DUAL WALL VEHICLE STORAGE SYSTEM

A storage system for a pick-up truck is provided. The storage system includes a primary panel attachable to a sidewall of the truck and extending over a wheel well of the truck. A secondary panel is joined to the primary panel. The primary panel and secondary panel form a container therebetween having an opening which extends over the wheel well of the truck. A lid pivotably connects to either the primary panel or the secondary panel and covers the opening. At least one of the primary panel, the secondary panel and the lid is formed of twin sheet plastic material.

FIELD OF THE INVENTION

The inventions herein relate generally to storage containers or boxes, and more particularly to utility boxes or storage systems integrated with the cargo bed of a pick-up truck.

BACKGROUND

Truck bed liners and spray-on liners for truck beds are known and used to protect the surfaces of the truck bed from scratches, dents, and other damage. These liners are typically made of a plastic material.

Tool or utility boxes designed for use in the beds of trucks, and specifically, pick-up trucks to store tools and other equipment are also known. These utility boxes typically include a bin and a lockable lid. Some such utility boxes include dividers, trays, and drawers to compartmentalize the storage area. Many of these storage containers span the width of the truck bed and are supported on the rails. Utility boxes and other storage accessories are also known which have various mechanisms for supporting themselves within a pick-up cargo bed. For example, the utility box can be supported on the bed side walls of a truck so that it is positioned above the floor of the cargo bed. Others are supported on legs to provide a space beneath the box. Some boxes are secured to the truck bed using bolts or anchors extending through truck bed walls. Many of these utility boxes are provided on the interior side walls of the truck bed, but such storage systems take up space within the truck bed, limiting the diverse use of the truck bed. In addition, these systems do not fully utilize the space as they are often installed forward or rearward of the truck's wheel well. In an attempt to solve the space concerns noted above, it is also known to provide storage compartments integrated into the side walls of a truck bed. These storage compartments are limited in size to the size of the truck bed sidewall and are accessible from the exterior of the bed (i.e., on the ground next to the truck). Unfortunately, these storage compartments must be created as part of the original engineering or manufacturing of the vehicle, increase the dimensions of the truck bed side walls, and consequently may also limit the size of the bed.

Accordingly, a need exists for a storage compartment which can be integrated into the truck bed, but which does not significantly impact the available space in the truck bed, and in particular the space between the wheel wells.

SUMMARY

A storage system for a pick-up truck is disclosed as shown in the drawings and written description. The storage system includes a primary panel secured to an inside sidewall of the truck cargo bed and extending over a wheel well of the truck. A secondary panel is joined to the primary panel. The primary panel and secondary panel form a container therebetween having an opening which extends over the wheel well of the truck. A lid pivotably connects to either the primary panel or the secondary panel and covers the opening. At least one of the primary panel, secondary panel and lid are of dual wall plastic construction to provide strength and rigidity to the storage system.

Additionally, a storage container for use in the cargo bed of a pick-up truck is disclosed. The storage container has a bin defining a storage compartment. The bin includes an upper rim defining an opening into the storage compartment. The bin also includes a back wall, two side walls, a base and a front wall. A lid is pivotally secured to the bin so as to contact the upper rim and cover the opening into the storage compartment when the lid is in a closed position.

An alternative storage system for a truck is also disclosed. The storage system includes an upper storage container and a lid pivotable to open and close the upper storage container. A lower storage container is provided, seated below the upper storage container and having an access door which is movable to open and close the lower storage container.

These and other features and advantages of devices, systems, and methods according to this invention are described in, or are apparent from, the following detailed descriptions of various examples of embodiments and the drawings and illustrations thereof.

It should be understood that the drawings are not necessarily to scale. In certain instances, details that are not necessary to the understanding of the invention or render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.

