Foldable extension deck and ramp assembly for pickup truck

The foldable truck bed extension deck and ramp assembly are mountable in a short-box pickup truck. The bed extension deck and ramp assembly have a comparable length to a full-size pickup truck box when deployed for use, and are jointly foldable to fit into a short-bed pickup truck with its tailgate closed when not used. The bed extension deck has a strong upper surface to resist deformation in rough use. The ramp member can be deployed with its front end matching the surface of the extension deck so that a vehicle can be driven along the ramp member and onto the deck surface without encountering any transition step.

FIELD OF THE PRESENT INVENTION

The present invention pertains to the field of truck ramps stowed inside truck-bed liners, and more particularly, it pertains to foldable bed extension deck and ramp assemblies for use in short-box pickup trucks.

BACKGROUND OF THE PRESENT INVENTION

Modern pickup trucks have extended cabs capable of sitting five passengers comfortably. The boxes of these modern pickup trucks have a length of 6 ft.-6 in., basically. These short boxes cannot transport trail-type or mountain-type snowmobiles with lengths of 11 and 13 feet respectively, even with the tailgate in the open position. Similarly, lumber and other residential construction materials are sold in 8, 10 and 12 foot lengths. Transporting these materials in a short-box pickup truck can sometimes be a challenge. For these reasons, it is believed that modern short-box pickup trucks have created a market need for truck bed extension decks that can be used to transport material and equipment that is best transported in a conventional 8-foot truck box.

Conventional ramps for use with pickup trucks have a length of 8 feet. It is generally accepted that an 8-foot ramp provides an easy slope for loading a vehicle in the truck box. Short truck boxes are inherently associated with shorter ramps and a steeper climbing angle for loading sport or gardening equipment in the truck box. This inconvenience also points to a market need for truck bed extension decks that can be used to transport material and equipment that is best transported in a conventional 8-foot truck box.

In another aspect of truck bed liners, the most important factor in the design of a truck ramp and truck-bed liner or extension deck, is a weight-to-strength ratio of the deck itself. A truck owner does not want to carry extra weight in his truck and to spend unnecessary fuel. On the other hand, the buyer of a truck bed liner and ramp assembly wants this equipment to be strong, durable, usable and safe. In that point of view, a frame that is made of flat bars mounted on their edges offers the best weight-to-strength ratio, when compared to hollow structural tubing or structural angles of a same weight per foot for example. Despite this advantage, it is believed that a framing system made of flat bars in a truck bed liner has not been used in the past.

It is believed that a market need exists in the field of truck accessories for a foldable bed extension deck and ramp assembly having a good weight-to-strength ratio, and that can be mounted in a short-box pickup truck to provide the same advantages as those of a full size truck box, while preserving the integrity of the tailgate of the pickup truck.

SUMMARY OF THE PRESENT INVENTION

In the present invention, there is provided a foldable truck bed extension deck and ramp assembly that are mountable in a short-box pickup truck. The bed extension deck and ramp assembly according to the present invention have a comparable length to a full-size pickup truck box when deployed for use, and are jointly foldable for storage into a short-bed pickup truck with its tailgate closed.

In a first embodiment of the present invention, the bed extension deck and ramp assembly are foldable over a right angle to fit inside a short bed pickup truck with its tailgate closed. In a second embodiment of the present invention, the bed extension deck and ramp assembly are foldable over a straight angle to fit inside a short bed pickup truck with its tailgate closed, and so as to be completely concealed from view inside the truck box, such as under a tonneau cover for example, when not in use.

The bed extension deck and ramp member assembly also have other features that are advantageous to pickup truck owners. The bed extension deck has a strong upper surface to resist deformation in rough use. The ramp member can be deployed with its front end matching the height of the surface of extension deck so that a vehicle can be driven along the ramp member and onto the deck surface without encountering any transition step.

More specifically, in a first aspect of the present invention, there is provided a truck bed extension deck and a ramp member that is telescopically mounted inside the bed extension deck. The bed extension deck has a channel on each side thereof. The ramp member has two sides, a front end and a dolly mounted on each side, near the front end. Each of the dollies has a pair of closely spaced casters mounted thereon. Each of these dollies are guided for movement along a lower flange of one of the channels inside the bed extension deck. Each dolly also has an arm extending backward from the pair of casters. Each arm is pivoted to a respective side of the ramp member at a distance from the front end of the ramp member.

Each channel has a guide block mounted to a web thereof at a distance from the lower flange at the rear end thereof. At the rear end of its travel, each dolly is movable to precisely fit between the guide block and the lower flange of the channel. In this position, each dolly is held firmly between the guide block and the lower flange of the channel when upward or downward forces are applied to the arms of the dolly.

