Abstract:
A cargo hauling system is dimensioned to fit within a bed of a light truck. The bin moves forwardly and rearwardly relative to the truck bed along rollers provided on a tailgate of the truck. The tailgate is modified by reinforcing a perimeter of the tailgate, adding rollers to the tailgate, substituting reinforced linkages and hinges for factory originals, and adding a support member that extends between the trailer hitch and tailgate.

Description:
This application claims the priority benefit of U.S. Provisional Application Ser. No. 60/695,623, filed Jun. 30, 2005 and of U.S. patent application Ser. No. 10/881,383, filed Jun. 30, 2004, which claims the benefit of U.S. Provisional Application 60/483,871, filed Jun. 30, 2003, the disclosures of which are incorporated herein by reference. 

   BACKGROUND OF INVENTION 
   Sales of light trucks and sport utility vehicles (SUV) have steadily grown year after year and recently outsold cars for the first time in history. The demand for these multi-purpose vehicles has led to the creation of numerous makes and models, and also the need for new, innovative accessories that take advantage of the heavy-duty nature of these vehicles. 
   Light trucks have a truck bed and SUVs typically have a large cargo space for hauling or transporting goods and materials. For example, the truck bed is typically an open topped chamber or cavity in which a rear end is selectively closed by a pivoting or removable tailgate. It is well known to employ truck bed liners, normally a liner that is permanently installed to the interior surface of the truck bed. Similarly, with SUVs, a pivoting hatchback door allows access to a rear storage compartment. Manufacturers provide for fold-down seats to maximize the amount of cargo space available to the user. Unfortunately, these cargo spaces are also a part of the SUV interior and only certain types of materials are conveniently mounted in the rear storage compartment. 
   It is common to use these light trucks and SUVs for hauling a variety of materials. For example, construction tools, mulch, topsoil, debris, etc. are temporarily stored in the truck bed or SUV cargo space. A need exists, however, for a vehicle bin that maximizes the efficient use of these storage areas. Moreover, a need exists for such an arrangement that can be provided without undue alteration or modification of the truck bed or cargo space of the light truck or SUV. 
   Increased loads may be exerted on the OEM tailgate. Thus, a need exists to provide additional reinforcement because of the increased loads imposed on the tailgates. Any such modifications, however, must be economical and simple to use for the consumer. 
   SUMMARY OF THE INVENTION 
   The present invention provides a cargo hauling system that is dimensioned to fit the truck bed or SUV cargo space. The bin is adapted to move forwardly and rearwardly relative to the truck bed or cargo space, selectively pivot for dumping the load contents of the bin from the rear of the vehicle, be selectively removed from the vehicle to leave at a job site, and/or allow the vehicle to be used without the removable bin. 
   The invention includes a pivot arm assembly advantageously mounted to a conventional trailer hitch receiver installed on vehicles of this type. The pivot arm assembly includes a support bar received within the trailer hitch receiver. A generally U-shaped support structure includes a transverse arm and first and second upright arms extending therefrom having first, lower ends secured to the transverse arm. The support structure receives a storage bin, particularly, the bin is adapted for selective sliding and pivoting movement relative to the support structure. First and second rollers are preferably rotatably secured adjacent outer terminal ends of the first and second upright arms, respectively. The rollers cooperate with first and second guide rails secured to an underside of the bin. In addition, roller members are preferably provided along an undersurface of the bin to facilitate rolling movement of relative to the truck bed/cargo space. 
   A loading, unloading ramp assembly is independently and conveniently secured to the pivot arm assembly. Wheels are preferably provided adjacent an outer terminal end of a ramp and cooperate with a closed loop assembly for selectively loading and unloading the bin from the vehicle along the ramp. The closed loop assembly includes a continuous, flexible drive member such as a chain that passes around a first or idler sprocket located adjacent the pivot arm assembly end of the ramp and about a second or drive sprocket rotatably secured adjacent the outer terminal end of the ramp. The drive sprocket is operatively connected to, i.e., driven by, a chain drive wheel also mounted adjacent the outer terminal end. By using the motive power of the vehicle, the bin is urged by the closed loop chain along the ramp, carried by the chain that is driven by the drive wheel and drive sprocket. 
   A self-tightening mounting assembly is preferably used to secure the pivot arm assembly to the receiver of the trailer hitch. In one arrangement, the mounting assembly includes first and second members angled in two directions so that as a fastener, such as elongated threaded bolt received through the angled members, is tightened, the angled members securely engage an interior surface of the receiver tube. In another embodiment, a wedge member cooperates with outwardly expanding pads to engage the interior surface of the receiver tube. Either of these self-tightening mounting assemblies limits any loose fit or play between the pivot arm assembly and the trailer hitch receiver. 
