Utility vehicle tray deck surface apparatus, system, and method

Apparatus for a tray deck for providing a selectable appearance outer surface for at least one component of the tray deck, the apparatus including for the at least one component a component substrate (902) including a plurality of connectors (907, 908, 909, 910, 911, 912, 913, and 914) for accepting a plurality of complementary connectors (922, 924, 926) on a panel (900) having a selected appearance for connection to the component substrate, wherein the panel, when connected to the component substrate, comprises at least part of the surface presenting outwardly of the tray deck, wherein each of the plurality of connectors on the component substrate includes an elongate protrusion (907, 909, 911) depending outwardly from the component substrate and along an edge of the elongate protrusion distal from the component substrate each connector including an elongate grooved connector (908, 910, 912), the elongate grooved connector configured to accept a complementary elongate projection (922, 924, 926) of the panel.

BACKGROUND

The present invention relates to decks and tray decks for vehicles, and particularly relates to decks and tray decks for utility type vehicles.

Utility vehicles, sometimes referred to as utes, pick-ups or pick-up trucks, typically are equipped with a tray or tray deck at the rear of the vehicle, which serves to carry loads of various types. The loads may include equipment, sand, gravel and various other kinds of items and materials.

Some utility vehicles have a flat area, which may be referred to as a tray, a cargo bed or a deck. Other utility vehicles have a flat area which is surrounded by up to four sides to form a container, which may also be referred to variously as a tray or a cargo bed. The sides may be fixed or moveable, and may be a combination of fixed and moveable sides. Sometimes the side at the back is referred to as a tail gate.

In this specification, for consistency and ease of understanding, the vehicle will be referred to as a utility or utility vehicle; the flat area will be referred to as a deck; each of the sides will be referred to as side gates (front, rear, left and right); and the deck and side gates together (whether there be one, two, three or four side gates) will be referred to as a tray deck.

In some utility vehicles, the sides of the tray deck are fixed in position, the deck and sides forming what is sometimes referred to as a tub. In other utility vehicles, one or more of the sides are moveable between open and closed configurations. In this specification, unless otherwise indicated, the term side gate will refer to a side of a tray deck, wherein the side gate is moveable at least between open and closed positions. Some utility vehicles have side gates which are detachable. Typically, if a utility vehicle tray deck has a front side (usually adjacent a cab of the utility vehicle), the front side is in a fixed position, and in this specification the front side may be referred to as a fixed side or also referred to as a side gate, though it will be understood that the front side is typically in a fixed position.

Typically, a deck or tray deck will be provided with a utility vehicle when sold to a customer. The type of tray deck is either dictated by the model of the vehicle or there may be a very limited range of options available from which a customer can select.

It is also possible to buy utility vehicles without a deck or tray deck fitted, and the customer can select a deck or tray deck for their vehicle after purchase, but the customer will have a very limited range of options for a deck or tray deck.

Further, decks and tray decks are typically manufactured or supplied as a single unit, and can be fitted only to one vehicle model or a very limited range of vehicle models. Such units are bulky, which causes them to be inconvenient and expensive to transport, for example, form a place of manufacture to a place where the deck or tray deck is to be fitted to a utility vehicle.

Many decks and tray decks are not configurable or may have very limited options for configuration. A customer may want to include various features to make a deck or tray deck more suitable for that customer's intended use of the utility vehicle.

Decks and tray decks typically have a very square appearance, being manufactured for industrial purposes and for fitting to a range of vehicles. More recently, shaped tray decks have become popular, where the surface, outer shell, or skin of the deck, the tray deck, the side gates, the deck sides, and other components having an outward facing part, is formed to have a shape, often similar in styling with the vehicle on which the deck or tray is placed. However, due to the particular shapes of vehicle models, these decks or tray decks with shaped, surfaces, outer shells, or skins have been restricted to being appropriate only for one vehicle model or a small range of vehicle models with a shape and/or styling matching the shape and/or styling of the surface, outer shell, or skin of the deck or tray deck.

It is an object of the present invention to overcome, or at least ameliorate, at least one of the above-mentioned problems in the prior art, and/or to overcome, or at least ameliorate, at least one problem in the prior art, which has not been mentioned above and/or to provide at least a useful alternative to prior art devices, systems and/or methods.