Because the ramp member is pivoted to the arms of the dollies, at a distance from the front end thereof, the front end of the ramp member, in use, extends higher than the dollies to match the level of the floor surface on the bed extension deck. Equipment may be rolled onto the ramp member and deck surface without encountering a transition step at the rear edge of the bed extension deck.

In a second aspect of the present invention, there is provided a truck bed extension deck and a ramp member telescopically mounted inside the bed extension deck. The bed extension deck has a top plate; a channel on each side thereof and a structural frame system extending between the channels and the top plate.

The structural frame system comprises transverse flat bars extending across the channels and longitudinal flat bars extending across the transverse flat bars. The structural frame system also comprises angle joiners and fasteners retaining each end of one of the longitudinal flat bars to one of the transverse flat bars; and angle clips affixed exclusively to the longitudinal flat bars and the top plate for retaining the top plate to the structural frame.

The transverse flat bars are held against canting by the longitudinal flat bars. A deformation or sagging in the top plate is not transmitted to the transverse flat bars, and does not reduce the tensile strength of these transverse flat bars.

In a third aspect of the present invention, there is provided a truck bed extension deck having a ramp member telescopically mounted inside the bed extension deck. The bed extension deck has a front segment and a rear segment. The rear segment is joined to the front segment by a first hinge such that the rear segment is foldable upwardly relative to the front segment.

Similarly, the ramp member has a front portion and a rear portion. The rear portion is joined to the front portion by a second hinge such that the rear portion is foldable upwardly relative to the front portion.

The ramp member also has a pair of lock bars movably mounted thereto, extending in the ramp end section and in the end of the ramp member, such as dead bolts, for preventing a folding movement of the ramp end section relative to the ramp member.

In yet another characteristic, a bar locking mechanism including a handle are included on the ramp end section for locking a position of the lock bars when the ramp assembly is in use.

DETAILED DESCRIPTION OF THE FIRST AND SECOND PREFERRED EMBODIMENTS

There are two preferred embodiments of the present invention presented herein. The first and second preferred embodiments of the bed extension deck and ramp assembly according to the present invention are described herein below with reference to the attached drawings.

Referring firstly toFIG. 1, a modern short-box pickup truck20is illustrated therein as a reference, to better understand the foldable bed extension deck and ramp assembly according to the first preferred embodiment of the present invention.

This short-box pickup truck20has the preferred bed extension deck mounted therein in a folded mode, such that the tailgate of the short-box truck can be closed. The foldable segment22′ of the bed extension deck is visible inFIG. 1. As it will be understood, the first preferred bed extension deck has a length of slightly under 6 feet in a folded mode, and a total length of about 8 feet when extended over the tailgate of the truck in a deployed mode. For clarity, only the box portion24of that pickup truck20is illustrated in subsequent drawings included herein.

Referring toFIG. 2, the bed extension deck22is preferably fastened to the floor of the box24of the pickup truck by brackets26bolted to the front end of the deck22. The floor28of the truck box22is shown in cross-section shading inFIG. 2. Also inFIG. 2, it can be appreciated that the ramp member32is telescopically mountable into the bed extension deck22. In this illustration, the ramp member32is shown in an extended, deployed mode. Although the box24is a short box, the ramp member32has a length of about 8 feet or more in a deployed mode.

As it will be better explained later, the bed extension deck22has a piano-type hinge34thereon retaining a foldable rear segment22′ to a fix front segment22. Similarly, the ramp member32has a piano-type hinge36thereon retaining a foldable rear portion32′ to a front portion32. The foldable rear segment22′ and portion32′ have a respective length of 2 feet or more.

InFIGS. 3 and 4, it can be seen that a pair of latches38are used to stiffen the ramp member32in use. The latches38are mounted to both portions32′ and32to prevent folding of these portions about the hinge36in use. The capacity of each latch38is preferably one ton or more.

The ramp member32has a shoulder40along both side edges thereof. These shoulders40are used for enclosing the latches38within the width of the ramp member and serve as guides for guiding the ramp member32inside the bed extension deck22. The ramp member32also has a pair of handles42, or handle-openings as illustrated, on its rear end to push and pull the ramp member32in and out from the bed extension deck22by hand.

Referring now toFIGS. 5 and 6, the structural frame system of the bed extension deck22will be explained. The bed extension deck22has two structural channels50forming its sides; a first metal plate52on top, and optionally a second metal plate54closing the bottom of the bed extension deck. The preferred channels50are nominal 6 inch channels with 2 inch flanges.

