Load bearing panel member

摘要

A load bearing panel member having a first portion, a second portion, and an appearance surface portion is formed by injection molding such that the first portion includes a plurality of ribs forming a grid pattern on the first portion and another plurality of ribs extending toward the periphery of the first portion which may be non-orthogonal to each other and to the ribs forming the grid pattern. An internal channel may be formed within each of the non-orthogonal ribs by injecting a gas into the rib during the molding process forming the panel. An appearance surface portion attached to the first portion and second portion of the panel member forms an integral hinge between the first and second portions of the panel member. The panel member may be configured as a floor panel of a vehicle.

主权项

1. A method of forming a load bearing panel member, the method comprising:
inserting an appearance surface portion into a mold cavity having a first chamber, a second chamber, and a mold feature configured to separate the first chamber and the second chamber such that the appearance surface portion spans the first and second chambers and the mold feature; injecting molten plastic into the first and second chambers of the mold to form a first portion of the panel member in one of the first and second chambers and a second portion of the panel member in the other of the first and second chamber; wherein the one of the first and second chambers defines:
a first plurality of ribs forming a grid pattern on the first portion;a second plurality of ribs positioned adjacent the periphery of the first portion;a third plurality of ribs extending toward the periphery of the first portion, wherein each of the third plurality of ribs is non-orthogonal to another of the third plurality of ribs and non-orthogonal to each of the second plurality of ribs; the method further comprising:
forming each of the first plurality of ribs as solid ribs; andforming an internal channel within each of the second plurality of ribs and each of the third plurality of ribs.