Abstract: A load floor (22) for a motor vehicle (20) has a foamed substrate layer (34) having a peripheral edge (42) and a facing layer (32), formed from hardboard or other sheet material. An adhesive layer (36) adheres the substrate layer (34) to the facing layer (32). Grooves (68, 70) are formed on a top surface (40) of the substrate layer (34) and extend to the peripheral edge (42) to provide an egress for fluids at the peripheral edge (42) during curing of the adhesive layer (36). The grooves (68, 70) are curved to prevent cracking of the substrate layer (34) under an applied load (74).

Abstract: A storage system (14) of a motor vehicle (10) presenting a cargo space defining an opening (18) for storing spare tires, tools, and the like. A load floor assembly (22) is configured to cover the opening (18) and to support various loads (41) positioned thereon. A cover (24) of the load floor assembly (22) is molded from a polystyrene or other foam composite. At least one laminate (18), formed from a hard board or other sheet material, is adhered to the cover (24). A support frame (40), formed from a foamed polypropylene, includes a density greater than the density of the cover (24) and therefore has a higher mass to provide a significant amount of structural benefits to the load floor assembly (22) for supporting and preventing a deflection of the cover (24) under the force of the loads (41) applied thereto.

Abstract: A load floor (22) for a motor vehicle (20) has a foamed substrate layer (34) having a peripheral edge (42) and a facing layer (32), formed from hardboard or other sheet material. An adhesive layer (36) adheres the substrate layer (34) to the facing layer (32). Grooves (68, 70) are formed on a top surface (40) of the substrate layer (34) and extend to the peripheral edge (42) to provide an egress for fluids at the peripheral edge (42) during curing of the adhesive layer (36). The grooves (68, 70) are curved to prevent cracking of the substrate layer (34) under an applied load (74).

Abstract: A storage system (14) of a motor vehicle (10) presenting a cargo space defining an opening (18) for storing spare tires, tools, and the like. A load floor assembly (22) is configured to cover the opening (18) and to support various loads (41) positioned thereon. A cover (24) of the load floor assembly (22) is molded from a polystyrene or other foam composite. At least one laminate (18), formed from a hard board or other sheet material, is adhered to the cover (24). A support frame (40), formed from a foamed polypropylene, includes a density greater than the density of the cover (24) and therefore has a higher mass to provide a significant amount of structural benefits to the load floor assembly (22) for supporting and preventing a deflection of the cover (24) under the force of the loads (41) applied thereto.