A front vertical guard plate56is preferably provided along the front end of the deck22to protect the front end of the truck box against damage from equipment loaded on the deck22. The foldable segment22′ of the extension deck22is separated from the front segment22along cut line58. As it will be understood, the top and bottom plates52,54and the structural, frame system60are also separable at line58.

Below the top plate52, there is provided an array of flat bars mounted on edge and jointly forming the structural frame system60of the bed extension deck22. The structural frame system60is made of transverse flat bars62, which extend the full width of the bed extension deck22, between the channels50. These transverse flat bars62are spaced apart about 16 to 24 inches.

The transverse flat bars62provide substantially the entire structural strength of the bed extension deck22to prevent a transverse deflection of the deck22. A series of longitudinal flat bars64are mounted between the transverse flat bars62, also at spacings of about 16 to 24 inches. The longitudinal flat bars64are precisely cut at a right angle, and are precisely fitted between the transverse flat bars62. The longitudinal flat bars64are held to the transverse flat bars62by means of angle joiners66and rivets68. The preferred flat bar dimensions for both the longitudinal flat bars64and the traverse flat bars62are 2.5 inch high by ¼ inch thick. The preferred angle size for the angle joiners66is 2.5 inch by 2.5 inch by ¼ inch thick. The preferred material of construction of all structural members, sheets and top plate of the bed extension deck and ramp assembly is aluminum.

It will be appreciated that the longitudinal flat bars64and angle joiners66prevent the transverse flat bars62from canting under load, thereby maintaining their full strength despite sagging of the top plate52.

Another important feature in the preferred bed extension deck22is that the top plate52is fastened to the array of flat bars60by means of rivets (not shown) and angle clips70that are affixed exclusively to the longitudinal flat bars64. The reason for the mounting of the angle clips70to the longitudinal flat bars64is to further prevent the canting of the transverse flat bars62when the top plate52is sagging under load.

Although the structural frame system60of the bed extension deck22has been described herein, the structure of the ramp member32is built in a similar manner as the bed extension deck22and therefore, the advantages described herein-above also apply to the ramp member32.

The forward end of the ramp member32has a dolly80mounted to each side thereof; only one side is visible inFIGS. 7 and 8. Although only one dolly is visible, it is believed that the person skilled in the art will understand the structure, mounting and operation of these dollies from the following description.

The views inFIGS. 7 and 8is a longitudinal cross-section view through the flanges of the near side channel50. The dollies80are rolling along the bottom flanges of these channels50and are guided sideways against the web of these channels.

For reference purposes, the frame portion60of the bed extension deck22is represented by the dimension ‘A’ and the ramp storage compartment under the frame portion, is represented by dimension ‘B’ as seen inFIG. 8.

The front end of the ramp member32has two arms82pivoted to a respective side thereof. These arms82are part of the dollies80mentioned before. These arms82are made of structural angles for example. Each arm82extends forward inside the rear end of the bed extension deck22, into the ramp storage compartment ‘B’. Each arm82has a pair of closely-spaced in-line casters84mounted to its forward end, and a cap plate86extending above the casters84. The casters84have a larger diameter than a height of the structural angle of the arms82. The casters84on one arm82are aligned with the lower flange88of a respective structural channel50enclosing a respective side of the bed extension deck22. The dollies80guide the ramp member inside the bed extension deck22, and for support the front end of the ramp member32inside the bed extension deck22.

There are provided inside the side channels50, a pair of horizontal guide blocks90affixed to the web of the channels50at the rear end of the channels. These horizontal guide blocks90are mounted in a parallel relationship with the lower flange88of a respective channel50. The clearance between these horizontal guide blocks90and the lower flanges88of the channel50is basically the same as a distance between the lower segment of the casters84and the cap plate86of each arm82plus a free sliding fit. Each dolly80is thereby movable in a precisely fitted manner inside a gap between a respective guide block90and a flange88, at the end of its rearward travel.

A stopper block92is mounted vertically to the web of each of the side channels50at the rear end of the ramp storage compartment ‘B’. These stopper blocks92are used to prevent the dollies82from sliding out of the ramp storage compartment ‘B’. In use, the cap plate86and/or the rear caster84of a dolly abuts against a stopper blocks92on the rear end of the channels50so as to retain both dollies80captive inside the bed extension deck22.

The guide block90and the stopper block92shown inFIGS. 7 and 8are those mounted to the far side channel50, while the casters84are those facing the near side channel50, on the near side dolly80. The drawing has been prepared in this manner for convenience to better explain the operation of the dollies80.

