fastening points disposed on the structural lining and each end of each of the connection elements is inserted into a housing disposed on a stiffener. The rigidity of the connection elements is adapted to suppress a vibration response of the stiffeners. The housing and the connection element may form a flush-mounted connection.

A door of a vehicle may include a first door module forming a door skeleton; a second door module coupled with the first door module and forming a door window; and a door frame coupled to the first door module and engaged with the second door module; wherein the second door module may include a relatively lightweight material as compared to the first door module, reducing weight and cost of the door for the vehicle.

A carrier of a carrier module for a motor vehicle door assembly and method of manufacture thereof is provided. The carrier has a body with opposite wet and dry sides bounded by an outer periphery configured for attachment to an inner panel of the motor vehicle door assembly. The body is made of a recyclable, environmentally sustainable natural fibrous material.

A method of assembling at least two types of vehicles with different powertrain requirements on the same assembly line is provided. The method includes assembling a first structural body component for a first vehicle type including a first powertrain requirement. The first structural body component comprises a first structural core surrounded by a first fiber reinforced material having a first thickness. The first structural body component has a first external geometry. The method includes assembling a second structural body component for a second vehicle type that has a second powertrain requirement different from the first powertrain requirement. The second structural body component comprises a second structural core surrounded by a second fiber reinforced material having a second thickness different from the first thickness. The second structural body component has a second external geometry that is the same in shape and dimension as the first external geometry.

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 vehicle door enables introduction of a plastic resin through penetration holes formed in the reinforcement bracket that is inserted into the window frame portion in injection molding of the door module assembled between the door trip and the door panel to improve structural bonding force and at the same time assure structural rigidity by forming various ribs and bosses to thereby prevent separation of the reinforcement bracket due to torsion, and particularly, prevents deformation by strengthening bending strength by filling a plastic resin in a space formed between ribs in a portion where structural strength is required.