   Reinforcement means if provided for the tailgate. In one embodiment, perimeter reinforcement is provided to the OEM tailgate and also incorporates means to facilitate removal of a cargo bin. In an other embodiment, reinforcement is provided through an interconnection with a trailer hitch receiver. 
   A primary advantage of the invention is found in an improved cargo hauling system. 
   One benefit resides in the ability to protect the interior cargo space or truck bed from potential contamination or damage by the material carried in the bin. 
   Another advantage is found in the ability to selectively remove the bin from the vehicle. 
   Still another advantage resides in the ease in which the cargo hauling system is mounted to the vehicle via a conventional trailer hitch assembly. 
   Yet another advantage of the invention results in the self-powered ramp that facilitates installation and removal of the bin from the truck bed or SUV cargo space. 
   A further advantage is found in the ease with which a conventional tailgate may be reinforced. 
   Still other benefits and advantages of the invention will become apparent to those skilled in the art upon reading and understanding the following detailed description. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  shows a prototype cargo bin in accordance with the present invention. 
       FIG. 2  is a perspective view of a preferred form of pivot arm assembly. 
       FIG. 3  illustrates installation of the pivot arm assembly of  FIG. 2  to a conventional trailer hitch assembly. 
       FIG. 4  is an illustration of a bin received in a truck bed with the tailgate removed and the support assembly mounted in place. 
       FIG. 5  is a view, partly in cross-section, of the interconnection of the pivot arm assembly with the trailer hitch assembly. 
       FIG. 6  is a view taken generally along the lines  6 - 6  of  FIG. 5 . 
       FIGS. 7-9  show a perspective, and sectional views thereof of an alternative interconnection of the pivot arm assembly with the trailer hitch assembly. 
       FIGS. 10A and 10B  show a ramp assembly extending from the pivot arm assembly to a cargo bin disposed on the ground surface. 
       FIG. 11  is a view from a truck bed of the underside of the cargo bin in a dump position. 
       FIG. 12  is a view of the cargo bin shown partially extended from the truck bed. 
       FIG. 13  is an elevational view of the pivot arm assembly in operative association with the underside of the cargo bin. 
       FIG. 14  is a side elevational view of the cargo bin in a dump position. 
       FIG. 15  is a perspective view of a first embodiment of a reinforcing mechanism for a conventional OEM tailgate. 
       FIGS. 16 and 17  are side and front elevational views, respectively, of a second embodiment providing reinforcement for the tailgate. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Turning to  FIGS. 1-4 , a-prototype of a cargo bin  20  is shown both separated from the associated light truck ( FIG. 1 ) and installed in the bed of a light truck ( FIG. 4 ). More particularly, the bin includes a base wall member  22  and at least first, second and third sidewalls  24   a,    24   b,    24   c  that enclose a bin cavity  26 . Although not shown, it will be appreciated that an additional sidewall could be provided to close the remaining open side or rear end of the bin, and/or likewise, a top or lid (i.e., removable, hinged, etc.) could also be provided to enclose the upper surface of the bin. Although the prototype is illustrated as formed wood panel portions, commercial units will more likely be formed from a plastic material or composite plastic, for example in conjunction with a durable frame such as an angle iron frame. 
   The bin is dimensioned for close receipt within the footprint or outline area of the cargo space of an SUV or bed of a light truck. Thus, the precise configuration of a bin may differ slightly from one vehicle to another, although it is generally contemplated that the bin will have a box-like conformation that closely matches that of the volume of the vehicle in which it is received in order to maximize storage volume or capacity. 
   As will also be appreciated from  FIGS. 1 and 4 , the bin may include a transition portion  28  that merges with the roofline, for example, of the vehicle. In other instances, the transition portion will conform to the interior of the cargo space of the SUV or other outline of the truck. Likewise, recessed cutout regions  30  may be provided along lower, opposite edges of the bin sidewalls  24   a,    24   c  in order to accommodate a raised wheel well area in the cargo space or truck bed. 
   Preferably, the bin is a one-piece, integral unit so that any material stored therein is not inadvertently spilled or released into the truck bed or cargo space of the SUV. Received on a lower surface of the base wall are a series of roller members  40  that facilitate rolling movement of the bin, and particularly the base wall thereof, along the horizontal surface of the associated bed or cargo space, or along the ground surface as will be appreciated from further discussion below. The particular number or spacing of the roller members may vary depending on the size of the bin, intended use, etc. 
