A load floor for a vehicle includes a carpet having a tuft attached to a backing, a plurality of inserts attached to a second side of the backing, a top surface fused to the carpet and encapsulating the inserts, and a bottom surface fused to the encapsulated inserts. The inserts may be varied in material, shape, thickness, and spacing to provide a tunable stiffness. A related method includes forming a parison feeding the parison between mold halves shaped like a load floor, hanging a carpet and a plurality of inserts in the first mold half, clamping the parison by moving the mold halves together to form a mold, and pushing the parison outward, using blown air, such that the parison is adjacent the backing in the first mold forming a top surface and encapsulating the inserts, and adjacent the second mold half forming a bottom surface fused to the parison encapsulating the inserts.

Included are a first board and a second board that include hard polyurethane foam layers and formed respectively in spaces sandwiched between pairs of thin plates, and a coupling member having a porous structure where a recessed groove is formed, parts of the coupling member being arranged in the spaces. The hard polyurethane foam layers are also formed in gaps between the thin plates and the coupling member to join the boards to the coupling member. Consequently, the step of molding the first board can mold, join, and integrate the boards, and mold a bendable, lightweight, and very strong vehicle interior board.

A liner system for a bed of a material hauling machine is provided. The liner system includes a first panel having a first surface and a second surface. The second surface includes a plurality of projected sections and defines a recess between each of the plurality of projected sections and a keyway recess. The liner system also includes a second panel having a first lip portion and a second lip portion configured to interconnect with the second and first lip portion of adjacent second panels respectively. The second panel also includes a first protruding portion configured to be received into the recess and a second protruding portion configured to be received into the keyway recess. The liner system further includes a locking panel having a first extension member, a second extension member and one or more fastening means configured to fasten the second panel to the first panel.

Aspects of the disclosure include a pull and push two steps load floor system. An exemplary pull and push two steps load floor system can include a first two-track transition support feature including a first track having an open end and a second track having an open end and a second two-track transition support feature including a third track having an open end and a fourth track having an open end. The load floor system can further include a load floor having a hinge and four pins positioned such that the load floor can be coupled to the first two-track transition support feature and to the second two-track transition support feature by placing the four pins into respective tracks of the first two-track transition support feature and the second two-track transition support feature through the respective open ends.