Truck cap with heavy duty mounting rack

A cap for the cargo bed of a pickup truck has a rigid internal frame with spaced front and rear frame members connected by longitudinally extending upper side rails and longitudinally extending bottom plates, said frame being supported on side walls of the pickup truck. A lightweight shell extends over the rigid frame and is supported on the side walls of the truck. A plurality of posts are attached to the side rails and extend vertically through holes formed in the shell and have one or more storage racks attached to the posts whereby all of the weight of the storage racks and cargo supported thereon is transmitted through the internal frame and supported by the truck body. The frame members are formed of T-slotted members providing support for sundry items inside the shell.

BACKGROUND OF THE INVENTION

1. Technical Field

The invention relates to truck caps, and in particular to an outer shell in combination with an internal rigid frame and an exterior mounting rack able to support heavy loads. Even more particularly, the invention relates to such a truck cap in which the weight of the heavy load that is supported on an external rack is supported by the truck body through the internal frame concealed within the cap shell.

2. Background Information

A considerable number of pickup-type trucks are used by individuals for many types of business activities or just as a personal vehicle. These pickup trucks have an open rear bed or cargo area which is exposed to the weather. Various types of enclosures are used to protect this cargo area from the weather and to secure cargo, tools, etc. stored in the rear area from theft. These enclosures are referred to as a shell, canopy, topper, bed cap, box cap etc. and come in numerous configurations and sizes. These enclosures are usually attached to and supported by the side rails or frame of the truck body which form two sides of the open cargo area. Many of these enclosures are made of fiberglass, aluminum, wood etc., with fiberglass being the most common.

Many of these pickup trucks are used in various industries and hold various types of tools and other equipment for use on a job site. However, due to the construction of the enclosure, usually of a lightweight material such as fiberglass, they are not able to support appreciable weight, even though it is desirable to mount ladders and other equipment on top of the enclosure. In order to be able to accommodate greater loads, the enclosure must be made of a more rigid material with internal reinforcing, which adds appreciable to the weight, size, and cost for the truck enclosure or have a type of support frame which extends externally about the weather-proof shell such as shown in U.S. Pat. No. 8,087,716. Although some of these prior art reinforced caps and external frames enable the external load to be heavier than heretofore possible, they increase the cost of the truck enclosure, increase the external size of the vehicle cap and detract from the appearance thereof.

Therefore, there is a need for an improved truck enclosure or cap for the rear cargo area which is able to support greater loads externally of the enclosure adjacent the top thereof without detracting from the appearance of the vehicle while still providing weather-proof protection for the heretofore open truck bed or cargo area.

SUMMARY

In one aspect, the invention may provide a truck cap comprising: a frame for mounting on a vehicle body including front and back vertically extending frame members connected by a pair of spaced side rails extending generally horizontally therebetween; a shell extending over the frame adapted to be supported on the vehicle body; a plurality of posts attached to the frame and extending upwardly through respective holes formed in the shell; and a first rack attached to and extending between at least two of the posts externally of the shell.

In another aspect, the invention may provide a vehicle having an open rear portion, a rigid frame mounted adjacent the open rear portion and supported on the vehicle, and a shell extending over the frame and open rear portion of the vehicle, said frame including spaced front and back vertically extending frame members and a pair of side rails extending between said frame members and a plurality of posts attached to the frame and extending upwardly through a plurality of holes formed in the shell.

In another aspect, the invention may provide a truck cap for mounting on a rear portion of a vehicle body defining an open rear bed of the vehicle comprising: a rigid frame supported by the rear portion of the vehicle body and extending over the open rear bed; a shell covering the rigid frame and open rear bed and supported by the rear portion of the vehicle body; a plurality of posts attached to the rigid frame and extending through the shell; and a rack attached to the posts externally of the shell whereby the weight of a load supported on the rack is supported by the vehicle body through the rigid frame.

