TONNEAU COVER AND ADJUSTABLE FRAME FOR A PICKUP TRUCK
20230065116 · 2023-03-02
Inventors
Cpc classification
B60J7/141
PERFORMING OPERATIONS; TRANSPORTING
International classification
Abstract
A tonneau cover frame for use with a bed of a pickup truck. The frame including a plurality of side rails, a plurality of end rails and a plurality of cross rails. The side rails being configured for extending along sides of the bed of the pickup truck, the end rails extending between the side rails adjacent to front and rear ends of the frame, and the cross rails extending between the side rails at a location between the front and rear ends of the frame. The plurality of end rails and the plurality of cross rails each having an adjustable length, whereby the frame is adjustable in width for use in connection with differently sized beds of different pickup trucks.
Claims
1. A tonneau cover frame for use with a bed of a pickup truck, the frame comprising: a plurality of side rails, the side rails being configured for extending along sides of the bed of the pickup truck; a plurality of end rails, the end rails extending between the side rails adjacent to front and rear ends of the frame; a plurality of cross rails, the cross rails extending between the side rails at a location between the front and rear ends of the frame; and the plurality of end rails and the plurality of cross rails each having an adjustable length, whereby the frame is adjustable in width for use in connection with differently sized beds of different pickup trucks.
2. The frame according to claim 1, wherein at least one of the end rails or one of the cross rails includes an inner member and an outer member, the inner and outer members being in telescoping engagement with one another.
3. The frame according to claim 2, wherein at least one of the end rails or one of the cross rails includes two inner members and one outer member, the two inner members being engaged with opposing ends of the outer member.
4. The frame according to claim 1, wherein the end rails and the cross rails each include an engagement member, the engagement members selectively fixing the length of the end rails and cross rails.
5. The frame according to claim 4, wherein the engagement member is carried by a first portion of the end and cross rails and fixedly engages a second portion of the end and cross rails.
6. The frame according to claim 5, wherein the engagement member is a detent.
7. The frame according to claim 1, wherein the plurality of side rails each have an adjustable length, whereby the frame is adjustable in length and width.
8. The frame according to claim 7, wherein each of the side rails includes an inner member and an outer member, the inner and outer members being in telescoping engagement with one another and selectively positionable in at least first and second lengths.
9. The frame according to claim 1, wherein the frame is moveable between an extended position covering the bed of the pickup truck and a folded positon wherein panels sections of the frame are folded one a top another.
10. The frame according to claim 9, wherein each panel section includes one of the side rails, and side rails of adjacent panel sections are connected by hinges.
11. The frame according to claim 10, wherein each of the side rails includes an inner member and an outer member, the inner and outer members being in telescoping engagement with one another and selectively positionable in at least first and second lengths.
12. A tonneau cover frame for use with a bed of a pickup truck, the frame comprising: a plurality of side rails, the side rails being configured for extending along sides of the bed of the pickup truck; a plurality of end rails, the end rails extending between the side rails adjacent to front and rear ends of the frame, the end rails each including end rail length adjustment means for selectively adjusting the end rails in length; and a plurality of cross rails, the cross rails extending between the side rails at location between the front and rear ends of the frame, the cross rails including cross rail lengths adjustment means for selectively adjusting the cross rails in length; whereby the frame is adjustable in width for use in connection with differently sized beds of different pickup trucks.
13. The frame according to claim 12, wherein the plurality of end rails and the plurality of cross rails are telescoping rails selectively positionable in at least first and second lengths.
14. The frame according to claim 12, wherein the side rails include side rail length adjustment means for selectively adjusting the side rails in length.
15. The frame according to claim 14, wherein the side rails are telescoping rails selectively positionable in at least first and second lengths.
16. A tonneau cover assembly for use with a bed of a pickup truck, the tonneau cover assembly comprising: a frame having a plurality of side rails and being configured for extending along the sides of the bed of the pickup truck; a plurality of end rails, the end rails extending between the side rails adjacent to front and rear ends of the frame; and a plurality of cross rails, each of the cross rails extending between the side rails at a location between the front and rear ends of the frame; at least one of the plurality of side rails or the plurality of end rails and cross rails having an adjustable length, whereby the frame is adjustable in width and/or length for use in connection with differently sized beds of different pickup trucks; and a cover, the cover being of fixed length and width.
