# US 10,369,937 B2 · Multilayer load bearing panel > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,369,937 B2 - Document ID: US10369937B2 - Status: Granted - Kind: B2 - Application number: 14/958,108 - Filed: 2015-12-03 - Published: 2016-03-24 - Granted: 2019-08-06 - Earliest claimed: 2013-08-26 - Assignees: Century Plastics, Inc. - Applicants: Century Plastics, LLC - Inventors: Joseph W. Marchesano; Calvin A. Saur - Web page: https://patentgrep.com/patent/US10369937B2 ## CPC - B60R 13/01: Liners for load platforms or load compartments - B29C 43/203: {Making multilayered articles} - B32B 3/04: characterised by {at least one} layer folded at the edge, e.g. over another layer {; characterised by at least one layer enveloping or enclosing a material} - B32B 3/266: {characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12} - B32B 3/30: characterised by a layer formed with recesses or projections, e.g. {hollows, grooves, protuberances, ribs (apertured layer B32B3/266; layer with cavities or internal voids B32B3/26)} - B32B 5/028: {Net structure, e.g. spaced apart filaments bonded at the crossing points} - B32B 7/12: using interposed adhesives or interposed materials with bonding properties - B32B 27/12: next to a fibrous or filamentary layer - B32B 27/20: using fillers, pigments, thixotroping agents - B60R 13/013: {comprising removable or hinged parts, e.g. for accessing storage compartments} - B32B 2262/0253: Polyolefin fibres - B32B 2262/0276: Polyester fibres - B32B 2305/08: Reinforcements - B32B 2307/718: Weight, e.g. weight per square meter - B32B 2471/00: Floor coverings (B32B2419/04 takes precedence) - B32B 2605/003: Interior finishings - Y10T 29/49629: Panel - Y10T 428/239: Complete cover or casing - Y10T 428/24322: Composite web or sheet - Y10T 428/24612: Composite web or sheet - Y10T 428/31565: Next to polyester [polyethylene terephthalate, etc.] - B60R: VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A panel assembly includes a multilayer panel including first and second layers made of loftable material characterized by a molded orientation resultant from lofting and subsequently compressing the loftable material during molding of the multilayer panel. The panel assembly may be light-weight with a low profile to minimize protrusion into an opening or compartment enclosed by the panel. The multilayer panel may be configured to as a floor panel enclosing an opening defined by a floor structure, which may be a vehicle floor. The multilayer panel may include at least one recess portion configured to strengthen the multilayer panel. A method of making the multilayer panel includes tethering the loftable material in a tethering frame prior to lofting and transferring the tethering frame including the lofted material into a mold to form into the multilayer panel. The tethering frame retains offal for removal from the mold after forming the panel. ## Claims ### Claim 1 A multilayer panel configured to enclose an opening, the multilayer panel comprising: an exterior surface; an interior surface; a first layer including a molded loftable polymer composite characterized by a first oriented polymeric structure corresponding to the interior surface; a second layer including the molded loftable polymer composite characterized by a second oriented polymeric structure corresponding to the exterior surface; a core insert between the first and second layers and adhered to the first layer and to the second layer; and at least one recessed portion defined by the interior surface and the core insert; wherein the at least one recessed portion includes a base portion characterized by the first layer adhered directly to the second layer. ### Claim 2 (depends on 1) The multilayer panel of claim 1, wherein: the polymer composite includes chopped reinforcing fibers distributed in a thermoplastic matrix; and the first oriented polymeric structure is characterized by the chopped reinforcing fibers compressed and constrained in the thermoplastic matrix in an orientation corresponding to the exterior surface; and the second oriented polymeric structure is characterized by the chopped reinforcing fibers compressed and constrained in the thermoplastic matrix in an orientation corresponding to the interior surface. ### Claim 3 (depends on 1) The multilayer panel of claim 1, wherein the multilayer panel is configured as a load bearing panel configured to withstand a knee load of at least 250 pounds applied to a central portion of the multilayer panel. ### Claim 4 (depends on 1) The multilayer panel of claim 1, wherein the panel assembly is configured as a low-profile panel such that the overall thickness of the panel assembly does not exceed 25.4 mm. ### Claim 5 (depends on 1) The multilayer panel of claim 1, wherein the multilayer panel is configured to enclose an opening defined by a structure, the structure including a structure surface having a structure interface portion defining the opening, the multilayer panel further comprising: a central portion defined by the core insert; a peripheral portion surrounding the central portion and characterized by the first layer adhered directly to the second layer; and wherein the peripheral portion is configured to interface with the structure interface portion to enclose the opening. ### Claim 6 (depends on 5) The multilayer panel of claim 5, wherein: the structure is configured as a vehicle including a vehicle floor; the vehicle floor defining the structure surface and the opening; and a compartment accessible via the opening; wherein the multilayer panel is a load bearing panel configured to withstand a knee load of at least 250 pounds applied to a central portion of the multilayer panel. ### Claim 7 (depends on 5) The multilayer panel of claim 5, wherein: the multilayer panel is one of a first panel configured to enclose a first portion of the opening and a second panel configured to enclose a remaining portion of the opening; and wherein each of the first and second panels is configured to interface with the structure interface portion and the other of the first and second panels to enclose the opening. ### Claim 8 (depends on 1) The multilayer panel of claim 1, further comprising: an interior cover layer adhered to the first molded layer such that the first molded layer is between the core insert and the interior cover layer; and an exterior cover layer adhered to the second molded layer such that the second molded layer is between the core insert and the exterior cover layer. ### Claim 9 (depends on 1) The multilayer panel of claim 1, wherein the at least one recessed portion defines a recess having one of a frusto-polyhedral and frusto-conical shape. ### Claim 10 (depends on 1) The multilayer panel of claim 1, further comprising: a hinged portion hingedly connecting a first panel portion and a second panel portion; wherein the hinged portion includes at least one hinge characterized by the first layer adhered directly to the second layer. ### Claim 11 (depends on 1) The multilayer panel of claim 1, further comprising: an aperture defined by an aperture lip and configured to receive a panel detail; and wherein the aperture lip is defined by the first layer adhered directly to the second layer.