Tonneau cover having secured flexible hinge

A tonneau cover apparatus for removable attachment to a cargo box of a pickup truck including a support frame assembly and a cover assembly. The cover assembly includes a plurality of pivotally interconnected rigid panels that can be folded up and secured to the cargo box such that respective upper surfaces of at least two of the plurality of rigid panels reside in an upright folded orientation. The tonneau cover apparatus further includes a mechanism for securing the at least two of the plurality of rigid panels in the upright folded orientation. A method of removably securing the tonneau cover apparatus to the pickup truck is also described, as is an alternate embodiment of the tonneau cover apparatus, wherein the cover assembly includes first and second pivotally interconnected rigid panels and a pair of hinge support mechanisms that generally restrict the way the second rigid panel pivots.

FIELD OF THE INVENTION

A tonneau cover apparatus for covering an open bed or cargo box of a pickup truck. The tonneau cover apparatus preferably including a folding cover assembly having a plurality of rigid panels that are interconnected in series by a series of hinges in such a manner that the respective panels can pivot with respect to one another, so as to fold up while the cover assembly is secured to a support frame assembly, when the support frame assembly is secured to the cargo box of the pickup truck. In preferred embodiments a plurality of the rigid panels can be secured in an upright folded orientation when the cover assembly is detachably secured to the pickup truck. Alternately, a tonneau cover apparatus is provided that preferably includes two rigid panels, a cab panel that can be secured to a support frame assembly that is secured to a cargo box of a pickup truck and a lift-up panel that is pivotally interconnected in series with the cab panel when the cab panel is secured to the support frame assembly. The lift-up panel is interconnected to the cab panel by a hinge, preferably a flexible hinge, and the cover assembly includes two hinge support mechanism, each having opposing first and second hinge brackets secured to a lower surface of the cab panel and the lift-up panel, respectively, in such a manner that the respective panels can pivot with respect to one another with the guidance of the opposing guide brackets. Methods of covering a cargo box of a pickup truck are also provided.

DESCRIPTION OF THE RELATED ART

Numerous protective cover assemblies for preventing rain, debris and wind from damaging or disrupting the contents of a pickup truck bed or cargo box are currently available. Among these protective cover assemblies are tonneau covers. Some tonneau covers are made of a fabric material, often a fabric coated with a polymeric material, which is fastened to a rigid frame so as to enclose and protect the pickup truck cargo box. Various covering materials are used for such tonneau covers; some are flexible and/or stretchable, and others are more rigid, and they are secured to the pickup truck in various manners to cover the cargo box. Tonneau covers are opened in various manners to allow entry into the cargo box, such as by rolling the cover up, folding the cover up, lifting a hard cover upward or pivoting the cover upward, or disconnecting and removing the cover from the cargo box altogether, in some cases after the cover assembly is folded up.

Typical tonneau covers have support frames including a pair of elongated side rails that are secured to the sidewalls of the cargo box of the pickup truck. Known tonneau covers are often secured to the side rails using hook and loop strip fastener components secured to the side rail, typically within a horizontal channel (see, e.g., U.S. Pat. Nos. 4,036,521; 4,991,640; 6,752,449 and U.S. Patent Application Pub. No. 2004/0212212 A1). Some tonneau covers are secured to the side rails by latches (see. e.g., U.S. Pat. No. 7,104,586). Some tonneau covers include rigid panels which are folded up for cargo access (see e.g., U.S. Pat. No. 10,189,340). While there are many, many tonneau covers, too many to review them all in this space, the present inventions provide improvements that address limitations associated with the prior art.

SUMMARY OF THE INVENTION

The present invention preferably includes a tonneau cover apparatus for removable attachment about a top of a perimeter of a cargo box of a pickup truck, the perimeter of the cargo box including a forward end, two opposing sidewalls and a tailgate, the tailgate being positioned rearward of the forward end and having an open position and a closed position. The tonneau cover apparatus preferably includes a support frame assembly for attachment to the cargo box; and a cover assembly for attachment to the support frame assembly when the support frame assembly is attached to the cargo box; the cover assembly preferably including a plurality of rigid panels. In preferred embodiments the cover assembly includes a flexible hinge; wherein the plurality of rigid panels, including first and second rigid panels which are pivotally secured to one another by a hinge, preferably the flexible hinge.

In a preferred embodiment, the cover assembly includes a plurality of rigid panels that are foldably interconnected with one another in series; wherein each of the respective rigid panels have an upper surface and a lower surface; and wherein the plurality of rigid panels include first and second rigid panels foldably secured to one another such that the cover assembly can be folded up when the cover assembly is secured to the support frame such that respective upper surfaces of at least two of the plurality of rigid panels reside in an upright folded orientation in which the upper surfaces of the at least two of the plurality of rigid panels reside in a generally parallel orientation to one another. The tonneau cover apparatus preferably further includes a mechanism for securing the respective upper surfaces of the at least two of the plurality of rigid panels in the upright folded orientation; said mechanism for securing including a bracket secured to a portion of the pickup truck, preferably a cab positioned forward of the cargo box and a securing member attached to the cover assembly, wherein the securing member can engage the bracket so as to secure the cover assembly to the cab when the at least two of the plurality of rigid panels reside in the upright folded orientation. In preferred embodiments, the securing member and the bracket are magnetically attracted to one another and the bracket will preferably contain a magnet. In further preferred embodiments, the securing member is made of steel and is magnetically attracted to the magnet contained in the bracket and the bracket is adhesively secured to the cab. The securing member is preferably an elongated rigid member that has first and second ends and the elongated rigid member is bent in such a way that first and second upper surfaces of the respective first and second ends of the elongated rigid member are oriented at an angle to one another of from about 1 degree to about 16 degrees.

A method of removably securing the tonneau cover apparatus to the pickup truck is also provided. The method preferably including the steps of providing a support frame assembly for attachment to the cargo box; a cover assembly for attachment to the support frame assembly when the support frame assembly is attached to the cargo box; the cover assembly including a plurality of rigid panels that are foldably interconnected with one another in series; wherein each of the respective rigid panels have an upper surface and a lower surface; and wherein the plurality of rigid panels include first and second rigid panels foldably secured to one another such that the cover assembly can be folded up when the cover assembly is secured to the support frame such that respective upper surfaces of at least two of the plurality of rigid panels reside in an upright folded orientation in which the upper surfaces of the at least two of the plurality of rigid panels reside in a generally parallel orientation to one another; and 3) a mechanism for securing the respective upper surfaces of at least two of the plurality of rigid panels in the upright folded orientation; said mechanism for securing including a bracket secured to a portion of the cab and a securing member attached to the cover assembly, wherein the securing member can engage the bracket when the bracket is secured to the cab so as to secure the cover assembly to the cab when the at least two of the plurality of rigid panels reside in the upright folded orientation; wherein the securing member and the bracket are magnetically attracted to one another; and securing the support frame to the pickup truck; securing the cover assembly to the support frame and the bracket to the cab; positioning the cover assembly so that the cover assembly is folded up when the cover assembly is secured to the support frame, such that respective upper surfaces of at least two of the plurality of rigid panels reside in an upright folded orientation; and engaging the securing member to the bracket so as to secure the cover assembly to the cab when the at least two of the plurality of rigid panels reside in the upright folded orientation.

In a further embodiment of the present invention, a tonneau cover apparatus is provided for removable attachment about a top of a perimeter of a cargo box of a pickup truck, the perimeter of a cargo box including a forward end, two opposing sidewalls and a tailgate; the tailgate being positioned rearward of the forward end and having an open position and a closed position. The tonneau cover apparatus preferably includes a support frame assembly for attachment to the cargo box; and a cover assembly for attachment to the support frame assembly when the support frame assembly is attached to the cargo box. The cover assembly preferably having a plurality of rigid panels including first and second rigid panels that are pivotally interconnected with one another by a hinge; wherein each of the respective rigid panels have an upper surface and a lower surface; and wherein the first rigid panel can be secured to the support frame assembly when the support frame assembly is secured to the pickup truck; wherein the cover assembly further includes a pair of hinge support mechanisms that generally restrict the way in which the second rigid panel pivots with respect to the first rigid panel; wherein each of the hinge support mechanisms include opposing first and second hinge support brackets secured to the lower surfaces of the first and second rigid panels, respectively, proximate the hinge so that the opposing first and second hinge support brackets of each of the respective hinge support mechanisms are slideably engaged with one another when the first and second rigid panels pivot with respect to one another. In preferred embodiments, each of the respective opposing hinge support brackets include a guide pin and an arcuate guide slot; and wherein, when the support frame assembly is attached to the cargo box, the cover assembly is attached to the support frame assembly, and the second rigid panel pivots with respect to the first rigid panel, the respective guide pins of each of the opposing hinge support brackets slide within the respective arcuate slots of the opposing hinge support brackets.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings, a folding tonneau cover apparatus510of the present invention is attachable to sidewalls6a,6bof a cargo box5, such as the cargo box of a truck or pickup truck2, which is shown in phantom. InFIG.1, the folding tonneau cover apparatus510is shown in a typical application covering the top opening6f(shown in phantom inFIG.12) of the cargo box5of the pickup truck2. The pickup truck2and the cargo box5and the sidewalls6aand6band the front wall6c(FIG.12) at the forward end of the cargo box5and the tailgate6dat the rear end of the cargo box5are not a part of the present invention, but are shown in phantom to illustrate a typical application and function of the folding tonneau cover apparatus510in covering a cargo box5, which has a length7aand a width7b. The perimeter of the cargo box5includes the forward end or front wall6c, the opposing sidewalls6aand6b, and the rearward end or tailgate6d, which is shown in part. The rearward end or tailgate6dpreferably can be opened or closed. It will be appreciated that the perimeter of the top opening of the cargo box5will include top surfaces of the front wall6c, the two sidewalls6a,6b, and the tailgate6dwhen the tailgate is in a closed position (not shown). As further illustrated inFIGS.2A-3B, the folding tonneau cover apparatus510includes a folding tonneau cover assembly, tonneau cover assembly or cover assembly530and a support frame assembly518, including side rails or rails520aand520b. In preferred embodiments, side rails520aand520bare secured to sidewalls6aand6bwith clamps514. In preferred embodiments, the folding cover assembly530is configured to be opened to an open position and closed to a closed position, and easily removed and reinstalled by a driver or other operator8(FIG.12), as needed. The side rails520aand520bare constructed and arranged to facilitate securement of the folding cover assembly530to the side rails520aand520b. In some embodiments, the side rails520aand520bhave a side rail lip524and a side rail engagement portion522a. In this example, there are eight clamps514arranged to hold the side rails520aand520bto the sidewalls6a,6bof the pickup truck2, but other numbers of clamps514can be used. In some embodiments, the clamps include an outer member516a, an inner member516b, a clamp engagement portion516c, and a fastener assembly516d; the fastener assembly can, for example, include a bolt516e, a washer516fand a nut516gas illustrated.

Referring again toFIGS.2A-2C, the folding tonneau cover apparatus510ofFIG.1is shown in whole or in part, but the truck2and the cargo box5are not shown.FIG.2Ashows a top view of the folding tonneau cover assembly530ofFIG.1. The top532aof the folding cover assembly530is shown. The folding cover assembly530includes rigid panels or panels536. In this example, panels536include a rear panel536a, a middle panel536b, a front panel536c, and a spacer panel or hinge panel536d. For ease of discussion, panels536are specifically referenced herein as536a-536d, and non-specifically or collectively referenced as rigid panels536. The folding cover assembly530includes a plurality of such rigid panels536, and could potentially have from two to 8 panels536; for example, 6 panels536could be used, including 4 “longer” panels (similar to panels536a-536cshown herein) and2“shorter” panels (similar to panels536dshown herein). While a smaller or a larger number of panels536can be used (not shown), the inventors have found that the configurations illustrated herein provide a good trade-off of convenient folded configuration vs. complexity.

As shown inFIG.2A, and also as further described herein with respect toFIGS.20A-20E, the length539of each of the panels536a-536dis indicated as539a-539d, respectively. In this example, the spacer panel536dhas a substantially smaller length539dthan the other panels, as will be further described herein. In preferred embodiments, the length539dof the spacer panel536dis preferably no greater than about one-third of the length539a-539cof the other panels536a-536c. Panels536a-536dcan have similar length539, or the length of some or all of panels536a-536dcan differ. The width540of each of the panels536a-536dis indicated as540a-540d, respectively. Panels536a-536dcan have the same width540, or the width of some or all of panels536a-536dcan differ. The side angle542of each of the panels536a-536dis indicated as542a-542d, respectively, inFIG.20A. Panels536a-536dcan have the same side angle542, or the side angle542of some or all of panels536a-536dcan differ. Alternative configurations of folding tonneau covers530appropriate for covering the cargo box5of various models of pickup truck2are further described below. Each panel536has a top surface537and a bottom surface or underside538; panel536ahas a top surface537aand a bottom surface or underside538a, panel536bhas a top surface537band a bottom surface or underside538b, panel536chas a top surface537cand a bottom surface or underside538c, panel536dhas a top surface537dand a bottom surface or underside538d.

As further described herein and illustrated in drawingFIGS.2A-5F, the present invention includes a folding tonneau cover assembly530having a plurality of rigid panels536arranged in a series, with adjacent rigid panels536secured to each other by a flexible hinge544, so that the folding cover tonneau cover assembly530can be unfolded to cover a top opening6f(FIG.12) of a cargo box5of a truck2, and folded up to uncover at least a portion of the top opening6fof the cargo box5of the truck2. Each rigid panel536has a front edge541band a rear edge541cand a driver's side edge541dand a passenger side edge541eand a top surface537and a bottom surface or underside538. When the folding tonneau cover assembly530is unfolded and arranged to cover the top opening6fof the cargo box5, each of the rigid panels536extends between the driver's side3aand the passenger side3bof the cargo box5, and each flexible hinge544extends between the driver's side and the passenger side of the cargo box. In embodiments having 4 rigid panels536, for example, there are 3 flexible hinges544, each flexible hinge544being secured to two adjacent rigid panels536. Other configurations are possible, including embodiments having two rigid panels536and one flexible hinge544, embodiments having three rigid panels536and two flexible hinges544, embodiments having five rigid panels536and four flexible hinges544, embodiments having six rigid panels536and five flexible hinges544, and so forth. In preferred embodiments, the number of rigid panels536is 1 greater than the number of flexible hinges544; alternative embodiments include folding tonneau cover assemblies530having at least three rigid panels536and at least one flexible hinge544, as described herein, and at least one other hinge or connection as may be known in the art (not shown) have been envisioned by the inventors. The present invention includes such embodiments, as long as the embodiments include at least one flexible hinge544as described herein.

Also illustrated inFIG.2A, is a protective film574on the top surface537cof the front panel536c. As described further herein and illustrated inFIGS.2A,9A,10A, and10B, alternate embodiments of the folding tonneau cover assembly530include the protective film574, which protects the top surface537cof the front panel536cwhen the folding tonneau cover assembly530is folded up and the standoffs558are in contact with the top surface537c. As described below, a protective pad558ais preferably attached to the bottom of each standoff558, but abrasion of the top surface537ccan occasionally occur when the protective pads558aare in direct contact with the top surface537c, especially when the pickup truck on which the folding cover assembly530resides is travelling on rough road surfaces that cause the protective pads558ato vibrate on the top surface537c. While the protective film574is optional to reduce or prevent such abrasion in some embodiments, they are not required. Such alternate embodiments of the present invention, which include the protective film574to minimize abrasive damage to the top surface537c, are disclosed herein. Protective film574can be obtained from a variety of suppliers, including Avery Dennison (Glendale, Calif.), 3M (St. Paul, Minn.), Arlon (Placentia, Calif.), and XpeI (San Antonio, Tex.). One preferred protective film574is Avery Dennison SW 900 Series Supreme Wrapping Film. The protective film574is preferably applied to specific locations on the top surface537cwhich will align with the standoffs558when the folding tonneau cover assembly530is folded up as shown and described herein. For example, for embodiments including 4 standoffs558, protective film can be applied to the top surface537cin the locations shown inFIG.2B. The protective film574is preferably located in locations on the top surface537cas schematically illustrated onFIG.2Athat correspond to the locations that the protective pads558aof the standoffs558will assume when they engage the top surface537cof the front panel536c, when the folding cover assembly530is in a fully folded up orientation.

FIG.2Bshows a bottom view of the folding tonneau cover apparatus510. Visible in this view are hinges or flexible hinges544, which are situated between adjacent panels536and adjoin adjacent panels536. For ease of discussion, hinges544are specifically referenced herein as544a-544c, and non-specifically or collectively referenced as544. Specifically, situated between the rear panel536aand the middle panel536bis hinge544a. Similarly, situated between the middle panel536band the spacer panel536dis hinge544b, and situated between the spacer panel536dand the front panel536cis hinge544c. Hinges544allow the folding cover assembly530to be folded up and will be more fully described below. Support bows550are attached to the panels536to provide additional support and rigidity to the panels536, and also provide a structure for mounting of various other components as described in detail later herein. For ease of discussion, support bows550are specifically referenced herein as550a-550g, and non-specifically or collectively referenced as550. The folding tonneau cover assembly530is removably secured to the support frame assembly518by securing apparatus551a. Preferably, securing apparatus551aincludes at least one locking member551bwhich is engageable and disengageable from the support frame assembly518. Preferably, the locking member551bincludes latches552which are located at the support bows as shown and secure the folding cover assembly530to the side rails520aand520b. Release cords554are attached to the latches552. For ease of discussion, latches552are specifically referenced herein as552a-552d, and non-specifically or collectively referenced as552. Also for ease of discussion, release cords554are specifically referenced herein as554a-554b, and non-specifically or collectively referenced as554. The release cords554pass through cord guides555which are attached to support bows550as shown. Cord guides555preferably include clip cord guides555aand retainer cord guides555b, which will be described in further detail below. Standoffs558are shown, and will be described in further detail below. Sidebars or handles559are attached to panels536a,536b, and536c, near each side of each panel536to further support the panels536. Perimeter seal534is located on the bottom532bof the folding cover assembly530and is arranged to seal against top of the perimeter of the cargo box5at the sidewalls6aand6band the front wall6cand the tailgate6dof the cargo box5as shown; some portions of perimeter seal534are behind side rails520aand520band not visibleFIG.2B. The perimeter seal534is further described herein.

The support bows or transverse frame members or channels550provide additional support for the panels536. In this embodiment, the panels each have two support bows550, one located near each of the front and rear ends of each panel536, except for the spacer panel536d, which has only a single support bow550. In this embodiment, there are latches552mounted in pairs, one of each pair mounted near each end of each of the support bows550aand550fas shown. As further described below, the latches552engage the side rails520aand520bto secure the folding cover assembly530, and can slide a short distance towards or away from the side rails520aand520bto engage or release the folding cover assembly530or portions thereof or selected panels536from the side rails520aand520bas further described below. Note that the support bows550b,550c,550d,550e, and550gdo not have associated latches552in this embodiment. In this embodiment, there are two latch release cords or release cords or cords554, each of which are connected to opposing pairs of latches552which secure the panels536to the side rails520aand520b. The release cords554preferably pass through cord guides555which are mounted to the support bows550; the release cords554can slide within or behind the cord guides555as further described herein. The release cords554generally extend from the latches552along the support bows550. As illustrated inFIGS.2B and2C, the clamps514secure the side rails520aand520bto the sidewalls6aand6bof the cargo box5. The folding tonneau cover apparatus510is seen in a side view from the driver's side inFIG.2C.

In further reference toFIGS.2C-2E, the portion of the folding tonneau cover apparatus510that includes the rear hinge544a, as indicated by the encircled area labeled2D inFIG.2C, is illustrated in an enlarged partial cutaway view inFIG.2D. Similarly, the portion of the folding tonneau cover apparatus510that includes the middle and front hinges544band544c, respectively, as indicated by the encircled area labeled2E inFIG.2C, is illustrated in an enlarged partial cutaway view inFIG.2E. The folding cover assembly530preferably includes extended hinge support flange(s)586located adjacent the bottom surface or underside538of the respective panel536and near the front and rear edges541band541c, respectively, of the rigid panels536to which the flexible hinges544are secured (for example,FIG.5A). As will be described in further detail below, the flexible hinges544each preferably includes a flexible hinge body545awhich includes a central portion546a, side portions546band546c, and intermediate portions546dand546e. Each side portion546band546cpreferably extends between the extended hinge support flange586and the rigid panel536. Adhesive570ais preferably located between each side portion546band the respective rigid panel536to protect against passage of debris or precipitation into the cargo box5; the adhesive570acan also aid in securement of the hinge body545ato the respective rigid panel536. The support bows or channels550are preferably secured to the bottom surface or underside538of the rigid panels536, near the front edge541band/or rear edge541cof the rigid panels536. Each support bow550that is adjacent a flexible hinge544preferably includes the extended hinge support flange586. Further details regarding the structure of the flexible hinge body545aand securement to the rigid panels536are described below.

The folding tonneau cover apparatus510preferably includes containment brackets525aand525b. The structure and function of the containment bracket525ais further illustrated inFIG.2F. Note that inFIG.2F, portions of the rigid panels536and the flexible hinges544are broken away to reveal the underlying structure, and many elements are illustrated in phantom to emphasize the elements being described. When the engaging portion553bis engaged under the side rail520aand is contained by the containment bracket or anchor socket525aas illustrated inFIG.2F, the engaging portion553bis contained by the containment bracket525aso that it cannot slide frontwards or rearwards along the side rail520a. The containment bracket525ais preferably secured to the side rail by a fastener assembly526, which may include a bolt, nut, washer, or other fasteners known in the art. In this configuration, the spring556is urging the latch slide553outwards towards the side rail520a. To release the latch552and allow the folding cover assembly530to be lifted off and removed from the side rail520, the release cord554eis pulled. When the release cord554ehas been pulled, retracting the latch slide553and compressing the spring556, and disengaging the engaging portion553bfrom the side rail520aand the containment bracket525a, and releasing the latch552, the configuration is as illustrated in phantom inFIG.2F. The side rail520bpreferably has a mirror-image configuration to the side rail520a, with a side rail front portion521cand side rail rear portion521d, and a containment bracket525bfunctioning in a similar manner.

