US 11,707,910 B2
Sandwich-type, composite component having an injection molded backside protective covering
Darius J. Preisler, Macomb, MI (US); Christopher A. Heikkila, Washington Township, MI (US); Scott A. Grajek, Washington Township, MI (US); and Jason T. Murar, Macomb, MI (US)
Assigned to Global IP Holdings, LLC, Sterling Heights, MI (US)
Filed by Global IP Holdings, LLC, Sterling Heights, MI (US)
Filed on Jul. 22, 2019, as Appl. No. 16/518,199.
Prior Publication US 2021/0023811 A1, Jan. 28, 2021
This patent is subject to a terminal disclaimer.
Int. Cl. B32B 3/30 (2006.01); B32B 3/12 (2006.01); B60R 5/04 (2006.01); B60R 13/01 (2006.01)
CPC B32B 3/30 (2013.01) [B32B 3/12 (2013.01); B32B 2605/003 (2013.01); B60R 5/04 (2013.01); B60R 13/013 (2013.01); B60Y 2306/09 (2013.01)] 12 Claims
OG exemplary drawing
 
1. A sandwich-type, carpeted, vehicle load floor comprising:
a sandwich-type, carpeted cover including: a first outer layer having an outer surface; a protective, acoustic barrier layer bonded to the outer surface of the first outer layer wherein the barrier layer overlies and is in contact with the first outer layer; a second outer layer having an outer surface; a substantially continuous carpet layer which covers and is bonded to the outer surface of the second outer layer and is bonded to a top surface of the rest of the load floor wherein an intermediate portion of the carpet layer between the carpeted cover and the rest of the load floor is not bonded to either the carpeted cover or the rest of the load floor to form a living hinge which allows the carpeted cover to pivot between covered and uncovered positions relative to the rest of the load floor; and a cellular core positioned between the outer layers and having a plurality of cavities wherein the outer layers are bonded to the core and wherein the barrier layer is integrally formed from at least one elastomeric, sound-damping material, the elastomeric, sound-damping material being a rubberized plastic material comprised of a mixture of a thermoset material and a thermoplastic material and the elastomeric, sound-damping material including 3-D structures bonded to the outer surface of the first outer layer, the 3-D structures being embossments sized, shaped, and arranged in at least one pattern at the outer surface of the first outer layer and wherein the at least one pattern comprises indicia indicative of instructions for use of the carpeted cover and wherein the barrier layer reduces a level of undesirable noise in the covered position of the carpeted cover and provides an aesthetically pleasing appearance to the carpeted cover in the uncovered position of the carpeted cover and wherein the protective, acoustic barrier layer is bonded to a backside of the rest of the load floor to reduce the level of undesirable noise in a passenger compartment of the vehicle.