17. The tonneau cover assembly according to claim 16, wherein at least one of the end rails or one of the cross rails includes an inner member and an outer member, the inner and outer members being in telescoping engagement with one another and being selectively positionable in at least first and second lengths.
18. The tonneau cover assembly according to claim 16, wherein the plurality of side rails each have an adjustable length, whereby the frame is adjustable in length and width.
19. The tonneau cover assembly according to claim 18, wherein the side rails include an inner member and an outer member, the inner and outer members being in telescoping engagement with one another and being selectively positionable in at least first and second lengths.
20. The tonneau cover assembly according to claim 19, wherein the side rails include an adapter block engaged between the inner member and the outer member and preventing relative movement therebetween.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
[0052] As used in the description that follows, directional terms such as “upper” and “lower” are used with reference to the orientation of the elements as presented in the figures. Accordingly, “upper” indicates a direction toward the top of the figure and “lower” indicates a direction toward the bottom of the figure. The terms “left” and “right” are similarly interpreted. The terms “inward” or “inner” and “outward” or “outer” indicate a direction that is generally toward or away from a central axis of the referred to part whether or not such an axis is designated in the figures. An axial surface is therefore one that faces in the axial direction, along the central axis. A radial surface therefore faces radially, generally away from or toward the central axis. It will be understood, however, that in actual implementation, the directional references used herein may not necessarily correspond with the installation and orientation of the corresponding components or device. When discussed in connection with a truck, “forward” is a direction toward the cab, “rearward’ is a direction toward the tailgate, “transverse” or “lateral” is a direction toward a side of the truck, generally, but not necessarily, perpendicular to the forward and rearward directions.
[0053] Referring now to the drawings, a tonneau cover embodying the principles of the present invention is generally illustrated in
[0054] As previously mentioned, tonneau covers themselves come in variety of different styles. As described herein, the invention is embodied in a soft fold tonneau cover. However, it will be appreciated that the invention is not limited to that embodiment and may be used in other varieties of tonneau covers. Accordingly, as described below, a reference to tonneau cover 10 is generic to all types of tonneau covers, unless the language or context of the description specifically requires a different interpretation or the description otherwise indicates to the contrary.
[0055] As seen in
[0056] As illustrated in
[0057] When folding the tonneau cover 10 from its extended/unfolded position into its folded position, the section 28′ adjacent to the tailgate 22 is first folded on top of the immediately adjacent intermediate section 28. Next, these two sections 28, 28′ are folded on top of the next intermediate section 28. Finally, all three of these sections are folded on top of the section 28″ adjacent to the bulkhead 20 or cab 16 to form the stack 34. In the stack 34 of tonneau sections 28, the tonneau sections 28″ forms the bottom of the stack 34.
[0058] As mentioned above and as will be readily appreciated, the tonneau cover 10 of
[0059] Referring now to
[0060] The frame 30 and sub-frames 36 are formed by three basic members, side rails 38, end rails 40 and cross rails 42. The side rails 38 extend along and rest upon the bed rails 24 of the bed 12. The end rails 40 extend along and rest upon the bulkhead 20 and tailgate 22, between the side rails 38 of the front-most and rear-most sub-frames 36. The cross rails 42 extend between opposing the side rails 38 of each of the sub-frames 36. Each sub-frame 36 incudes at least one cross rail 42. It will be appreciated that both the end rails 40 and cross rails 42 are transverse rails extending laterally relative to a central axis through the front and rear of the pickup truck 14.
[0061] Unlike prior tonneau covers, the present tonneau cover 10 and frame 30 have a construction that permits a “knock-down” configuration that not only allows the tonneau cover 10 and frame 30 to be shipped in smaller packaging, but also allows the tonneau cover 10 and frame to be assembled by the end user and allows for a single frame 30 to be employed with a wide variety, if not all, sizes of pickup trucks and not just a few. With regard to this latter feature, the frame 30 is adjustable in both its length and its width. Thus, only a specific sized cover 32 is required for a particular pickup truck 14. As seen in
[0062] To enable the knock-down configuration, the rails 38, 40, 42 of the frame 30 are each composed of telescoping members that can be selectively fixed to one another to define a specific length and width for the particular pickup truck 14 of the end user. As such the rails 38, 40, 42 have a wide adjustability in their lengths. Since both the side rails 38 and the transverse rails 40, 42 are adjustable, the frame 30 is adjustable in both its width and length, allowing one frame 32 to be configured for either full or compact pickup trucks. Alternatively, only one of the width or length may be provided as adjustable.