SUMMARY OF THE INVENTION

1. In one aspect, the present invention provides apparatus for a tray deck for providing a selectable appearance outer surface for at least one component of the tray deck, the apparatus including:

for the at least one component:

a component substrate including a plurality of connectors for accepting a plurality of complementary connectors on a panel having a selected appearance for connection to the component substrate, wherein the panel, when connected to the component substrate, comprises at least part of the surface presenting outwardly of the tray deck, wherein each of the plurality of connectors on the component substrate includes an elongate protrusion depending outwardly from the component substrate and along an edge of the elongate protrusion distal from the component substrate each connector including an elongate grooved connector, the elongate grooved connector configured to accept a complementary elongate projection of the panel.

In another aspect, the present invention provides a system for a tray deck for providing a selectable appearance outer surface for at least one component of the tray deck, the system including:

for the at least one component:

a component substrate including a plurality of connectors for accepting a plurality of complementary connectors on a panel having a selected appearance for connection to the component substrate, wherein the panel, when connected to the component substrate, comprises at least part of the surface presenting outwardly of the tray deck, wherein each of the plurality of connectors on the component substrate includes an elongate protrusion depending outwardly from the component substrate and along an edge of the elongate protrusion distal from the component substrate each connector including an elongate grooved connector, the elongate grooved connector configured to accept a complementary elongate projection of the panel; and

the panel.

In another aspect, the present invention provides a method for a tray deck for providing a selectable appearance outer surface for at least one component of the tray deck, the method including:

providing an at least one component of the tray deck including a component substrate including a plurality of connectors for accepting a plurality of complementary connectors on a panel having a selected appearance for connection to the component substrate, wherein the panel, when connected to the component substrate, comprises at least part of the surface presenting outwardly of the tray deck, wherein each of the plurality of connectors on the component substrate includes an elongate protrusion depending outwardly from the component substrate and along an edge of the elongate protrusion distal from the component substrate each connector including an elongate grooved connector, the elongate grooved connector configured to accept a complementary elongate projection of the panel; and,

providing a panel, the method further including:

connecting the panel with the component substrate using the plurality of connectors of the component substrate and the plurality of complementary connectors on the panel.

SUMMARY OF SOME OPTIONAL EMBODIMENTS OF THE INVENTION

In embodiments, the at least one component includes any one or more of a side gate, a deck side, a side gate corner, a deck corner, and a wheel arch. In some embodiments, the at least one component includes multiples of the side gate, the deck side, a side gate corner, a deck corner, and the wheel arch.

In embodiments, the means for accepting of the component substrate includes an at least one ridge on the component substrate operable with an at least one corresponding channel of the panel, wherein the channel is configured for a force fit on the ridge. Alternatively, the means for accepting of the component substrate includes an at least one channel on the component substrate operable with an at least one corresponding ridge of the panel, wherein the channel is configured for a force fit on the ridge.

In further embodiments, the means for accepting of the component substrate includes an at least one ridge and an at least one channel on the component substrate operable, respectively, with an at least one corresponding channel of the panel and an at least one corresponding ridge of the panel, wherein the channel is configured for a force fit on the ridge.

In other embodiments, the means for accepting of the component substrate includes one or more clips, operable to clip and hold the panel to the component substrate. In other embodiments, the means for accepting of the component substrate includes threaded or threadable bores for accepting threaded fasteners, such as screws and bolts.

In yet other embodiments, the means for accepting of the component substrate includes an at least one channel on the component substrate, operable to accept an edge of the panel, such that the panel can be bonded to the component substrate. In some such embodiments, the bonding may be by adhesive. In other such embodiments, the bonding may be by welding.

In various embodiments, the apparatus, system and method, is adapted so that the panel can be disconnected from the component substrate. This may be useful for selectively changing the appearance of the outer surface of a vehicle, or may be useful to replace panels which have been damaged, for example, in and automotive accident.

It will be appreciated that there many means and methods for connecting a panel with a corresponding component substrate. It will also be appreciated that panels may have a range of different shapes, some to be suitable, for example, for blending the appearance of a utility vehicle tray deck with the utility vehicle cab, some may be suitable for providing a chosen fancy appearance, which may juxtapose with the appearance of a vehicle's styling.

DETAILED DESCRIPTION OF SOME EMBODIMENTS

FIG. 1shows a tray deck100of a utility vehicle, the tray deck including side gates on the deck, a left side gate102, a rear side gate104, right side gate106and a front side gate120. The left and right sides being defined from a rear perspective of the tray deck. Each side gate includes a side gate substrate, with the left side gate component114, the rear side gate component116, and the right side gate component118. The side gates are shown without panels, and so, in this embodiment, the depicted side gate components are shown a single skin, comprising the internal skin (or internal surface) of each side gate when a panel is attached thereto. The side gate components are depicted as having a plain exterior surface, but the side gate substrates may have shape details, such as the reverse side of channels, which are open to the interior of the tray deck when the side gates are closed. Such shape details of the side gate substrates have been omitted fromFIG. 1and others of the Figures for simplicity.