Some embodiments include the alternative side rail520cwhich includes a plurality of sections521as illustrated inFIG.2G; the side rail520cpreferably includes side rail front portion521aand side rail rear portion521b. The containment bracket525ais preferably secured to the side rail520cby a fastener assembly526, which may include a bolt516e, nut516f, washer516g, or other fasteners known in the art. In these embodiments, in addition to its function to retain the latch552as previously described, the containment bracket525apreferably facilitates securement of the side rail front portion521aand side rail rear portion521btogether. One advantage of the “split” side rail520cis that storage and shipment of the side rail520can be more practical; a one-piece side rail would be long and in some cases could be more difficult or expensive to transport, for example. The side rail520dpreferably has a mirror-image configuration to the side rail520c, with a side rail front portion521cand side rail rear portion521d, and a containment bracket525bfunctioning in a similar manner as the similar elements just described. The alternative side rail520c, containment bracket525a, and fastener assembly526are illustrated in exploded view inFIG.2H. Preferably, a tether580is attached to the containment bracket525band is releasably secured by a link581when desired to a ring582that is secured to the support bow550e; this arrangement provides additional stabilization of the folding cover assembly530when the folding cover assembly530is secured to the side rails520a,520band will secure the folding cover assembly530to the side rail520if other attachments fail.

In describing preferred embodiments of the present invention in the description that follows, it will be appreciated that reference will be made either to the “driver's side” or “passenger side” or to the “front” or to the “rear” of the folding tonneau cover apparatus or portions thereof in a manner that is consistent with the orientation of the folding tonneau cover apparatus when it is secured to a vehicle as envisioned, so that the “rear” of a folding tonneau cover apparatus or portion thereof will be consistent with what is seen when one is looking at the rear of such a vehicle when the folding tonneau cover apparatus or portion(s) thereof are attached to such a vehicle as envisioned herein, or such portion thereof which is closer to the rear. The “driver's side” refers to the side corresponding to the side of the vehicle typically used by the driver to operate the vehicle in North America, and the “passenger side” refers to the side opposite the “driver's side”. For clarity, the “length” of the folding tonneau cover apparatus, the folding cover assembly, the hinges, and the panels described herein, refers to a measurement of the “front” to “rear” dimension, since the pickup truck and the cargo box are typically longer in that direction. Similarly, “width” of the folding tonneau cover apparatus, the folding cover assembly, the hinges, and the panels described herein, generally refers to the “driver's side” to “passenger side” direction, since the pickup truck and the cargo box are typically shorter in that direction. However, these terminologies, that are used as a matter of convenience, are not intended to be limiting; the folding tonneau cover apparatus could be shorter in the “length” direction than in the “width” direction, for example. For other items such as support bows and sidebars, “length” has the normal meaning, referring to the longer dimension or to the dimension along an extruded shape, for example; any potential confusion in terminology can be eliminated by examination of the various Figures in the accompanying drawings.

Referring now toFIGS.3A and3B, the release cord554anear the rear end of the rear panel536apasses through cord guides555,555a,555b.FIG.3Bis an enlarged partial section view of the driver's side end portion of the support bow550aas indicated inFIG.3A. The cord guides555are preferably molded and made of a strong polymer such as Nylon, which may be reinforced with fiberglass or other embedded material to strengthen the polymer. In alternate embodiments, the cord guides555can made of polymeric, metallic or ceramic materials using three-D printing methods or three-D etching methods or other additive or subtractive machining process. One of the standoffs558can be seen inFIG.3A, and will be described in more detail later.

As seen inFIG.3B, the latch552includes latch slide553having an engaging portion553bwhich extends forward to engage the lip524of the side rail520a, so as to secure the respective panel530to the side rail520a. The latch slide553preferably includes a stiff polymer, composite, or metal, although other materials and combinations can be used. Preferably, the latch slide553includes fiberglass-reinforced nylon. The latch slide553is biased by a biasing member or spring556towards the side rail520aso that the engaging portion553bengages the side rail520ato form a secured configuration in which the respective panel530is restricted from being lifted up from the cargo box5; in this example, the spring556is a compression spring, but an extension spring, or an elastic element, or other known elements could alternatively be used to bias the latch slide553towards the side rail520aso that the engaging portion553bengages the side rail520aso that the latch552is in the secured configuration. In this embodiment, the spring556is held between the latch slide553and a spring retainer assembly557. The spring retainer assembly557is secured in the desired location in the support bow550a. The side rails520aand520bpreferably include extruded metal, and have a side rail engagement portion522a(FIG.3B), arranged to approximate a portion of the sidewall6a,6bof the pickup truck2. The clamp514is shown in detail inFIG.3B. The clamps514preferably include aluminum, although other metals or alloys or polymers or other composite materials can be used. Clamps514preferably have an outer member516aand an inner member516bwhich are tightened towards each other and held as an assembly on the sidewall6aby a fastener assembly516dwhich preferably includes a bolt516e, a washer516f, and a nut516g. Preferably, inner member516bhas a clamp engagement portion516cwhich, together with side rail engagement portion522aof side rail520a, aids in securing the clamps514in place on the side rail520a. Preferably, the clamps514are arranged and tightened to secure the side rail520ato the sidewall6a, with a sidewall gasket522carranged between the side rail520aand the sidewall6aas illustrated. A bow end cap565is located at the end of the support bow550a. A release cord554and a cord guide555are shown, and will be described in further detail herein. In the present example, the side rail engagement portion522ais a generally vertically-oriented portion which configured to be located adjacent a similarly vertically-oriented portion of the sidewall6a,6b. In the example ofFIG.3B, a portion of the sidewall6aof a cargo box5of a Chevrolet Silverado pickup truck is illustrated; however, other sidewalls of other cargo boxes of other pickup trucks and the like can be accommodated, by incorporating a side rail engagement portion522aalong the length of the side rails520aand520bthat are appropriately configured and oriented. In this example, the cargo box5of the pickup truck2includes a sidewall cap6e, but other cargo boxes5lack a sidewall cap. A sidewall6aand sidewall cap6eare similarly illustrated in subsequent drawings herein, includingFIGS.4B6B,7B,8B and9B. Preferably, the side rail engagement portion522ahas a side rail engagement feature522b, such as ridges, knurling, surface patterns or textures, or other features which aid in securing the clamps514. Preferably, a sidewall gasket522cpreferably made of polymeric material is located between the side rail engagement portion522aand the sidewall6a; the sidewall gasket522ccan provide protection against damage to the sidewall6aby abrasion against the side rail520a. Other flexible material can also be used. The sidewall gasket522ccan provide leak resistance to prevent water, dust, or other debris from passing into the cargo box5along the side rail engagement portion522a. The side rail520ahas a flange or side rail lip524along the length of the side rail520a. The side rail lip524provides support for the folding cover assembly530. In addition, the side rail lip524provides a feature for engagement of the engaging portion553bof the latches552. The driver's side portion of the support bow550ais shown inFIG.3B; the other end of the support bow550a(toward the passenger side) has a mirror-image configuration, with a latch552engaging side rail520b, and side rail520bbeing attached to sidewall6bin a similar manner.

As illustrated inFIGS.4A and4B, when it is desired to release the latches552at the rear end of the rear panel536a, the release cord554acan be pulled, which will retract each of the latches552against the force of the respective biasing member or spring556. Typically, the release cord554awill be pulled as illustrated inFIG.4A, by a driver (not shown) who has walked to the rear of the cargo box5and has opened the tailgate6dand reaches in to access and pull the release cord554a. When the release cord554ais pulled, the engaging portion553bof the latch552is retracted away from the lip524of the side rail520aas shown inFIG.4B, releasing the latch552from the side rail520aand allowing the rear portion of the rear panel536ato be lifted up from the side rail520a. The cord guides555adjacent to the latches552help to maintain alignment of the ends of the release cord554aso that the latches552are retracted in alignment with the support bow550a, to avoid excessive friction, wear and potential binding. The driver's side portion of the support bow550ais shown inFIG.4B; the other end of the support bow550a(toward the passenger side) has a mirror-image configuration, and when the release cord554ais pulled, the latches552at both ends of the support bow550aare retracted, so that the rear end of the rear panel536acan be lifted up from both side rails520aand520b.

Referring now also toFIGS.5A-5D, which illustrate a portion of the folding cover assembly530in schematic cross section views as indicated by the line5A-5A inFIG.2A, each of the hinges544(544a,544b, and544c) preferably includes the flexible hinge body545awhich is elongated and extends between the driver's side3aand the passenger side3bof the cargo box5when the folding cover assembly530is unfolded to cover the cargo box5. The flexible hinge body545ahas a hinge longitudinal axis545bwhich is oriented along the length of the hinge body545a, and a hinge body profile545c, which is the shape of a transverse vertical cross section taken perpendicular to the hinge longitudinal axis545b. The hinge body profile545cis preferably uniform along the hinge longitudinal axis545bof the hinge body545a. In embodiments having more than one flexible hinge544, each of the flexible hinges544can have a similar hinge body profile545c. Alternatively, the hinge body profile545cof the flexible hinge bodies545acan differ from the profile of at least one other of the flexible hinge bodies545a.

The folding tonneau cover assembly530of the present invention may include one of several different hinge body embodiments545a,545a′,545a″,545a′″ (see alsoFIGS.17C-18F). The first embodiment545a, shown inFIGS.5A-5CandFIGS.17A-17D, is a dual durometer hinge having a more flexible polymer material547cmaking up the central portion546aand a portion of the intermediate portion546d,546eadjacent to and on each side of the central portion546a, and a more rigid or stiff polymer material547dmaking up the side portions546b,546cand a portion of the intermediate portion546d,546eon each side of the central portion546aof the first embodiment of the hinge body545a. The first embodiment of the hinge body545awill take more than one form depending on the format of the adhesive material attached to the hinge body for the purpose of sealing and sealing the hinge body545ato the underside of the respective rigid panels536on either side of the respective hinge544a,544b,544c. In reference to the first embodiment of the hinge body545ashown inFIG.5A, hinge body545ais secured to the underside of the respective rigid panels546by an adhesive material570adescribed elsewhere herein. In reference to the hinge body545ashown inFIG.5B, hinge body545ais secured to the underside of the rigid panels536a,536b, respectively, by an adhesive member571adescribed elsewhere herein. In reference to the hinge body545ashown inFIG.5C, the hinge body545ais secured to the underside of the respective rigid panels536a,536bwith a three-part adhesive member having first, second, and third layers572a,572b,572c, as further described elsewhere herein. The first embodiment is also shown inFIGS.17A-17Din the first adhesive format employing the adhesive material570a.

A further embodiment of the hinge body545a′ having similar adhesive570afor sealing and securing the hinge body545a′ to the underside of rigid panels536but having only a single durometer polymer design is shown inFIG.17E. This single-durometer embodiment of the hinge body545a′ is also shown inFIG.18B, but with a different adhesive571format. A further embodiment of the hinge body545a″ is shown inFIG.18Cand is generally the same as the single-durometer hinge body545a′ shown inFIG.18B, except that the central portion546″ of the hinge body545a″ does not include a concave upper surface like hinge body545a′, but has instead a flat central portion546″ in which water will not pool or run off along the length of the hinge body toward the sidewalls of the pickup truck2. The hinge body545a′″ shown inFIGS.17F-17HandFIGS.18D-18Fis also a single-durometer hinge body made of a flexible polymer material547cand it does not need an adhesive member to secure it to the underside of the rigid panels, because the close proximity of the rigid panel536and the support bow550, which has ha hinge support flange586having a flange lip587, which cooperate to form a partial enclosure592, described elsewhere herein, which will hold the hinge body545a′″ in place on each side of the hinge body545a′″ as shown inFIGS.17G,17H, and18D-18F. The inventors have found that even when adhesive570a,5701a, or other adhesives or adhesive members as described herein are not required for securement of the hinge body545a,545a′,545a″,545a′″ to the partial enclosure592, such adhesives or adhesive members can be advantageously included to provide a seal between the hinge body and the respective adjacent panels536against intrusion by moisture or debris into the cargo box5when the folding cover apparatus530is unfolded and covering the cargo box5.

The flexible hinge body545a′″ preferably includes a single polymer material547a, and provides an effective barrier against influx of moisture, precipitation or debris into the cargo box5between the adjacent rigid panels536when the folding cover assembly530is unfolded and in place covering the cargo box5. The hinge body polymer material547apreferably includes an elastomeric polymer material547band more preferably includes a thermoplastic polymer. The elastomeric polymer material547bis preferably extruded to form an elongated structure having the desired hinge body profile545c. Examples of the preferable elastomeric polymer material547binclude Sarlink® TPE RV-2250D BLK 111 thermoplastic elastomer and Sarlink® TPV 5765B thermoplastic vulcanizate, both available from Teknor Apex Company, Pawtucket, R.I.

Each flexible hinge body545apreferably includes the two side portions546band546c, and the central portion546alocated between the two side portions546band546c; each flexible hinge body545apreferably includes the two intermediate portions546dand546e, each one of the intermediate portions546dand546elocated between the central portion546aand one of the two respective side portions546band546c. The central portion546a, side portions546band546c, and intermediate portions546dand546eof the flexible hinge body545apreferably extend along the length of the flexible hinge body545a, and the hinge thickness545dof the central, side, and intermediate portions546a-546etogether at least partially define the hinge body profile545c. Each of the two side portions546band546cis preferably secured to a respective adjacent rigid panel536. When it is desired to fold up the folding tonneau cover assembly530, one of the adjacent rigid panels536is lifted up and folded towards the other of the adjacent rigid panels536, and the central portion546abends to function as a hinge as further described herein.

In some embodiments, such as schematically illustrated inFIGS.5A-5C, the flexible hinge body545aincludes more than one polymeric material such as those described herein; for example, the flexible hinge body545amay include a softer or lower-durometer elastomeric polymer material547cand a harder or higher-durometer elastomeric polymer material547d. The central portion546apreferably includes the softer elastomeric polymer material547c, and the side portions546band546c, which are secured to the rigid panels536as stated, preferably include the harder elastomeric polymer material547d. In such embodiments, a transition or mixing of the materials preferably occurs in the intermediate portions546dand546e. This arrangement preferably provides a structure with the central portion546abeing more flexible in bending than the intermediate portions546dand546eand the side portions546band546c, so that bending of the flexible hinge body545apreferentially occurs in the central portion546a, although some flexing and bending can occur in other portions of the flexible hinge544in addition to the central portion. This arrangement is schematically illustrated inFIG.5C, which shows the hinge illustrated inFIG.5Bsomewhat bent. In the drawings, which illustrate embodiments of the hinge body545ahaving more than one polymeric material, the intermediate portions546dand546ehave a transition between polymeric materials schematically indicated by a partially diagonal line in the drawings. As just described, the transition between materials may be gradual with a mixing of the polymeric materials in the intermediate portions, which will generally occur during either a molding process or an extrusion process, either of which could be used to manufacture a dual-durometer hinge body, so, for that reason, the line is not intended to define a precise sudden transition, but rather just generally indicate that the respective intermediate portion includes a transition between the different polymeric materials that have different durometers. Depending on the process and mixing of materials during fabrication of the hinge body, the transition can be more sudden or more gradual. The transition between polymeric materials will generally be located in the respective intermediate portions546dand546eas indicated by the schematic transition line shown in these portions.

For example, in one preferred embodiment, the central portion546aincludes the softer elastomeric polymer material547c, one example of which is Sarlink® TPE RV-2250D BLK 111 thermoplastic elastomer, and the side portions546band546cinclude the harder or higher-durometer elastomeric polymer material547d, one example of which is Sarlink® TPV 5765B thermoplastic vulcanizate. These materials can be extruded together to form the disclosed structure, with a mixing of these materials occurring in the intermediate portions546dand546e. The thickness545dof the various portions of the flexible hinge body545acan also affect the bending properties, but the variation of polymeric materials as just described can be useful in facilitating bending of the hinge544in the central portion546a, which in use is located between the adjacent panels536, and in facilitating securement of the side portions546band546cto the adjacent panels536.

While forming the flexible hinge body545aby extrusion of thermoplastic elastomers such as those listed above is preferred, other materials and fabrication methods can be utilized. For example, the flexible hinge body545acan include a structure fabricated by molding or other additive or subtractive manufacturing process. The flexible hinge body545amay have additional material added, such as reinforcing fibers or filaments (not shown) adhered to or incorporated into the flexible hinge body545a, including cloth-inserted, cloth-reinforced, fiberglass-reinforced, and fiber-reinforced polymer materials. The hinge body polymer material547acan include a vinyl material, natural or synthetic rubber or other flexible polymeric material, EPDM rubber, neoprene rubber, nitrile rubber, latex, silicone rubber, polyurethane material, or other polymer materials known in the art, or combinations of materials. The flexible hinge body545apreferably includes a flexible material that can withstand deformation without failure due to cracking or breakage to allow bending of the hinge544to fold up the folding cover assembly530, and that is moisture-resistant to avoid leakage into the cargo box5.

As stated above, adhesive570ais preferably located between each side portion546band the respective rigid panel536as illustrated inFIG.5Ato protect against passage of debris or precipitation into the cargo box5; the adhesive570acan also aid in securement of the flexible hinge544to the respective rigid panel536. The adhesive570acan include known adhesives and sealant materials which can be used to protect against passage of debris or precipitation between the rigid panel536and the respective flexible hinge544or to secure the flexible hinge544to the respective rigid panel536. In some preferred embodiments, the adhesive570aincludes a double-sided adhesive tape571a, which preferably includes an acrylic foam material572a, with adhesive layer572barranged on one side of the acrylic foam material572a, and adhesive layer572carranged on the other side of the acrylic foam material572a, for example. For example, the double-sided adhesive tape571acan be 3M 5933 from 3M, St. Paul, Minn. (“thermal adhesive tape”), the adhesive layer572bincludes heat-activated adhesive and an adhesive layer572cincludes pressure-sensitive adhesive which may be protected by a release strip (not shown) until it is desired to activate the pressure-sensitive adhesive layer572c. Preferably, the adhesive layer572b(in this example, heat-activated adhesive) is aligned with the flexible hinge body545awhile the heat-activated adhesive is activated to adhere the double-sided adhesive tape571ato the flexible hinge body545a; the flexible hinge body545atogether with the attached double-sided adhesive tape571ais subsequently aligned with the rigid panel536and the release strip is removed. Preferably, after the adhesive layer572cis aligned with the panel536, the flexible hinge body545ais attached to the rigid panel536by activating the adhesive layer572c(in this example, pressure-sensitive adhesive). The adjacent rigid panel536is similarly attached to the flexible hinge body545awith double-sided adhesive tape571aforming the structure of hinge544illustrated inFIG.5B. The flexible hinge body545aallows the hinge544to take a flat or open configuration as illustrated inFIGS.5A and5B, or to flex or bend as illustrated inFIGS.5C,7C, and other figures herein, providing a flexible hinge544that allows the folding cover assembly530to fold as illustrated throughout the Figures and described herein, with rigid panels536folding up and rotating towards other rigid panels536as shown. Preferably, the flexible hinge body545ais adhered to the respective bottom or underside538of the rigid panels536(specifically, the underside538a-538doff respective adjacent panels of536a-536das described herein) of the folding cover assembly530as shown. In the preferred arrangements discussed herein, the hinges544are securely attached to the respective rigid panels536and are sealed to prevent water or debris from entering the cargo box through the folding cover assembly530at the hinges544, and are generally impervious to environmental factors such as precipitation, wind, and temperatures to which a typical cargo box5would be exposed.

The support bows550are also schematically illustrated inFIGS.5A-5C. The support bows preferably include a bow main portion584including a generally C-shaped channels with a bow upper portion585configured for attachment to the bottom surface538of the respective panel536and oriented with a channel opening566cat the bottom. The support bows550which are located at the flexible hinges544preferably include the hinge support flange586,586a,586b; the support bows which are located at the flexible hinges544preferably also include the flange lip587,587a,587b.

As stated above, the support bows550are secured to the respective panel536. The support bows550are preferably located at the bottom surface538of the respective panel536, and near the front edge541bor rear edge541cof the respective panel536. The support bows550are preferably secured to the bottom surface538of the respective panel536by an adhesive570b, which may include a layer or coating of adhesive or a double-sided adhesive tape571b, for example. Alternatively, a thermal or hot-melt or chemically activated adhesive, or a mechanical attachment, or a weld, or a combination, can be used to attach the support bows550, to the respective panels536. The double-sided adhesive tape571bpreferably includes an acrylic foam material572dwith adhesive layer572earranged on one side of the acrylic foam material572dand adhesive layer572farranged on the other side of the acrylic foam material572d, for example.

