Tonneau cover

Rigid panel sections can include a rigid panel, a first frame member, a second frame member and a coupling mechanism. The rigid panel can have a first face, a second face opposite the first face, and an edge therebetween. The first face can having a first margin adjacent the edge and the second face can have a second margin adjacent the edge. The first frame member can be disposed along at least a portion of the edge and can have a first flange overlying the first margin. A second frame member, distinct from the first frame member, can be disposed along at least a portion of the edge and can have a second flange overlying the second margin. The coupling mechanism connecting the second frame member and the first frame member together can be positioned outboard of the edge. Methods of assembling the rigid panel sections are also provided.

FIELD

The present disclosure relates to tonneau covers for vehicles and, more particularly, relates to a two-piece frame member connected to an edge of a rigid panel of a tonneau cover.

BACKGROUND

Tonneau covers have been used for a number of years to cover the truck bed or cargo box of pickup trucks, to protect against dirt, debris, and other environmental contaminants, and to improve the aesthetic quality thereof. Such tonneau covers can be foldable when not being used to cover the bed of the pickup truck or for cargo protection or to otherwise allow access to the truck bed. Tonneau covers which include solid panels can be desirable, for example, to provide strength and rigidity and for their aesthetic quality. The present disclosure provides improvements in foldable tonneau covers incorporating rigid panels and in methods of assembling such tonneau covers.

SUMMARY

In accordance with one aspect of the present disclosure, a tonneau cover for covering a truck bed can include a plurality of rigid panel sections foldable between a deployed arrangement for covering the truck bed and a folded arrangement wherein the panel sections are stacked for accessing the truck bed. Such a tonneau cover can include at least one rigid section including a rigid panel, a bottom frame member, a top frame member and a coupling mechanism connecting the top frame member and bottom frame member together. The rigid panel can have a bottom face adapted to face the truck bed when the tonneau cover is in the deployed arrangement. The rigid panel can further have a top face opposite the bottom face, and an edge therebetween. The top face can have a top margin adjacent the edge, and the bottom face can have a bottom margin adjacent the edge. The bottom frame member can be disposed about the edge and can have a bottom flange overlying the bottom margin of the rigid panel. The coupling mechanism can connect the top frame member and the bottom frame member together via coupling elements positioned outboard of the edge.

In accordance with another aspect of the present disclosure, a tonneau cover for covering a truck bed can include a plurality of rigid panel sections configured to cover the at least a portion of the truck bed. At least one of the plurality of rigid panel sections can include a rigid panel, a first frame member, a second frame member and a coupling mechanism connecting the first frame member and the second frame member together. The rigid panel can have a first face, a second face opposite the first face, and an edge therebetween. The first face of the rigid panel can having a first margin adjacent the edge. The second face of the rigid panel can have a second margin adjacent the edge. The first frame member can be disposed along at least a portion of the edge and can have a first flange overlying the first margin. The second frame member can be distinct from the first frame member and can be disposed along at least a portion of the edge and can have a second flange overlying the second margin. The coupling mechanism can connect the second frame member and the first frame member together outboard of the edge.

In accordance with a further aspect of the present disclosure, a method of assembling a tonneau cover can include providing a rigid panel having a first face, a second face opposite the first face, and an edge therebetween, with the second face having a second margin adjacent the edge, and the first face having a first margin adjacent the edge. A first frame member can be disposed along at least a portion of the edge of the rigid panel such that a first flange of the first frame member is overlying the first margin. A second frame member, distinct from the first frame member, can be disposed along at least a portion of the edge of the rigid panel such that a second flange of the second frame member is overlying the second margin. The first frame member and the second frame member can be coupled together via a coupling mechanism that is positioned outboard of the edge of the rigid panel.

DETAILED DESCRIPTION

At the outset, it should be noted thatFIGS. 1 through 6illustrate various example embodiments of the present tonneau cover10having alternative structures. However, in the interest of brevity, the embodiments will be described herein using common reference numerals to identify common elements, although the corresponding elements in the various embodiments may not be identical. It should be understood, however, that the present description should not be regarded as limiting the invention to any singular configuration and that alternative configurations, not illustrated, are further within the scope of the present teachings.

With particular reference toFIG. 1, a tonneau cover10for covering a truck bed or cargo box11is provided. In some cases, the truck bed or cargo box11can be part of a pickup truck13as shown. In some embodiments, the tonneau cover10can include a plurality of rigid panel sections12foldable between a deployed arrangement covering the truck bed11and a folded arrangement wherein the panel sections12are stacked, allowing access to the truck bed11.

Referring toFIGS. 1 through 6, the tonneau cover10can include at least one rigid section12. This rigid section12can include a rigid panel14having a bottom face16adapted to or positioned to face the truck bed11when the tonneau cover10is in the deployed arrangement. The rigid panel14can have a top face18opposite the bottom face16, and an edge20between the top face18and the bottom face16. The top face18can include a top margin22adjacent the edge20. Similarly, the bottom face16can include a bottom margin24adjacent the edge20.

