Sandwich-type, structural, composite component including at least one hingedly-connected portion, cargo management system and automotive vehicle load floor utilizing the component

1. 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.

2. The component as claimed in claim 1 , wherein the clearance extends from an outer edge of the first portion to the living hinge in a direction substantially perpendicular to the pivot axis.

3. The component as claimed in claim 2 , wherein the component at least partially defines a vehicle load floor and wherein the first portion of the component is a hingedly connected close-out panel.

4. The component as claim in claim 1 , wherein the clearance extends from one end of the living hinge to an opposite end of the living hinge and wherein the clearance and the living hinge form a substantially closed loop.

5. The component as claimed in claim 4 , wherein the first portion of the component is a hingedly connected lid.

6. The component as claimed in claim 5 , wherein the component at least partially defines a vehicle load floor which divides a cargo compartment into upper and lower storage areas, and wherein the lid allows access to the lower storage area in an open position of the lid.

7. The component as claimed in claim 1 , further comprising an upper carpet layer bonded to an upper surface of the first outer layer by the press molding.

8. The component as claimed in claim 7 , further comprising a lower carpet layer bonded to a lower surface of the second outer layer by the press molding.

9. The component as claimed in claim 1 , further comprising a thermoplastic covering layer for covering the first outer layer.

10. The component as claimed in claim 9 , wherein the covering layer is a resin carpet.

11. The component as claimed in claim 10 , wherein the resin is polypropylene.

12. The component as claimed in claim 1 , wherein the core is a cellular core.

13. The component as claimed in claim 12 , wherein the cellular core is a honeycomb core.

14. The component as claimed in claim 1 , wherein each of the first and second outer layers is fiber-reinforced.

15. The component as claimed in claim 1 , wherein the first and second outer layers are reinforced thermoplastic outer layers and wherein the core is a thermoplastic cellular core.

16. The component as claimed in claim 15 , wherein the thermoplastic of the outer layers and the core is polypropylene.

17. The component as claimed in claim 1 , wherein the component has a thickness in the range of 5 to 25 mm.

18. The component as claimed in claim 1 , wherein at least one of the outer layers is a woven outer layer.

19. The component as claimed in claim 18 , wherein at least one of the outer layers is a woven polypropylene outer layer.

20. A cargo management system including at least one sandwich-type, structural, composite component having at least one hingedly connected portion which pivots with reduced or eliminated hinge binding, each component comprising:

a 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.

21. An automotive vehicle load floor including at least one sandwich-type, structural, composite component having at least one hingedly connected portion which pivots with reduced or eliminated hinge binding, each 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.