Preferably, the adhesive570bincludes a double-sided adhesive tape571bsuch as 3M CV62F from 3M, St. Paul, Minn. (“pressure adhesive tape”), wherein the double-sided adhesive tape571bis an acrylic foam tape having an adhesive layer572ewhich includes pressure-sensitive adhesive and having an adhesive layer572fwhich includes pressure-sensitive adhesive which may be protected by a release strip (not shown) until it is desired to activate the pressure-sensitive adhesive, adhesive layer572f. Preferably, the adhesive layer572e(in this example, pressure-sensitive adhesive) is aligned with and adhered to the upper surface566dof the support bow550to adhere the double-sided adhesive tape571bto the support bow550; the support bow550together with the attached double-sided adhesive tape571bis subsequently aligned with the panel536and the release strip is removed. Preferably, the adhesive layer572fis then aligned with the panel536and the support bow550is attached to the respective panel536by activating the adhesive layer572f(in this example, pressure-sensitive adhesive). While the arrangement just described is a preferred configuration, any of the adhesive layers just described can include heat-activated adhesive or pressure-sensitive adhesive, and the acrylic foam material572a,572dis also preferable but not always required. For example, in alternative configurations, a single layer of adhesive could be used, similar to the arrangement schematically illustrated inFIG.5A. Other pressure-activated acrylic adhesive foam tape can be used, such as Lamatek 5357 from Lamatek, Inc., West Deptford, N.J. The sidebars or handles559are preferably also attached to the bottom surface or underside538of the respective panels536, preferably in a similar manner as that just described for the support bow550. Although adhesive570bcan be applied at selected portions of the length of the support bow550or the sidebar559, adhesive570bis preferably applied along substantially the entire length of the support bow550and the sidebar559, to enhance stability and to minimize unwanted vibrations. Alternatively, the sidebars559and support bows550can be attached to the panels536with adhesives such as glue, or with fasteners, or spot welds.

In some apparatus and methods embodiments, the folding cover assembly530folds in stages or steps; a preferred embodiment is schematically illustrated inFIG.5D. In this embodiment, starting from the unfolded or closed configuration of the folding cover assembly530(configuration 1), the hinge544aflexes to allow the rear panel536ato fold up, passing through 90 degrees (configuration 2) towards the middle panel536b, and fold over onto the middle panel536b(configuration 3). The hinge544bflexes to allow the middle panel536b(together with the rear panel536awhich is folded onto the middle panel536b) to fold up, passing through 90 degrees (configuration 4) towards the spacer panel536d, passing through a point at which standoffs558contact the front panel (configuration 5). The hinge544bflexes back towards 90 degrees as the hinge544cflexes to allow the spacer panel536dto fold up, and continue to fold over (together with the rear panel536awhich is folded onto the middle panel536b, and the middle panel536b) towards the front panel536c(configuration 6), until the folding cover assembly30is folded up (configuration 7). Note thatFIG.5Dis a schematic overview of the general folding of the folding cover assembly530; the various configurations are further illustrated and described elsewhere herein in greater detail.

An alternate configuration of an alternate folding cover assembly530′ folded up is schematically illustrated inFIG.5E. In some embodiments, the front panel536c′ is noticeably longer than panels536aand536b. In some embodiments, the spacer panel536dis oriented approximately vertically when the folding cover assembly530is folded up, and the front panel536csimply extends farther frontward than the middle panel536band the rear panel536a. In the example illustrated inFIG.5E, the spacer panel536dis correspondingly longer to accommodate the lengths of the panels536a,536b, and536c′ as illustrated. In this case, the spacer panel536dis noticeably non-vertical when the folding cover assembly530′ is folded up. The alternate folding cover assembly530′ also preferably includes corresponding flexible hinges544a,544b,544cand standoffs558.

Another alternate configuration of an alternate folding cover assembly530″ folded up is schematically illustrated inFIG.5F, similar to the illustration ofFIG.5E. In some embodiments, the front panel536c″ is noticeably shorter than panels536aand536b. In some embodiments, the spacer panel536dis oriented approximately vertically when the folding cover assembly530is folded up, and the middle panel536band the rear panel536asimply extend farther frontward than the front panel536c. In the example illustrated inFIG.5F, the spacer panel536dis correspondingly longer to accommodate the lengths of the panels536a,536b, and536c″ as illustrated. In this case, the spacer panel is noticeably non-vertical when the folding cover assembly530″ is folded up. The alternate folding cover assembly530″ also preferably includes corresponding flexible hinges544a,544b,544cand standoffs558.

In the examples illustrated inFIGS.5E and5F, the spacer panel536dcan be oriented preferably from about zero to about 60 degrees from a vertical orientation; the orientation is determined by the various lengths of the panels536and a standoff distance561a(seeFIG.14C). When the cover assembly is in the fully folded position, the top surface537dof the spacer panel536dcan stand generally at an angle of from about 30 to about 150 degrees to the top surface537cof the front panel536c, preferably from about 40 to about 140 degrees to the top surface537cof the front panel536c; more preferably from about 50 to about 130 degrees to the top surface537cof the front panel536c; even more preferably from about 60 to about 120 degrees to the top surface537cof the front panel536c, and even more preferably from about 80 to about 100 degrees to the top surface537cof the front panel536c, generally depending upon the length of the front panel536c, which can be varied in various embodiments of the cover assembly. In the preferred embodiment shown inFIG.1, the top surface537dof the spacer panel536dwill generally reside at an angle of about 90 degrees to the top surface537cof the front panel536c.

Referring now also toFIGS.20A-20B, the length539aof the rear panel536ais preferably somewhat smaller than the length539bof the middle panel536bso that the rear panel536adoes not interfere with the hinges544b,544c, support bow550e, or other nearby structures when the folding cover assembly530is folded up or unfolded. If the length539aof the rear panel536ais too much smaller than the length539bof the middle panel536b, the standoffs558attached to the support bow550awill be farther removed from the respective edges of the front panel536cand the middle panel536band may not provide the desired support in the folded up configuration. More preferably, the length539aof the rear panel536ais from about 0.25 inch to about 8 inches smaller than the length539bof the middle panel536b. Still more preferably, the length539aof the rear panel536ais from about 0.5 inch to about 2 inches smaller than the length539bof the middle panel536b. Even more preferably, the length539aof the rear panel536ais about 0.75 inch smaller than the length539bof the middle panel536b.

Preferably, the length539dof the spacer panel536dis large enough to accommodate the hinges544band544cwithout interference with the support bow550e, but is preferably not significantly larger than required to accommodate the hinges544b,544cand support bow550eso that the stored profile of the folding cover assembly530is minimized, and the folded profile when the folding cover assembly530is folded up but remains attached to the side rails520a,520bas illustrated inFIG.10Dis minimized, which is believed to reduce any tendency for the folding cover assembly530to catch wind when the folding cover assembly530is folded up but remains attached to the side rails520a,520band when the truck2is in motion. In some embodiments, the length539dof the spacer panel536dis no greater than about one-third the lengths539a,539b,539cof the other respective panels536a,536b,536c.

Preferably, the length539bof the middle panel536bis somewhat smaller than the length539cof the front panel536cso that the driver or operator8can easily grasp the storage straps543aand strap brackets543b, when the folding cover assembly530is in the folded up configuration illustrated inFIG.10A, to hook the strap brackets543bin the bracket slots543cat the front of the front panel536cas described below and illustrated inFIG.10A-10D. If the length539cof the front panel536cis longer than the length539bof the middle panel536b, the folded up configuration of the folding cover assembly530, as illustrated inFIG.10D, will cover a larger portion of the cargo box5so that there is a more limited opening to the cargo box5when the folding cover assembly530is folded up and secured on the truck2as illustrated inFIG.10D. More preferably, the length539bof the middle panel536bis from about 0.25 inch to about 6 inches smaller than the length539cof the front panel536c. Still more preferably, the length539bof the middle panel536bis from about 1 inch to about 3 inches smaller than the length539cof the front panel536c. Even more preferably, the length539bof the middle panel536bis about 1.733 inches smaller than the length539cof the front panel536c.

Once the latches552at both ends of the support bow550aare retracted as shown inFIGS.4A and4Band described above, the rear end of the rear panel536acan be lifted up from both side rails520aand520b, bending the hinge544aas illustrated inFIGS.6A and6B. As the rear panel536ais lifted up, hooks562at the ends of the support bow550at the front of the rear panel536adisengage from the respective catches564; specifically, hook562adisengages from catch564aattached to side rail520a, and hook562bdisengages from catch564battached to side rail520b. The structure and function of the hooks562and catches564are described in further detail elsewhere herein (see, for example,FIG.19A).

The rear panel536ais rotated further, onto the middle panel536bas illustrated inFIGS.7A and7B. At this point, the middle panel536bcan be lifted from the side rails520aand520b, with the middle panel536b(together with the rear panel536awhich is folded onto the middle panel536b) pivoting upwards and frontwards, bending the hinge544b. A portion of the folding cover assembly530in schematic cross section view similar to the views ofFIGS.5A and5Bis illustrated inFIG.7A, which shows the hinge544afolded in the configuration ofFIGS.7A and7B.

With lifting and rotating of the middle panel536btogether with the rear panel536auntil the middle panel536bis approximately vertical, the configuration is as depicted inFIG.8A-8B. With continued lifting and rotating of the middle panel536bfrontwards, the middle panel536btogether with the rear panel536arotates frontwards towards the front panel536c. Preferably, the folding cover assembly530includes standoffs558, located on the underside538aof the rear panel536c. The standoffs558can be attached to the bottom side of the rear panel536aor attached to other structures such as support bows550or handles559; in the example illustrated inFIGS.8A-8E, there are four standoffs558, two of which are attached to each of two sidebars or handles559on the underside538aof the rear panel536c. The standoffs558are preferably located so that two are proximate the front edge541bof the rear panel536a, and two are proximate the rear edge541cof the rear panel536a. The standoffs558, and a preferred attachment of the standoffs558to the handles559, are described further below, including with reference toFIGS.14A-14C. Through the folding and rotating of the middle panel536band the rear panel536aas just described, the standoffs558proximate the rear edge541cof the rear panel536acontact the top surface537cof the front panel36cas shown inFIG.8C. The standoffs558help to maintain a spaced relationship between the rear panel536aand the front panel536c. With continued rotating of the middle panel536b(together with the front panel536a) the hinge544cbends and the spacer panel536dlifts off the side rails520aand520bas illustrated inFIG.8D. With continued rotating of the middle panel536bfrontwards, together with the rear panel536aand the spacer panel536d, and pivoting and sliding of the standoffs558, the middle panel536b, the rear panel536a, and the spacer panel536drotate progressively farther frontwards towards the front panel536c, as illustrated inFIG.8E, until the standoffs558all contact the front panel536c(FIG.9A). During this folding of the folding cover assembly530, the hinges544band544cflex as the middle panel536b, the rear panel536a, and the spacer panel536drotate towards the front panel536cas schematically illustrated inFIGS.8F and10E. Depending on forces applied by the driver or other operator8, the hinges544band544ccan flex to pass through various increasing or decreasing angles. Most commonly, however, the angles will vary in the following manner. Referring toFIGS.8A,8C-8E, and10D, during the folding up of the folding cover assembly530, the angle A between the middle panel536band the spacer panel536d(which is about 180 degrees before beginning the folding up of the middle panel536bonto the front panel536c, as in the configuration illustrated inFIG.7A) initially decreases to angle A1which is about 90 degrees as shown inFIG.8A, then decreases past 90 degrees to angle A2at which point the standoffs558contact the top surface537cof the front panel536cas shown inFIG.8C; angle A2may be about 35 degrees, but may be somewhat larger or smaller than about 35 degrees depending on the standoff distance561a(FIG.14C) and a setback distance561b(FIG.10D) between the standoff558proximate the rear edge541cof the rear panel536aand the rear edge541cof the rear panel536a, and also depending on the relative lengths539aand539bof the rear panel536aand the middle panel536b, respectively. Angle B between the spacer panel536dand the front panel536c(which is about 180 degrees before beginning the folding up of the folding cover assembly530, as in the configuration illustrated inFIG.7A) is shown as angle B1in the configuration ofFIG.8Aas about 180 degrees, and is shown as angle B2in the configuration ofFIG.8C, preferably remaining at about 180 degrees until the standoffs558contact the top surface537cof the front panel536cas shown inFIG.8C. Angle C between the rear panel536band the front panel536c(which is about 180 degrees before beginning the folding up of the folding cover assembly530, as in the configuration illustrated inFIG.7A) initially decreases to angle C1which is about 90 degrees as shown inFIG.8A, then decreases past 90 degrees to angle C2at which point the standoffs558contact the top surface537cof the front panel536cas shown inFIG.8C. With continued rotation of the rear panel536aand middle panel536band spacer panel536d, depending on the forces and manipulations applied by the driver or operator8, the angle A may remain about the same or may increase again as the angle B begins to decrease and the angle C continues to decrease, as shown as angles A3, B3, and C3inFIG.8D. With still continued rotation of the rear panel536aand middle panel536band spacer panel536d, the angles A and B continue to approach about 90 degrees as the angle C continues to approach zero degrees as shown as angles A4, B4, and C4inFIG.8E. When the folding cover assembly530is completely folded, the angles A and B are preferably about 90 degrees and the angle C is preferably about zero degrees, as shown as angles A5, B5and C5inFIG.10D, with the rear panel536a, the middle panel536b, and the front panel536cbeing approximately parallel to each other, and the spacer panel536dapproximately vertical, oriented at about 90 degrees with respect to the panels536a,536b, and536d.

As the folding cover assembly530is folded up, the angle C between the rear panel536aand the front panel536cdecreases towards about zero degrees, passing through the configurations depicted inFIGS.8C-8E. For embodiments in which the folded configuration of the folding cover assembly530has the rear panel536afolded so that it is parallel to the front panel536c, the approximate relationship between the angles A, B, and C is believed to be given by the equation (angle C)=(angle A)+(angle B)−(180 degrees).

At this point, as illustrated inFIGS.9A,9B, and10A, the folding cover assembly530is folded up, but is still attached to the side rails520aand520b, with the latches552cand552d(proximate the ends of the support bow550f) engaged with the side rail lip524of the side rails520aand520b, respectively, and the hooks562eand652fproximate ends of the support bow550gengaged with the catches564eand564f, respectively, as illustrated inFIGS.10C-11A. Preferably, the containment bracket or anchor socket525ais affixed to the side rail520a(see for exampleFIGS.2E and9B), and a mirror-image anchor socket525bis affixed to side rail520b(see for exampleFIG.11A). The anchor sockets or containment brackets525aand525bkeep the engaging portion553bof the latches552proximate each end of the support bow550gin a desired location along the side rail lip524of the side rails520aand520band thereby aid in positioning the folding cover assembly530in a desired alignment with respect to the cargo box5when the engaging portion553bof the latches552at each end of the support bow550gare engaged with the side rail lip524of the side rails520aand520b.

Referring now toFIGS.10A-10D, bundling means such as bungee cords or storage straps543acan be utilized to fix the folding cover assembly530in the folded configuration; other straps, buckles, or hooks can be utilized as bundling means.FIGS.10A-10Dshow a preferred embodiment, in which two elastic storage straps543aare provided, one towards either side of the middle panel536b, for securing the folding cover assembly530in a folded configuration. Preferably, strap brackets543bare provided for each storage strap543a, for hooking the storage straps543ato the front panel536c; the strap brackets543bare preferably formed of a strong polymer such as a polyamide, although other materials, including composites and metals, can be used. More preferably, the strap brackets543bare formed of nylon. Preferably, bracket slots543care provided in the front panel536c, and accommodate the strap brackets543b. The strap brackets543bare attached to or captured on the storage straps543a, and the strap brackets543bhook to the bracket slots543cin the front panel536cto secure the folding cover assembly530in the folded configuration when desired. In the front perspective view ofFIG.10Bof the folded folding cover assembly530, a storage strap543ais hooked to the front panel536cwith a strap bracket543b. Also illustrated onFIG.10Bare support bows including support bows550b,550c,550d, and550g, swing latches562b,562d, and562f, standoff558, protective pad558a, and protective film574.FIG.10Cis a front view which illustrates a storage strap543anear each side of the middle panel536bwhich is hooked to the front panel536cwith corresponding strap brackets543bto secure the folded folding cover assembly530in a folded configuration as shown.FIG.10Dshows a side view of this folded configuration of the folding cover assembly530, with the rear panel536asecured to the front panel536c. The folding cover assembly530can be left in this folded configuration, as illustrated inFIG.10D, covering only the front portion of the cargo box5.

The protective film(s)574is preferably located on the top surface537cof the front panel536cso that the protective film574is aligned with the respective standoff558as illustrated inFIGS.9A,10, and10B, which illustrate the folding tonneau cover assembly530folded up. When the protective film574is located as shown between the standoff558and the top surface537cof the front panel536c, damage to the top surface537cby contact and abrasion by the protective pad558ais minimized. When traveling, the folding tonneau cover assembly530may be in the folded up configuration such as illustrated inFIG.10B, with the strap bracket543bof each storage strap543aengaged with the bracket slot543cas illustrated.

The folding cover assembly530, folded up and bundled and left secured to the side rails520aand520bin the configuration ofFIGS.10B-10Dis illustrated in a rear perspective view, viewed from slightly below and to the driver's side of the folding tonneau cover apparatus inFIG.11A. As state above, the cord guides555preferably include clip cord guides555aand retainer cord guides555b; the clip cord guides555aand retainer cord guides555bare further illustrated inFIG.11B. The truck can be driven with the folding cover assembly530in this folded up configuration if desired.

Alternatively, if it is desired to remove the folding cover assembly530to leave the cargo box5completely uncovered, the folding cover assembly530can be removed as follows. As illustrated inFIG.11Athe release cord554bis accessible and can easily be grasped by a driver or other operator8. Pulling on the release cord554bwill retract the latches552at the ends of the support bow550fagainst the force of the biasing members or springs556, similar to the way in which pulling on the release cord554aretracts the latches552at the ends of the support bow550aas illustrated inFIG.4B. Typically, the release cord554bwill be pulled by a driver or other operator8; the operator8preferably has entered the cargo box5via the tailgate6dto grasp the release cord554b. When the release cord554bis pulled, the engaging portions553bof the latches552at the ends of support bow550fare retracted away from the lips side rail lips524of the side rails520aand520b, releasing the latches552from the side rails520aand520b, and allowing the rear portion of the front panel536cto be lifted up from the side rails20aand20band rotated to disengage the hooks562eand562ffrom the catches564eand564f, respectively. In this configuration, the folded folding cover assembly530is free from the side rails520aand520bof the support frame assembly518and can be lifted up and off the cargo box5as illustrated inFIG.12; the folding cover assembly530can be moved away from the pickup truck2, or stowed in the cargo box5or elsewhere as desired. In this case, the top opening6fof the cargo box5is not partially covered by the folded up folding cover assembly530.

When it is desired to replace the folding cover assembly30on the cargo box5, or to close one or more panels36, the various steps illustrated can be done in the reverse order, as described in further detail below in reference toFIG.19C. To latch the various latches552, however, it is not necessary to manually retract any of the release cords554, since the latch slide553has an inclined bottom surface553a. When the latch slide553contacts and is forced further towards the side rail lip524of the side rails520aor520b, the inclined bottom surface553aof the latch slide553will retract the engaging portion553bto allow the engaging portion553bto move past the side rail lip524, whereupon the spring556will move the engaging portion553binto the secured configuration, such as illustrated inFIG.3Band elsewhere herein.

Referring now toFIGS.13A-13D, the cord guides555are schematically illustrated. As stated above, the cord guides555preferably include clip cord guides555aand retainer cord guides555b. Each clip cord guide555ais preferably attached to a support bow550as illustrated inFIGS.13A-13C. The clip cord guide555apreferably has a securement feature or securement portion560awhich is configured for attachment to the support bow550. The securement feature650ais preferably oblong and is narrow enough to fit into the channel opening566c, and when aligned with the open bottom of the bow bottom portion566bas illustrated inFIG.13A, the securement feature650acan be inserted into the support bow550as shown inFIG.13B. The clip cord guide555ais then rotated as indicated by the arrow onFIG.13Bso that the securement feature650asecures the clip cord guide555ato the support bow550as shown inFIG.13C. Each retainer cord guide555bis preferably inserted into the open end of the support bow550and slid along the support bow550to a desired location. The release cord554passes between the retainer cord guide555band the support bow550as schematically illustrated inFIG.13Dso that the retainer cord guide555bretains the release cord554. The combination of clip cord guide(s)555aand retainer cord guide(s)555bkeep the respective release cord positioned in alignment with the latches552and adjacent to or within the respective support bow550. Note that in the schematic illustrations ofFIGS.13A-13D, some elements are not shown, such as the adhesive570b(which may include adhesive tape571b), hinge544, hinge support flange586, and so forth, in order to highlight the particular features being described. The elements shown in the schematic illustrations ofFIGS.13A-13Dare not necessarily drawn to scale.

Referring now toFIGS.14A-14C, attachment of a standoff558to a sidebar or handle559is illustrated. The standoff558preferably has a securement portion560bwhich is configured for attachment to the sidebar or handle559. Preferably, the securement portion560bpreferably includes two longitudinal grooves558band558cwhich can engage the handle559. The standoff558preferably includes an elongated projection558dwhich can be grasped to snap the standoff558onto the handle559or to remove the standoff558from the handle559. Further, the elongated projection558dis preferably angled to aid in guiding the standoff558into engagement with the handle559. Preferably, the longitudinal groove558bis hooked onto the handle559as illustrated inFIG.14B, and the elongated projection558dis used to aid in hooking the longitudinal groove558conto the handle559to secure the standoff558on the handle559as illustrated inFIG.14C. The dimensions of the standoff558and position of the standoff558, including the standoff distance561aand the setback distance561b(FIG.10D) when secured to the handle559together determine the angle C2(FIG.8C) at which the standoff558contacts the front panel536cwhen the folding cover assembly530is being folded up. Preferably, a protective pad or insert or rubber foot558ais attached to the end of the standoff558as shown; the protective pad558apreferably secures to the standoff558by adhesive such as those described herein or other adhesive known in the art. The protective pad558aserves to reduce impact or abrasion damage to the front panel536cwhen the folding cover assembly530is folded up onto the front panel536c.

