Cargo management system including a vehicle load floor to compartmentalize a cargo area

A cargo management system including a vehicle load floor to compartmentalize a cargo area into an upper compartment and a covered lower compartment, the system comprising:

• a composite plastic first outer layer having a substantially planar upper support surface to support cargo in the upper compartment;
• a composite plastic second outer layer having at least one cavity defined by lower surfaces of the second outer layer, each cavity having a size and shape which corresponds in size and shape to a vehicle component to restrain movement of the vehicle component and to prevent sudden transfer of vehicle component weight during vehicle acceleration and deceleration;
• and
• a core including first, second and third adjacent core portions having first, second and third thicknesses, respectively, wherein at least two of the core portions have a large number of cavities and wherein the first and second thicknesses are different from each other and the second and third thicknesses are different from each other;
• the first, second and third core portions being positioned between and bonded to the outer layers by press molding to form first, second and third panel portions, respectively.

A cargo management system including a vehicle load floor to compartmentalize a cargo area into an upper compartment and a covered lower compartment, the system comprising:

• a composite plastic first outer layer having a substantially planar upper support surface to support cargo in the upper compartment;
• a composite plastic second outer layer having at least one cavity defined by lower surfaces of the second outer layer, each cavity having a size and shape which corresponds in size and shape to a vehicle component to restrain movement of the vehicle component and to prevent sudden transfer of vehicle component weight during vehicle acceleration and deceleration;
• a core including adjacent core portions having different thicknesses wherein at least one of the core portions has a large number of cavities and each of the core portions being positioned between and bonded to the outer layers by press molding to form corresponding first and second panel portions wherein the first panel portion is pivotally connected to the second panel portion;
• and
• a first living hinge which allows the second panel portion to pivot between different use positions relative to the first panel portion.