Abstract: A method of fabricating a laminated layer includes the step of supplying first and second layer of a polymeric material, followed by serially removing blanks of the polymeric material from the first layer to produce an excess and useable layers. The blanks of the polymeric material are disposed serially along and fused to the second layer to provide a contoured pad.

Abstract: An apparatus (10) of the present invention is designed for assembling a load floor (12) having a peripheral slot (22) and an overlaying layer (24, 28). The apparatus (10) tucks the overhang of the overlaying layer (24, 28) into the peripheral slot (22). At least one holding device (52) holds the load floor (12). At least one tucking tool (54) tucks the overhang of the overlaying layer (24, 28) into the peripheral slot (22) to fold the overhang over the peripheral slot (22) and thereafter tucking the overhang into the peripheral slot (22). The invention includes a method of sequentially folding and thereafter tucking the overhang of the overlaying layers (24, 28) into the peripheral slot (22).

Abstract: A method of fabricating a laminated layer includes the step of supplying first and second layer of a polymeric material, followed by serially removing blanks of the polymeric material from the first layer to produce an excess and useable layers. The blanks of the polymeric material are disposed serially along and fused to the second layer to provide a contoured pad.

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 assembly for a motor vehicle includes a core sandwiched between opposing hardboards. The core defines a slot with one of the hard boards that encircles a peripheral surface defined by the core and the opposing hardboards. A first fabric is adhered to the first hardboard and a second fabric is adhered to the second hardboard. The first fabric defines a first peripheral edge and a second fabric defines a second peripheral edge. Each of the first and the second peripheral edges are retained in the slot in an adhesive free manner.