Load bearing panel

Abstract

A panel assembly includes a multilayer load bearing panel configured to enclose an opening to an interior compartment by positioning the panel in the opening. The panel has opposing first and second appearance layers and is reversible in the opening between first and second positions. In the first position, the first appearance layer is outwardly facing in the opening and the second appearance layer faces inwardly to the compartment. In the second position, the second appearance layer is outwardly facing in the opening and the first appearance layer faces inwardly to the compartment. One of the appearance layers is made of a protective polymeric coating such as a thermosetting polyurethane-based coating or thermoset polyurea coating. The other appearance layer is made of one of a laminate structure which can include a wood veneer, a textile, or a carpeting material. A method for making the multilayer panel is provided.

1 . A load bearing panel configured to enclose an opening of an interior compartment; the panel comprising:
 a core member made of a cellular material and defining a perimeter edge;   wherein the core layer is disposed between opposing first and second appearance layers;   wherein the panel is reversible in the opening between a first position and a second position;   wherein the panel in the first position is positioned in the opening such that the first appearance layer is outwardly facing and the second appearance layer is inwardly facing, relative to the interior compartment;   wherein the panel in the second position is positioned in the opening such that the second appearance layer is outwardly facing and the first appearance layer is inwardly facing, relative to the interior compartment; and   wherein the second appearance layer is made of a polyurea material;   wherein the second appearance layer includes a closure trim made of the polyurea material;   wherein the closure trim is integral to the second appearance layer and extends continuously from the first appearance layer to the second appearance layer such that the second appearance layer is sealed to the first appearance layer and encapsulates the perimeter edge of the core layer.   
     
     
         2 . (canceled) 
     
     
         3 . (canceled) 
     
     
         4 . The load bearing panel of  claim 1 , further comprising:
 at least one of a textured surface finish, a ridge, and a rib formed in the second appearance layer.   
     
     
         5 . The load bearing panel of  claim 1 , further comprising:
 a trim element attached to one of the first and second appearance layers; and   wherein the trim element protrudes outwardly from the one of the first and second appearance layers.   
     
     
         6 . The load bearing panel of  claim 1 , wherein the first appearance layer is made of a laminate structure. 
     
     
         7 . The load bearing panel of  claim 6 , wherein the laminate structure includes a layer made of a wood material. 
     
     
         8 . The load bearing panel of  claim 6 , wherein the first appearance layer further comprises:
 a decorative element;   a sealant layer; and   wherein the decorative element is intermediate the laminate structure and the sealant layer.   
     
     
         9 . The load bearing panel of  claim 1 , wherein the first appearance layer is made of a natural wood veneer. 
     
     
         10 . The load bearing panel of  claim 1  wherein the first appearance layer is made of at least one of a textile material and a carpeting material. 
     
     
         11 . (canceled) 
     
     
         12 . The load bearing panel of  claim 1 , wherein the panel is a first panel;
 the panel further comprising:
 a second panel including opposing first and second appearance layers; 
 a hinge member connecting the first and second panels to form a panel assembly; and 
   wherein the panel assembly is reversible in the opening between the first position and the second position.   
     
     
         13 . The load bearing panel of  claim 1 , wherein the opening and the interior compartment are defined by a vehicle; and
 wherein the interior compartment is accessible via the opening from an exterior compartment of the vehicle.   
     
     
         14 . A method of forming a load bearing panel configured to enclose an opening of an interior compartment; the method comprising:
 providing:
 a core layer made of a cellular material; 
 first and second cover layers made of a polymer material; 
 a first adhesive part; and 
 a second adhesive part; 
   forming a layered structure by:
 layering the core layer between the first cover layer and the second cover layer; 
 spraying the first adhesive part and the second adhesive part on the first cover layer such that the first and second adhesive parts activate to form a first adhesive layer on the first cover layer; and 
 spraying the first adhesive part and the second adhesive part on the second cover layer such that the first and second adhesive parts activate to form a second adhesive layer on the second cover layer; 
   forming a core member by:
 inserting the layered structure into a mold; and 
 molding the layered structure to form the core member; 
   forming a laminate structure by:
 layering a laminate adhesive between a decorative layer and a substrate layer; and 
 laminating the layered laminate adhesive, decorative layer and substrate layer to form the laminate structure; 
   wherein the decorative layer includes a wood layer;   the method further comprising:
 removing the core member from the mold; 
 after removing the core member from the mold, bonding the laminate structure to the first cover layer by adhering the substrate layer to the first adhesive layer. 
   
     
     
         15 . The method of  claim 14 , wherein molding the layered structure to form the core member further comprises:
 migrating the first adhesive layer into the first cover layer and the cellular material to bond the first cover layer to the cellular material;   migrating the second adhesive layer into the second cover layer and the cellular material to bond the second cover layer to the cellular material; and   wherein the first and second adhesive layers are made of a thermoset polymer.   
     
     
         16 . The method of  claim 14 , further comprising:
 after removing the core member from the mold, applying a polymer coating material to the second cover layer to form a second appearance layer; and   wherein the polymer coating material is made of a thermoset polymer.   
     
     
         17 . (canceled) 
     
     
         18 . The method of  claim 14 , further comprising:
 inserting a second appearance layer into the mold;   wherein the second appearance layer is layered on the second adhesive layer; and   molding the layered structure and second appearance layer such that the second appearance layer is bonded to the second cover layer.   
     
     
         19 . (canceled) 
     
     
         20 . The method of  claim 16 , wherein the thermoset polymer is one of a polyurethane-based material and a polyurea material. 
     
     
         21 . The method of  claim 14 , further comprising:
 attaching a closure trim to a perimeter edge of the core member such that the closure trim encapsulates the perimeter edge.   
     
     
         22 . The method of  claim 21 , wherein the closure trim is configured as a bezel. 
     
     
         23 . The method of  claim 22 , wherein the bezel defines a flange in contact with the decorative layer. 
     
     
         24 . The method of  claim 14 , wherein the wood layer includes a wood veneer layer. 
     
     
         25 . The load bearing panel of  claim 1 , the second appearance layer further comprising:
 at least one of a ridge and a rib such that the second appearance layer has a variable thickness;   wherein the at least one of the ridge and the rib is made of the polyurea material and is integral to the second appearance layer.