DETAILED DESCRIPTION

As illustrated in the Figures, a storage container100or storage system is provided which, in the arrangement shown in the Figures, is designed for use in one or more examples as a utility box for a vehicle. More specifically, the storage container100is for use with a truck102, such as a pick-up truck (seeFIGS. 1-2). The storage container100may be mounted in the cargo bed104of a pick-up truck102, and in particular along the sidewall or rail and over the wheel well106of the truck bed104.

In the illustrated embodiment, the truck cargo bed104is standard and its construction is known to those skilled in the art. Briefly, as shown inFIG. 1, the cargo bed104includes a bottom wall or floor108, opposite side walls110that include wheel well portions106, and a front wall112. The cargo bed104may be provided with a bed liner, such as a known “drop-in” under-the-rail plastic bed liner. However, it is also contemplated that the storage container100may be provided or used without a bed liner, or alternatively may be used with an alternative liner type, such as a conventional spray-in liner114, schematically shown inFIG. 1by stippling in the area of the reference number114.

As shown inFIGS. 1-5, the storage container100includes a container portion or bin that defines a storage compartment with an interior116for stowing tools, equipment, material, etc. Preferably, the panels and doors/lid of the storage compartment (described in more detail below) are formed of a material that is durable and water resistant, and more preferably of a material having higher dimensional stability and impact resistant characteristics, such as but not limited to thermoplastic polyolefins. In one or more examples of embodiments, the storage container100is preferably formed of panels of twin sheet thermoformed plastic or polymeric material, with each panel having a unitary construction. It is also contemplated that the storage container100can be so formed from sheets of thermoplastic material, such as high density polyethylene. Such plastic panels can also be formed by blow-molding, wherein the panels are formed by a different known process, but the resulting integral plastic panel consists of a unitary closed dual sheet structure as generally shown and described herein. Any such construction as described above is referred to herein as “dual wall” construction. In one or more embodiments, the material has a high density polyethylene surface, which can correspond to the headwall, floor, and/or tailgate liner material used. The panels and doors/lid (described in further detail below) can optionally be further insulated, such as by the inclusion of foam or other insulating material within the formed dual wall panels and/or lid.

The storage container100, in one or more examples of embodiments, is shown as provided or used in an area (or areas if two such containers are provided) covering or overlapping the wheel well(s)106in the bed104of the truck102. However, it is contemplated that storage containers may be provided for use with the headwall or front wall112, floor108and/or tailgate118. The storage container100design is adaptable to any specific bed design and bed length. While the container100may be installed during manufacture of the vehicle, it is preferably an aftermarket part which is installed post manufacture. The storage container100preferably substantially maintains the standard bed width of the truck bed104, and in particular the distance between the wheel wells106, and integrates with standard and optional bed features.

Referring toFIGS. 2-5, the storage container100is formed generally of a primary panel120, a secondary panel122joined to the primary panel, and a lid124. The respective panels may be separately formed and secured together by suitable fasteners (including but not limited to threaded fasteners such as screws) or alternatively each can be integrally formed as one or more units by use of twin sheet thermoforming or blow-molding equipment, methods and techniques, or other known plastic forming processes as previously described.

Additional accessories may be provided which are coupled to or integral with the storage container100. For example, a frame and access panel sub-assembly128may be provided which provides additional storage or alternatively, provides a structure surrounding or covering an electrical outlet (not shown). The frame130can be formed from or integral with the primary panel120. Additionally, as can be seen in the Figures, one or more tie downs132or loops may be provided in the storage container100or alternatively apertures may be provided in the primary panel120such that tie downs132such as loops or other structure provided on the truck bed104extend through apertures in the panel, e.g., panel120. One or more open storage bins with netting partially or completely forming one or more walls (not shown) for retention of stored articles may also be used in one or more examples of embodiments.