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[0064] While the shape of the side rails 38 is more fully discussed below, it is noted that the extrusion forming the outer member 46 of the side rails 38 is additionally provided with a projecting profile or flange 48 (see
[0065] Once the inner and outer members 44, 46 of the end and cross rails 40, 42 have been extended to the desired length, establishing the desired width of the frame 30 for the pickup truck 14, the members 44, 46 may be secured in this position through the use of a detent or similar engagement device for holding the relative positions of the members 44, 46 until released. As illustrated herein the detent is in the form of a detent spring 52 that engages in index holes 54 provided on the inner and outer members 44, 46. While illustrated as a spring detent, it will be appreciated that the present invention is not limited thereto. Other detents and other types of fastening means may be used, including, without limitation spring and ball detents, magnetic detents, detent pins (also known as cotterless pins) and other types of fasteners, such as nuts and bolts, screws, plungers, pins and cotters/catches or even an over-center cam latch mechanism allowing for more infinite adjustment, particularly of the cross rails 42.
[0066] In
[0067] The detent spring 52 is illustrated as a stamped and bent spring metal which forms a button 56 and a spring leg 58. The button 56 extends through a pilot hole 60, seen in
[0068] With the frame 30 properly sized to the bed 12 of the pickup truck 14, the inner and outer members 44, 46 of the side rails 38 and end rails 40, as well as the cross rails 42, may be additionally secured together, thereby rigidifying the members and reducing or eliminating rattle or noise therebetween. To achieve this rigidifying of the inner and outer members 44, 46, an adapter block 47 is provided in each end, of the outer members 46, that receive an inner member 44 therein to.
[0069] As seen in
[0070] As a result of the bridge 53 and an enlarged head 65 adjacent thereto and from which the inner slide 49 extends, the adapter block 47 is limited as to how far it may be inserted into the end of the outer member 46 by abutment of the bridge 53 and head 65 with the terminal end of the outer member 46. As seen in
[0071] With the adapter block 47 mounted to the end of the outer member 46, the inner member 44 is slid into the outer member 46 and onto the outer slide 51. During insertion of the inner member 44 into the outer member 46, the outer slide 51 is received into the inboard channel 41 of the inner member 44 with the bridge 53 extending through the opening 43 of the channel 41.
[0072] A bore 69 is defined transversely through the inner slide 49 of the adapter block 47 so as to be aligned with the opening 59 of the outer member's inboard channel 57. A corresponding bore 71 is defined through the outer slide 51. Extending through the bores 69, 71 is a threaded fastener 73, such as a wood screw, machine screw, self-tapping screw, or similar article, which includes an enlarged head 75 with a shank 77 extending therefrom to a terminal end 79.
[0073] By extending the fastener 73 progressively through the opening 59 of channel 57, the bore 69 of the inner slide 49, the opening 43 of channel 41 and the bore 71 of the outer slide 51, the terminal end 79 of the fastener 73 can be brought into engagement with the base wall 81 of the channel 41 and operate as a set screw, forcing the outer slide 51 into fixed engagement with the legs 45 defining the opening 53 into the channel 41 of the inner member 44. Simultaneously, the inner slide 49 is pulled toward the base wall 76 of the channel 57 of the outer member 46, and the outer and inner members 44, 46 are fixed together.
[0074] The side and end rails 38, 40 are provided with an angled and slotted outboard walls 84, 85, the purpose of which is smoothly received the cover 32 there over and engage the cover with the rails 38, 40. The cross rails 42 do not require the angled and slotted outboard walls and are preferably be square or rectangular in cross section, but may have other shapes as well.
[0075] Because of the telescoping nature of the inner and outer members 44, 46, the side and end rails 38, 40 each have different standoff distances from the upper surface of the bed rails 24, bulkhead 20 and tailgate 22. Accordingly, different sealing strategies are used for the inner and outer members 44, 46.
[0076] The extrusion of the inner member 44 is formed with a channel profile 66 in the outboard side of the lower wall 62. (See
[0077] The extrusion of the outer member 46 is formed with an inverted hat profile 39 in the outboard portion of its lower wall 63. (See
[0078] The side and end rails 38, 40 are connected by corner members 82 that may be secured therebetween by fasteners or a press-fit engagement.
