Patent ID: 8808831

Claim:
A sandwich-type, structural, composite component including at least one hingedly connected portion which pivots with reduced or eliminated hinge binding, the component comprising: first and second outer layers and a core positioned between the first and second outer layers and having a plurality of cavities, wherein the first and second outer layers are bonded to the core by press molding and wherein elongated first and second interior portions of the component are locally crushed by the press molding to form a living hinge having a pivot axis and an elongated depression, respectively; and an elongated cut-out which extends completely through the component at the elongated depression to obtain a clearance between a first portion of the component hingedly connected to a second portion of the component by the living hinge wherein the living hinge and the clearance allow pivotal movement of the first portion between different use positions relative to the second portion with reduced or eliminated hinge binding during the pivotal movement about the pivot axis.