Abstract: A sandwich-type composite component having imprinted 3-D structures which provide at least one pattern at an outer surface of the component is provided. The component includes a first outer layer having an outer surface, a second outer layer and a core positioned between the outer layers and having a large number of cavities. The outer layers are bonded to the core by press molding. The first outer layer comprises an integral, unitary structure including 3-D structures imprinted by the press molding. The 3-D structures are sized, shaped and arranged in one or more patterns at the outer surface. The one or more patterns may form a textural surface finish, a logo or indicia such as instructions at the outer surface. The component may be a vehicle interior component such as a vehicle load floor component.

Abstract: A compression-molded, composite component having a sandwich structure and having integrally formed strengthening structures is disclosed. The component includes a first outer layer having an outer surface, a second outer layer, and a core positioned between the outer layers and having a large number of cavities. The outer layers are bonded to the core by press molding. Portions of at least one of the outer layers are sized, shaped and arranged laterally adjacent to each other in a pattern to provide the component with strength to resist deflection from a load at various positions and orientations at the outer surface.

Abstract: A sandwich-type, structural, composite panel having a pattern of depressions formed at a lower outer surface thereof and stiffening supports received and retained therein is provided. The panel includes a first outer layer having a first outer surface, a second outer layer having a second outer surface and a core positioned between the outer layers and having a large number of cavities. The outer layers are bonded to the core by press molding. Crushed portions of the panel having a reduced thickness form the pattern of depressions at the second outer surface of the second outer layer. The stiffening supports are bonded or joined to the second outer layer within the pattern of depressions. The stiffening supports are sized, shaped and arranged within the pattern of depressions to provide the panel with strength to resist deflection from a load at various positions and orientations at the first outer surface.

Abstract: A cargo management system including a vehicle load floor having a vehicle component receiving feature is provided. The load floor compartmentalizes a cargo area into an upper compartment and a covered lower compartment. The system includes a first generally planar member having a first depression of a first predetermined depth and a compression-molded, composite, second generally planar member having a second depression of a second predetermined depth. A portion of the second member is locally crushed by press molding to form the second depression. Opposed surfaces of the first and second depressions cooperate to restrain movement of a vehicle component positioned in a cavity defined by the first and second depressions between the first and second members and prevent sudden transfer of vehicle component weight during vehicle acceleration and deceleration.

Abstract: A sandwich-type, structural, composite component including at least one hingedly connected portion which pivots with reduced or eliminated hinge binding and a cargo management system and vehicle load floor utilizing the component are provided. Elongated first and second interior portions of the component are locally crushed by the press molding to form a living hinge having a pivot axis and an elongated depression, respectively. The component includes an elongated cut-out which extends completely through the component at the elongated depression to obtain a clearance between a first portion of the component hingedly connected to a second portion of the component by the living hinge. The living hinge and the clearance allow pivotal movement of the first portion between different use positions relative to the second portion with reduced or eliminated hinge binding during the pivotal movement about the pivot axis.

Abstract: Cargo management system including a vehicle load floor to compartmentalize a cargo area into an upper compartment and a covered lower compartment is provided. The system includes a composite plastic first outer layer having a substantially planar upper support surface to support cargo in the upper compartment. A composite plastic second outer layer has at least one cavity defined by lower surfaces of the second outer layer. Each cavity has a size and shape which corresponds in size and shape to a vehicle component to restrain movement of the vehicle component and to prevent sudden transfer of vehicle component weight during vehicle acceleration and deceleration. A core including adjacent core portions has different thicknesses. At least one of the core portions has a large number of cavities and each of the core portions is positioned between and bonded to the outer layers by press molding to form corresponding panel portions.

Abstract: A sandwich-type, structural, composite component having a cut-out feature with a substantially hidden core, assembly utilizing same and panel for use in a vehicle load floor assembly are disclosed. The component includes a first outer layer, a second outer layer and a core positioned between the outer layers and having a large number of cavities. The outer layers are bonded to the core by press molding. An interior portion of the component enclosed by the rest of the component is locally crushed by the press molding to form at least one depression. A cut-out extends completely through the component at the interior portion of the component. Side surfaces of the at least one depression substantially hide the core at the cut-out without compromising the structural integrity of the component.

