CARPETED, VEHICLE LOAD FLOOR INCLUDING A PIVOTABLE COVER SEGMENTED INTO ARTICULATED, SECTIONAL MEMBERS

• US 20130278009A1
• Filed: 06/14/2012
• Published: 10/24/2013
• Est. Priority Date: 04/23/2012
• Status: Active Grant

• Current Assignee: Global IP Holdings LLC
• Original Assignee: Global IP Holdings LLC
• Inventors: Preisler, Darius J., Heikkila, Christopher A.
• Granted Patent: US 8,852,711 B2
• Time in Patent Office: Days
• US Class Current: 296/97.23
• CPC Class Codes: B60R 13/0275 comprising removable or hinged parts for accessing storage compartments B60R7/04; for airbag deployment B60R21/215
• CPC Class Codes: Y10T 428/23979 Particular backing structure or composition
• CPC Class Codes: Y10T 428/24 Structurally defined web or sheet [e.g., overall dimension, etc.]
• CPC Class Codes: Y10T 428/24008 including fastener for attaching to external surface
• CPC Class Codes: Y10T 428/24149 Honeycomb-like

Abstract

A carpeted, vehicle load floor including a pivotable, carpeted cover segmented into articulated sectional members is provided. The load floor includes a compression-molded composite panel and the segmented cover to removably cover a storage area in the interior of the vehicle. The cover is segmented into articulated, planar sectional members to allow desired cover positioning over the storage area. The members are pivotally connected to one another for folding one over the other. The load floor also includes a substantially continuous carpet layer bonded to a top support surface of the panel and top support surfaces of each of the members. A first living hinge allows the carpeted cover to pivot between different use positions and a second living hinge allows the members to easily pivot and fold one over the other in a compact, folded, open position of the cover.

Claims

1. A carpeted, vehicle load floor including a pivotable cover segmented into articulated, sectional members, the load floor comprising

a compression-molded, planar, composite panel including first and second outer layers and a core positioned between the outer layers and having a large number of cavities wherein the outer layers are bonded to the core by press molding, the first outer layer having a top support surface;

a segmented cover to removably cover at least one storage area in the interior of the vehicle, the cover being segmented into articulated, planar, sectional members to allow desired cover positioning over the at least one storage area, the cover being pivotally connected to the composite panel, the sectional members being pivotally connected to one another for folding one of the members over the other one of the members, each member having a top support surface;

a substantially continuous carpet layer bonded to the top support surface of the panel and the top support surface of each of the members to at least partially form a carpeted load floor having a carpeted cover;

a first living hinge which allows the carpeted cover to pivot between different use positions including open and closed positions relative to the rest of the load floor; and

a second living hinge which allows the members to pivot and fold one over the other in a folded, open position of the cover.

2. The load floor as claimed in claim 1, wherein the first living hinge includes a portion of the carpet layer not bonded to the panel or either of the segments.

3. The load floor as claimed in claim 1, wherein portions of the carpet layer not bonded to the cover at least partially form the living hinge.

4. The load floor as claimed in claim 1, wherein the second living hinge is a two-way living hinge.

5. The load floor as claimed in claim 1, wherein the second living hinge includes a portion of the carpet layer not bonded to either of the members.

6. The load floor as claimed in claim 1, wherein each of the living hinges includes a portion of the carpet layer not bonded to the panel or either of the members.

7. The load floor as claimed in claim 1, wherein a portion of the composite panel has a reduced thickness to form a depression which receives the carpeted cover in at least one of the use positions and wherein thickness of the carpeted panel is substantially equal to depth of the depression.

8. The load floor as claimed in claim 7, wherein the cover-receiving depression receives the carpeted cover in two use positions and wherein the cover extends from the first living hinge in opposite directions in the two use positions.

9. The load floor as claimed in claim 1, wherein the cover is a thermoplastic cover.

10. The load floor as claimed in claim 9, wherein the carpet layer is a thermoplastic carpet layer and wherein the thermoplastic of the cover and the carpet layer is polypropylene.

11. The load floor as claimed in claim 1, wherein the composite panel has a thickness in the range of 5 to 25 mm.

12. The load floor as claimed in claim 1, wherein the carpet layer is a thermoplastic carpet layer having thermoplastic fibers.

13. The load floor as claimed in claim 1, wherein the first member comprises a compression-molded, composite panel including third and fourth outer layers and a second core having a large number of cavities positioned between the third and fourth outer layers and wherein the third and fourth outer layers are bonded to the second core by press molding.

14. The load floor as claimed in claim 13, wherein the second member comprises a compression-molded, composite panel including fifth and sixth outer layers and a third core having a large number of cavities positioned between the fifth and sixth outer layers and wherein the fifth and sixth outer layers are bonded to the third core by press molding.

15. A carpeted, vehicle load floor including a pivotable cover segmented into articulated, sectional members, the load floor comprising:

a compression-molded, planar, composite panel having first and second reinforced thermoplastic skins and a core having a large number of cavities disposed between the skins, the skins being bonded to the core by press molding, the first skin having a top support surface;

a segmented cover to removably cover at least one storage area in the interior of the vehicle, the cover being segmented into articulated, planar, sectional members to allow desired cover positioning over the at least one storage area, the cover being pivotally connected to the composite panel, the sectional members being pivotally connected to one another for folding one of the members over the other one of the members, each member having a top support surface;

a substantially continuous carpet layer bonded to the top support surface of the panel and the top support surface of each of the members to at least partially form a carpeted load floor having a carpeted cover;

a first living hinge which allows the carpeted cover to pivot between different use positions including open and closed positions relative to the rest of the load floor; and

a second living hinge which allows the members to pivot and fold one over the other in a folded, open position of the cover.

16. The load floor as claimed in claim 15, wherein a portion of the carpet layer not bonded to the panel or either of the members at least partially forms the first living hinge.

17. The load floor as claimed in claim 15, wherein a portion of the carpet layer not bonded to the panel or either of the members at least partially forms the second living hinge.

18. A carpeted, vehicle load floor including a pivotable cover segmented into articulated, sectional members, the load floor comprising:

a compression-molded, planar, composite panel having first and second reinforced thermoplastic skins and a core having a large number of cavities and disposed between and bonded to the skins by press molding, the first skin having a top support surface;

a segmented, compression-molded, composite cover to removably cover at least one storage area in the interior of the vehicle, the cover being pivotally connected to the composite panel, the cover being segmented into articulated, planar, sectional members to allow desired cover positioning over the at least one storage area, the members being pivotally connected to one another for folding one of the members over the other one of the members, each member having a top support surface, one of the members comprising third and fourth reinforced thermoplastic skins and a core having a large number of cavities and disposed between and bonded to the third and fourth skins by press molding;

a substantially continuous carpet layer bonded to the top support surface of the panel and the top support surface of each of the members to form a carpeted load floor having a carpeted cover;

a first living hinge which allows the carpeted cover to pivot between different use positions including open and closed positions relative to the rest of the load floor; and

a second living hinge which allows the members to pivot and fold one over the other in a folded, open position of the cover.

19. The load floor as claimed in claim 18, wherein a portion of the carpet layer at least partially forms the first living hinge.

20. The load floor as claimed in claim 18, wherein a portion of the carpet layer at least partially forms the second living hinge.