   As illustrated in  FIGS. 2 and 3 , pivot arm assembly  50  includes a support bar  52  secured to a transverse arm  54 , preferably at approximately mid-length of the transverse arm. Outer, terminal ends of the transverse arm are secured to first and second upright arms  56 ,  58 . The upright arms include rollers  60  on the outer terminal ends thereof for reasons, which will become more apparent below. They also include terminal rollers  62 . The pivot arm assembly is preferably channel or tube stock and is either welded or fastened together and the transverse arm and first and second upright arms define a generally U-shaped member. The support bar is dimensioned for receipt in the trailer hitch receiver. For example, a conventional two-inch trailer hitch would receive the support bar therein, and a cross pin extending through the trailer hitch member and the support bar secures the pivot arm assembly to the vehicle. The support arms have a dimension that extends upwardly from the transverse arm to the base of the truck bed or cargo space of the SUV. Thus, when mounted in place, for example as illustrated in  FIGS. 3 and 5 , the arms  56 ,  58  do not interfere with rear door operation of the SUV, or when used with the tailgate removed on a truck, the arms preferably do not extend above the lower surface of the truck bed. 
   Alternatively, and as shown in  FIGS. 5 and 6 , the pivot arm assembly eliminates the support bar and uses an elongated fastener with a pair of cooperating wedge members to secure the pivot arm assembly to the trailer hitch receiver. Fastener  70  includes external threads  72  at one end that cooperate with a fastening nut  74  and a fastener head or bolt head  76  at the other end preferably has tool-engaging flats. A shank  78  of the fastener is received through an opening  80  in the transverse arm. Likewise, suitable dimensioned openings are provided through first and second wedge members  82 ,  84  that have selectively mating angled surfaces  86  that allow relative sliding movement as the wedge members are urged into tight gripping engagement with an internal surface  90  of the trailer hitch receiver  92 . Thus, as the fastener is rotated in the desired direction, the wedge members are drawn toward one another, in sliding engagement along mating surface  86 , and the longitudinal surfaces  94  of the wedge members expand outwardly into tight, securing engagement with the internal surface  90  of the trailer hitch receiver. As will be appreciated from  FIGS. 5 and 6 , mating surfaces  86  are angled in both the X and Y directions so that tight engagement with the internal surfaces  90  of the receiver is achieved in perpendicular directions, i.e., along the entire inner perimeter of the trailer hitch receiver. 
   Turning now to  FIGS. 7-9 , an alternative assembly is shown for securing the pivot arm assembly to the trailer hitch receiver. Where possible, like parts are identified by like reference numbers with a primed suffix, e.g., trailer hitch receiver  92  is identified as receiver  92 ′, and new components by new reference numerals. Particularly, the receiver  92 ′ receives a hollow square tube  96  that includes multiple engaging pads  98  that are selectively moved inwardly and outwardly through corresponding openings in the tube in response to movement of wedge member  82 ′. The wedge member includes an outer inclined surface that engages the pads and upon selective rotation of the fastener  70 ′, the nut  74 ′ is moved along shaft  72 ′ and moves the pads either inwardly or outwardly relative to the axis of the tube to either release or grippingly engage the inner surface of the trailer hitch receiver. As shown, two pads are provided and oriented to engage inner surfaces disposed at ninety degrees relative to one another in the hitch receiver to assure secure engagement of the pivot arm assembly. 
   Referring to  FIGS. 10A and 10B , installation of the bin into the truck bed or cargo space is illustrated. A loading/unloading ramp assembly  100  includes first and second support members or ramps  102 ,  104  that are interconnected adjacent a first end by a wheel assembly  110 . The wheel assembly includes first and second wheels  112 ,  114  interconnected by an axle  116 . The axle also receives a sprocket or gear  118  that is secured to the axle. Thus, the gear is adapted to rotate with the axle that, in turn, rotates with the wheels as the wheels roll along the ground surface in response to forward or rearward movement of the vehicle. At a second end of the ramp assembly is a second axle or rotating idler shaft  120  that includes a sprocket or gear  122  mounted thereon. A flexible drive member such as chain  124  defines a continuous loop about the gears  118 ,  122 , and additionally around idler gears  126  rotatably secured to the ramps. In this manner, the motive power of the vehicle is used to pull or haul the bin along the support members  102 ,  104  and into or out of the truck bed. That is, the assembly is set up as illustrated in  FIG. 10 . By moving the vehicle in reverse, the chain rotates (generally counterclockwise as shown) to pull the bin upwardly, the driving force being provided through rotation of the wheels  112 ,  114  via axle  116 . As will be appreciated, the reverse situation also advantageously uses the motive power of the vehicle to pull the bin from the truck bed or cargo space. 
     FIGS. 11-14  illustrate various positions of the bin once it has been loaded into the truck bed. First and second channel members  140 ,  142  are preferably secured to the bottom surface of the bin to facilitate such movement. The channel members are located inwardly of the roller members  40  in the exemplary embodiment, disposed in parallel relation and for cooperation with respective rollers  60  provided on the upper ends of the upright arms  56 ,  58 . The rollers provide a low friction, roller engagement of the bin with the pivot arm assembly so that the bin can be easily inserted into and withdrawn from the truck bed/cargo space. The intercooperation of the rollers with the channels is perhaps best illustrated in  FIG. 13  where the bin is fully installed into a truck bed. Thus, the rollers  60  advancing in the channels, in conjunction with the roller members  40 , allow a vehicle operator to easily slide the bin forwardly and rearwardly within the truck bed or cargo space as demonstrated in  FIG. 12 . 