Referring toFIGS. 6-7, the exemplary primary dual wall panel120is shaped to conform with the contours of a truck sidewall and bed104. The primary panel120has a structure defining a pair of side walls134, a back wall136, and a base138of the container100. The back wall136and base138of the primary panel120include an upwardly arcuate portion140, or wheel well clearance area which corresponds to the wheel well106of the vehicle. In this regard, the base138may rest on the truck bed floor108along the side walls110of the truck, with the upwardly arcuate portion140accounting for the variation in truck bed104dimension. The base138may also include one or more drains142and drain plugs144. A portion146of a lock assembly is secured to an upper area148of the primary panel120. However, it is contemplated that said portion146of the lock assembly may also, or alternatively, be provided on the secondary panel122. The backwall136is also shown inFIGS. 6-7to have a plurality of spaced locking flanges137which extend upwardly therefrom for engagement by a retaining rail(s)111fastened to the sidewalls110of the truck cargo bed104. The retaining rail(s)111, best shown inFIG. 104, secure the overlapped locking flanges137against the truck sidewall110to thereby secure the storage container100in position along the sidewall as the storage container is further supported by the floor108and/or wheel well housing106of the truck cargo bed104.

It can be observed fromFIGS. 6-7that the mating inside sheet of the dual wall, twin-sheet primary panel120shown inFIG. 6, and outside sheet of primary panel120shown inFIG. 7, have different contours, with the outside surface ofFIG. 7in particular showing various depressed areas121. Such depressed areas121, which may be in the form of shallow depressions or ribs, as shown, together with the margins and other engineered contact portions of the two sheets are fused together during pressure forming of the twin-sheet primary panel to form an integral, generally rigid structural panel120, as known to persons skilled in the twin sheet thermoforming arts and shown inFIGS. 6 and 7.

The primary panel120also includes one or more widened clearance areas150and one or more lights or windows or lenses152useable to provide light to the interior116of the bin. In one exemplary embodiment, the lenses152permit natural light or light from the vehicle lighting system to enter the interior116of the bin. In the alternative, lights, such as but not limited to LED lights, may also be provided. The primary panel also has various attachment apertures154, permitting an attachment device or fastener156, such as shown inFIG. 9, to extend through the panels and into a portion of the vehicle102for securing the primary and secondary panels together.

Referring further toFIGS. 8-9, the secondary panel122is secured to the primary panel120at one or more panel wall edges158,160,162formed at the edges of the side walls134and base138of the primary panel120. In the illustrated example, a seal164or sealant is provided between the panels120and122. In one or more examples of embodiments, adhesive, e.g., mastic, may also be used to seal the primary panel120and secondary panel122together, to further assist in forming a water tight seal. The secondary panel122is secured to the panel wall edges158,160,162by one or more fasteners156, such as ringed or threaded fasteners or screws. The outside sheet of the secondary panel122may have a plurality of ridges and/or recesses or corrugations166on one or more surfaces, as best shown inFIG. 9. The ridges, recesses, corrugations and mating edges and surfaces of the panel122are typically pressure fused within the twin-sheet panel122to the opposing sheet at their contact areas by die pressure during pressure forming so as to provide integral structural rigidity for the panel122. In the illustrated embodiment, the height of the secondary panel122is shorter than the height of the primary panel120, consequently permitting easy access to the interior116of the bin. In the embodiment shown inFIG. 9, the secondary panel122also includes a wheel well recess168which is shaped to mate with the corresponding upwardly arcuate wheel well clearance area140of the primary panel120. The wheel well recess168provides a close fit or flush mounting of the secondary panel122with the outer edge of the wheel well106(i.e., the innermost edge of the wheel well in the truck bed).

Referring again toFIGS. 4-5, the primary panel120of the bin or container100includes an upper annular rim170that defines the opening through which access to the storage compartment is obtained. The upper rim170includes an annular seal surface172which in the illustrated arrangement is molded integrally with the rest of the bin. The seal surface172is engageable by a sealing gasket174along its periphery (see gasket174shown secured to lid124inFIG. 4). More particularly, a full perimeter gasket174co-extensive with the length of the seal surface172is provided so as to help maintain a water tight compartment when the lid124is closed.