In this example, the length539dof the spacer panel536dis substantially smaller than the lengths539a,539b,539cof the other panels536a,536b,536c(FIG.2A). The dimensions of the standoff558are chosen to accommodate the length539dof the spacer panel536d, so that the front panel536aand the rear panel536care preferably parallel and separated from one another in the folded configuration such as is illustrated inFIG.10D. The larger lengths539a,539b,539cof panels536a,536b,536cprovide for efficient coverage of the cargo box5, while the smaller length539dof the spacer panel536dprovides for folding up of the folding cover assembly530to a convenient folded size, while providing space for the various hinges544, support bows550, and other components within the folded-up folding cover assembly530. As the spacer panel536d, the middle panel536b, and the rear panel536aare folded together onto the front panel536c, the standoff558the rear end of each of the handles559attached to the bottom surface538aof the rear panel536acontacts the front panel536cand provides a pivot point and sliding support to aid in orienting the panels536in the folded configuration as shown. Preferably, the standoff558is long enough to ensure contact between the protective pad558aand the top surface537cof the panel536cin order to minimize movement and stress on the hinges544band544cand to minimize any damage due to abrasion between the protective pad558aand the top surface537cof the panel536c. Preferably, the standoff558is short enough to avoid undue stress on the panel536cand the hinges544band544cwhen the folding cover assembly530is folded up as illustrated inFIGS.10A-10D.

Referring toFIGS.15A-15C, the perimeter seal534provides a seal against the entry of water, dust, or other debris into the cargo box5around the perimeter of the folding cover assembly530. The perimeter seal534can also adapt to irregularities in the fit between the folding cover assembly530and the sidewalls6a,6b, front wall6c, and tailgate6dof the cargo box5. The perimeter seal534is preferably attached to the panels536with adhesive such as adhesive570a,570bdescribed above, although other attachment mechanisms can be used to secure the perimeter seal534to the underside538of the respective panel536, such as those described herein for attachment of the flexible hinge544or the support bows550or the handle559to the panels536.FIG.15Aschematically illustrates one example perimeter seal534ahaving D-shaped cross section as shown. Preferably, adhesive535is used to secure the perimeter seal534to the panels536; although other types of adhesive, such as pressure-activated, heat-activated, UV-activated, chemical-reaction-cure, or other adhesives that are known in the art, can be used, preferably adhesive535is an adhesive such as the previously described adhesives570a,570b,571a,571b.FIG.15Bschematically illustrates another example perimeter seal534bhaving a perimeter seal lip534d; perimeter seal lip534dcan aid in alignment of the perimeter seal534at the edge of the panel536, and can also provide some protection when manipulating panel536so that injury from contact with any narrow or sharp edges of the panel536is avoided.FIG.15Cschematically illustrates another example perimeter seal534chaving an extended perimeter seal flange534ewhich provides similar advantages as the perimeter seal lip534dbut also extends a short distance over the top surface of the panel536; the example perimeter seal534chas an open cross section with an extended sealing feature534f. Different configurations of the perimeter seal534can be used in different portions of the folding cover assembly530. For example, the perimeter seal534acould be used along the front of the front panel536cto seal against the front wall6cof the cargo box5, while the perimeter seal534bcould be used along the sides of the panels536to seal against the sidewalls6a,6b(or sidewall cap6e, if the truck2is so equipped), while the perimeter seal534ccould be used along the rear of the rear panel536ato seal against the tailgate6d. Further example perimeter seals include perimeter seal534g, schematically illustrated inFIG.15D, which has an open cross section similar to perimeter seal534cbut without an extended lip or flange.FIG.15Eillustrates an example perimeter seal534hwhich is similar to perimeter seal534bbut also includes an extended perimeter seal flange similar to that shown inFIG.15C.FIG.15Fshows an edge guard534ifor attachment at an exposed edge of a panel536but with minimal intrusion along the top surface537or the bottom surface or underside538of the respective panel536(corresponding to the top surface532aor the bottom surface532b, respectively, of the folding cover assembly530); edge guard534ican be used for protection at the rear edge of the rear panel536a, for example. Edge guard534iis preferably secured by an interference fit with the respective panel536; alternatively, edge guard534ican be secured to the respective panel536by an adhesive such as adhesive535illustrated inFIGS.15A-15E,15G-15H.FIG.15Gschematically illustrates a perimeter seal534jsimilar to perimeter seal534gofFIG.15Dbut having an extended sealing feature534fsomewhat shorter than the perimeter seal ofFIG.15D, as shown. A preferred perimeter seal534kis schematically illustrated inFIG.15H. The perimeter seal534kpreferably includes extended sealing feature534fand a thick back portion534m, with the adhesive535located at the thick back portion534mfor securing the perimeter seal534kto the respective panel(s)536. The perimeter seal534can be formed into a bend at the corners of the cargo box5, or separate segments of the perimeter seal534can be applied near each of the driver's side, passenger side, front side, and rear side of the folding cover apparatus530, preferably cut to meet at a 45 degree angle to provide an essentially continuous perimeter seal around the perimeter. In a similar manner, differing configurations of perimeter seal534, such as various perimeter seals534a,534b,534c,534g,534h,534j, and534kdescribed herein can be used along different portions of the perimeter, preferably cut to meet in close approximation and thereby providing an essentially continuous perimeter seal around the perimeter but with differing seal configurations at different portions of the perimeter. An edge guard such as edge guard534ican be used to protect against damage or injury from the edge of the panel536. Preferably, the perimeter seal534is arranged to provide an essentially continuous seal around the perimeter of the cargo box5, and in addition, the rear edge of the rear panel536apreferably has an edge guard534i. Thus, some portions of the folding cover assembly530have perimeter seals534(which may include perimeter seals534a,534b,534c,534g,534h,534j,534k, for example) in addition to edge guard534i. Alternatively, the extended perimeter seal flange534ecan be incorporated into the perimeter seal534so that a separate edge guard534iis not required. Various perimeter seals and edge guards made of polymeric material, as shown inFIGS.15A-15H, are available from Lakeview Industries, Chaska, Minn. Preferably, the folding cover assembly530described herein includes a perimeter seal such as a perimeter seal disclosed herein, such as perimeter seal534,534a,534b,534c,534g,534h,534j,534k. In some views in the drawings, the perimeter seal is not shown for clarity of illustration. The folding cover assembly530preferably includes the perimeter seal534aalong each of the sidewalls6aand6b, and the perimeter seal534kalong the front wall6c, and the perimeter seal534halong the rear portion (proximate the tailgate6d).

The panels536preferably include sheet metal, although a rigid and tough polymer sheet can be used. In particular, lightweight and strong metal alloys, such as aluminum alloys, are preferred. The panels536are preferably relatively rigid as compared to the hinges544, so that when the folding cover assembly530is folded up as described herein, the panels536remain relatively flat, while the hinges544can flex to fold up the folding cover assembly530. Preferably, the panels536are from about 0.020 inches to about 0.200 inches thick. More preferably, the panel material is 5052-T34 rolled aluminum alloy from Aleris Inc., Cleveland, Ohio, which has a thickness of about 0.063 inches thick and is coated on the top with a Krystal Kote™ polyester paint system coating from Valspar Sourcing, Inc., Minneapolis, Minn. and on the bottom with a clear epoxy coating while it is in the factory. The rolled aluminum alloy is manufactured into a coil of rolled aluminum. Once cooled, the coil is unrolled and separately coated on the top and the bottom surfaces of the aluminum material, heat treated and recoiled for delivery to a material handler or to the buyer. The coated panel material is then unrolled and panels are cut using a laser cutting machine or such other equipment that allows the panels to be effectively cut to desired size and shape specifications. The thickness of the respective panels is minimized to limit the weight of the respective panels and the cost of the materials, but it the panels are too thin they will be subject to deformation between supporting structures. The panel material will preferably have a thickness of from about 0.020 inches to about 0.200 inches, more preferably from about 0.030 inches to about 0.126 inches, still more preferably from about 0.040 inches to about 0.100 inches, even more preferably from about 0.050 inches to about 0.080 inches, and most preferably about 0.063 inches. Other protective coatings can be used, such as urethane coatings, which may include UV protection. Protective coatings may be obtained, for example, from BASF (Wyandotte, Mich.) and Glasteel (Moscow, Tenn.). One preferred protective coating is BASF Elastocoat R85A92 WHT. Other rigid panels such as fiber reinforced plastic panels, such as can be obtained from Polser FRP Panels, Inc. (Izmir, Turkey).

This most preferred thickness was selected for a number of reasons including strength and process limitations. For the preferred coating described above, 0.063 inches is the thickest size that is believed to be presently available from manufacturers of the product. Since this was the thickest material that could be obtained with the preferred coating, the rigid alloy 5052-T34 with the aforementioned coatings was selected from a number of other materials having a number of other sizes. The inventors have determined that using an aluminum alloy allows the cover to be both light weight and rigid. The 5052-T34 material was chosen because it allows the cover to be strong and resistant to permanent deflections under static loads, denting, bending and long term abuse. The thickness also creates limitations if it is too thick because the panels536may interfere with one another at the hinge locations when the folding tonneau cover530is folded up and can therefore add a lot of unwanted stress on the hinge flexible hinge body545aor the adhesive570a,571awhere the respective hinges544are attached and sealed to the adjacent panels536. If the panel material is too thin, the panels536will sag and easily deform with static loads. In alternate embodiments, other materials are used to make the panels536such as steel, aluminum, fiberglass, carbon fiber, ceramic, thermoset plastics, thermoplastics, HDPE, LDPE, ABS, PVC, Nylon, titanium alloy, magnesium alloy, copper, brass, stainless steel, rubber, fiber-reinforced or glass-containing polymeric materials and the like.

As noted, the preferred coatings on the panels536are a Kyrstal Kote™ polyester paint system from Valspar, preferably a black polyester base coat with a clear texture top coat on the top surface537and a clear epoxy coating on the underside or bottom surface538of the panels536. Other coatings that could be used in alternate embodiments include acrylic paints, polyester paints, epoxy coatings, galvanized coatings, zinc plating, anodizing, other plating systems and the like. Alternative coatings include any combination of the above-mentioned coatings on either the top or the bottom sides of the panels536. The texture on the top surface537, bottom surface538of the respective panels536can be smooth, brushed, embossed, dented, sandblasted, rolled, waved and the like. Although a black top surface is preferred on the panels536, coating including others colors that are well known in the art may also be applied on the top surfaces537and the bottom surfaces538of the respective panels536in alternative embodiments. It will be appreciated that the coating on the respective surfaces are desirable both aesthetically and functionally to enable the respective surfaces to hold up over time in harsh environments.

Now referring also toFIGS.16A-16K, the support bows550are preferably metal channels, more preferably extruded aluminum, although a strong thermoplastic or other polymeric material that is either molded or extruded could be used. Preferably, the support bows550b-550fhave a slight bend or bow, and are curved so that they are downwardly concave or concave down as shown (deflection distance d is exaggerated in some views for clarity of illustration). When the panels536are attached to the bent support bows550b-550f, the panels536deflect and take on a corresponding slight bend or bow, except for the rear portion of the rear panel536aand the front portion of the front panel536c, which are preferably flat so that they approximate the shape of the tailgate6dand the front wall6cof the cargo box5. For this reason, the support bows550aand550gare preferably straight. The resulting slight bow in the folding cover assembly530aids in shedding of water or debris from the folding cover assembly530. Although the support bows550preferably include extruded channel, as long as the upper surface566dof the support bow550has this downward curvature, the curvature will be imposed upon the panels536in the manner described. An example support bow550which is straight is schematically illustrated inFIG.16A; the support bow550aat the rear of the rear panel536aand support bow550gat the front of the front panel536care preferably straight. Support bows550which are curved or bent are schematically illustrated inFIGS.16B,16C,16E,16G,16I, and16K; the support bows550b,550c,550d,550e, and550fare preferably curved. Such curved support bows550are referenced as550′ inFIGS.16B,16C, and16E,550a′ inFIG.16G,550d′,550f′ inFIG.16I, and550e′ inFIG.16K, to distinguish them from the straight support bows550,550a,550d,550f, and550e, respectively, inFIGS.16A,16F, and16H, and16J. The upper surface566dof each respective support bow550′,550a′,550d′,550f′ is preferably curved so that the upper surface566dat the ends of the respective support bow550are a deflection distance d lower than a highest extent of the upper surface566dof the support bow550as shown (between the ends of the support bow550, but preferably at the center portion of the support bow550as shown inFIG.16B). The deflection distance d is preferably between about zero and about 1 inch; more preferably, the deflection distance d is preferably between about 1/64th inch and about ½ inch; still more preferably, the deflection distance d is about ⅛ inch. These example approximate deflection distances are for a typical cargo box5of a typical pickup truck2; for wider or narrower cargo boxes, the length of the respective panels536and the respective support bows50may be longer or shorter, and the deflection distance d is preferably correspondingly larger or smaller, in order to provide a similar function in aiding the run-off of water or other debris from the panels536. Currently, for example, most common pickup truck cargo boxes are from about 3.5 feet to about 6 feet in width; the deflection distance is preferably correspondingly smaller or larger when the folding cover assembly is sized to cover a cargo box which is narrower than about 3.5 feet or wider than about 6 feet, respectively. The inventors have found that for most common trucks, a deflection distance d which is about 1/16 inch or less typically does not provide the preferred water run-off. The inventors have also found that a deflection distance d which is about 3/16 inch or more can create unwanted stress particularly in the panels536aand536cwhich preferably have one curved support bow550and one generally straight support bow550configured to approximate the shape of the tailgate6dand the front wall6cof the cargo box5. Therefore, we have found that for the typical truck cargo boxes5about 3.5 to about 6 feet in width, the preferred deflection distance is between about 1/16 inch and 3/16 inch. In some embodiments, support bows550include optional opposed support holes574ein the front and rear portions of the support bow as illustrated.

Support bow550eis shown inFIG.16J, which also illustrates bow main portion584, bow upper portion585, hinge support flange586, and flange lips587aand587b. Similarly, curved support bow550e′ is shown inFIG.16K, which also illustrates bow main portion584′, bow upper portion585′, hinge support flanges586a′ and586b′, and flange lips587a′ and587b′.

In preferred embodiments, the support bows550include the bow main portion584including a generally C-shaped channel with the bow upper portion585configured for attachment to the bottom surface538of the respective panel536and oriented with the channel opening566cat the bottom. Some components of the folding tonneau cover apparatus510preferably slide into or are attached to the support bows550, including the latch slides553, the cord guides555, the standoffs558, spring556, and the spring retainers557a. The bow end caps565preferably slide into the ends of the support bows550.

Some embodiments include support bows550that are straight, such as the support bows550that are schematically illustrated inFIGS.16F,16H, and16J, which include no hinge support flange586a,586b, one hinge support flange586a,685b, or two hinge support flanges586a,586b, respectively. Some embodiments include support bows550that are curved or bent, such as the support bows550that are schematically illustrated inFIGS.16G,16I and16K, which include no hinge support flange586a,586b, one hinge support flange586a,685b, or two hinge support flanges586a,586b, respectively. The folding cover assembly530preferably includes support bows550that are straight as support bows550aand550gillustrated inFIGS.2B,16A, and16F; support bows550aand550gare not adjacent to a hinge544and therefore do not require a hinge support flange586aor586b(FIGS.16A,16F). The folding cover assembly530preferably includes support bows550that are curved or bent (concave down) and include a hinge support flange586alocated to one side of the bow main portion584and extending to support the hinge side portion546b,546cas described above and further illustrated inFIGS.16H and16I. The folding cover assembly530more preferably includes support bows550that are bent and have a hinge support flange586aas support bows550b,550c,550dand550f(FIG.2B). Preferably, the folding cover assembly530includes a support bow550that includes two hinge support flanges586aand586b, located on opposed sides of the bow main portion584, each hinge support flange586a,586bextending to support the hinge side portion546b,546cof hinge544b,544c, as described above and further illustrated inFIGS.16J and16K. The folding cover assembly530more preferably includes a support bow550that is bent and has two hinge support flanges as support bow550e(FIGS.2B,16K).

The sidebars or handles559are attached to panels536a,536b, and536cnear each side of each panel536. The sidebars559provide additional support along the side portions of the panels536. The sidebars559are preferably metal, although a strong polymer can be used. More preferably, the sidebars559are formed of aluminum. The sidebars559are preferably formed with recesses or other grasping features, to facilitate grasping for lifting and positioning the panels536during opening and closing of the folding cover assembly530. Preferably, the support bows550and the sidebars or handles559are elongated, so that they can provide support across the width540or length539, respectively, of the respective panel536.

Referring now toFIGS.17A-17B, viewed along the viewing line17A-17A inFIG.3A, additional details in the vicinity of the side of the spacer panel536dare illustrated. These views show hinges544band544c, latch552d, and support bows550d,550e,550f, and the containment bracket525b. InFIG.17B, the middle panel536bhas been raised up to begin folding this portion of the folding cover assembly530. The hinge544bis shown flexing, and the hook562dis rotated and displaced from the catch564dso that the spacer panel536dcan also be lifted up. Some elements shown elsewhere herein are not shown inFIGS.17A and/or17Bto show the hinge function more clearly.

The hinge body545ais further illustrated inFIG.17C, which is an isolated perspective view of the hinge body545aand the adhesive570a, illustrating the hinge longitudinal axis545b, the hinge body profile545calong a representative vertical front-rear section plane597, the hinge body upper surface595, the hinge body lower surface596, representative hinge thickness545din two locations, the central portion546a, the side portions546b,546c, and the intermediate portions546d,546e.

As described above in relation to the schematic illustrations inFIGS.5A-5B, the flexible hinge body545apreferably includes more than one polymeric material such as those described herein; for example, the flexible hinge body545amay include a softer or lower-durometer elastomeric polymer material547cand a harder or higher-durometer elastomeric polymer material547d. The central portion546apreferably includes the softer elastomeric polymer material547c, and the side portions546band546c, which are secured to the rigid panels536as stated, preferably include the harder elastomeric polymer material547d. In such embodiments, a transition or mixing of the materials preferably occurs in the intermediate portions546dand546e. This arrangement preferably provides a structure with the central portion546abeing more flexible in bending than the intermediate portions546dand546eand the side portions546band546c, so that bending of the flexible hinge body545apreferentially occurs in the central portion546a, although some flexing and bending can occur in other portions of the flexible hinge544in addition to the central portion. Embodiments of the hinge544aare further illustrated inFIGS.18A-18F, which are schematic illustrations similar to those ofFIGS.5A and5B, with similar orientation as viewed from line5A-5A onFIG.2A.

A portion of the hinge body545ais shown in a perspective view inFIG.17Dtaken from the dashed rectangle17D shown inFIG.17C, which shows the hinge body profile545cof the hinge body545a, and also showing the central portion546a, the side portions546band546c, the intermediate portions546dand546e, more flexible polymer material547c, stiffer polymer material547d, intermediate polymer material547e, adhesive570aand570b, hinge body upper surface595, and hinge body lower surface596.

A portion of the hinge body545a′ is shown in perspective view inFIG.17Ewhich is similar to the view shown inFIG.17D, except that the hinge body that is shown is an alternate hinge body545a′, which shows the hinge body profile545c′ of the hinge body545a′, and also showing the central portion546a′, the side portions546b′ and546c′, the intermediate portions546d′ and546e′, hinge body polymer material547a′, and double-sided adhesive tape571a.

A portion of the hinge body545a′″ is shown in perspective view inFIG.17Fwhich is similar to the view shown inFIG.17D, except that the hinge body that is shown is an alternate hinge body545a′″, which shows the hinge body profile545c′″ of the hinge body545a′″, and also showing the central portion546a′″, the side portions546b′″ and546c′″, the intermediate portions546d′″ and546e′″, hinge body polymer material547a′, and double-sided adhesive tape571a.

A portion of the hinge body profile545c′″ of hinge body545a′″ is shown inFIG.17G, in an enlarged schematic illustration similar to that shown inFIG.18J, which is referenced herein below, except that the hinge body545a, shown inFIG.18J, is somewhat different from that of the hinge body545a′″ which allows the configuration of the partial enclosure592to engage the alternate hinge body545a′″ in a slightly different manner wherein the panel336does not abut against the hinge body545a′″ the same way that is shown inFIG.18J.

The hinge body545a′″ is shown in a further enlargement, shown inFIG.17H, which is taken from the dashed circle17H ofFIG.17G, which illustrates a portion of the hinge body545a′″ and the partial enclosure592in which the hinge body is secured and also showing the gap590between a first point593aon the lip587bof the support flange586bof the support bow550and a second point593bat the lower corner of the rigid panel536.

In preferred embodiments of the present folding tonneau cover assembly530, the preferred hinge body545a′″ will be made of a single polymeric material547ahaving a single durometer, as shown inFIGS.17F,17G,17H,18D,18E and18Fand no adhesive material will be required to secure the hinge body545a′″ within the partial enclosure592created in part by both the bottom surface538of the respective rigid panel536and a support bow550secured to the bottom surface538of the rigid panel536on each side of the hinge544so as to secure the respective side portion546b,546cand intermediate portion546d,546eat least partially within the respective partial enclosure592. In other embodiments disclosed herein, various ways of incorporating adhesive materials into the folding tonneau cover assembly540are used to secure the respective hinge body545awithin the respective partial enclosure592, but with this embodiment of the hinge body545a′″ it will be appreciated that the partial enclosure592is sufficient to retain the hinge body545a′″ without having a need for adhesive material to secure the hinge body545a′″ within the partial enclosure592. The hinge body592a′″ may also be made of multiple polymeric materials and be made of dual or multiple durometer material (not shown) and not require adhesive material for suitable securement in the partial enclosure592and adhesive material can, of course, be used to secure the alternate hinge body within the partial enclosure592.