It will be understood that when the ramp24is fully deployed, each dolly80is held fix between the lower flange88, the stopper block92and the guide block90, with the arms82extending rigidly, parallel with the floor of the bed extension deck22. A cross-member (not shown) may be provided across the bed extension deck22between the dollies80to add stability to these dollies30.

Because of the arm82extending rigidly rearward on each dolly80, the ramp member32is pivoted at a distance from its front end. When the ramp member is lowered to the ground, as illustrated inFIGS. 2 and 7, the front end of the ramp member32extends higher than the arms82to reach a same height ‘H’ as the floor surface52of the bed extension deck22.

The pivot points94on the arms82and ramp member32can be relocated to other pivot holes96along the sides of the ramp member32to accommodate different heights of pickup truck bed, so that the ramp's front end, in use, is of a same height ‘H’ as the floor surface of the bed extension deck22. This feature is advantageous for driving a vehicle over the ramp member32and the bed extension deck22without encountering a transition step at the intersection of both elements.

Because each dolly80has closely spaced casters84, the arms82of these dollies80are stable and rigidly held to resist downward forces when the ramp is used normally. The arms82of these dollies80are also stable and rigidly held to resist upward forces when a vehicle climbs the ramp with substantial momentum. For reference purposes, the spacing between the casters84is about 1.5 to twice the diameter of one caster.

For reference purposes, the bed extension deck22may have overall dimensions of 48 inch wide by 96 inch long when unfolded. The ramp member32with its dollies may have dimensions of 47-¾ inch wide by 95-½ inch long. The deployed ramp member32has a slope of about 23 degrees, when used on horizontal grounds.

Referring now toFIGS. 9 and 10, the folding of the bed extension deck will be described. As mentioned before, the preferred bed extension deck22has a separation58therein and a foldable rear portion22′. The rear portion22′ is foldable on the piano-type hinge34from a flat position over the tailgate98, to a vertical position inside the tailgate98of a short box pickup truck.

When the foldable segment22′ of the bed extension deck22is in a flat position as shown inFIG. 9, the space available over the deck22is substantially the same as inside a full-length box of a conventional pickup truck. The truck can be used with the tailgate98open to carry common building materials and other equipment that is best transported in a conventional pickup truck.

When the foldable segment22′ of the bed extension deck is in a folded position as shown inFIG. 10, the bed extension deck22and ramp member32do not prevent the tailgate98of a short box pickup truck from being closed as if nothing was mounted in the truck box24.

Referring toFIGS. 11 and 12, cross-section views of the bed extension deck22during folding are illustrated. Firstly, the latches38on both sides of the ramp member32are unlocked and tucked under the shoulders40along the edges of the ramp member32before the ramp member32is inserted fully inside the storage compartment ‘B’ of the extension deck22.

The ramp member32is stowed inside the storage compartment ‘B’ so that the second hinge36is vertically inline or slightly rearward relative to the first hinge34as illustrated inFIG. 11.

The tilting upward of the foldable segment22′ of the bed extension deck causes the ramp member32to move backward, and causes the foldable ramp portion32′ to move forward and downward such that the second hinge36is automatically pulled forward or backward to lie in a position near to or on a median100of the angle of displacement ‘C’ of the foldable segment22′ of the bed extension deck.

The ramp storage compartment ‘B’ together with its channels50and the ramp's dollies80jointly constitute a guiding arrangement for maintaining the ramp member32in a parallel alignment with the bed extension deck. Because of this guiding arrangement, the ramp member is easily adjustable inside the storage compartment ‘B’ for maintaining the second hinge36in alignment with the median line100. The bed extension deck22with the ramp member32stowed therein are easily foldable by hand.

When the bed extension deck22is in its folded position, as shown inFIG. 12the tailgate98of the pickup truck can be closed to retain the bed extension deck22in that folded position. Springs and shock absorbers can also be used to assist in the working of the bed extension deck between a deployed and a folded positions.

When the bed extension deck is folded back to a flat alignment, the ramp member32returns to its initial position inside the storage compartment ‘B’, and can be withdrawn for normal use.

Although the bed extension deck22and ramp member32are described herein as accessories for a pickup, truck, it will be appreciated that this invention can also be used in other environments including loading docks, trailers, cargo vans, etc.

Referring now toFIGS. 13-19, the bed extension deck and ramp assembly according to the second preferred embodiment120of the present invention will be described. The distinguishing characteristics of the bed extension deck and ramp assembly according to the second preferred embodiment of the present invention is that the foldable deck extension22′ and the ramp end section124of the ramp assembly can be folded flat over the bed extension deck22in a stowed mode. The bed extension deck and ramp assembly according to the second preferred embodiment120can be completely concealed from view in a short box of a pickup truck with the tailgate closed, under a tonneau cover for example, when not in use.