As indicated, the storage container100also includes a lid124. Referring toFIGS. 10-14, a lid124is provided which is hingedly or pivotably coupled to the container100. As shown inFIGS. 2-5 & 10, the lid124is pivotally mounted on the bin100for movement between a closed position (shown inFIGS. 2-3) and an open position (shown inFIGS. 4-5). More specifically, the lid124is pivotally mounted on the front wall (i.e., the secondary panel122) of the storage container100. As indicated, to prevent leakage between the lid124and the bin, the lid124may include a sealing surface176which engages the gasket174and the corresponding sealing surface172and overlies the sealing surface172of the upper rim170on the container100when the lid124is closed.

The lid124has a curved or angled shape. To this end, the lid124has a first segment178and a second segment180. The second segment180is provided at an angle to the first segment178. Preferably, the angle between the first and second segments178,180is an angle other than 180 degrees, e.g., an angle less than 180 degrees, and in one example preferably approximately 90 degrees. As a result, when in the closed position (shown inFIG. 2) the lid124has a substantially vertical portion which accounts for the height difference between the secondary panel122and the primary panel120, and the lid124has a substantially horizontal portion which covers the opening in the container.

The dual wall lid124also may have one or more ribs182, or other structure which provides added structural rigidity to the lid124when the two sheets thereof are fused together during the forming operation as previously described with respect to the primary panel120and the secondary panel122. As can be seen inFIG. 5, the lid124may also have additional structural features, such as one or more cup or beverage holders184and/or one or more containment areas186. In the illustrated embodiment, these cup holders184and containment areas186are provided on the interior sheet or side188of the lid124, but the cup holders184and/or containment areas186may also, or alternatively, be provided on the exterior sheet or side190of the lid124, which may be generally planar or have longitudinal inverse ribs, as best shown inFIG. 2. Typically, in an exemplary embodiment, the valleys of the ribs182of the interior side188of the lid124will run at angles to the inverse ribs of the exterior side190, and the two sides will be fused together in the forming operation between the ribs and at other junction points at the margins and engineered interior junction points to provided rigidity and strength to the lid124.

In the illustrated example, the lid124is hingedly connected to a top portion192of the secondary panel122. However, the lid124may be otherwise connected to the primary panel120or another structure without departing from the overall scope of the present invention. In the illustrated example, the lid124is pivotally mounted to the front wall or secondary panel122with a fixed hinge194. More specifically, the lid124is secured to one “wing” of a hinge194. A second wing of the hinge194is also secured to the secondary panel122. In one or more examples of embodiments, the hinge194is secured to the lid124and panel by one or more ringed or threaded fasteners196. However, variations thereon may be suitable for the purposes provided. The hinge194illustrated in the Figures is a common “piano” type hinge, but alternative hinges, more than one hinge, and other various means of pivotably securing the components together may be acceptable. As a non-limiting example, the secondary panel122and lid124may be joined by a “living” flexible plastic hinge integral or connected to the secondary panel122and the lid124. The lid124is connected such that it opens by rotating into or toward the center of the truck bed104. As indicated, the lid124, optionally, includes a seal or gasket surrounding an outer edge of the lid124, useful for preventing water and other environmental elements from entering the closed container100.

The lid124also includes a lock sub-assembly198. The lock sub-assembly198includes a locking mechanism200and a corresponding latch bracket assembly202. The latch bracket assembly202is secured to the lid124and holds the locking mechanism200. As shown inFIGS. 12-14, a latch mechanism may be provided for locking and unlocking the lid124. In one or more examples of embodiments, a programmable lock may be provided which may be keyed to match the vehicle key. Any conventional lock and latching mechanism may be provided as required.