Referring now further toFIGS.17F,17G and17H, the partial enclosure592on each side of the hinge body545a′″ is constructed and arranged to retain one of the respective side portions546b,546cand the adjacent intermediate portions546d,546ewithin the partial enclosure592without a need for any adhesive. It will be appreciated that the lack of a need for an adhesive is especially advantageous during the assembly process and also if a need arises to remove and replace the hinge body after manufacture. The key to retaining the hinge body545a′″ within the partial enclosure592is the limited width of a gap590that exists between a first point593aon an inside surface of the lip587of the support flange586of the support bow or support member550that is secured to a bottom surface538of the proximate panel536and a second point593bat the bottom corner of the adjacent rigid panel536. This gap590is constructed and arranged to be large enough to accommodate a portion of the hinge body545a′″ that resides between the central portion546a′″ and the respective intermediate portion546d′″,546e′″ to fit within the gap590. As shown inFIG.17H, the length of gap590, which is the same as the length of the dashed line594, that extends from the first point593aon the inside surface of the lip587bto the second line593bat the lower corner of the bottom surface538of the rigid panel536. This dashed line594, which has the same length as the gap590, is longer than the line576that extends from the upper surface595of the hinge body545a′″, proximate the second point593b, to the lower surface596of the hinge body545a′″, proximate the first point593a. Lines577a,577b, and577care each parallel to line576and also parallel to dashed line594. As can be seen, lines577a577b, and577care each successively longer in length than the line594and line576, because the width of the intermediate portion546d′″ and546e′″ on each side of the central portion546a′″ become progressively wider or larger as the lines grow progressively further away from the gap590and the upper surface595and the lower surface596diverge from one another as these respective surfaces become farther away from the gap in the immediate vicinity of the intermediate portions546d′″,546e′″, respectively. As the respective intermediate portion546d′″,546e′″ descends away from the central portion546a′″, the hinge thickness545dof the respective intermediate portion546d′″,546e′″ becomes enlarged, so much so that respective intermediate portion or shoulder546d′″,546e′″ is restricted from passing through the gap590under normal conditions that generally exist during the use of such a folding tonneau cover assembly530. This restriction is generally believed to be sufficient to prevent the disengagement of the respective shoulders546d′″,546e′″ and side portions546b′″,546c′″ from the partial enclosure592under normal conditions generally experienced by truck owners.

The edges of the gap590are generally unyielding because the preferred rigid panels536and the preferred support bows550are preferably made of aluminum which is generally unyielding when a polymeric material such as the polymeric material preferably used to make the hinge bodies545aof the present invention are drawing against the aluminum under great force. In most cases, the polymeric material will tear or deform before the aluminum material will bend significantly or break, but in any case, such levels of force are not generally expected under the anticipated conditions under which such tonneau cover assemblies are generally required to operate. As shown in the drawings, the thickness of the respective shoulder or intermediate portion546d′″,546e′″ of the hinge body545a′″ becomes greater as the thickness is measured in lines577a,577b, and577c, which are each of incrementally greater length than the prior line as the distance from the central portion546a′″ of the hinge body545a′″ increases in series:577ato577bto577c. Each of these lines are incrementally greater in length than line575that stretches from a point on the upper surface595of the hinge body proximate the second point593bon the lower corner of the most proximate rigid panel536to a point on the lower surface596proximate the first point593aon the lip587of the support flange respective586. Each of the lines577a,577b,577care parallel to line275and each is incrementally longer and incrementally farther away from the line275. Because the shoulder546d′″,546e′″ becomes wider or thicker as the shoulder becomes farther removed from the central portion546a′″ the shoulders546d′″,546e′″ and the side portions546b′″,546c′″ of the hinge body545a′″ are restricted from becoming disengaged from the partial enclosure592by being drawn out of the partial enclosure592through the gap590.

In the embodiment schematically illustrated inFIG.18A, the configuration is similar to that illustrated inFIG.5A; the support bows550band550chave hinge support flanges586aand586b, respectively, but lack the flange lips587aand587bwhich are present in the embodiment illustrated inFIG.5A. In the embodiment ofFIG.18A, the arrangement preferably includes adhesive570ato secure and seal the respective side portions546b,546cto the bottom surface537of the respective rigid panels536aand536b.

In the embodiment schematically illustrated inFIG.18B, the configuration is similar to that illustrated inFIG.5A, except that an alternate hinge544′ is shown, having a hinge body545a′ that has a single hinge body polymer material547a(which preferably includes an elastomeric polymer material547band more preferably includes a thermoplastic polymer as stated above) is used throughout the central portion546a′ and the side portions546b′ and546c′ of the flexible hinge body545a′. Preferably, bending of the flexible hinge body545a′ preferentially occurs in the central portion546a′ based on the hinge thickness545dof the central portion546a′ and the side portions546b′ and546c′ of the flexible hinge body545a′.

In the embodiment schematically illustrated inFIG.18C, the configuration is similar to that illustrated inFIG.18B, but an alternate hinge544″ is shown, having a hinge body545a″ that has hinge body profile545c″ that is different, having a more uniformly flat profile in the central portion546a″ than in the embodiment illustrated inFIG.18B.

In the embodiment schematically illustrated inFIG.18D, the configuration is similar to that illustrated inFIG.18B, but an alternate hinge544′″ is shown, having a hinge body545a′″ but the adhesive570ais not used at the side portions546b′″ and546c′″ and instead the hinge thickness545dat the side portions546b′″ and546c′″ is such that each side portion546b′″,546c′″ preferably contacts both the respective hinge support flange586a,586band the respective bottom surface538of the respective rigid panel536without intervening adhesive570a.

The portion of the folding cover assembly530illustrated inFIG.5Ais schematically illustrated in further detail inFIG.18E, which shows a portion of one of the panels536broken away to show the underlying structure of the hinge544′″, and which shows the flexible hinge body545a′″, and the central portion546a′″, and illustrates the partial enclosure592in which a portion of the hinge body545′″ is secured.

An enlarged view of the portion of the flexible hinge544′″ shown in the encircled area labeled18F inFIG.18Eis illustrated inFIG.18F. A portion of the hinge body545a′″ and the central portion546a′″, and the lip587are shown, and the hinge body545a′″ is partially enclosed in the partial enclosure592. The lip587has a point593aclosest to the panel536.

The partial enclosure592is illustrated inFIG.18Gin a further schematic perspective view similar toFIG.18Ebut showing the structure of the partial enclosure592with the hinge body545ashown only partially and in phantom, with the rigid panels536and support bows550shown in cooperation with one another as shown inFIG.18D.

A portion of the folding tonneau cover assembly530is illustrated inFIG.18H, which is an enlarged view providing a transverse vertical cross section of the portion of the folding tonneau cover assembly shown inFIG.18A, but showing the hinge body545ain phantom. A portion of the folding tonneau cover assembly530is illustrated inFIG.18Iin a further enlarged view similar to that shown inFIG.18H, except that the hinge body545ais shown in cross section and the rigid panels536and the support bows550are shown in phantom.

A further enlarged view of the portion of the folding tonneau cover assembly530shown in the dashed circle18J ofFIG.18Iis illustrated inFIG.18J. Portions of the partial enclosure592, hinge544, hinge body545a, central portion546a, side portions546band546c, intermediate portions546dand546e, hinge body profile545c, hinge thickness545d, hinge adhesive570a, hinge body upper surface595, and hinge body lower surface596are shown. Portions of the support bows550and rigid panels536are shown in phantom.

Preferably, the hinge thickness545dbetween the hinge upper surface595and the hinge lower surface596is large enough in comparison to the gap590to provide a degree of securement of the flexible hinge body545aso that the respective side portion546b,546cis retained between the hinge support flange586a,586band the respective bottom surface538a,538bof the respective rigid panel536a,536b. The hinge thickness545dat the respective intermediate portion546d,546eis greater than the gap590, thereby reducing the possibility of the respective intermediate portion546d,546epassing through the gap590due to movements and stresses anticipated in use of the folding tonneau cover apparatus510. In embodiments which include the adhesive570a(such as the double-sided adhesive tape571a, for example), the adhesive570aprovides further securement of the flexible hinge body545ato the respective rigid panels536.

As described above, adhesive570ais preferably located between each side portion546b,546cand the respective rigid panel536(536a,536b,536c,536d) to protect against passage of debris or precipitation into the cargo box5; the adhesive570acan also aid in securement of the flexible hinge body545ato the respective rigid panel536. Alternatively, the side portions546b,546ccan fit tightly between the respective extended flange or hinge support flange586(586a,586b) and the respective rigid panel536, to provide a degree of protection against passage of debris or precipitation into the cargo box5. The folding cover assembly530preferably includes support bows or channels550(550a,550b,550c,550d,550e,550f,550g) secured to the underside538(538a,538b,538c,538d) of at least some of the rigid panels536, near the front edge541band/or the rear edge541cof the respective rigid panels536, and which extend between the driver's side and the passenger side of the rigid panels536. The support bows550are preferably secured to the underside538of the respective rigid panels536by adhesive570b. In preferred embodiments, the support bows550include the hinge support flanges586.

The extended flanges586are preferably separated a short distance from the respective rigid panel536, so that there is a gap590between the hinge support flange586and the respective rigid panel536. The hinge support flange586and the respective rigid panel536form a partial enclosure592into which the side portions546b,546cextend. The hinge support flanges586each preferably include a raised lip587a,587bto further secure the flexible hinge body545ato the respective rigid panel536. The raised lip is preferably positioned to create a restricted gap590between the raised lip587a,587band the respective rigid panel536, so that the side portion546b,546ccannot easily slip out from the partial enclosure592through the gap590, further securing the flexible hinge body545ato the respective rigid panel536. The intermediate portion546b,546cpreferably has a hinge thickness545dwhich does not permit the intermediate portion546b,546cto easily pass through the restricted gap590, further securing the flexible hinge body445ato the respective rigid panel536. In some embodiments, the geometry of the partial enclosure592, gap590, side portion546b,546c, and intermediate portion546b,546cprovides a mechanical interlock to secure the flexible hinge body545ato the respective rigid panel536without the need for adhesive or other fastening mechanism. In other embodiments, adhesive570ais used to secure the flexible hinge body545ato the respective rigid panel536; in alternative embodiments, adhesive570ais located at an interface between the flexible hinge body545aand the hinge support flanges586, adhesive570ais located at an interface between the flexible hinge body545a(at the hinge body upper surface595) and the bottom surface or underside538of the respective rigid panel536, or adhesive570ais located both at an interface between the flexible hinge body545a(at the hinge body lower surface596) and the hinge support flanges586and at an interface between the flexible hinge body545aand the bottom surface or underside538of the respective rigid panel536. In further embodiments, a mechanical interlock together with adhesive570asecures the flexible hinge body545ato the respective rigid panel536. In still further embodiments which include the flange lip587, the mechanical interlock includes the geometry of the intermediate portion and the geometry of the lip.

As stated above, the flexible hinge body545apreferably includes polymer material547a, which more preferably includes an elastomeric polymer material547b. In some embodiments, a single type of elastomeric polymer material547bis used in the central portion546a, side portions546b,546c, and intermediate portions546d,546eof the flexible hinge body545a. In other embodiments, the flexible hinge body545aincludes a plurality, i.e. more than one type of polymer material547a, which differ in elastic properties; for example, a more flexible elastomeric polymer material547cmay be preferably incorporated in the central portion546aand a stiffer elastomeric polymer material547dmay be preferably incorporated in the side portions546b,546c. In this case, the intermediate portion546d,546emay include an intermediate polymer material547ewhich may be a mixture or combination of the more flexible elastomeric polymer material547cand the stiffer elastomeric polymer material547d, and may provide a transition from the more flexible elastomeric polymer material547cto the stiffer elastomeric polymer material547d. In some embodiments, the flexible hinge body545aincludes more than one type of polymer material to provide for more optimal properties in the various portions; for example, a more flexible elastomeric polymer material547cmay be utilized advantageously in the central portion546cto provide for bending of the flexible hinge body545awhen folding or unfolding the folding cover assembly530, while a stiffer elastomeric polymer material547dmay be utilized advantageously in the side portion546b,546cto provide for securement of the flexible hinge body545ato the respective rigid panel536. Preferably, in embodiments which incorporate more than one type of polymer material547a, the flexible hinge body545ais fabricated by co-extruding the more than one type of polymer material547ato form the flexible hinge body545aof materials which vary along the hinge body profile545cbut which are generally the same along the hinge longitudinal axis545bof the flexible hinge body545a.

A portion of the folding tonneau cover apparatus510that includes the rear hinge544a, as indicated by the encircled area labeled2D,19A inFIG.2C, is further illustrated in an enlarged partial phantom view inFIG.19A, with the driver's-side side rail220ashown in phantom and the truck2removed to show the underlying structure, and showing in phantom an alternate position of the same portion of the folding tonneau cover apparatus510in which the rear panel536ahas been lifted up and rotated frontward somewhat in the direction of the arrow so that the hook562ais disengaged from the catch564a. With further rotation of the rear panel536aas illustrated inFIG.19B, the rear panel536ahas been rotated completely forward onto the middle panel536b, and the hook562ais disengaged from the catch564a, so the middle panel536bis free to be lifted up if desired. The other hooks562and catches564described herein function in a similar manner as hook562aand catch564ajust described.

When it is desired to replace the folding cover assembly230onto the cargo box5and cover the cargo box5, the folding cover assembly230can be placed onto the side rails520and unfolded as schematically illustrated inFIG.19C, beginning with (1) placing the bundled folding cover assembly530on the side rails520with the hooks562at the front of the front panel536caligned with the respective catches564on the respective side rails520; (2) lowering the folding cover assembly530onto the side rails520until the latches552at the rear of the front panel536care engaged with the side rail lip524of the respective side rails520and the containment brackets525aand525b. The bundled folding cover assembly530can be left secured in this configuration, or if it is desired to unfold the folding cover assembly530to cover the cargo box5, the strap brackets543bcan be disengaged from the bracket slots543c, and (3) the middle panel536bcan be rotated rearward onto the side rails520, with the hooks562at the front of the middle panel536bengaging the respective catches564, and (4) the rear panel536acan be rotated rearward onto the side rails520, with the hooks562at the front of the rear panel536aengaging the respective catches564and the latches552at the rear of the rear panel536aengaging with the side rail lip524of the respective side rails520.

FIGS.20A-20Eare schematic illustrations of the folding tonneau cover apparatus510for various configurations of cargo box5geometries as may be found on various trucks2. Preferred embodiments of the folding cover assembly530include the rear panel536a, the middle panel536b, the front panel536c, and the spacer panel536d, as previously described. InFIGS.20A-20E, the overall length533of the folding cover assembly530is shown for each example, and the length539of each of the panels536a-536dis indicated as539a-539d, respectively, and the width540of the panels536a-536dis indicated as540a-540d, respectively, and the side angle542of the panels536a-536dis indicated as542a-542d, respectively. Panels536a-536ccan have similar length539a-539c, or the length of some or all of panels536a-536ccan differ. Panel536dcan have a similar length539das panels536a-536c, but preferably the length539dof panel536dis substantially smaller than the lengths539a-539cof panels536a-536c. Panels536a-536dcan have similar width540, or the width of some or all of panels536a-536dcan differ. Panels536a-536dcan have the same side angle542, or the side angle542a-542dof some or all of panels536a-536dcan differ.

FIG.20Ashows the folding cover assembly530as configured for a cargo box having angled sides; since this example folding cover assembly530has angled sides, the width540is different at the front and rear of a panel. In this example, the width540of the rear panel536aat the rear of the rear panel536ais labeled540a′, to distinguish it from the width540aof the rear panel536aat the front of the rear panel546a. The width540of the panel536bat the rear of the panel536bis similar to the width540aof the panel536aat the front of the panel536a, and so forth.

FIG.20Bis a schematic illustration of the folding cover assembly530as configured for a cargo box having parallel sides; in this example, the width540of each of the panels is similar.FIG.20Cis a schematic illustration of the folding cover assembly530as configured for an elongated cargo box; in this example, the overall length533is longer than in the example ofFIG.20B.FIG.20Dis a schematic illustration of the folding cover assembly530as configured for a shorter cargo box; in this example, the overall length533is shorter than in the example ofFIG.20B.FIG.20Eis a schematic illustration of the folding cover assembly530as configured for a cargo box with arbitrary shape; in this example, the sides of the panels536are angled, and the rear of the rear panel536ais curved, extending a curved extension distance539ein the central portion with respect to the side portions of the rear panel536a. The folding cover assembly530can be configured for a variety of other configurations of truck box5, with any of the panels536a-536dconfigured with straight or angled or curved shapes such as those illustrated in the examples ofFIGS.20A-20E, in various combinations.

Further advantages to the structure described herein of the flexible hinge544are illustrated inFIGS.21A and21B. The hinge544as described herein is low profile, reducing the overall thickness, bulk, and weight of the folding cover assembly530. The flexible hinge544can tolerate some deformation, so that if adjacent panels536are not aligned perfectly, or are not perfectly flat, the hinge544can still function to allow the folding cover assembly530to fold without binding. The configuration disclosed herein of hinge544can accommodate panels536, some of which are preferably slightly bowed as described herein and illustrated inFIG.16E.FIG.21Ais a schematic illustration of a portion of the folding tonneau cover apparatus510showing a respective flexible hinge544interconnecting two respective adjacent panels536, showing bent or bowed support bows550creating a bending or bowing of the panels536attached thereto (see alsoFIGS.16B-16E), with the bending or bowing exaggerated for illustration, with the panels536unfolded.FIG.21Bis a schematic illustration similar to that ofFIG.21A, showing the two respective adjacent panels536folded up in the direction indicated by the arrow.FIGS.21A-21Billustrate how the flexible hinge544can accommodate the folding up and unfolding of such bent or bowed panels536.

FIG.22is a rear perspective view of an alternate embodiment of folding tonneau cover apparatus410having a folding cover assembly430incorporating a cab panel436eonto which the rear, middle, spacer, and front panels436a,436b,436d, and436c, respectively, can fold, with the folding tonneau cover apparatus410attached to a pickup truck2which is shown in phantom.

FIG.23is a bottom plan view of the folding tonneau cover apparatus410ofFIG.22. Visible in this view are hinges444, which are situated between adjacent panels436and adjoin adjacent panels436. Each panel436has a top surface437and a bottom surface or underside438; panel436ahas a top surface437aand a bottom surface or underside438a, panel436bhas a top surface437band a bottom surface or underside438b, panel436chas a top surface437cand a bottom surface or underside438c, panel436dhas a top surface437dand a bottom surface or underside438d, and panel436ehas a top surface437eand a bottom surface or underside438e. For ease of discussion, hinges444are specifically referenced herein as444a-444d, and non-specifically or collectively referenced as444. Specifically, situated between the rear panel436aand the middle panel436bis hinge444a. Similarly, situated between the middle panel436band the spacer panel436dis hinge444b, situated between the spacer panel436dand the front panel436cis hinge444c, and situated between the front panel436cand the cab panel436eis hinge444d. Hinges444allow the folding cover assembly430to be folded up and will be more fully described below. Optional hinge guards463are shown; hinge guards463provide additional support to the hinges444when the folding cover assembly430is unfolded and in place covering the cargo box5of truck2(FIG.22). Hinge guards463also provide protection against slicing through the hinges444; further description of the hinge guards463is provided herein. Support bows450are attached to the panels436to provide additional support and rigidity to the panels436, and also provide a structure for mounting of various other components as described in detail herein. For ease of discussion, support bows450are specifically referenced herein as450a-450i, and non-specifically or collectively referenced as450. Similar to support bows550,650,750described herein, bow end caps (not visible in the figures but similar to other bow end caps shown and described herein, such as bow end caps565shown inFIG.3B) are preferably secured to each end of the support bows450. The folding tonneau cover apparatus410is removably secured to the support frame assembly418by securing apparatus451a. Preferably, securing apparatus451aincludes at least one locking member451bwhich is engageable and disengageable from the support frame assembly418. Preferably, the locking member451bincludes latches452which are located at the support bows as shown and secure the folding cover assembly430to the side rails420aand420b. The latches are similar to latches552,652,752shown and described herein, and preferably include a latch slide with inclined bottom surface, an engaging portion, a spring, and a spring retainer, similar to corresponding elements653,653a,653b,656,657, and657aof latches562, for example, shown and described herein and illustrated inFIG.33Band elsewhere herein. Release cords454are attached to the latches452. For ease of discussion, release cords454are specifically referenced herein as454a,454d, and454f, and non-specifically or collectively referenced as454. The release cords454pass through cord guides455which are attached to support bows450as shown. For example, the cord guides455can be retainer cord guides455b, which are similar to retainer cord guides555billustrated inFIG.11B. The cord guides are non-specifically or collectively referenced herein as455, but cord guides455c-455dare specifically referenced herein to facilitate the detailed description herein. Standoffs458are shown, and are described in further detail herein. Sidebars or handles459are preferably attached to panels436a,436b,436c, and436enear each side of each respective panel436to further support the respective panels436. Perimeter seal434is located on the bottom432bof the folding cover assembly330and is arranged to seal against the sidewalls6aand6band the front wall6cand the tailgate6dof the cargo box5; some portions of perimeter seal434are behind side rails420aand420band not visible inFIG.23. The perimeter seal434is further described herein. Clamps414secure the side rails420aand420bto the sidewalls6aand6bof the cargo box5in a similar manner as other clamps514,614,714described herein.