DETAILED DESCRIPTION

The truck cap of the present invention is indicated generally at1, and is shown mounted on a usual vehicle3such as a pickup truck, having an open rear cargo area5(FIG. 2). Vehicle3can have various configurations and will have some type of rear side rails or flanges7which extend along the top of vehicle side walls9and define cargo area5. Truck cap1includes a usual enclosure indicated generally at11, which preferably is made out of fiberglass, although it could be made out of wood, aluminum, or other types of material or combination thereof. Enclosure11is referred to hereinafter as a shell or cap although it is known by various other nomenclatures as discussed above.

Shell11will have a usual construction with side walls13and an integral top wall or roof15. Side walls13usually will terminate in some type of inturned bottom flanges17which rest on and extend along side rails7of the vehicle body as shown inFIGS. 2 and 2A. Bottom flanges17of shell11are usually secured to the truck body by C-clamps20or various other types of fasteners to removably mount shell11on the vehicle body with the weight of the shell being supported on rails7of the vehicle body. If desired, shell11can be permanently attached by bolts, rivets, etc. to the vehicle body.

Referring toFIGS. 2 and 3, truck cap1, in addition to shell11, includes a rigid internal support frame indicated generally at21. Frame21includes front and rear frame members23and25, respectively, which are connected by a pair of spaced parallel side rails27which extend horizontally therebetween. In a first embodiment of frame21, front and rear frame members23and25are similar in size and configuration, each being a three-member generally trapezoidal configuration with a pair of side legs29and a horizontal cross beam31. Frame legs29are connected to cross beams31by angle plates39and a plurality of fasteners40such as rivets, bolts, T-slot fasteners or other types of well-known fasteners. Cross beams31may be a single member or could be two sections connected together by a fastening plate41.

An angled steel plate33extends horizontally between the bottom ends35of each pair of legs29of the front and rear frame members (FIGS. 2 and 3). Angled plates35will rest upon the top of shell flanges17and supported on side rails7of the vehicle body as shown inFIGS. 2 and 2A. Plates33may be connected to frame legs29by rivets, bolts, welds, or other types of fasteners (not shown). Plates33preferably are secured to the vehicle body side rails by C-clamps20or other type fasteners well known in the truck cap industry. Preferably the frame members, and in particular frame legs29, cross beams31, and side rails27have a double slotted configuration referred to in the industry as double T-slotted members. This type of member is usually formed of an extruded aluminum and referring to side rails27in particular as shown inFIG. 5, has spaced outer parallel walls27A each formed with an aligned pair of slots27B for receiving fasteners40therethrough for engagement with T-slot nuts40A contained within elongated rectangular-shaped channels32. Each of the spaced ends of the T-rails27have T-shaped slots34formed therein. It is readily understood that other types of frame members can be used in forming frame21within the concept of the present invention, although the1-rail configuration of the frame members has advantages discussed further below.

In accordance with a feature of the invention, a plurality of posts43, preferably four, are quadrilaterally placed in a rectangular configuration on the top of frame21, each being located generally adjacent the junction of side rails27with cross beams31(FIG. 3). As shown inFIG. 5, each post43is connected to its respective side rail27by spaced pairs of fasteners40and1-slot nuts40A which sit inside of the elongated channels32of the cross beam. Each post43preferably is a hollow tubular member which extends vertically upwardly from a respective side rail27and extends through aligned holes51formed in top wall15of shell11terminating a short distance above the top of wall15.

A sealing ring or grommet59is placed about the outer circumference of each post43within holes51to seal the post and shell11providing a weatherproof seal therebetween. These seals can be various types of elastomer rings or even some type of applied sealant.