   The material in the bin can also be dumped without removing the bin from the truck. This is illustrated in  FIG. 14  where the bin is withdrawn and the center of gravity ultimately allows the bin to pivot along the rollers provided in the upright arms of the pivot arm assembly to a dump position. If topsoil, mulch, or the like needs to be further spread, advancement of the vehicle (leftward as illustrated) allows the remaining contents of the bin to be dumped onto the ground surface. The operator can then easily and manually pivot the bin upwardly and then slide the bin into the truck bed/cargo space. 
   As will be appreciated, the bin can be completely removed from the vehicle through use of the ramp assembly. Thus, if the bin is filled with constructions materials or tools, it can be transported to a work site, removed from the vehicle, and placed at a desired location on the ground surface where it is chained to a support post, or the like. Once construction is complete or if it becomes necessary to move the bin to another site, the bin is reloaded into the vehicle through use of the ramp assembly of  FIG. 10 . This allows the vehicle operator to continue to use the vehicle without unnecessarily hauling the materials stored in the bin back and forth to the construction site. On the other hand, the bin can remain installed in the truck bed/cargo space and material or goods stored therein and selectively removed or dumped as illustrated in  FIG. 14 . In both situations, the interior of the truck bed or SUV is protected through use of the durable material of construction of the bin. 
     FIG. 15  shows a conventional factory or OEM tailgate TG that includes reinforcing means RM that includes a perimeter reinforcing frame  150  that may be one generally rectangular frame component or four individual components  150   a,    150   b,    150   c,    150   d  disposed about the inner peripheral portion of the tailgate TG to add further strength and rigidity to the tailgate. The reinforcing means further includes stronger support straps  152   a,    152   b  which are two bar linkages that are pivotally secured at one end  154  to a reinforced hinge RH that receives the reinforced hinge portion RH′ provided on the perimeter of the tailgate. This assures that there is sufficient strength to accommodate the increased loads and forces imposed thereon. The second bar of the two bar linkage is pivotally secured at end  156  to the outer edge of the tailgate. 
   In addition, track means such as wheels  160  are provided on an upper perimeter portion of the reinforcing frame. The wheels are functionally equivalent to the wheels  60  of the embodiment of  FIG. 5 . In this manner, the cargo bin may be longitudinally removed from the truck bed and pivoted and travel relative to wheels  160   a,    160   b  in order to allow the storage bin to be unloaded relative to the truck bed. 
     FIGS. 16 and 17  illustrate an alternative embodiment wherein additional support is provided via the trailer hitch. As previously noted, a conventional two inch trailer hitch tube  180  is provided on the vehicle below the bumper B. The tube  180  is adapted to receive correspondingly configured wedge members  182 ,  184  (not shown) of the type shown in  FIGS. 5 and 6 . Here, a support strap or reinforcing strap  190  is pivotally mounted on one end to the cooperative wedge members of the trailer hitch receiver noted by reference numeral  192  and has a U-shaped opening  194  at an opposite end that receives pin  196  of a reinforcing frame  198 . The reinforcing frame is secured by suitable means to the conventional tailgate, the pin extends outwardly therefrom, and is selectively received in the slot  154 . In this manner, any additional load imposed on the tailgate is transferred from the tailgate through the reinforcing strap  190  and transferred to the frame via the trailer hitch receiver  180 . 
   Although a single reinforcing strap  190  is shown in the figures, it will be appreciated that two or more reinforcing straps may be used with equal success. It may be desirable in certain instances to locate the straps in spaced relation so that the strap(s) do not cover the license plate, for example. 
   The invention has been described with reference to the preferred embodiment. Modifications and alterations will occur to others upon reading and understanding this specification. It is contemplated, for example, that drive assemblies other than the chain  124  may be used for assisting in loading and unloading of the bin. A worm gear or threaded rod would be a suitable alternative that provides a reliable, compact drive assembly. The system can also incorporate features such as a braking mechanism that assists in slowing or stopping movement of the cargo bin in and out of the vehicle. Likewise, a dampener can be used to reduce the rate at which the bin tilts relative to the vehicle. Any suitable dashpot or dampener could be added to the cargo hauling system to provide greater control to movement of the bin as it tilts or dumps relative to the vehicle. For example, various other manufacturing steps may be employed or in a different sequence. Likewise, different materials may be used or alternative processes without departing from the present invention. It is intended to include all such modifications and alterations in so far as they come within the scope of this discclosure. 
   The invention has been described with reference to the preferred embodiment. Obviously, modifications and alterations will occur to others upon a reading and understanding of this specification. The invention is intended to include all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.