The support bows or transverse frame members or channels450provide additional support for the panels436. In this embodiment, the panels each have two support bows450, one located near each of the front and rear ends of each panel436, except for the spacer panel436d, which has only a single support bow450. In this embodiment, there are latches452mounted in pairs, one of each pair mounted near each end of each of the support bows450a,450fand450has shown, similar to the latches552,652,752of other embodiments described herein. As further described herein, the latches452engage the side rails420aand420bto secure the folding cover assembly430, and can slide a short distance towards or away from the side rails420aand420bto engage or release the folding cover assembly430or selected panels436or portions thereof from the side rails420aand420bas further described herein. In this embodiment, there are three latch release cords or release cords or cords454, each of which are connected to opposing pairs of latches452which secure the panels436to the side rails420aand420b. The release cords454pass through cord guides455which are mounted to the support bows450; the release cords454can slide within the cord guides455. The release cords454generally extend from the latches452along the support bows450. The release cords454can be actuated to release each pair of latches452by a driver or operator8when desired, to open the folding cover assembly430. Also seen onFIG.23are optional hinge guards463; the optional hinge guards463are preferably attached to one of the support bows450adjacent to each of the respective hinges444. In this example, the hinge guards463are shown attached to the support bows450b,450d, and450f. Optionally, hinge guards463can be attached to the support bow450gor450hto provide support for the hinge444din a similar manner. The hinge guards463provide support for the hinges444, such as to support weight or pressure applied to the hinges444, the panels436, or other portions of the folding cover assembly430. The hinge guards463can also provide some protection against cutting through a hinge444to enter the cargo box5.

In the folding tonneau cover apparatus410, hooks462are attached to some of the support bows450. Preferably, hooks462are located adjacent each end of each of the support bows450b,450d, and450i, and are aligned with respective catches464which are attached to the side rails420aand420bas illustrated. Similar to other embodiments further described herein, when the folding cover assembly430is in place covering the cargo box5, the hooks462are engaged with the catches464and help to secure the folding cover assembly430to the side rails420aand420b.

When a panel430is rotated upward, the hooks462disengage from the catches464, allowing the panel to be rotated and stacked onto other panels430, as shown herein. Preferably, the hooks462slide into the support bows450and are secured in position; preferably, the hooks462are secured by an interference fit with the support bows450, but other securement mechanisms can be utilized, such as screws or other fasteners or adhesives known in the art, or a combination of securement mechanisms. In various embodiments disclosed herein, hooks and catches such as hooks462and catches464are located along selected support bows450,550,650,750. In the folding tonneau cover apparatus410, hooks462aand462bare located near the driver's side end and passenger side end, respectively, of support bow450b(near the front end of the rear panel436a), hooks462c,462don support bow450d(near the front end of the middle panel436b); hooks462gand462hare located near the driver's side end and passenger side end, respectively, of support bow450i(near the front of the cab panel436e). Together, the various latches452and hooks462engage the catches464and the side rails420aand420bto secure the folding cover assembly430to the side rails420aand420band thereby to the cargo box5in order to cover the cargo box5when desired, but can be disengaged as described herein to open the folding cover assembly430to enter the cargo box5when desired. The containment brackets425a,425bare shown, which help to secure the folding cover assembly430in position on the side rails420a. Similarly, the containment brackets425a′,425b′ are shown, which help to secure the folding cover assembly430in position on the side rails420a,420bespecially when the folding cover assembly430is in a folded configurations such as those illustrated inFIGS.30,31A-31E. Note that in some embodiments, the containment brackets425a,425bcan be omitted, as long as the containment brackets425a′,425b′ are present. Preferably, the tonneau cover apparatus410includes containment brackets425a,425b,425a′ and425b′.

FIG.24is a partial section view of the rear portion of the folding tonneau cover apparatus410ofFIG.22as indicated onFIG.23and illustrating the edge guard434iat the rear portion of the rear panel436a. Preferably, the folding cover assembly430includes a perimeter seal434, such as the perimeter seal434a(or other perimeter seals shown inFIGS.15A-15E,15G, for example) around substantially the entire perimeter, attached to the bottom surface438of each respective panel as described with regard to other embodiments herein. Preferably, the folding cover assembly430also includes the edge guard434i(such as the edge guard34ishown inFIG.15F) at the rear portion of the rear panel436a. This edge guard will minimize potential contusions or abrasions that may arise to an operator8, if the operator8accidentally allows one or more of his or her fingers to rest of the top of the tailgate when securing the rear panel to the respective side rails.

Referring now toFIGS.25A-27, hinges444include flexible sheet material or flexible material447which is attached to each of the adjacent panels436(specifically, respective adjacent panels of436a-436das described herein). Flexible sheet material447is moisture resistant to avoid leakage into the cargo box5. Flexible sheet material447can include fabric, or a polymeric layer, and may have a reinforcing fiber which can be separate fibers, long (generally continuous) or short (generally discrete) fibers, fibrous yarns, or a web material, or woven material, single-axis or biaxial oriented fibers, or a braid or a felt of fibers, for example. For example, flexible material447can be a vinyl material, preferably a polyvinyl chloride or PVC covered fabric, a fiber-reinforced rubber or other flexible polymeric material, or a fabric having a water-resistant coating or impregnation. In additional examples, the flexible material447can be cloth-inserted EPDM rubber, cloth-inserted neoprene rubber, nylon cloth reinforced nitrile rubber, fiberglass-reinforced silicone rubber, polyester-reinforced neoprene sheet, nylon-reinforced neoprene sheet, and other materials available from multiple sources; information regarding example materials is available from www.rubbersheetroll.com and from www.mscdirect.com; note that not all materials listed on those web sites would be preferred for this application. A variety of materials could be used as flexible hinge material, such as neoprene, EPDM, flexible PVC, nitrile, natural rubber, flexible thermoplastics, silicone, latex, Hypalon rubber, butyl rubber, recycled rubber, Viton rubber, Santoprene rubber, Skirtboard rubber, SBR rubber, and so forth, that can be used in conjunction with a reinforcing fiber such as EPDM, Nylon, polyester, fiberglass, carbon fiber, aramid fibers, boron fibers, metal fibers, cellulose, wood-derived fibers, and so forth can be used for the flexible hinge material447. The hinge or flexible hinge444is preferably made of a flexible material that can withstand deformation without failure due to cracking or breakage and that is selected from the group consisting of a laminated polymeric material, a fiber-reinforced polymeric material, an elastomeric material, a woven material and a laminated material that is includes a woven material and a moisture-resistant polymeric material. Preferably, a hinge material447is chosen that can be heat bonded to the thermal adhesive tape471asuch as 3M 5933 from 3M, St. Paul, Minn. described herein. Other considerations in choosing an acceptable flexible hinge material447are durability over time and resistance to environmental factors such as precipitation, sunlight, temperature ranges, and physical stresses such as impacts and abrasions. Preferably, the flexible material447is polyester fiber reinforced polymeric material. More preferably, flexible material447is PVC-coated woven polyester material such as part number 90749 available from Lakeview Industries, Chaska, Minn.

Attachment of the flexible sheet material447to the panels436is preferably by an adhesive470awhich may include a layer or coating of adhesive or a double-sided adhesive tape471afor example. Alternatively, a contact adhesive, or a thermal or hot-melt or chemically activated adhesive, or a mechanical attachment, or a combination, can be used to attach the flexible sheet material447to the panels436,436. Double-sided adhesive tape471acan include an acrylic foam material472a, with adhesive layer472barranged on one side of the acrylic foam material472a, and adhesive layer472carranged on the other side of the acrylic foam material472afor example. Preferably, the adhesive470aincludes a double-sided adhesive tape471asuch as 3M 5933 from 3M, St. Paul, Minn. (“thermal adhesive tape”), wherein the double-sided adhesive tape471ais an acrylic foam tape having an acrylic foam material472aand an adhesive layer472bwhich includes heat-activated adhesive and an adhesive layer472cwhich includes pressure-sensitive adhesive which may be protected by a release strip (not shown) until it is desired to activate the pressure-sensitive adhesive, adhesive layer472c. Preferably, the adhesive layer472b(in this example, heat-activated adhesive) is aligned with the flexible sheet material447while the heat-activated adhesive is activated to adhere the double-sided adhesive tape471ato the flexible sheet material447; the flexible sheet material447together with the attached double-sided adhesive tape471ais subsequently aligned with the panel436and the release strip is removed. Preferably, after the adhesive layer86cis aligned with the panel436the flexible sheet material447is attached to the panel436by activating the adhesive layer472c(in this example, pressure-sensitive adhesive). The adjacent panel436is similarly attached to the flexible sheet material447with double-sided adhesive tape472aforming the structure of hinge444as shown inFIG.25B. The flexible sheet material447allows hinges444to take a flat or open configuration as illustrated inFIGS.25A and25B, or to flex or bend as illustrated inFIGS.25C,26and27, providing a hinge444that allows the folding cover assembly430to fold as illustrated throughout the Figures and described herein, with panels436folding up and rotating towards other panels as shown. Preferably, the flexible sheet material447is adhered to the respective bottom or underside438of the panels436(specifically, the underside438a-438dof respective adjacent panels of436a-436das described herein) of the folding cover assembly430as shown. In the preferred arrangements discussed herein, the hinges444are securely attached to the respective panels436, are sealed to prevent water or debris from entering the cargo box through the folding cover assembly430at the hinges444, and are generally impervious to environmental factors such as precipitation, wind, and temperatures to which a typical cargo box5would be exposed. Preferably, the hinge444is low profile, so that the thin structure provides an effectively continuous seal along the perimeter seal434to prevent ingress of precipitation or debris or loss of contents from the cargo box5, or lifting of the folding cover assembly by the wind under normal circumstances. All of the respective seals that are disclosed herein and can be used as a perimeter seal434are water resistant, preferably water proof such that water cannot flow through the seal material and is prevented from egress into the cargo box5through the respective seal material. In preferred embodiments, the perimeter seal434will be secured with an adhesive material to the underside of each of the respective panels proximate an outer portion of each of the respective panels and an outer portion of each of the respective flexible hinges proximate the outer edges of each of the respective panels, so that the passage of moisture through the juncture of any areas where such bonding occurs is minimized, if not entirely prevented. Furthermore, when the perimeter seal434is secured to each of the respective rigid panels proximate an outer portion of each of the respective panels and to an outer portion of each of the respective flexible hinges proximate the outer edges of each of the respective panels and compressed between the outer edges of each of the respective panels and each of the respective side rails420a,420b, the top of the tailgate6dand the top of front wall6c, wherein the cover assembly430is fully secured to the support frame assembly418, the perimeter seal434will act to minimize the egress of moisture, wind and debris into the cargo box5, preferably completely preventing moisture, wind and debris of any kind from entering the cargo box5when the cover assembly is fully secured to the support frame and the pickup truck.

FIG.25Balso schematically illustrates support bows450which are preferably attached to respective panels436by an adhesive470b, which may include a layer or coating of adhesive or a double-sided adhesive tape471b, for example. Alternatively, a thermal or hot-melt or chemically activated adhesive, or a mechanical attachment, or a weld, or a combination, can be used to attach the support bows450to the respective panels436. Double-sided adhesive tape471bpreferably includes an acrylic foam material472d, with adhesive layer472earranged on one side of the acrylic foam material472d, and adhesive layer472farranged on the other side of the acrylic foam material472d, for example. Preferably, the adhesive470bincludes a double-sided adhesive tape471bsuch as 3M CV62F from 3M, St. Paul, Minn. (“pressure adhesive tape”), wherein the double-sided adhesive tape471bis an acrylic foam tape having an adhesive layer472ewhich includes pressure-sensitive adhesive and having an adhesive layer472fwhich includes pressure-sensitive adhesive which may be protected by a release strip (not shown) until it is desired to activate the pressure-sensitive adhesive, adhesive layer472f. Preferably, the adhesive layer472e(in this example, pressure-sensitive adhesive) is aligned with and adhered to the upper surface474dof the support bow450to adhere the double-sided adhesive tape471bto the support bow450; the support bow450together with the attached double-sided adhesive tape471bis subsequently aligned with the panel436and the release strip is removed. Preferably, the adhesive layer472fis then aligned with the panel436, and the support bow450is attached to the respective panel436by activating the adhesive layer472f(in this example, pressure-sensitive adhesive). While the arrangement just described is a preferred configuration, any of the adhesive layers just described can include heat-activated adhesive or pressure-sensitive adhesive, and the acrylic foam material is also preferable but not always required. For example, in alternative configurations, a single layer of adhesive could be used, similar to the arrangement shown inFIG.55A. Other pressure-activated acrylic adhesive foam tape can be used, such as Lamatek 5357 from Lamatek, Inc., West Deptford, N.J. The sidebars or handles459are preferably also attached to the underside438of the respective panels436, preferably in a similar manner as that just described for the support bow450. Although adhesive470bcan be applied at selected portions of the length of the support bow450or the sidebar459, adhesive470bis preferably applied along substantially the entire length of the support bow450and the sidebar459, to enhance stability and to minimize unwanted vibrations. Alternatively, the sidebars459, support bows450, or the flexible sheet material447of hinges444can be attached to the panels436with adhesives such as glue, or with fasteners, or spot welds.

FIG.26is a schematic illustration showing the hinge ofFIG.5Bbut with the hinge folded about 180 degrees.

FIG.27is a schematic illustration showing a cross section similar to that ofFIG.25Cbut showing a spacer panel and two adjacent hinges of the folding tonneau cover ofFIG.22illustrating both hinges in a partially folded configuration.

FIG.28is a schematic illustration showing a preferred embodiment of general steps and configurations of the folding cover assembly ofFIG.22as it is folded up or unfolded. In this embodiment, starting from the unfolded or closed configuration of the folding cover assembly430(configuration 1), the hinge444aflexes to allow the rear panel436ato fold up, passing through 90 degrees (configuration 2) towards the middle panel436b, and fold over onto the middle panel436b(configuration 3). The hinge444bflexes to allow the middle panel436b(together with the rear panel436awhich is folded onto the middle panel436b) to fold up, passing through 90 degrees (configuration 4) towards the spacer panel436d, passing through a point at which standoffs458contact the front panel (configuration 5). The hinge444bflexes back towards 90 degrees as hinge444cflexes to allow the spacer panel436dto fold up, and continue to fold over (together with the rear panel436awhich is folded onto the middle panel436b, and the middle panel436b) towards the front panel436c(configuration 6), until the rear panel436a, middle panel436b, and spacer panel436dare folded onto the front panel436c(configuration 7). The hinge444dflexes to allow the rear panel436a, middle panel436b, spacer panel436d, and front panel436cto fold up into a generally vertical orientation onto the cab panel444d(configuration 8). The hinge444dflexes further to allow the rear panel436a, middle panel436b, spacer panel436d, and front panel436c, folded up onto the cab panel444d, to be secured near or adjacent or touching the cab (configuration 9) with folded cover forward securing assembly419, including various securing members465as are described below. Note thatFIG.28is a schematic overview of the general folding of the folding cover assembly430; the various configurations are further illustrated and described elsewhere herein in greater detail in relation to the folding cover assembly430or other folding cover assemblies530,630described herein.

FIG.29is a side perspective view from the driver's side of the folding tonneau cover apparatus410ofFIG.22, showing a configuration in which the rear panel436a, the middle panel436b, and the spacer panel436dare folded onto the front panel436cand secured with storage straps494a. The various mechanisms and methods in releasing latches450, disengaging hooks462from catches464, bending the hinges444, rotating and folding up of panels436of the folding cover assembly430to the configuration ofFIG.29are generally similar to those described herein in relation to folding cover assemblies530and630, and particularly similar to that of the folding cover assembly630described herein. In this embodiment, the storage straps494acan attach to the panel brackets466which are attached to the top surface437eof the cab panel436e. The folding cover assembly430can be further folded up onto the cab panel436eas illustrated inFIG.30, and panel brackets466also provide support to the panels436a,436b,436c,436das seen inFIGS.30-31E. This configuration allows entry into a substantial portion of the cargo box5. If entry into a greater portion of the cargo box5is desired, then the folding cover assembly430can be folded up onto the cab panel436eas shown inFIG.30; as with other latches52described herein, the driver or operator8can pull release cord454fto release the latches452kand452mat the ends of the support bow450hat the rear of the cab panel436e, disengaging them from the side rails420a,420band the containment brackets425a′,425b′ in a manner similar to that already described herein with regard to other latches552,652,752. In the configuration illustrated inFIG.30, the rear panel436a, the middle panel436b, the front panel436cand the spacer panel or hinge panel436dare folded together and are turned upward on top of the cab panel436e, with the rear panel436a, the middle panel436b, and the front panel436c, oriented in a generally vertically orientation while resting upon the cab panel436e.

The folding cover assembly430can be secured in the generally vertical position with the with the rear panel436a, the middle panel436b, and the front panel436c, oriented generally vertically, by securing member(s)465(such as cab strap465a, side strap465b, cab panel strap465c, securing magnet465d, or securing bracket465e) that are used to secure the folding cover assembly430in this configuration, as illustrated inFIGS.31A-31E. In some of the configurations illustrated inFIGS.31A-31E, cab securement member(s)467(such as cab bracket467aor cab magnet467b) facilitate securement of the folding cover assembly430with the securing member(s)465as shown.FIG.31A, for example, illustrates cab straps465awhich are secured to cab brackets467awhich are preferably secured to the cab4by adhesive such as adhesives70a,470b,471a,471b, or other adhesives described herein.

FIG.31Billustrates a side strap465bwhich secures the folding cover assembly430in position as shown. A side strap465bcan be provided on both the driver's side and the passenger side, or on only one side. The side strap465bcan form a single long loop which passes through the cab4(such as by temporarily opening the doors or the windows of the cab). Alternatively, the side strap465bcan attach using a buckle to a separate strap which is secured inside the cab4.

FIG.31Cillustrates a cab panel strap465cwhich secures the folding cover assembly430in position as shown. A cab panel strap465ccan be provided on both the driver's side and the passenger side, or on only one side. The cab panel strap465ccan attach to the cab panel436e; alternatively, the cab panel strap465ccan attach using a buckle to a separate strap which is secured to the cab panel436e.

FIG.31Dillustrates a securing magnet465dwhich secures the folding cover assembly430in position as shown. A single securing magnet465dcan be provided or a plurality of securing magnets465dcan be provided. The securing magnet465dcan magnetically attach to a cab magnet467bfor securement to the cab4. Alternatively, the securing magnet465dcan magnetically attach to a portion of the cab4.

FIG.31Eillustrates a securing bracket465ewhich secures the folding cover assembly430in position as shown. A securing bracket465ecan be provided on both the driver's side and the passenger side, or on only one side. The securing bracket465ecan retain the middle panel436band the front panel436cand the cab panel436ein the illustrated configuration (with the rear panel436aand spacer panel436dalso held since they are attached to the other panels436by the hinges444). Alternatively, the securing bracket465ecan attach to the respective support bows450to secure the folding cover assembly in the illustrated configuration. In some embodiments, the securing bracket465eattaches to the panel bracket466.

Another preferred embodiment of the folding tonneau cover apparatus of the present invention is illustrated inFIGS.32-40H. A rear perspective view of a folding tonneau cover apparatus610is illustrated inFIG.32, which includes a support frame assembly618, a folded cover forward securing assembly619, and a folding cover assembly630incorporating a cab panel636eonto which rear panel636a, middle panel636b, spacer panel636d, and front panel636ccan fold, with the folding tonneau cover apparatus610attached to a pickup truck2which is shown in phantom, with a cab4, a drivers side3a, a passenger side3b, a front3c, and a rear3d. The folding tonneau cover apparatus610is secured to the truck2to cover a cargo box5having a drivers side sidewall6a, a passenger side sidewall6b, a front wall6c(FIG.40), and a tailgate6d, which define a top opening6f(FIG.40), a cargo box length7a, and a cargo box width7b. Preferably, the panels636are secured to side rails620a,620bby latches652, of which latches652aand652bare partially shown onFIG.32. The folding cover assembly630has a top632aand a bottom632b.

Preferably, the folded cover forward securing assembly619secures the folded folding cover assembly630in an upright folded orientation in which the top or upper surface637a,637b,637cof the rear panel636a, middle panel636b, front panel636c, respectively, are in an upright or generally vertical orientation. The folded cover forward securing assembly619preferably includes two cab bracket assemblies667c, two cab braces668a, two storage retainers643e, and two storage straps643d. Alternatively, the folded cover forward securing assembly619can include other elements such as the securing members465disclosed herein, including the cab strap465a, the side strap465b, the cab panel strap465c, the securing magnet465d, the securing bracket465ethe panel bracket466, the cab securement member467, the cab bracket467a, the cab magnet467b(FIGS.29-31E) or combinations of the elements disclosed herein.

A top plan view of the folding cover assembly630is illustrated inFIG.32A, which shows the panels636, namely the rear, middle, front, spacer, and cab panels636a,636b,636c,636d,636e, each having a top surface637a,637b,637c,637d,637e, and a width640, namely640a,640b,640c,640d,640e, respectively, and a length639, namely639a,639b,639c,639d,639e, respectively; the folding cover assembly630has a length633, and a gap641between adjacent panels636. The folding cover assembly630preferably includes storage retainers643eattached to the cab panel636e.