[0079] As will be appreciated from the above, once the width of the frame 30 is determined (as described above) and the detent springs 52 engaged in the end rails 40 and cross rails 42, the length of the side rails 38 may be similarly adjusted to the pickup truck's bed 12 or adjusted to a provided dimension for the specific pickup truck 14.
[0080] Contrary to the frame 30, which is adjustable, the cover 32 is specific to the pickup truck 14. The cover 32 may be shipped in the same box or a different box from the various members 44, 46 forming the rails 38, 40, 42.
[0081] As noted above, the angled outboard walls 84, 85 of the inner and outer members 44, 46 of the side rails 38 and end rails 40 are provided with slots 86, 87 extending along their lengths. The cover 32 is retained to the side and end rails 38, 40 by plastic fastener strips 88 sewn to the material of the cover 32. The fastener strips 88 include a tree fastener 90 that is pressed into the slots 86, 87 to retain the cover 32. Notably, the tree fastener 90 includes lips or branches 92 at differing positions along its trunk 94 enabling the fastener 90 to engage each of the inner and outer members 44, 46, simultaneously where they overlap or individually where they do not overlap. A cross sectional view of the fastener strip 88 and the tree fastener 90 is seen in
[0082] At the center of the fastener strip 88, opposite of the base of the tree fastener 90, the fastener strip 88 is provided with an outwardly bowed profile 96. The bowed profile 96 keep tension on the tree fastener 90 and aids in its installation through the slots 86, 87 via pressing thereon. Along the upper and lower edges of the fastener strip 88, adjacent to the bowed profile 96, are provided raised profiles 98, 99. The raised profiles 98, 99 provide surfaces for the cover material to rest upon while preventing the cover material from applying pressure on the bowed profile 96.
[0083] Alternative fastener strips 88′, 88″ and outer member 46′ are seen in
[0084] The fastener strip 88′ is provided with extended flanges 100, 101 off of the raised profiles 98, 99. A hook profile 102 is also provided off of the extended flange 101 to engage with a flange 104 provided along the outboard edge of the side rail 38. The extended flanges 100, 101 provided addition room for sewing of the material of the cover to the fastener strip 88′, while the hook profile 102 provides support to the tree fastener 90 in retaining the cover 32 to the side and end rails 38, 40.
[0085] The fastener strip 88″ includes extended flange 100 off of raised profile 98, but varies with respect to the extended flange off of the raised profile 99. Fastener strip 88″ includes an extended flange 106 off of raised profile 99 that includes raised lands 108, 110, which define top surfaces that are flush with the top surface of raised profile 99. The flush top surfaces of the raised profile 99 and lands 108, 110 provide a series of coplanar surfaces that effectively form a flat surface for securement of the cover 32 to the fastener strip 88″. This provides a flat appearance to the cover 32 at the fastener strip 88″ and aids in stitching of the cover 32 to the fastener strip 88″. Additionally, adhesive may be applied to these top surfaces of the fastener strip 88″, as well as fastener strips 88 and 88′, for further securing of the cover to the fastener strip 88″. Like the embodiment of
[0086] In view of the above description, it will be appreciated that the frame 30 is adjustable for various sizes of beds 12 of pickup trucks 14. The frame's construction allows for the inner and outer members 44, 46 of the rails 38, 40 and 42 to be provided to the end user in a fully retracted or disassembled condition and allows the end user to assemble the frame 30 to required dimensions of the bed 12 of the end user's pickup truck 14. With the present tonneau cover and frame, the only components specific to a given make and model of a pickup truck, or a limited number of pickup trucks, is the cover 32. As a result, a manufacturer of tonneau covers 10 to provide a single frame 30 that is usable with many different pickup trucks 14, thereby reducing manufacturing and shipping costs. The present invention, also, amalgamates many tonneau cover models into one, semi-universal frame. This, therefore, reduces inventory and SKU requirements by dealers. The present invention, in one embodiment, would allow one frame to fit the beds of all North American pickup truck models.
[0087] Although the invention has been described with reference to certain specific embodiments incorporating the principles of the invention. One skilled in the art will readily appreciate that the invention is susceptible to modification, variation and change without departing from the true spirit and fair scope of the invention, as defined in the claims that follow. The scope of the claims should therefore not be limited by the preferred embodiments, but should be given the broadest interpretation consistent with the description as a whole. The terminology used herein is therefore intended to be understood in the nature of words of description and not words of limitation.