In some instances, the top face18and bottom face16can be provided by top and bottom outer sheet layers or skins,19and17, respectively, which can be made of metal or plastic material, that sandwich a central rigid foam core21. As non-limiting example materials, skins17,19can be made of aluminum or fiberglass reinforced polymer and the core21to which they can be laminated, can be made of a rigid polymeric or thermoplastic olefin.

The tonneau cover10can further include a bottom frame member26disposed about the edge20and having a bottom flange28overlying the bottom margin24. The tonneau cover10can also include a top frame member30, distinct from the bottom frame member26, disposed about the edge20and having a top flange32overlying the top margin22. Although the faces, margins, and flanges are distinguished in this description using the terms “top” and “bottom,” it is equally appropriate to use alternative distinguishing language, such as “first” and “second” frame members, or “main” and “secondary” (or “lock strip”) frame members.

The tonneau cover10includes a coupling mechanism34connecting the top frame member30and the bottom frame member26outboard the edge20. The coupling mechanism34can include a coupling element40on one of the frame members30and a cooperating coupling element36on the other of the frame members26that cooperate to couple the top frame member30and bottom frame member26together. For example, the coupling elements36and40can interlock or inter-engage with each other.

In some embodiments, one of the top frame member30and bottom frame member26can comprise a coupling element in the form of a hook36, and the other of the top frame member30and bottom frame member26can comprise a cooperating coupling element in the form of a catch feature40, which can be disposed within a receptacle38to insure and retain the interlocking arrangement or position. The coupling mechanism34can thus comprise hook36received in receptacle38to engage cooperating catch feature40. In some embodiments, catch feature40can extend in a direction laterally away from edge20and hook36can include a flange extending laterally toward edge20and engaging the catch feature40.

In some embodiments, top frame member30and bottom frame member26can either or both be formed as a unified one-piece extruded strip. For example, in the embodiment ofFIGS. 2 through 4C, both of the top frame member30and bottom frame member26can be a unified extruded metal strip, such as a unified extruded aluminum strip. In the example embodiment ofFIGS. 5 and 6, the bottom frame member26can be a unified extruded metal strip, while the top frame member30can be a unified extruded strip that is more flexible, such as a thinner or more flexible metal material or a plastic material, which can aid in sealing between the panel14and the top frame member30.

In some embodiments, the coupling mechanism, such as the cooperating hook36and catch40coupling elements, can be integrally formed as a part of such respective extruded strips. In some cases, the coupling mechanism34can include automatic or one-step cooperating coupling elements, such as the cooperating inter-engaging or interlocking hook36and catch40elements. In other words, the coupling mechanism34can couple the top frame member30and bottom frame member26together simply by appropriately positioning them with respect to each other, which can include positioning the hook36within a receptacle38housing the catch40.

In other cases, the coupling mechanism34can include one or more distinct or separate components beyond the top frame member30and the bottom frame member26. For example, the coupling elements of the coupling mechanism34can include screws, pins, rivets, or clips, or other elements while cooperating coupling elements40can include threaded or non-threaded apertures, or other separate elements or integral features of one of the top frame member30or bottom frame member26.

In some embodiments, top flange32and bottom flange28apply a compressive force against opposing sides of the rigid panel14when the top frame member30and the bottom frame member26are coupled together by the coupling mechanism34to retain the rigid panel14therebetween. In other words, top frame member30and bottom frame member26and the coupling mechanism34can be positioned, can have a structure, or both, that can exert a compressive force against rigid panel14when the rigid panel14is retained between the top frame member30and bottom frame member26with these components assembled together in a collective, mated arrangement.

Referring toFIGS. 4A-4C, tonneau cover10can comprise a material42disposed along an interface between any combination of top frame member30, bottom frame member26, and rigid panel14. In some embodiments, the material42can be an adhesive, a sealant, or other suitable material. The material42can be applied as a strip, a bead, a liquid, a solid, or any other suitable means. In particular, in some embodiments, the material42can be an adhesive and/or sealant applied in the form of a bead to one or both of the top flange32or top margin22to provide sealing and/or bonding between the top flange32and top margin22. In some embodiments, the material42can alternatively or additionally be applied as a bead to one or both of the bottom flange28or bottom margin24to provide sealing and/or bonding between the bottom flange28and the bottom margin24.

In other cases, the material42can alternatively or additionally be applied in the form of a weather-strip or vibration isolation strip as described above with respect to the adhesive and/or sealant bead(s). In other cases, sealing can be partially or completely provided by forming one of the top frame member30or bottom frame member26of a flexible or resilient material. For example, top frame member30or panel lock strip ofFIGS. 5 and 6can comprise a unified extruded plastic flexible, resilient member. Such a structure can provide sealing and or vibration dampening instead of or in addition to the bead or strip material42described above.

The description herein of the panels14being rigid does not exclude the situation where the rigid panels14are partially or completely covered with fabric, textile or other flexible sheet material (not shown). For example, any of the panel14, top frame member30, bottom frame member26, can be partially or fully covered by such a sheet material. As but one example, such a sheet material can cover the top surfaces of the panel14and top frame member30and can extend into and terminate within a cover retention slot41.