A bottom plan view of the folding tonneau cover apparatus610is illustrated inFIG.32B, which shows the folding cover assembly630, the bottom surfaces638a,638b,638c,638d,638eof panels636a,636b,636c,636d,636e, respectively, and support bows650a,650b,650c,650d,650e,650f,650g,650h, latches652a,652b,652c,652d,652e,652fengaged with side rails620a,620b, and with latches652eand652falso engaged with containment brackets625a,625bwhich aid in maintaining the position of the folding cover assembly630with respect to the side rails620a,620band the cargo box5. Note that the spacer panel636dand corresponding bottom surface638dare obscured inFIG.32Bbut are in the indicated location, behind support bow650e. Handles659are attached to the bottom surfaces638of panels636a,636b, and636c, preferably by adhesive670b, such as double-sided adhesive tape671bor by other adhesive elements such as are described herein. Standoffs658are preferably attached to handles659that are attached to the rear panel636aas shown; the standoffs658are preferably attached similar to the attachment of standoffs558to support bows550as illustrated inFIGS.14A-14C. The folding cover assembly630preferably includes perimeter seal634located at the perimeter of the folding cover assembly630; various configurations of perimeter seal are envisioned, such as the perimeter seals534,534a-534kshown inFIGS.15A-15H. The cab panel636eis secured to the side rails620a,620bby cab panel retainers679and retainer bolt678; two retainer bolts are illustrated as examples, including hex bolt678aand handle bolt678b(FIG.32K).

A side view of portions of the folding tonneau cover apparatus610is illustrated inFIG.32C, as viewed from line32C-32C ofFIG.32A, and give further understanding of the relative positioning of the elements. Further detailed views of the folding tonneau cover apparatus610are illustrated inFIGS.32D-32F.FIG.32Dshows a portion of the folding tonneau cover apparatus610as viewed from line32D-32D ofFIG.32A, illustrating the spacer panel636dand adjacent hinges644b,644c, hook662a, catch664a, and containment bracket625awhich keeps latch652ein position when the latch652eis engaged with the side rail lip624(FIG.33B) of side rail620aand helps to maintain the folding cover assembly630at the desired location to cover the cargo box5. Similarly,FIG.32Eshows a portion of the folding tonneau cover apparatus610as viewed from line32E-32E ofFIG.32A, illustrating the front hinge644dand adjacent panels636c,636e. An alternative perimeter seal634j, storage retainer643e, cab panel retainer679, and hex bolt678a, are illustrated. A tether680, secured to support bow650g(not visible onFIG.32E) by ring682, and link681are shown, which provide for an additional safety securement when the link is attached to the side rail620aat aperture683(FIG.32J) as illustrated onFIGS.39C-E, for example.

As further illustrated inFIGS.32F and32G, the folding tonneau cover apparatus preferably includes the storage retainer643e, which is secured to the cab panel626eby a retainer fastener643k. The storage retainer643epreferably includes a retainer protrusion643hthat engages a retainer slot643jin the cab panel636eto aid in maintaining proper position and orientation of the storage retainer643e. The storage retainer643ealso preferably includes a retainer hook643fto which a storage strap643dcan be secured (FIG.39E) and a retainer nest643gwhich is configured and arranged to accommodate the folding cover assembly630in a folded-up configuration as illustrated inFIG.40A, for example. is an enlarged detailed front perspective view of a portion of the folding tonneau cover apparatus encircled by dashed line32F-32F ofFIG.32C, showing a storage retainer and a tether and link.

Portions of the folding tonneau cover apparatus ofFIG.32are illustrated inFIGS.32H-Jto show the structure and elements near passenger side of the spacer panel636dand the cab panel636e. Middle panel636b, front panel636c, and bottom surfaces of the middle panel, front panel, and cab panel, respectively, are shown, with the hook662fengaged with the catch664f, the latch652fengaged with the containment bracket525band the side rail620b, cab brace668asecured by cab brace fastener assembly668dto the support bow650eand engaged with cab brace retainer668f. The release cord654cand handles659are also shown. The tether680is secured to support bow650gby ring682, and is also attached to link681which can be attached to side rail620bat aperture683for additional securement of the folding cover assembly630to the side rail620b; similar elements are located at the drivers side of the folding tonneau cover apparatus610. The retainer fastener643kcan be seen engaged with the cab panel636e. The cab panel retainer679is engaged with the support bow650hand is secured to the side rail620bby a retainer bolt678, such as retainer hex bolt678a, although other fasteners such as retainer handle bolt678b(FIG.32K) can be utilized.

An alternative retainer handle bolt or lever clamp bolt678bis illustrated inFIG.32K; also inFIG.32K; the tether680is not shown in this view.

Referring now toFIGS.33A and33B, the release cord654near the rear end of the rear panel636apasses through cord guides655,655c.FIG.33Bis an enlarged partial section view of the driver's side end portion of the support bow650aas indicated inFIG.33A. The cord guides655,655care preferably molded and made of a strong polymer such as Nylon, which may be reinforced with fiberglass or other embedded material to strengthen the polymer. In alternate embodiments, the cord guides655can made of polymeric, metallic or ceramic materials using three-D printing methods or three-D etching methods or other additive or subtractive machining process.

As seen inFIG.33B, the latch652aincludes latch slide653having an engaging portion653bwhich extends forward to engage the lip624of the side rail620a, so as to secure the panel630ato the side rail620a. The latch slide653preferably includes a stiff polymer, composite, or metal, although other materials and combinations can be used. Preferably, the latch slide653includes fiberglass-reinforced nylon. The latch slide653is biased by a biasing member or spring656towards the side rail620aso that the engaging portion653bengages the side rail620ato form a secured configuration in which the respective panel636is restricted from being lifted up from the cargo box5; in this example, the spring656is a compression spring, but an extension spring, or an elastic element, or other known elements could alternatively be used to bias the latch slide653towards the side rail620aso that the engaging portion653bengages the side rail620aso that the latch652is in the secured configuration. In this embodiment, the spring656is held between the latch slide653and a spring retainer assembly657. The spring retainer assembly657is secured in the desired location in the support bow650a. The side rails620aand620bpreferably include extruded metal, and have a side rail engagement portion622a, arranged to approximate a portion of the sidewall6a,6bof the pickup truck2. The clamp614is shown in detail inFIG.33B. The clamps614preferably include aluminum, although other metals or alloys or polymers or other composite materials can be used. Clamps614preferably have an outer member616aand an inner member616bwhich are tightened towards each other and held as an assembly on the sidewall6aby a fastener assembly616dwhich preferably includes a bolt616e, a washer616f, and a nut616g. Preferably, inner member616bhas a clamp engagement portion616cwhich, together with side rail engagement portion622aof side rail620a, aids in securing the clamps614in place on the side rail620a. Preferably, the clamps614are arranged and tightened to secure the side rail620ato the sidewall6a, with a sidewall gasket622carranged between the side rail620aand the sidewall6aas illustrated. A bow end cap665is located at the end of the support bow650a. A release cord654and a cord guide655are shown, and will be described in further detail herein. In the present example, the side rail engagement portion622ais a generally vertically-oriented portion which configured to be located adjacent a similarly vertically-oriented portion of the sidewall6a,6b. In the example ofFIG.33B, a portion of the sidewall6aof a cargo box5of a Chevrolet Silverado pickup truck is illustrated; however, other sidewalls of other cargo boxes of other pickup trucks and the like can be accommodated, by incorporating a side rail engagement portion622aalong the length of the side rails620aand620bthat are appropriately configured and oriented. In this example, the cargo box5of the pickup truck2includes a sidewall cap6e, but other cargo boxes5lack a sidewall cap. A sidewall6aand sidewall cap6eare similarly illustrated in subsequent drawings herein. Preferably, the side rail engagement portion622ahas a side rail engagement feature622b, such as ridges, knurling, surface patterns or textures, or other features which aid in securing the clamps614. Preferably, a sidewall gasket622cpreferably made of polymeric material is located between the side rail engagement portion622aand the sidewall6a; the sidewall gasket622ccan provide protection against damage to the sidewall6aby abrasion against the side rail620a. Other flexible material can also be used. The sidewall gasket622ccan provide leak resistance to prevent water, dust, or other debris from passing into the cargo box5along the side rail engagement portion622a. The side rail620ahas a flange or side rail lip624along the length of the side rail620a. The side rail lip624provides support for the folding cover assembly630. In addition, the side rail lip624provides a feature for engagement of the engaging portion653bof the latches652. The driver's side portion of the support bow650ais shown inFIG.33B; the other end of the support bow650a(toward the passenger side) has a mirror-image configuration, with a latch652engaging side rail620b, and side rail620bbeing attached to sidewall6bin a similar manner.

As illustrated inFIGS.34A and34B, when it is desired to release the latches652at the rear end of the rear panel636a, the release cord654acan be pulled, which will retract each of the latches652against the force of the respective biasing member or spring656. Typically, the release cord654awill be pulled as illustrated inFIG.34A, by an operator8who has walked to the rear of the cargo box5and has opened the tailgate6dand reaches in to access and pull the release cord654a. When the release cord654ais pulled, the engaging portion653bof the latch652is retracted away from the lip624of the side rail620aas shown inFIG.34B, releasing the latch652from the side rail620aand allowing the rear portion of the rear panel636ato be lifted up from the side rail620a. The cord guides655adjacent to the latches652help to maintain alignment of the ends of the release cord654aso that the latches652are retracted in alignment with the support bow650a, to avoid excessive friction, wear and potential binding. The driver's side portion of the support bow650ais shown inFIG.34B; the other end of the support bow650a(toward the passenger side) has a mirror-image configuration, and when the release cord654ais pulled, the latches652at both ends of the support bow650aare retracted, so that the rear end of the rear panel636acan be lifted up from both side rails620aand620b.

Referring now also toFIGS.35A-35D, which illustrate a portion of the folding cover assembly630in schematic cross section views as indicated by the line35A-35A inFIG.32A, each of the hinges644(644a,644b,644c, and644d) preferably includes the flexible hinge body645awhich is elongated and extends between the driver's side3aand the passenger side3bof the cargo box5when the folding cover assembly630is unfolded to cover the cargo box5. The flexible hinge body645ais similar to the flexible hinge body545aofFIG.17C, with similar elements and configuration, with a hinge longitudinal axis645bwhich is oriented along the length of the hinge body645a, and a hinge body profile645c, which is the shape of a transverse vertical cross section taken perpendicular to the hinge longitudinal axis645b(not shown separately; refer to corresponding elements for flexible hinge body545ainFIG.17C, including the hinge longitudinal axis545bwhich is oriented along the length of the hinge body545a, and the hinge body profile545c, which is the shape of a transverse vertical cross section taken perpendicular to the hinge longitudinal axis545b). The hinge body profile645cis preferably uniform along the hinge longitudinal axis645bof the hinge body645a. In embodiments having more than one flexible hinge644, each of the flexible hinges644can have a similar hinge body profile645c. Alternatively, the hinge body profile645cof the flexible hinge bodies645acan differ from the profile of at least one other of the flexible hinge bodies645a.

The hinge644preferably includes a hinge body645a, which is similar to the hinge body545adescribed herein; several hinge body embodiments are shown and described in detail elsewhere herein, including hinge body545a, hinge body545a′, hinge body545a″, and hinge body545a′″ (FIGS.17C-18F).

In preferred embodiments illustrated inFIGS.35A-35C, flexible hinge body645aincludes central portion646a, side portion646b, and side portion646c. Adhesive670ais preferably located between each side portion646b,646cand the respective rigid panel636as illustrated inFIG.35Ato protect against passage of debris or precipitation into the cargo box5; the adhesive670acan also aid in securement of the flexible hinge644to the respective rigid panel636. The adhesive670acan include known adhesives and sealant materials which can be used to protect against passage of debris or precipitation between the rigid panel636and the respective flexible hinge644or to secure the flexible hinge644to the respective rigid panel636. In some preferred embodiments, the adhesive670aincludes a double-sided adhesive tape671a, which preferably includes an acrylic foam material672a, with adhesive layer672barranged on one side of the acrylic foam material672a, and adhesive layer672carranged on the other side of the acrylic foam material672a, for example. For example, the double-sided adhesive tape671acan be 3M 5933 from 3M, St. Paul, Minn. (“thermal adhesive tape”), the adhesive layer672bincludes heat-activated adhesive and an adhesive layer672cincludes pressure-sensitive adhesive which may be protected by a release strip (not shown) until it is desired to activate the pressure-sensitive adhesive layer672c. Preferably, the adhesive layer672b(in this example, heat-activated adhesive) is aligned with the flexible hinge body645awhile the heat-activated adhesive is activated to adhere the double-sided adhesive tape671ato the flexible hinge body645a; the flexible hinge body645atogether with the attached double-sided adhesive tape671ais subsequently aligned with the rigid panel636and the release strip is removed. Preferably, after the adhesive layer672cis aligned with the panel636, the flexible hinge body645ais attached to the rigid panel636by activating the adhesive layer672c(in this example, pressure-sensitive adhesive). The adjacent rigid panel636is similarly attached to the flexible hinge body645awith double-sided adhesive tape671aforming the structure of hinge644illustrated inFIG.35B. The flexible hinge body645aallows the hinge644to take a flat or open configuration as illustrated inFIGS.35A and35B, or to flex or bend as illustrated inFIG.35C, and other figures herein, providing a flexible hinge644that allows the folding cover assembly630to fold as illustrated throughout the Figures and described herein, with rigid panels636folding up and rotating towards other rigid panels636as shown. Preferably, the flexible hinge body645ais adhered to the respective bottom or underside638of the rigid panels636(specifically, the underside638a-638eoff respective adjacent panels of636a-636edas described herein) of the folding cover assembly530as shown. In the preferred arrangements discussed herein, the hinges44are securely attached to the respective rigid panels636and are sealed to prevent water or debris from entering the cargo box through the folding cover assembly630at the hinges644, and are generally impervious to environmental factors such as precipitation, wind, and temperatures to which a typical cargo box5would be exposed.

The support bows650are also schematically illustrated inFIGS.35A-35C. The support bows650are similar to support bows550described herein (FIGS.16A-16K) which preferably include a bow main portion584including a generally C-shaped channels with a bow upper portion585configured for attachment to the bottom surface538of the respective panel536and oriented with a channel opening566cat the bottom. The support bows650which are located at the flexible hinges644preferably include a hinge support flange686similar to hinge support flange586,586a,586b; the support bows which are located at the flexible hinges644preferably also include a flange lip similar to flange lip587,587a,587b.

As stated above, the support bows650are secured to the respective panel636. The support bows650are preferably located at the bottom surface638of the respective panel636, and near the front edge641bor rear edge641cof the respective panel636. The support bows650are preferably secured to the bottom surface638of the respective panel636by an adhesive670b, which may include a layer or coating of adhesive or a double-sided adhesive tape671b, for example. Alternatively, a thermal or hot-melt or chemically activated adhesive, or a mechanical attachment, or a weld, or a combination, can be used to attach the support bows650, to the respective panels636. The double-sided adhesive tape671bpreferably includes an acrylic foam material672dwith adhesive layer672earranged on one side of the acrylic foam material672dand adhesive layer672farranged on the other side of the acrylic foam material672d, for example. Preferably, the adhesive670bincludes a double-sided adhesive tape671bsuch as 3M CV62F from 3M, St. Paul, Minn. (“pressure adhesive tape”), wherein the double-sided adhesive tape671bis an acrylic foam tape having an adhesive layer672ewhich includes pressure-sensitive adhesive and having an adhesive layer672fwhich includes pressure-sensitive adhesive which may be protected by a release strip (not shown) until it is desired to activate the pressure-sensitive adhesive, adhesive layer672f. Preferably, the adhesive layer672e(in this example, pressure-sensitive adhesive) is aligned with and adhered to the upper surface666dof the support bow650to adhere the double-sided adhesive tape671bto the support bow650; the support bow650together with the attached double-sided adhesive tape671bis subsequently aligned with the panel636and the release strip is removed. Preferably, the adhesive layer672fis then aligned with the panel636and the support bow650is attached to the respective panel636by activating the adhesive layer672f(in this example, pressure-sensitive adhesive). While the arrangement just described is a preferred configuration, any of the adhesive layers just described can include heat-activated adhesive or pressure-sensitive adhesive, and the acrylic foam material672a,672dis also preferable but not always required. For example, in alternative configurations, a single layer of adhesive could be used, similar to the arrangement schematically illustrated inFIG.35A. Other pressure-activated acrylic adhesive foam tape can be used, such as Lamatek 5357 from Lamatek, Inc., West Deptford, N.J. The sidebars or handles659are preferably also attached to the bottom surface or underside638of the respective panels636, preferably in a similar manner as that just described for the support bow650. Although adhesive670bcan be applied at selected portions of the length of the support bow650or the sidebar659, adhesive670bis preferably applied along substantially the entire length of the support bow650and the sidebar659, to enhance stability and to minimize unwanted vibrations. Alternatively, the sidebars659and support bows650can be attached to the panels636with adhesives such as glue, or with fasteners, or spot welds.

In some apparatus and methods embodiments, the folding cover assembly630folds in stages or steps; a preferred embodiment is schematically illustrated inFIG.35D. In this embodiment, starting from the unfolded or closed configuration of the folding cover assembly630(configuration 1), the hinge544aflexes to allow the rear panel636ato fold up, passing through 90 degrees (configuration 2) towards the middle panel636b, and fold over onto the middle panel636b(configuration 3). The hinge644bflexes to allow the middle panel636b(together with the rear panel636awhich is folded onto the middle panel636b) to fold up, passing through 90 degrees (configuration 4) towards the spacer panel636d, passing through a point at which standoffs658contact the front panel (configuration 5). The hinge644bflexes back towards 90 degrees as the hinge644cflexes to allow the spacer panel636dto fold up, and continue to fold over (together with the rear panel636awhich is folded onto the middle panel636b, and the middle panel636b) towards the front panel636c(configuration 6), until the folding cover assembly30is folded up onto the front panel636c(configuration 7). The hinge644dflexes to allow the front panel636c(together with the rear panel636a, middle panel636b, and spacer panel636d) to a generally vertical orientation onto the cab panel636e(configuration 8). The cab brace668asecures to the cab bracket assembly667cto secure the folding cover assembly630adjacent to the cab4. Note thatFIG.35Dis a schematic overview of the general folding of the folding cover assembly630; the various configurations are further illustrated and described elsewhere herein in greater detail.

Once the latches652at both ends of the support bow650aare retracted as shown inFIGS.34A and34Band described above, the rear end of the rear panel636acan be lifted up from both side rails620aand620b, bending the hinge644aas illustrated inFIGS.36A and36B. As shown inFIG.36B, the engaging portion653bof the latch slide653of latch652cis engaged with the side rail620ato restrict the middle panel636bfrom being lifted up from the cargo box5.

The rear panel636ais rotated further, onto the middle panel636bas illustrated inFIGS.37A and37B. At this point, the engaging portion653bof latch slide653of the latch652cis engaged with the side rail620ato restrict the middle panel636bfrom being lifted up from the cargo box5. When it is desired to release the latches652at the rear end of the middle panel636b, the release cord654bcan be pulled, which will retract each of the latches652cand652dagainst the force of the respective biasing member or spring656, as shown inFIG.37C, releasing the latches652from the side rails620aand620band allowing the rear portion of the rear panel636ato be lifted up from the side rails620aand620b. The driver's side portion of the support bow650cis shown inFIGS.37B-37C; the other end of the support bow650c(toward the passenger side) has a mirror-image configuration, and when the release cord654bis pulled, the latches652at both ends of the support bow650care retracted, so that the rear end of the middle panel636b, together with the rear panel636a, can be lifted up from both side rails620aand620b.

Once the latches652at both ends of the support bow650bare retracted as shown inFIG.37Cand described above, the rear end of the middle panel636bcan be lifted up from both side rails620aand620b, bending the hinge644bas illustrated inFIGS.38A and38B.FIG.38Ashows the configuration in which the rear panel636ais folded over onto the middle panel636band wherein both the rear panel636aand the middle panel636bhave been lifted up and pivoted forward generally about 90 degrees with respect to the front panel636cthat is resting on the side rails620a,620band is generally in a horizontal plane with respect to the pickup truck which is shown in part in phantom. The hook662dis disengaged from the catch664das the middle panel636bis lifted up from the cargo box5, as shown inFIG.38B.

With continued lifting and rotating of the middle panel636bfrontwards, the middle panel636btogether with the rear panel636arotates frontwards towards the front panel636c. Preferably, the folding cover assembly630includes 4 standoffs658. The standoffs658are preferably attached to the handles659near the front and back of the panel636aas shown inFIG.37Aand elsewhere herein; alternatively, the standoffs658can be attached to the bottom surface638aof the rear panel636aor attached to other structures such as support bows650a,650b. The standoffs658are preferably located so that two are proximate the front edge641bof the rear panel636a, and two are proximate the rear edge641cof the rear panel636a. Through the folding and rotating of the middle panel636btogether with the rear panel636aas just described, the standoffs658proximate the rear edge641cof the rear panel636acontact the top surface637cof the front panel636cand help to maintain a spaced relationship between the rear panel636aand the front panel636c. With continued rotating of the middle panel636b(together with the front panel636a) the hinge644cbends and the spacer panel636dlifts off the side rails620aand620b, and the middle panel636b, the rear panel636a, and the spacer panel636drotate progressively farther frontwards towards the front panel636cuntil the standoffs658all contact the front panel636c(FIG.39A). During this folding of the folding cover assembly630, the hinges644band644cflex as the middle panel636b, the rear panel636a, and the spacer panel636drotate towards the front panel636c. The configurations as the folding cover assembly630is folded up in this manner are similar to those illustrated for folding up of the folding cover assembly530inFIGS.8A-9A. When the folding cover assembly630is folded onto the front panel636c, the rear panel636a, middle panel636b, front panel636c, and cab panel636eare approximately parallel to each other, and preferably oriented about horizontally, provided the cargo box5and side rails620a,620bare oriented horizontally; in this configuration, the spacer panel636dis preferably oriented approximately vertically, although it can be somewhat off vertical as illustrated inFIGS.5E and5Ffor alternate folding cover assemblies530′ and530″.

