Load bearing panel member

Abstract

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 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.

1 . A load bearing panel member for a vehicle, comprising:
 a first portion including:
 a first plurality of ribs formed on the first portion; 
 a second plurality of ribs formed on the first portion; 
 the first plurality of ribs formed orthogonally to the second plurality of ribs; and 
 a third plurality of ribs formed on the first portion; 
 wherein at least one rib of the third plurality of ribs obliquely intersects and is non-orthogonal to at least one rib of the first plurality of ribs; 
 wherein the at least one rib of the third plurality of ribs obliquely intersects and is non-orthogonal to at least one rib of the second plurality of ribs; 
   a second portion;   wherein the first and second portions are separated by a gap such that the first portion is not in contact with the second portion.   
     
     
         2 . The load bearing panel member of  claim 1 , further comprising:
 a living hinge intermediate the first and second portions;   wherein the first portion is made of a first material; and   the living hinge is made of a second material which is different from the first material.   
     
     
         3 . The load bearing panel member of  claim 1 , further comprising:
 a third portion attached to the first and second portions; and   wherein the third portion defines the gap.   
     
     
         4 . The load bearing panel member of  claim 1 , wherein the third plurality of ribs includes a first rib and at least a second rib; and
 wherein the first rib is non-orthogonal and non-parallel to the second rib.   
     
     
         5 . The load bearing panel member of  claim 1 , further comprising:
 a periphery defined by the first portion; and   a peripheral rib formed on the first portion adjacent the periphery.   
     
     
         6 . The load bearing panel member of  claim 5 , wherein at least one rib of the third plurality of ribs is oblique to the peripheral rib. 
     
     
         7 . The load bearing panel member of  claim 5 , wherein the first plurality of ribs are parallel to the peripheral rib. 
     
     
         8 . The load bearing panel member of  claim 5 , wherein the second plurality of ribs are orthogonal to the peripheral rib. 
     
     
         9 . A load bearing panel member for a vehicle, comprising:
 a first portion including:
 a first plurality of ribs formed on the first portion; 
 wherein each rib of the first plurality of ribs is parallel to each other rib of the first plurality of ribs; 
 a periphery defined by the first portion; 
 a peripheral rib formed on the first portion adjacent the periphery; 
 wherein the peripheral rib is one of orthogonal and parallel to the first plurality of ribs; 
 a second plurality of ribs formed on the first portion; 
 wherein each rib of the second plurality of ribs obliquely intersects and is non-orthogonal to at least one rib of the first plurality of ribs; 
   a second portion;   a surface portion spanning the first and second portions to define a gap between the first portion and the second portion; and   wherein the first portion is not in contact with the second portion.   
     
     
         10 . The load bearing panel member of  claim 9 , further comprising:
 a third plurality of ribs formed on the first portion;   wherein each rib of the third plurality of ribs is parallel to each other rib of the third plurality of ribs.   
     
     
         11 . The load bearing panel member of  claim 10 , wherein each rib of the second plurality of ribs obliquely intersects at least one rib of the third plurality of ribs. 
     
     
         12 . The load bearing panel member of  claim 10 , wherein each rib of the first plurality of ribs is orthogonal to at least one rib of the third plurality of ribs. 
     
     
         13 . The load bearing panel member of  claim 9 , wherein the peripheral rib is orthogonal to the first plurality of ribs; and
 wherein the peripheral rib and at least one rib of the first plurality of ribs intersect.   
     
     
         14 . The load bearing panel member of  claim 9 , wherein the peripheral rib is a first peripheral rib; and
 wherein the first portion includes a second peripheral rib formed on the first portion adjacent the periphery;   wherein the first peripheral rib is parallel to the second peripheral rib.   
     
     
         15 . A load bearing panel member for a vehicle, comprising:
 a first portion including:
 a first plurality of ribs formed on the first portion; 
 wherein each rib of the first plurality of ribs is parallel to another rib of the first plurality of ribs; 
 a second plurality of ribs formed on the first portion; 
 wherein each rib of the second plurality of ribs is parallel to another rib of the second plurality of ribs; 
 a third plurality of ribs formed on the first portion; 
 wherein at least one rib of the third plurality of ribs obliquely intersects at least one rib of the first plurality of ribs; 
 wherein the at least one rib of the third plurality of ribs obliquely intersects at least one rib of the second plurality of ribs; and 
   a surface appearance portion attached to the first portion.   
     
     
         16 . The load bearing panel member of  claim 15 , further comprising:
 a periphery defined by the first portion; and   wherein the surface appearance portion includes a first section attached to the first portion, and a second section extending from the periphery.   
     
     
         17 . The load bearing panel member of  claim 16 , further comprising:
 a living hinge defined by the surface appearance portion;   wherein the second section is rotatable relative to the first portion via the living hinge.   
     
     
         18 . The load bearing panel member of  claim 15 , further comprising:
 a second panel portion attached to the appearance surface portion such that the first and second portions are separated by a gap.   
     
     
         19 . The load bearing panel member of  claim 15 , wherein at least one rib of the first plurality of ribs is orthogonal to at least one rib of the second plurality of ribs. 
     
     
         20 . The load bearing panel member of  claim 15 , wherein:
 the third plurality of ribs includes a first rib and at least a second rib; and   the first rib is non-orthogonal to the second rib.