According to the present teachings, a method of assembling the tonneau cover10is further provided. Referring toFIGS. 2 through 4C, the method can include providing a rigid panel14having a first or top face18, a second or bottom face16opposite the first face18, and an edge20therebetween. The first face18includes a first margin22adjacent the edge20and the second face16includes a second margin24adjacent the edge20.

The method includes disposing a first frame member30along at least a portion of the edge20of the rigid panel14such that a first flange32of the first frame member30is overlying the first margin22. A plurality of first frame members30can in some embodiments be pre-assembled together to form a rectangular frame that is sized to correspond to the dimensions of the rigid panel14. Such a pre-assembled rectangular frame can be formed, for example, of four first frame members30having an identical cross-section. Alternatively, two first frame members30can be positioned on opposite sides of the rigid panel14and interconnected by intermediate frame members having a different configuration.

Alternatively, an assembled rectangular frame comprising a plurality of the first frame members30, these second frame members26can be formed in place, by individually or separately serially positioning first frame members30adjacent a corresponding side or edge20of the panel14. In other embodiments a complete rectangular frame assembly need not be formed at all. For example, in some embodiments, a first frame member30coupled to a second frame member26can be provided along only one edge20of the rigid panel14. As another example, a first frame member30coupled to a second frame member26the first frame members30can be provided along only two opposite edges20of the rigid panel14parallel to each other, without any other frame members along the other set of parallel edges of the panel14to complete a rectangular frame. Of course, other embodiments may include any other possible arrangements.

As illustrated inFIG. 4A, the first frame member30can, for example, be positioned such that first flange32faces generally upwardly. The adhesive and/or sealant material42can be readily applied upon the generally upwardly facing first flange32. The first margin22of the rigid panel14can then be positioned directly over the first flange32and lowered into place against the adhesive and/or sealant material42, first flange32, or both, without the need for relative lateral movement between the first flange32and the first margin22or rigid panel14. Avoiding such relative lateral movement can facilitate better adhesion or sealing by the material42between the components.

As illustrated inFIG. 4B, the material42can be applied to the second margin24of the rigid panel14, with the second margin24positioned facing generally upwardly. As illustrated inFIG. 4C, the method can further include disposing a second frame member26or locking strip, distinct from the first frame member30, along at least a portion of the edge20of the rigid panel14such that the second flange28of the second frame member26overlays the second margin24. The second flange28of the second frame member26can be positioned directly over the bottom or second margin24of the rigid panel14and lowered into place against the intervening material42, bottom or second flange28, or both, without the need for relative lateral movement between the second flange28or the material42, and the second margin24of the rigid panel14, which also can facilitate better adhesion or sealing by the material42between the components.

As described above, regarding the first frame members30, these second frame members26can be pre-assembled into a rectangular frame assembly, or can be individually or separately serially positioned above and coupled to a corresponding first frame member30along the sides of the panel14. As the first flange32and second flange28of the first frame member30and the second frame member26is being positioned against the corresponding first and second margins,22and24, respectively, the coupling elements36and40of the coupling mechanism34can inter-engage or interlock to couple the first frame member30and the second frame member26together. In some embodiments, the method can include coupling the first frame member30and the second frame member26together outboard the edge20of the rigid panel14. In other words, the coupling elements36and40can be positioned outboard of the edges20of the rigid panel14.

In some embodiments, first and second frame members30and26, respectively, can be coupled together around opposing sides of the panel14. A first coupling extension of corner frame members31can next be inserted into ends of these opposing coupled frame members30,26. Then, first and second frame members30and26, respectively, can be positioned and coupled together along the remaining two sides of the panel14and around second coupling extensions of each corner frame member31.

In some embodiments, the adhesive and/or sealant material42can be applied between the first flange32of the first frame member30and the first margin22prior to the step of disposing the first frame member30along at least the portion of the edge20of the rigid panel14. In some embodiments, the method can include applying an adhesive and/or sealant42between the second flange28of the second frame member26and the second margin24prior to the step of disposing the second frame member26along at least the portion of the edge20of the rigid panel14. In other embodiments, such adhesive and/or bonding material, may be provided at only one of these interfaces, or at neither interface.

The method as described above with regard to the embodiment ofFIGS. 2 through 4Cidentifies the first frame member as the top frame member30and the second frame member as the bottom frame member26. This need not be the case. For example, with regard to the embodiment ofFIGS. 5 and 6, the first frame member in the method description above can be bottom frame member26and the second frame member can be top frame member30. Likewise, the method described above with regard to the embodiment ofFIGS. 2 through 4Cidentifies the first flange and first margin as the top flange32and top margin22, respectively, and the second flange and second margin as the bottom flange28and bottom margin24, respectively. With regard to the embodiment ofFIGS. 5 and 6, the first flange and first margin can be the bottom flange28and bottom margin24, respectively, and the second flange and second margin can be the top flange32and top margin22, respectively.

Example embodiments are provided so that those who are skilled in the art can fully understand the tonneau covers for truck beds in accordance with this disclosure. These example embodiments provide numerous specific details such as examples of specific components, shapes, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. Similarly, any aspect or combination of aspects illustrated or described in reference to one embodiment may be used in combination with one or more aspects illustrated or described in reference to any other embodiments. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.