Abstract: A system including a panel assembly having a container and a compression-molded, composite cover for covering the container is provided. The system may be a flooring system such as a vehicle flooring system and the assembly may be a floor panel assembly. The assembly includes at least one load-bearing component positioned between a lower outer layer of the cover and a bottom wall of the container in a closed position of the cover. Each component is bonded or joined to the outer layer and is in abutting engagement with the bottom wall in the closed position of the cover to transfer a load appearing at an outer surface of an upper outer layer of the cover to the bottom wall of the container. The system also includes a structure such as floor having a cavity for receiving the panel assembly.

Abstract: A panel assembly including a compression-molded, composite panel is provided. The panel has first and second outer layers and a core positioned between the outer layers. The core has a large number of cavities. The outer layers are bonded to the core by press molding. The assembly also includes a component pivotally connected to the panel and a living hinge which allows the component to pivot about a pivot axis between different use positions relative to the panel. The assembly further includes a stiffening support having a support axis substantially parallel to the pivot axis. The support is bonded or joined to the panel to locally reinforce the panel adjacent the living hinge. The stiffening support eliminates the need for a metal hinge and provides for a light weight assembly with improved aesthetics and function.

Abstract: A method of making a sandwich-type, compression-molded, composite component having improved surface appearance is provided. Resin skins and a core of a blank or stack of sandwich materials are heated to a softening temperature of the resin. A compression mold is provided including component-forming, upper and lower dies with opposing molding surfaces cooperating to define a mold cavity. The heated blank or stack is allowed to cool in the mold cavity until inner surfaces of the skins are bonded to top and bottom surfaces of the core to seal core cavities. Air in the sealed cavities urges softened portions of the skins inwardly towards the cavities of the core as the air in the cavities cools. A vacuum is applied at a first outer surface of the blank or stack in the mold cavity sufficient to prevent debossing and improve appearance of the first outer surface.

Abstract: A unitary structural assembly including a first component having a plateau-receiving aperture and a compression-molded, composite second component having a sandwich structure is provided. The second component includes a first outer layer, a second outer layer, and a core positioned between the outer layers and having a large number of cavities. The outer layers are bonded to the core by a press molding. A portion of the second component including the first layer and the core defines a raised plateau having upper and side surfaces. The plateau has a size and shape corresponding to the size and shape of the plateau-receiving aperture. A height of the plateau corresponds to the depth of the plateau-receiving aperture. The plateau is inserted into the plateau-receiving aperture so that corresponding surfaces of the plateau and the plateau-receiving aperture are in abutting engagement to unitarily connect the components and form the assembly.

Abstract: A method of making a sandwich-type composite panel having a living hinge from a stack of material is provided. The stack includes first and second reinforced thermoplastic skins heated to a softening temperature and a thermoplastic cellular core disposed between the skins. The first skin is stretchable when heated to the softening temperature. A pressure is applied to the stack after the step of heating to form the composite panel. A portion of the composite panel is crushed at a predetermined location simultaneously with the step of applying to locally compact and separate the cellular core at the predetermined location to form two side portions of the panel and a crushed portion of the panel between the two side portions. The first skin stretches during the step of crushing while remaining intact between the two side portions. The skins bond together at the predetermined location to form the living hinge.

Abstract: An antimicrobial, molded laminate shopping cart part and method of manufacturing same are provided. The part, such as a small child seat, includes a structural carrier made from a thermoplastic resin and having an outer surface. The part further includes a formed plastic film sheet having upper and lower surfaces. The lower surface is bonded to the outer surface of the carrier. The film sheet includes an outer clear plastic layer including at least one antimicrobial agent disbursed throughout the plastic layer. The antimicrobial agent exhibits controlled migration through the clear plastic to the outer surface of the clear plastic layer.