The extension deck and ramp assembly according to the second preferred embodiment120has many similarities with the extension deck and ramp assembly according to the first preferred embodiment22,32. Therefore, the following description is limited to the distinguishing characteristics in the second preferred embodiment. For convenience, the labelling of the elements in both embodiments is the same as long as the function of the corresponding elements do not differ substantially from each other.

A first characteristic in the extension deck and ramp assembly according to the second preferred embodiment120is a pair of lock pin and button assemblies122mounted to the side of the foldable deck extension22′. When pushed in, the lock pins prevent the ramp dollies80from sliding inside the foldable deck extension22′. When pulled out, the lock pin and button assemblies122allows a free sliding of the dollies80and the ramp member32inside the bed extension deck22.

The extension deck and ramp assembly according to the second preferred embodiment120has a ramp end section124that is retained to the ramp member32by a link segment126. The stiffening of the link segment126relative to the end section124and the ramp member32is effected by a pair of lock bars130movably mounted inside a pair of channel link members132. The ramp end section124also has on each of its sides, a respective bar locking mechanism134for locking the lock bars130. A transverse handle136is mounted to the nose of the ramp end section124and is used for operating the mechanisms134. It will be appreciated that the bar locking mechanism134on one side of the ramp end section is a mirror image of the other mechanism on the other side, and therefore, only one side is illustrated. The handle136operates both mechanisms134simultaneously.

Referring particularly toFIGS. 13 and 14, the ramp end section124is connected to the ramp member32by the link segment126. This link segment126has a pair of piano hinges36mounted thereto, and a pair of channel-link members132. A pair of lock bars130slide fitly, such as deadbolts, from inside the ramp end section124, into a respective one of the channel-link members132, and in a respective “precise fit” pocket (not shown) inside the ramp member32. The lock bars130are preferably made of high-strength steel. When the lock bars130are extended such as illustrated inFIG. 14, the ramp end section124forms a rigid platform with the ramp member32.

It will be understood that the distance between both piano hinges36on the link segment126is substantially a same measurement as the thickness of the bed extension deck22, or slightly more such that the foldable deck extension22′ can be folded a straight angle flat over the bed extension deck22with the ramp member22inside.

Each lock bar130is slid in and out of the ramp end section124by way of a respective knob140guided along a slot142in a respective side wall of the ramp end section124. Each bar locking mechanism134has cams144,144′ and a link bar146to secure the knob140in one extremity of the slot142or the other, as can be seen inFIG. 14andFIG. 17. As can be appreciated from these illustrations, both bar locking mechanisms134are operated by moving the handle136upward or downward. Both knobs140and lock bars130are free to move along the slots142when the handle136is in the raised position as illustrated inFIG. 17. When the handle is in the down position, as seen inFIG. 14, the knobs140and the lock bars130are locked in place by either cams144,144′, at either ends of the slots142.

The stowing of the ramp member and the foldable deck extension in the bed extension deck and ramp assembly according to the second preferred embodiment120is effected as follows: Starting with a deployed ramp member32and ramp end section124, as illustrated inFIG. 13, the lock pins122are pulled out to unlock the ramp dollies80from the foldable deck extension22′. The ramp member32and ramp end section124are lifted up in a horizontal alignment as shown inFIG. 15. Then, the ramp dollies80and the ramp member32are slid inside the bed extension deck22, as illustrated inFIGS. 16 and 17. As this point, or during the lifting of the ramp assembly to a horizontal position, the handle136is moved into an upper position, unlocking the movement of the lock bars130as previously explained.

The movement of the ramp member32along the bed extension deck22brings each of the knobs140to register into a respective seat150on the end of the foldable deck extension22′, as can be seen inFIG. 17. A further movement of the end section124inside the foldable deck extension22′ causes the knobs140and the lock bars130to move inside the end section124, and to free up to movement of the hinges36on the link segment126, as can be appreciated by looking atFIG. 18andFIG. 19.

The deployment of the ramp member32and ramp end section124in the bed extension deck and ramp assembly according to the second preferred embodiment120is done by reversing the steps mentioned above. The moving of the knobs140and lock bars130is done manually, preferably before the ramp member32is moved out of the foldable deck extension22′. The handle136is then position downward in its “in-use” position, thereby locking the lock bars130in place.

It should be noted that the handle136constitutes a fence on the ramp end section124when it is in a raised position. Because of this fence, the ramp assembly22,124cannot be used when the handle136is not in a downward “bar locking position”.