At this point, as illustrated inFIGS.39A-39E, and10A, the folding cover assembly630is folded up, but is still “flat” on the cargo box5and still attached to the side rails620aand620b, with the latches652eand652f(proximate the ends of the support bow650f) engaged with the side rail lip624of the side rails620aand620b, respectively, as illustrated inFIGS.39A-39B. In the view ofFIG.39B, a portion of the driver's side of the partially folded folding cover assembly630is illustrated, showing the engaging portion653of the latch652enear the driver's-side end portion of the support bow650fengaged with the lip624of the driver's side side rail620aand the containment bracket625a. The link681attached to tether680is shown detached from the side rail620afor illustration.

When it is desired to release the latches652eand652fat the rear end of the front panel636c, the release cord654ccan be pulled, which will retract each of the latches652eand652fagainst the force of the respective biasing member or spring656, as shown inFIG.39C, releasing the latches652from the side rails620aand620band allowing the rear portion of the front panel636ato be lifted up from the side rails620aand620b. The link681attached to tether680is shown attached from the side rail620a.

FIG.39Dshows a portion of the folding tonneau cover apparatus610in the configuration illustrated inFIGS.39A-39B, but seen from the line39D,E-39D,E ofFIG.39Aillustrating the driver's side of the partially folded tonneau cover assembly. In this view, the storage strap643dis seen, not secured to the storage retainer643e. A standoff658is also shown. The storage strap643dcan be pulled down and secured to the storage retainer643eas shown inFIG.39D(by engaging the storage strap643dwith the retainer hook643fshown inFIG.32G).

With the rear panel636a, middle panel636b, front panel636cand spacer panel636dsecured to the cab panel636e, the operator8can lift up the rear panel636a, middle panel636b, front panel636cand spacer panel636donto the cab panel636e, disengage the two cab braces668afrom the cab brace retainers668f(FIG.40C), pivot the cab braces668aforward and secure the cab braces668ato the cab bracket assemblies667cto secure the folded-up folding cover assembly630in a generally vertical orientation adjacent the cab4as illustrated inFIG.40. In this configuration, the operator8can attach or detach the cab braces668afrom the cab bracket assemblies667c, or actuate the retainer hex bolts678aor retainer handle bolts678bto disengage the folding cover assembly630from the side rails620a,620bto remove the folding cover assembly630from the support frame assembly618or attach the folding cover assembly630to the support frame assembly618as desired.

The folding cover assembly630is further illustrated in a folded-up vertical configuration inFIG.40A, which shows the rear panel636a, middle panel636b, front panel636cand spacer panel636drotated onto the cab panel636eand engaged with the retainer nest643gof each of the storage retainers643e, and the standoffs658maintaining the separation of the rear panel636aand the front panel636c. The tether680is secured by attaching the link681to the aperture683in the side rail620a. InFIG.40A, each cab brace668ais secured to the support bow650eby a cab brace retainer668f. A detailed view of a portion of the folding cover assembly630is illustrated inFIG.40C, which shows one of the cab braces668asecured to the support bow650ewhich is secured to the bottom surface638dof the spacer panel636d. The cab brace668ais secured to the support bow650eby the cab brace fastener assembly668dand by the cab brace retainer668f. The cab brace second end portion668cis also shown.

FIG.40Dis a similar view asFIG.40C, but shows the cab brace disengaged from the cab brace retainer668f. The cab brace first end portion668gand cab brace first end portion top surface668i, the cab brace body portion668band cab brace body portion top surface668h, and the cab brace second end portion668cand cab brace second end portion top surface668jare also shown. In most cases, the support bow650eof the folding cover assembly630, when in a generally vertical configuration such as that illustrated inFIG.40B, will be at a similar height or somewhat higher than the cab4. Depending on the relative height of the support bow650eand the cab4, the cab brace second end portion668cis preferably bent upward at a cab brace angle668ethat is preferably between about 1 degree to about 16 degrees, so that the cab brace second portion668cengages the anchor post667f(FIG.40G) perpendicularly. In one example, the cab brace angle668e′ is about 5 degrees; in another example, the cab brace angle668e″ is about 15 degrees. The cab brace second end portion668cis preferably adapted to secure to the cab bracket assembly667c. In preferred embodiments, the second end portion668cincludes a material which can be attracted by a magnet, such as a steel material, and the cab bracket assembly667cincludes a cab bracket magnet667to aid in retaining the cab brace668asecurely to the cab bracket assembly667c. A preferred material for the cab brace668ais ASTM A36 pickled and oiled hot-rolled steel, preferably about 0.125 inch thick.

If the support bow650eis much higher than the cab4, so that the cab brace angle668ewould be greater than about 16 degrees, the cab brace668ais preferably secured to an auxiliary support bow650jwhich is secured to the bottom surface638bof the middle panel636b. The auxiliary support bow650jis preferably oriented so that the cab brace is secured below the auxiliary support bow650jas illustrated. The auxiliary support bow650jis preferably secured to the bottom surface638bof the middle panel636bby double-sided adhesive tape671b, although other adhesive670bsuch as described herein can be utilized. Preferably, the auxiliary support bow650jis secured to the middle panel636bat a desired location so that the cab brace angle668is less than about 16 degrees. In this configuration, the cab brace second end portion668cis co-planar with the cab brace body portion668b, and the cab brace angle668eis zero.

The cab bracket assembly667cis further illustrated inFIGS.40F-40H. The cab bracket assembly667cpreferably includes a cab bracket body667d, which includes a cab bracket protrusion or667f. The cab bracket assembly667cpreferably includes a cab bracket magnet667ethat is secured to the cab bracket body667dby a cab magnet retainer667h. The cab bracket assembly667cis preferably secured to the cab4by cab bracket adhesive667j. The cab bracket adhesive667jis preferably an adhesive foam tape such as Tesa 7078 acrylic foam tape. Other adhesive such as double-sided adhesive tape671bor other adhesives such as those described herein can be utilized.

Another preferred embodiment of the folding tonneau cover apparatus of the present invention is illustrated inFIGS.41-48. A rear perspective view of the folding tonneau cover apparatus or hinged tonneau cover apparatus710is illustrated inFIG.41, which includes a support frame assembly718, and a folding cover assembly or hinged cover assembly730incorporating a cab panel736efrom which a rear panel736acan fold, illustrated with the folding or hinged tonneau cover apparatus710attached to a pickup truck2which is shown in phantom, with a cab4, a drivers side3a, a passenger side3b, a front3c, and a rear3d. The folding tonneau cover apparatus710is secured to the truck2to cover a cargo box5having a drivers side sidewall6a, a passenger side sidewall6b, a front wall6c(FIG.48), and a tailgate6d, which define a top opening6f(FIG.48), a cargo box length7a, and a cargo box width7b. Preferably, the panels736are secured to side rails720a,720bby latches752, latches752aand752bbeing partially shown onFIG.41. The folding cover assembly730has a top732aand a bottom732b.

A top plan view of the folding cover assembly730is illustrated inFIG.42A, which shows the panels636, namely the rear panel736aand the cab panel736e, each having a top surface737a,737e, and a width740, namely740a,740e, and a length739, namely739a,739e, respectively; the folding cover assembly730has a length733and a top732a. The folding cover assembly730preferably includes storage retainers743eattached to the cab panel736e.

A bottom plan view of the folding tonneau cover apparatus710is illustrated inFIG.42B, which shows the folding cover assembly730, the bottom surfaces738a,738eof rear panel736aand cab panel736e, respectively, and support bows750, including support bow750a(rear of rear panel736a), support bow750b(front of rear panel736a), support bow750h(cab panel736e), and intermediate support bow(s)750spaced along the rear panel736abetween support bow750aand support bow750b. Also shown are latches752a,752bengaged with side rails720a,720b. Handles759are attached to the bottom surface738of rear panel736a, preferably by adhesive770b(similar to adhesive670billustrated onFIG.35A) or other adhesive elements such as are described herein. Preferably, adhesive770bis double-sided adhesive tape771b(FIG.35C). Handles759are preferably attached to the bottom surface738aof the rear panel736aas shown; the standoffs758are preferably attached in a similar manner as the attachment of standoffs558to support bows550as illustrated inFIGS.14A-14C. The folding tonneau cover apparatus710also preferably includes a drivers side support beam773aand a passenger side support beam773bwhich are secured to the handles759to provide additional structural support to the rear panel736a. The folding tonneau cover apparatus710also preferably includes two lift supports or gas struts774, with a gas strut774secured by a gas strut support beam fastener assembly775ato the drivers side support beam773aand by a gas strut side rail fastener assembly775bto the drivers side side rail720a, and a gas strut774secured by a gas strut support beam fastener assembly775ato the drivers side support beam773aand by a gas strut side rail fastener assembly775bto the drivers side side rail720. Suitable gas struts are available, for example from SUSPA® Inc., 3970 Roger B. Chaffee Memorial Dr., Grand Rapids, Mich. 49548. Alternate gas struts are available from various sources. The folding cover assembly730preferably includes snap clips776for securing the gas struts774to the support beams773a,773bwhen the folding cover assembly730is not attached to the truck2. The folding cover assembly730preferably includes perimeter seal734located at the perimeter of the folding cover assembly730; various configurations of perimeter seal are envisioned, such as the perimeter seals534,534a-534kshown inFIGS.15A-15H. The cab panel736eis secured to the side rails720a,720bby cab panel retainers779(FIG.42D) and retainer bolt778; two retainer bolts are illustrated as examples, including handle bolt778band hex bolt778a(FIG.42I). The cab panel retainers779are also engaged with containment brackets or swing containment brackets725c,725dwhich aid in maintaining the position of the folding cover assembly730with respect to the side rails720a,720band the cargo box5. In some embodiments, the folding tonneau cover apparatus730includes hooks762a,762bwhich secure to catches764a,764b. In some embodiments, the folding tonneau cover apparatus730includes hinge supports or hinge support mechanisms749(FIG.42I) described herein. The folding cover assembly730preferably includes a pull-down strap assembly729(FIG.42H) including a strap retainer729band a pull-down strap729a(FIG.48).

A side view of portions of the folding tonneau cover apparatus710is illustrated inFIG.42C, as viewed from line42C-42C ofFIG.42A, and give further understanding of the relative positioning of the elements. Further detailed views of the folding tonneau cover apparatus710are illustrated inFIGS.42D-42G.FIG.42Dshows a portion of the folding tonneau cover apparatus710encircled by line42D-42D onFIG.42C, illustrating the cab panel736e, the rear portion of the rear panel736a, the support bow750bmostly obscured by bow end cap765, the support bow750h, hinge744d, hook762e, catch764e(FIG.42F), swing containment bracket725cwhich keeps latch cab panel retainer779in position on the side rail720aand helps to maintain the folding cover assembly730at the desired location to cover the cargo box5. The cab panel retainer779is secured to the support bow750hby handle bolt778b.

A bottom perspective view of the folding tonneau cover apparatus710is illustrated inFIG.42E, with a detail view of the portion of the folding tonneau cover apparatus710encircled by line42F onFIG.42Ebeing illustrated inFIG.42F. The hinge744d, swing containment bracket725d, cab panel retainer779, handle bolt778b, passenger side support beam773b, and beam end cap773care also shown.

A portion of the driver's side of the hinged tonneau cover apparatus710is illustrated in a partial section view as seen from the line42G-42G ofFIG.42AinFIG.42G, which shows the side support beam773bsecured to handle759by adhesive770b. The support bow750bis in place on the side rail lip724of side rail720a, and perimeter seal734seals against the side rail720aand the side wall cap6eon the drivers side sidewall6a. The side rail720ais secured to the sidewall6aby a clamp714, which preferably includes the an outer member716a, an inner member716b, a clamp engagement portion716c, and a fastener assembly716d; the fastener assembly can, for example, include a bolt716e, a washer716fand a nut716gas illustrated. Preferably, inner member716bhas a clamp engagement portion716cwhich, together with side rail engagement portion722aof side rail720a, aids in securing the clamps714in place on the side rail720a. Preferably, the clamps714are arranged and tightened to secure the side rail720ato the sidewall6a, with a sidewall gasket722carranged between the side rail720aand the sidewall6aas illustrated. The cab panel retainer779and handle bolt are also shown.

An alternate folding tonneau cover apparatus710is shown inFIG.42H. In this embodiment, the folding cover assembly730includes retainer bolts778which are hex bolts778a. This embodiment also includes hinge supports or hinge support mechanisms749(FIG.42I) described herein. The folding cover assembly730preferably also includes a pull-down strap assembly729including a strap retainer729band a pull-down strap729a(FIG.48). Further details are illustrated inFIG.42I, which illustrates the front passenger portion of the folding tonneau cover apparatus710ofFIG.42H, similar to the view ofFIG.42F. A hinge support mechanism749is shown, as will be more fully described in reference toFIGS.45-47. Preferably, the folding cover assembly730includes a pair of hinge support mechanisms749located apart from each other such as illustrated onFIG.42H.

The hinged or folding cover assembly740ofFIG.42His further illustrated in a rear perspective view in Fig., with the folding tonneau cover apparatus730attached to a pickup truck2which is shown partially and in phantom. A partial section view as seen from the line43B-43B ofFIG.43Ais shown inFIG.43B, which shows the engaging portion of one of the latches on the rear support bow or support member of the rear panel engaged with the lip of the side rail, and the side rail clamped to the sidewall of the pickup truck with a portion of the truck sidewall and sidewall cap shown in phantom.

As seen inFIG.43B, the latch752aincludes latch slide753having an engaging portion753bwhich extends forward to engage the lip724of the side rail720a, so as to secure the panel730ato the side rail720a. The latch slide753preferably includes a stiff polymer, composite, or metal, although other materials and combinations can be used. Preferably, the latch slide753includes fiberglass-reinforced nylon. The latch slide753is biased by a biasing member or spring756towards the side rail720aso that the engaging portion753bengages the side rail720ato form a secured configuration in which the rear panel736ais restricted from being lifted up from the cargo box5; in this example, the spring756is a compression spring, but an extension spring, or an elastic element, or other known elements could alternatively be used to bias the latch slide753towards the side rail720aso that the engaging portion753bengages the side rail720aso that the latch752ais in the secured configuration. In this embodiment, the spring756is held between the latch slide753and a spring retainer assembly757. The spring retainer assembly757is secured in the desired location in the support bow750a. The side rails720aand720bpreferably include extruded metal, and have a side rail engagement portion722a(FIG.44B), arranged to approximate a portion of the sidewall6a,6bof the pickup truck2. The clamp714is shown in detail inFIG.43B. The clamps714preferably include aluminum, although other metals or alloys or polymers or other composite materials can be used. Clamps714preferably have an outer member716aand an inner member716bwhich are tightened towards each other and held as an assembly on the sidewall6aby a fastener assembly716dwhich preferably includes a bolt716e, a washer716f, and a nut716g. Preferably, inner member716bhas a clamp engagement portion716cwhich, together with side rail engagement portion722aof side rail720a, aids in securing the clamps714in place on the side rail720a. Preferably, the clamps714are arranged and tightened to secure the side rail720ato the sidewall6a, with a sidewall gasket722carranged between the side rail720aand the sidewall6aas illustrated. A bow end cap765is located at the end of the support bow750a. A release cord754and a cord guide755aare shown. The driver's side portion of the support bow750ais shown inFIG.43B; the other end of the support bow750a(toward the passenger side) has a mirror-image configuration, with latch752bengaging side rail720b, and side rail720bbeing attached to sidewall6bin a similar manner.

As illustrated inFIGS.44A and44B, when it is desired to release the latches752at the rear end of the rear panel736a, the release cord754acan be pulled, which will retract each of the latches752against the force of the respective biasing member or spring756. Typically, the release cord754awill be pulled by an operator8who has walked to the rear of the cargo box5and has opened the tailgate6dand reaches in to access and pull the release cord754a. When the release cord754ais pulled, the engaging portion753bof the latch752ais retracted away from the lip724of the side rail720aas shown inFIG.44B, releasing the latch752afrom the side rail720aand allowing the rear portion of the rear panel736ato be lifted up from the side rail720a. The cord guides755aadjacent to the latches752help to maintain alignment of the ends of the release cord754aso that the latches752are retracted in alignment with the support bow750a, to avoid excessive friction, wear and potential binding. The driver's side portion of the support bow750ais shown inFIG.44B; the other end of the support bow750a(toward the passenger side) has a mirror-image configuration, and when the release cord754ais pulled, the latches752at both ends of the support bow750aare retracted, so that the rear end of the rear panel736acan be lifted up from both side rails720aand720b. In the illustration ofFIG.44A, the release cord754ais depicted as being pulled in two location; typically the operator8would pull the release cord754ain only one location, causing both latches to release.

FIG.45illustrates a portion of the hinged cover assembly730similar to the portion shown inFIG.42I, except that the cover assembly is flipped upside down and the drivers side of the folding cover assembly730is shown (which is a mirror image of the passenger side of the folding cover assembly730) and some parts have been removed to reveal underlying structures including the hinge support mechanism749, and the rear panel736ahas been lifted up and is shown in a pivoted orientation with respect to the cab panel736e.FIGS.45-47further illustrate the hinge support mechanism749. As shown and described herein (seeFIG.42H), there are preferably two hinge support mechanisms749that help to support and stabilize the folding cover assembly730, and the rear panel736a, and the hinge744das the rear panel736ais lifted up and the hinge744dis bent, when the rear panel736apivots with respect to the cab panel736e. When it is desired to access the cargo box5, and the release cord754ais pulled, retracting the latches752a,752b, the rear panel736acan be lifted up and rotated forward around a pivot arc Dl. The rear panel736apivots with respect to the cab panel736eand generally rotates around a hinge pivot axis749h.

The structure of the hinge744d, support bows750b,750h, and hinge support mechanisms749are generally symmetric with respect to the hinge pivot axis749h. The support bow750bpreferably includes a hinge support flange786extending to support the hinge body745aand is located adjacent the front edge741bof the rear panel736ain a configuration that is a mirror image of the configuration of support bow750hlocated adjacent the rear edge741cof the cab panel736eas shown (see alsoFIGS.35A-35C). Preferably, each hinge support mechanism749includes a hinge bracket749aand a hinge bracket749b, and a bracket guide pin749cwhich is retained in bracket slots749din each of the hinge brackets749a,749b. Each hinge bracket749a,749bincludes a bracket block749ewhich protrudes from the respective hinge bracket749a,749band provides for securement of each hinge bracket749a,749bto the respective support bow750b,750h, by a bracket block nut749fand a bracket block bolt749g. Preferably, the bracket slots749dare each curved in a circular arc, and when the hinge brackets749a,749band bracket guide pin749care assembled and the hinge brackets749a,749bare secured to the support bows750b,750h, the bracket slots749dare each curved in a circular arc centered on the hinge pivot axis749h, so that when the rear panel736ais lifted up and the flexible hinge744dbends and the rear panel736arotates around the hinge pivot axis749h, the hinge brackets749a,749bhelp to constrain the rotation and restrict the pivoting of the rear panel736awith respect to the cab panel736eand support the rear panel736aso that stress on the hinge744dis reduced.

Preferably, there are two hinge support mechanisms749located apart from each other, a first hinge support mechanism749located closer to the side support beam773a, and a second hinge support mechanism749located closer to the side support beam773b, as illustrated herein. When arranged in this manner and secured as shown, the hinge support mechanisms749help to support the front portion of the rear panel736awhen the rear portion of the rear panel736ais lifted up off the side rails720a,720b, and help to maintain alignment of the rear panel736awith respect to the cab panel636e, minimizing any relative displacement or skewing, and reducing stress on the hinge744d. The hinge pivot axis749his generally parallel to the hinge longitudinal axis745b(see hinge longitudinal axis545bonFIG.17C) and may be within or proximate to the hinge body745c. A perspective view of portions of the hinge support mechanism749is shown inFIG.47to better show the detailed structure.

As illustrated onFIG.45, the hinge744dpreferably includes adhesive such as double-sided adhesive tape771cto seal the ends of the hinge body745aagainst the perimeter seal734to prevent precipitation or debris entry into the cargo box5past the hinge744d. Preferably, a short piece of double-sided adhesive tape771csuch as about ¼ inch by ⅝ inch is adhered at each end; suitable material includes an adhesive foam tape such as Tesa 7078 acrylic foam tape. Other hinges disclosed herein, including hinges444,544,644, can incorporate such double-sided adhesive tape to similarly provide a weather seal at each end of the respective hinge.

When the rear panel736ais lifted up as illustrated in the rear perspective view of the folding tonneau cover apparatus710shown inFIG.48, an operator8can access the cargo box5, while the gas struts774support the weight of the folding cover assembly730as necessary to support the rear panel736ain the raised position. When it is desired to lower the rear panel736ato cover the top opening6fand close the folding cover assembly on the cargo box5, the operator8can grasp the pull-down strap729a, which is secured to the support bow750aby a strap retainer729b. When the rear panel736ais lowered completely onto the side rails720a,720b, the latches752a,752bwill engage the side rail lip724of each of the side rails720a,720band secure the folding cover assembly730to the side rails720a,720b.