Abstract: A compression-molded, composite panel for a vehicle interior is provided. A substantially continuous facing material layer has an outwardly-facing surface for display in the interior of the vehicle. The facing material layer is bonded to the outer surface of a first skin of the panel by press molding. The press molding forms a first portion of the panel and a second portion of the panel pivotally connected to the first portion. A living hinge includes a portion of the facing material layer which allows the second portion of the panel to pivot between different use positions relative to the first portion of the panel. A score line formed by the press molding in the outwardly-facing surface of the portion of the facing material layer at least partially defines the living hinge and functions as a style line to mask facing material damage or imperfections at the outwardly-facing surface.

Abstract: A compression-molded, composite component having a sandwich structure and having integrally formed strengthening structures is disclosed. The component includes a first outer layer having an outer surface, a second outer layer, and a core positioned between the outer layers and having a large number of cavities. The outer layers are bonded to the core by press molding. Portions of at least one of the outer layers are sized, shaped and arranged laterally adjacent to each other in a pattern to provide the component with strength to resist deflection from a load at various positions and orientations at the outer surface.

Abstract: A sandwich-type composite component having imprinted 3-D structures which provide at least one pattern at an outer surface of the component is provided. The component includes a first outer layer having an outer surface, a second outer layer and a core positioned between the outer layers and having a large number of cavities. The outer layers are bonded to the core by press molding. The first outer layer comprises an integral, unitary structure including 3-D structures imprinted by the press molding. The 3-D structures are sized, shaped and arranged in one or more patterns at the outer surface. The one or more patterns may form a textural surface finish, a logo or indicia such as instructions at the outer surface. The component may be a vehicle interior component such as a vehicle load floor component.

Abstract: A sandwich-type, structural, composite panel having a pattern of depressions formed at a lower outer surface thereof and stiffening supports received and retained therein is provided. The panel includes a first outer layer having a first outer surface, a second outer layer having a second outer surface and a core positioned between the outer layers and having a large number of cavities. The outer layers are bonded to the core by press molding. Crushed portions of the panel having a reduced thickness form the pattern of depressions at the second outer surface of the second outer layer. The stiffening supports are bonded or joined to the second outer layer within the pattern of depressions. The stiffening supports are sized, shaped and arranged within the pattern of depressions to provide the panel with strength to resist deflection from a load at various positions and orientations at the first outer surface.

Abstract: A system including a panel assembly having a container and a compression-molded, composite cover for covering the container is provided. The system may be a flooring system such as a vehicle flooring system and the assembly may be a floor panel assembly. The assembly includes at least one load-bearing component positioned between a lower outer layer of the cover and a bottom wall of the container in a closed position of the cover. Each component is bonded or joined to the outer layer and is in abutting engagement with the bottom wall in the closed position of the cover to transfer a load appearing at an outer surface of an upper outer layer of the cover to the bottom wall of the container. The system also includes a structure such as floor having a cavity for receiving the panel assembly.

Abstract: A cargo management system including a vehicle load floor having a vehicle component receiving feature is provided. The load floor compartmentalizes a cargo area into an upper compartment and a covered lower compartment. The system includes a first generally planar member having a first depression of a first predetermined depth and a compression-molded, composite, second generally planar member having a second depression of a second predetermined depth. A portion of the second member is locally crushed by press molding to form the second depression. Opposed surfaces of the first and second depressions cooperate to restrain movement of a vehicle component positioned in a cavity defined by the first and second depressions between the first and second members and prevent sudden transfer of vehicle component weight during vehicle acceleration and deceleration.

Abstract: A unitary structural assembly including a first component having a plateau-receiving aperture and a compression-molded, composite second component having a sandwich structure is provided. The second component includes a first outer layer, a second outer layer, and a core positioned between the outer layers and having a large number of cavities. The outer layers are bonded to the core by a press molding. A portion of the second component including the first layer and the core defines a raised plateau having upper and side surfaces. The plateau has a size and shape corresponding to the size and shape of the plateau-receiving aperture. A height of the plateau corresponds to the depth of the plateau-receiving aperture. The plateau is inserted into the plateau-receiving aperture so that corresponding surfaces of the plateau and the plateau-receiving aperture are in abutting engagement to unitarily connect the components and form the assembly.