Front side gate120does not comprise a side gate component (or a panel connected thereto) as it is not visible as an outside surface when the tray deck is mounted to a utility vehicle.

The tray deck also includes various components which, in this depicted embodiment, do not make use of the invention, including the deck sides (rear deck side112and right deck side110), the side gate corners122,124, and126(the fourth deck corner not shown inFIG. 1), and the wheel arch108. It will be appreciated that, in other example application of embodiments of the invention, any one or more of those components could have the invention applied (see, for example,FIGS. 9, 10 and 11which depict panels applied to deck sides).

FIG. 2shows panels which are to be fitted to the side gate components to form an outer skin of the side decks. Panel200corresponds with right side gate component118, panel202corresponds with rear side gate component116, and panel204corresponds with left side gate component114.

Each panel200,202, and204has a design which suitable for its corresponding side gate. In this embodiment, the designs for each panel are different for each side gate. It will be appreciated that the panels may have a variety of designs, including a variety of shapes, a variety of colours, and a variety of patterns. The design of a panel may be decided by a manufacturer, for example, to accord with other design elements in a vehicle, or can be chosen by a customer when buying a vehicle. Further, in some embodiments, the panels may be detachable so that a different panel can be chosen according to the taste of the owner of a vehicle.

FIG. 3shows panels200and202connected, respectively, to right side gate component118and rear side gate component116. As depicted the side gate components118and116cannot be seen. The panel204is connected to left side gate component114, but that panel cannot be seen inFIG. 3.

The panels and side gate components, when connected together form double skin side gates, wherein the side gate components comprise internal surfaces (or skins), facing inwardly towards the tub of the tray deck100, and the panel comprise external surface (or skins), facing outwardly from the tub of the tray deck.

FIG. 4shows panels with a different design from that shown inFIGS. 2 and 3, the left side panel404to be connected (or fitted) to left side gate component114to form the double-skinned left side gate102, the rear side gate panel402to be connected (or fitted) to rear side gate component116to form the double-skinned rear side gate104, and the right side panel400to be connected (or fitted) to right side gate component118to form the double-skinned right side gate106.

InFIG. 4, each panel400,402,404has a same or similar design with an annular ellipse protruding from the surface of each panel.

FIG. 5shows a close up of around the corner122of the tray deck100, with panels400and402, respectively, connected to their corresponding side gate components.

FIG. 6shows a close up of around the corner122of the tray deck100, with a panel602connected to the rear side gate component116(not shown), and with a panel600disconnected from (or not yet connected to) right side gate component118. An embodiment of a means for accepting the panel600is shown on the right side gate component with top ridge604along the top edge of the right side gate component (or comprising the top edge of the right side gate component), and bottom ridge606protruding upwardly from the bottom edge of right side gate component118. The top ridge604is configured to accept a channel (or fold)608along the top edge of panel600, and the bottom ridge is configured to accept a channel610along the bottom edge of panel600. When fitting the panel600to the gate component substrate, the ridges604,606and channels608and610connect using a force fit allowed for by the configuration of the ridges and channels.

FIG. 7shows a different example of a panel706disconnected from (or not yet connected to) a side gate substrate700. The side gate substrate includes top ridge702, and bottom ridge704, respectively, to accept channel708and channel710. A further detail of the means of connecting the side gate component and the panel can be seen with a further ridge712protruding downwardly from the top ridge702, and a lip714protruding from a lower part of the panel channel708, towards the side gate component (when fitted).FIG. 8shows panel706connected to side gate component700.

FIG. 9shows another embodiment where the means of connecting a panel to a component substrate is different from that shown inFIGS. 6, 7, and 8. Further,FIG. 9shows both a side gate component902and a deck side component940can have panels connected thereto.

The side gate component substrate902depicted inFIG. 9includes various connection pints between the substrate902and the panel900to be fitted thereto. The substrate includes a top lip formed from the bottom side of channel906, a first elongate protrusion907depending outwardly from the substantially planar internal face of the side gate component substrate902, a second elongate protrusion909depending outwardly from the substantially planar internal face of the side gate component substrate902, a third elongate protrusion911depending outwardly from the substantially planar internal face of the side gate component substrate902, and a fourth elongate protrusion913depending upwardly from a lower portion of the substantially planar internal face of the side gate component substrate902.

