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 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: An integral sound absorber and water deflector door panel positionable in space defined between an inner wall and a passenger compartment door panel of an automobile vehicle door assembly. The integral panel is composed of a first polymeric layer made of a water impervious polymeric film having an essentially constant thickness. The first polymeric layer has a first face adapted to contact the interiorly oriented face on the inner wall of the vehicle door assembly and remain in overlying parallel orientation thereto. A second polymeric layer is composed of a polymeric foam integrally connected to the second face of the first polymeric layer in continuous overlying relationship thereto. The second polymeric layer has an outer face opposed to the first polymeric layer which, preferably, has at least one region adapted to directly contact a portion of the exteriorly oriented face of the passenger compartment door panel.