Referring toFIGS. 15-16, an access door206is provided in a frame portion130of the primary panel120. The combination of access door206and frame portion130provides an area of additional storage and/or provides a cover for an outlet or the like. In this regard, this accessory accommodates vehicle power outlets. In other words, an electrical outlet may be provided behind the access door206or at any convenient location accessible within or through the storage container100. As can be seen inFIG. 17, an outlet shroud212is provided on the back surface214of the primary panel120. (The storage container100may also, optionally, be provided with a DC/AC power inverter208, as in the alternate embodiment ofFIG. 18). The access door206is provided with a latch210that may be hand-operable and secures the access door206in place on the frame portion130. The access door206may also have one or more retaining protrusions or extensions216which engage a portion of the frame130or primary panel120on an end of the access door206. The latch210may receive and cooperate with a programmable key.

Referring toFIG. 18, an alternative example of embodiments is provided in which a plurality of storage bins300,310,320are provided in the storage container. In the illustrated example, an overwheel storage bin300is provided adjacent to an upper storage bin310and lower storage bin320. The upper storage bin310and overwheel storage bin300have hinged lids,330,340, respectively, while the lower storage bin320is provided with an access panel350. Other features as previously described herein are also shown and may be otherwise added to the assembly shown inFIG. 18.

One or more examples of assembly of the storage container100will now be described in reference to the drawings. The panels and various accessories of the storage container100may be assembled together and then placed into the vehicle bed104, or alternatively may be installed directly or individually in the vehicle bed104. The primary panel120is placed along the sidewall and over the wheel well106of the truck bed104. The primary panel120may be attached to the sidewall of the truck bed104by any suitable means, including the previously described backwall locking flanges137secured to the truck sidewall by retaining rail111. The secondary panel122is secured to the primary panel120using the mechanisms described above. The lid124may be secured to the secondary panel122with a hinge194. Various additional accessories may be added to the primary panel120as described herein, such as but not limited to, the outlet shroud and access door206.

Once installed, a user may access the interior of the storage container100or bin by pivoting or rotating the lid124about its hinge194from the closed position (FIG. 2) to the open position (FIG. 4). If a lock assembly is installed, the user may key open the lock prior to opening the lid124. Once the lid124is open, the user may access the interior to store or retrieve items, and then subsequently close the lid124.

Advantageously, the storage container described herein is integrated into the truck bed, but does not significantly impact the available space in the truck bed, and in particular the space between the truck wheel wells106. As a result, for example, standard sheets of plywood will still fit flat between wheel wells. Moreover, the storage container is easy to install and remove, and does not require damage to the truck bed as a drill is not required for installation. The storage container is also water tight, protecting the contents from the environment and allowing users to use the container like a cooler. The storage container may include lenses and/or lighting, increasing visibility within the container. The storage container is also adaptable for use with a vehicle on which it is installed, accommodating vehicle lighting and power outlet(s), and providing programmable locks to match the vehicle key.

It should be noted that references to relative positions (e.g., “top” and “bottom”) in this description are merely used to identify various elements as are oriented in the Figures. It should be recognized that the orientation of particular components may vary greatly depending on the application in which they are used.

It is also important to note that the construction and arrangement of the system, methods, and devices as shown in the various examples of embodiments is illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements show as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, particularly to accommodate the manufactured dimensions of any past or future marketed truck bed, the nature or number of adjustment positions provided between the elements may be varied (e.g. by variations in the number of engagement slots or size of the engagement slots or type of engagement). The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the various examples of embodiments without departing from the spirit or scope of the present inventions.

While this invention has been described in conjunction with the examples of embodiments outlined above, various alternatives, modifications, variations, improvements and/or substantial equivalents, whether known or that are or may be presently foreseen, may become apparent to those having at least ordinary skill in the art. Accordingly, the examples of embodiments of the invention, as set forth above, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit or scope of the invention. Therefore, the invention is intended to embrace all known or earlier developed alternatives, modifications, variations, improvements and/or substantial equivalents.

The technical effects and technical problems in the specification are exemplary and are not limiting. It should be noted that the embodiments described in the specification may have other technical effects and can solve other technical problems.