InFIG. 9, each of the first907, second909, third911, and fourth913elongate protrusions include an elongate grooved connector along their respective protrusion on an edge of the protrusion distal from the side gate component substrate, wherein each grooved connector projects outwardly away from the substantially planar internal face of the side gate component substrate902. The first elongate protrusion907includes first elongate grooved connector908, the second elongate protrusion909includes second elongate grooved connector910, the third elongate protrusion911includes third elongate grooved connector912, and the fourth elongate protrusion913includes fourth elongate grooved connector914.

The panel900depicted inFIG. 9includes elongate projections, each configured to fit, respectively, into a corresponding elongate grooved connector on the side gate component substrate902. A first elongate projection922fits into first elongate grooved connector908, a second elongate projection924fits into second elongate grooved connector910, a third elongate projection926fits into third elongate grooved connector912, and a fourth elongate projection928fits into fourth elongate grooved connector914.

In various embodiments, the elongate projections922,924,926, and928fit snugly into respective elongate grooved connectors908,910,912, and914. The fit may be a force fit or a friction fit to securely hold the panel900to the side gate component substrate902, but which may allow the panel and substrate to be later separated for repair or replacement of the panel for aesthetic purposes. In other embodiments, the elongate projections922,924,926, and928may be secured into respective elongate grooved connectors908,910,912, and914by use of an adhesive for a more permanent connection between the substrate and the panel. Other securing means, such as rivets, screws, nuts and bolts, may also be used to attach the panel900to the side gate component substrate902.

The panel900also has a top lip920, which is configured to abut against the top lip formed from the bottom side of channel906on the substrate902.

In some embodiments, the channel906extends around the top of the side gates on a utility vehicle tray deck to allow for an edge of a tarpaulin to be force or friction fitted into the channel. The tarpaulin edge may include a rubber or plastic tube which is adapted to deform under sufficient force, so as to provide a more secure force fit for the tarpaulin edge into the channel906.

Also shown inFIG. 9is a substantially cylindrical bore980towards the bottom of side gate component902. The bore980may be adapted for accepting a complementary protrusion to provide a hinged connection between the side gate component902and a tray of a utility vehicle.

Further shown inFIG. 9is a top strip904which connects to the top of the side gate component902, and which may provide a more aesthetically pleasing appearance to the side gate. The top strip904may also provide a protective surface for the side gate component, and which can be replaced if damaged at a far lesser cost than replacing or refurbishing the side gate component.

In the embodiment shown inFIG. 9, the deck side also uses the panel invention. The deck side has a deck side component substrate940including a square channel942for securing the deck (not shown inFIG. 9) of the utility vehicle. In some embodiments, the deck may comprise a plurality of connectable planks, the ends of which slide into the square channel942. The deck side component substrate940also includes an apron944(sometimes referred to as coaming) depending from the upper portion of the deck side component940, and to which the deck side panel960attaches.

The apron944includes elongate grooved connectors946,948, and950, and the deck side panel includes complementary respective elongate projections962,964, and966. Like the side gate component substrate902and the side gate panel900, the grooved connectors and the elongate projections for the deck side may be connected together using friction or force fit, by use of adhesives and may also include various other securing means, such as rivets, screws, nuts and bolts.

FIG. 10shows the connection between the side gate panel900and the side gate component substrate902via the elongate grooved connectors908,910,912, and914and the complementary elongate projections922,924,926, and928.FIG. 10also shows the connection between the deck side panel960and the deck side component substrate940via elongate grooved connectors946,948, and950and complementary respective elongate projections962,964, and966.

FIG. 11shows the features ofFIGS. 9 and 10from an exploded end cross-sectional view, where the panels900,960are shown separated from their respective substrates902,940to more easily see some of the details of those features.

Also depicted inFIG. 11is how the top strip904connects to the top of the side gate component902via a clipping means providing a force or friction fit. The side gate component substrate902includes outwardly projecting flanges934and936, which engage inwardly projecting flanges930and932located in the hollow of the top strip904.

It can also be seen inFIG. 11that the side gate component substrate includes channels970and972formed in the side gate, which are useful for clipping and holding various items to the side gates of the utility vehicle tray deck.

The side gate component substrate902also has a rubber strip982which softens the contact between the side gate and the upper edge of the deck side component940, against which the side gate rests when closed.

It will be appreciated that there are many other means of connecting a panel to a side gate component, just as there are many ways to connect a panel with any component to which the present invention is applied.