Various types of racks can be attached to the top ends of post43, one common type being a ladder rack as referred to in the vehicle rack industry, which is indicated generally at52and shown onFIGS. 2, 3, and 5. These racks consist of a pair of oval-shaped elongated rails53and have a generally oval shape with a longitudinally extending top slot or opening54and a pair of internal channels or voids55and56separated by a wall49. Rails53can be connected to top plates57which enclose the open tops of posts43by fasteners58and elongated nuts58A. Plate57may be attached to the open top of post43by welds64(FIG. 6) or other type of attachment. It is readily understood that other types of rails or cargo supporting members can be attached to the tops of posts43without affecting the concept of the invention.

A modified cargo-supporting frame is shown inFIG. 4and is indicated generally at65, and will be used with taller end cap shells. Frame65will have front and rear frame member66and67respectively, each having a three member trapezoid configuration. Front frame member66will have upwardly angled legs68and a horizontal cross beam69. Rear frame member67will have upwardly angled legs70and a cross beam71. Front frame member66will be taller than rear frame member67and is connected thereto by parallel side rails72and a pair of downwardly sloped side rail sections73and a connecting cross beam74.

This modified frame65enables a taller inside storage area, yet enables a usual tailgate and window to be installed adjacent the shorter rear frame member67. This is in contrast to frame21discussed above wherein the front and rear frame members are equal in size and configuration.

A usual ladder rack52similar to the ladder rack discussed above and attached to frame21having two spaced rails53, can be attached to posts43and may have a second ladder rack79mounted on ladder rack52. Rack79may be the same as or very similar to ladder rack52and have a pair of racks78connected to elongated rails53by a pair of fasteners or bolts80and nuts81. The spaced pair of rails78of ladder rack79will extend transversely across rails53of ladder rack52, as shown inFIGS. 1, 4, and 6.

Again, as with the embodiment ofFIGS. 2, 3, and 5, this modified frame construction will transfer all of its supported weight onto the truck body through frame65and not be placed on the shell which will cover and conceal internal support frame65. The frame members of frame65preferably are formed of the same single or double T-slot members as that of frame21.

The forming of frame members27,29, and31of frame21and the frame members68,69,70,71,73and74of frame65of a T-slot configuration or even a double T-slot configuration as shown in the drawings, provides numerous locations within the cargo storage area, such as shown inFIG. 7, in which various types of hangers85can be secured in one or more of the T-shaped grooves for supporting various types of tools or equipment, such as a cable or wire86as an example shown inFIG. 7. This provides numerous locations completely along the length and width of the storage area in which to attach various brackets or other supporting hardware for the storage of tools or other equipment. Also, as shown inFIG. 7, an interior tool box87can be suspended on one of the side rails and attached to one of the front and rear rails which would be readily accessible either from the interior of the truck cap or through an external door in the covering shell well-known in the art.

Thus, the truck cap of the present invention provides a rigid internal frame which is easily mounted within the truck cargo area by supporting it on the side rails or flanges of the truck body, in combination with a lightweight external shell, which also is supported on the side flanges of the frame of the truck body. This provides a complete weather enclosure to the open cargo area of the truck while providing access thereto by a usual rear gate, rear window, or even side opening windows and doors. The support posts which extend through openings in the top roof of the shell can have various racks or other cargo-supporting structures attached thereto for supporting or containing any type of external load. Most importantly, the weight of any external load or cargo supported on the roof rack is transmitted by the posts to the internal frame directly onto the side walls or flanges of the vehicle body. This avoids any of the load being supported in any manner by the lighter, flexible, outer weather-proof shell. Furthermore, the seals between the posts and holes formed in the shell prevent any water or weather from entering the cargo storage area and causing damage to the stored contents.

It is readily understood that the truck cap of the present invention can be constructed as a combination consisting of the rigid internal frame with the posts extending through and sealed to the outer shell, or can be installed as a retrofit internal frame requiring only four holes to be drilled in the top wall of the shell for insertion of the four posts therethrough, afterwhich seals can be placed in or formed about the post once the frame is properly positioned with respect to the shell.

Moreover, the description and illustration set out herein are an example and the invention is not limited to the exact details shown or described.