Patent ID: 10369937

Abstract:
A panel assembly includes a multilayer panel including first and second layers made of loftable material characterized by a molded orientation resultant from lofting and subsequently compressing the loftable material during molding of the multilayer panel. The panel assembly may be light-weight with a low profile to minimize protrusion into an opening or compartment enclosed by the panel. The multilayer panel may be configured to as a floor panel enclosing an opening defined by a floor structure, which may be a vehicle floor. The multilayer panel may include at least one recess portion configured to strengthen the multilayer panel. A method of making the multilayer panel includes tethering the loftable material in a tethering frame prior to lofting and transferring the tethering frame including the lofted material into a mold to form into the multilayer panel. The tethering frame retains offal for removal from the mold after forming the panel.