# US 2013/0278019 A1 · Assembly including a compression-molded, composite panel locally reinforced adjacent a living hinge of the assembly > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2013/0278019 A1 - Document ID: US20130278019A1 - Status: Published application - Kind: A1 - Application number: 13/687,213 - Filed: 2012-11-28 - Published: 2013-10-24 - Earliest claimed: 2012-04-23 - Assignees: Global IP Holdings, LLC - Applicants: Global IP Holdings, LLC - Inventors: Darius J. Preisler; Christopher A. Heikkila - Web page: https://patentgrep.com/patent/US20130278019A1 ## CPC - B60R 5/04: arranged at rear of vehicle {(B60R5/003, B60R5/006 take precedence; external trunks arranged at rear of vehicle B60R9/065)} - B29C 43/00: Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor {(by liberation of internal stresses B29C61/006)} - B32B 3/02: characterised by features of form at particular places, e.g. in edge regions {(non-uniform thickness B32B3/263)} - 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 3/085: {spaced apart pieces on the surface of a layer} - B32B 3/12: characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure - B32B 3/263: {characterised by a layer having non-uniform thickness} - 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 3/28: characterised by a layer comprising a deformed thin sheet {, i.e. the layer having its entire thickness deformed out of the plane}, e.g. corrugated, crumpled (B32B29/08 takes precedence) - B32B 5/022: {Non-woven fabric} - B32B 5/024: {Woven fabric} - B32B 27/065: {of foam} - B32B 27/08: of synthetic resin - B32B 27/12: next to a fibrous or filamentary layer - B32B 27/20: using fillers, pigments, thixotroping agents - B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)} - B29C 43/18: incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles {(B29C43/206 takes precedence)} - B32B 2250/40: Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA - B32B 2262/0253: Polyolefin fibres - B32B 2262/101: Glass fibres - B32B 2262/106: Carbon fibres, e.g. graphite fibres - B32B 2266/025: Polyolefin - B32B 2266/08: Closed cell foam - B32B 2307/738: Thermoformability - B32B 2605/003: Interior finishings - Y10T 428/23979: Particular backing structure or composition - Y10T 428/24: Structurally defined web or sheet [e.g., overall dimension, etc.] - Y10T 428/24008: including fastener for attaching to external surface - Y10T 428/24149: Honeycomb-like - Y10T 428/24612: Composite web or sheet - 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 including a compression-molded, composite panel is provided. The panel has first and second outer layers and a core positioned between the outer layers. The core has a large number of cavities. The outer layers are bonded to the core by press molding. The assembly also includes a component pivotally connected to the panel and a living hinge which allows the component to pivot about a pivot axis between different use positions relative to the panel. The assembly further includes a stiffening support having a support axis substantially parallel to the pivot axis. The support is bonded or joined to the panel to locally reinforce the panel adjacent the living hinge. The stiffening support eliminates the need for a metal hinge and provides for a light weight assembly with improved aesthetics and function. ## Claims ### Claim 1 A panel assembly comprising: a compression-molded, composite panel having 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, both outer layers having an outer surface; a component pivotally connected to the panel; a living hinge which allows the component to pivot about a pivot axis between different use positions relative to the panel; and a stiffening support having a support axis substantially parallel to the pivot axis, the support being bonded or joined to the panel to locally reinforce the panel adjacent the living hinge. ### Claim 2 (depends on 1) The assembly as claimed in claim 1, wherein a crushed portion of the composite panel adjacent the living hinge has a reduced thickness to form a depression which receives the stiffening support and wherein thickness of the stiffening support is substantially equal to depth of the depression. ### Claim 3 (depends on 1) The assembly as claimed in claim 1, wherein the first outer layer is a load-bearing outer layer made of reinforced thermoplastic material. ### Claim 4 (depends on 3) The assembly as claimed in claim 3, wherein each of the outer layers is made of a reinforced thermoplastic material. ### Claim 5 (depends on 1) The assembly as claimed in claim 1, wherein the stiffening support is u-shaped in cross-section. ### Claim 6 (depends on 1) The assembly as claimed in claim 1, wherein the component comprises a compression-molded, composite panel portion of the panel, the panel portion having third and fourth outer layers, each of the third and fourth outer layers having an outer surface. ### Claim 7 (depends on 6) The assembly as claimed in claim 6, wherein a portion of the first and third outer layers at least partially forms the living hinge. ### Claim 8 (depends on 1) The assembly as claimed in claim 1, further comprising a stiffening second support having a second support axis substantially parallel to the pivot axis, the second support being bonded or joined to the component to locally reinforce the component adjacent the living hinge. ### Claim 9 (depends on 6) The assembly as claimed in claim 6, further comprising a stiffening second support having a second support axis substantially parallel to the pivot axis, the second support being bonded or joined to the panel portion to locally reinforce the panel portion adjacent the living hinge. ### Claim 10 (depends on 9) The assembly as claimed in claim 9, wherein a crushed portion of the panel portion adjacent the living hinge has a reduced thickness to form a pocket which receives the second support and wherein thickness of the second support is substantially equal to depth of the pocket. ### Claim 11 (depends on 1) The assembly as claimed in claim 1, further comprising a substantially continuous carpet layer bonded to the outer surface of the first outer layer to form a carpeted panel, a portion of the carpet layer at least partially forming the living hinge. ### Claim 12 (depends on 6) The assembly as claimed in claim 6, further comprising a substantially continuous carpet layer bonded to the outer surface of the first outer layer and the outer surface of the third outer layer. ### Claim 13 (depends on 6) The assembly as claimed in claim 6, wherein the panel portion includes 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. ### Claim 14 (depends on 13) The assembly as claimed in claim 13, wherein the first and third outer layers comprise a single fiber-reinforced layer. ### Claim 15 (depends on 14) The assembly as claimed in claim 14, wherein a portion of the fiber-reinforced layer between the first and third outer layers at least partially forms the living hinge. ### Claim 16 (depends on 1) The assembly as claimed in claim 1 wherein a crushed portion of the composite panel at least partially forms the living hinge. ### Claim 17 (depends on 1) The assembly as claimed in claim 1, wherein the stiffening support is made of plastic and wherein the stiffening support is welded to the outer surface of the second outer layer. ### Claim 18 (depends on 8) The assembly as claimed in claim 8, wherein each of the supports is made of plastic. ### Claim 19 (depends on 1) The assembly as claimed in claim 1, wherein a portion of the second outer layer at least partially forms the living hinge. ### Claim 20 A vehicle panel assembly comprising: a compression-molded, composite panel having 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, both outer layers having an outer surface; a component pivotally connected to the panel; a living hinge which allows the component to pivot about a pivot axis between different use positions within the vehicle relative to the panel; and a stiffening support having a support axis substantially parallel to the pivot axis, the support being bonded or joined to the panel to locally reinforce the panel adjacent the living hinge. ### Claim 21 A vehicle floor panel assembly comprising: a compression-molded, composite panel having 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 and the second outer layer having a bottom surface; a component pivotally connected to the panel; a living hinge which allows the component to pivot about a pivot axis between different use positions within the vehicle relative to the panel; and a stiffening support having a support axis substantially parallel to the pivot axis, the support being bonded or joined to the panel to locally reinforce the panel adjacent the living hinge.