Tonneau cover system with intermediate automatic latching

A tonneau cover has rectangular elements pivotally connected together. An automatic latch can be coupled to a first rectangular element end of one of the rectangular elements. A latch actuator can extend from the automatic latch to a first latch-rearward rectangular element. The first latch rearward element can be rearward of the first rectangular element end. Movement of the first latch-rearward rectangular element relative to the first rectangular element end, as the tonneau cover moves between closed and open positions, can move the latch actuator which moves the first automatic latch between the latched and unlatched configurations, respectively.

FIELD

The present disclosure relates to tonneau cover systems with latches to lock the tonneau cover in a closed or extended configuration.

BACKGROUND

Trucks such as pickups having an open top cargo box can be a quite popular type of vehicle because the cargo box enables objects of various sizes to be placed therein and transported. Tonneau cover systems can be used to cover the top of cargo box in a closed or extended configuration to protect the contents against dirt, debris, and other environmental contaminants, and to improve the aesthetic quality thereof.

In some cases, the tonneau covers can be formed of a plurality of rectangular elements in the form of slats that are hingedly coupled together so they can be rolled-up into a tubular compact, storage, open or retracted storage configuration at the front of the cargo box to allow access to the cargo box. In some cases, the tonneau covers can be formed of a plurality of rectangular elements in the form of sections that are hingedly coupled together so they can be folded-up into a stacked compact, storage, open or retracted storage configuration at the front of the cargo box.

A front rectangular element is typically coupled to the sides of the cargo box in the closed or extended configuration to minimize the possibility that the front of the tonneau cover could be pulled upwardly away from the cargo box to allow unauthorized access to the front of the cargo box between the tonneau cover and sides of the cargo box. Similarly, a rear rectangular element typically includes a latch for latching or locking the tonneau cover to at least one side of the cargo box in the closed or extended configuration to minimize the possibility that the rear of the tonneau cover could be pulled upwardly away from the cargo box to allow unauthorized access to the cargo box between the tonneau cover and sides of the cargo box.

Additional protection against unauthorized access could potentially be provided by adding intermediate latches between the rear and front rectangular elements. Such additional intermediate latches, however, would make it unduly cumbersome to open the tonneau cover, since each latch would need to be manually unlatched during opening, and potentially manually latched during closing of the tonneau cover. The cumbersome nature of such an arrangement makes it unlikely that such latches would be consistently used.

SUMMARY

In accordance with one aspect of the present disclosure, a tonneau cover system can be provided for a truck cargo box including a forward end and a rear end, and first and second side walls therebetween. The tonneau cover system can include a tonneau cover having a plurality of rectangular elements including a forward and a rear rectangular element, and a first and a second latch-rearward rectangular element. The plurality of rectangular elements can have opposite ends supportable by the first and second side walls, respectively. The rectangular elements can be pivotally or hingedly connected together and moveable between a closed position in which the rectangular elements are in an extended configuration to cover the cargo box, and an open position in which the rectangular elements are in a retracted storage configuration to allow access to the cargo box. A first and a second automatic latch can be coupled to a first and a second rectangular element end at a first and a second side of the tonneau cover, respectively. The first and second rectangular element ends can each be an end of any rectangular element intermediate the forward and rear rectangular elements. Each of the first and second automatic latches can have a latched configuration in which each automatic latch is latched to the first and second side walls, respectively, of the cargo box, and an unlatched configuration in which each automatic latch is unlatched from the first and second side wall, respectively. A first and a second latch actuator can extend from the first and second latch, respectively, to the first and second latch-rearward rectangular element, respectively. Each latch-rearward rectangular element can be rearward of the first and second rectangular element end, respectively. Movement of the first latch-rearward rectangular element relative to the first rectangular element end, as the tonneau cover moves between the closed and open positions, can move the first latch actuator which moves the first automatic latch between the latched and unlatched configurations. Movement of the second latch-rearward rectangular element relative to the second rectangular element end, as the tonneau cover moves between the closed and open positions, can move the second latch actuator which moves the second automatic latch between the latched and unlatched configurations, respectively. The first and second latch actuators can be anchored to the first and second latch-rearward rectangular elements, respectively. The first and second latch-rearward rectangular elements can pull against the first and second latch actuators, respectively, to move the first and second latch actuators which moves the first and second automatic latches from the latched to the unlatched configurations or vice versa.

In accordance with another aspect of the present disclosure, a tonneau cover system can be provided for a truck cargo box including a forward end and a rear end, and first and second side walls therebetween. The tonneau cover system can include a tonneau cover having a plurality of rectangular elements including a forward and a rear rectangular element, and a first and a second latch-rearward rectangular element. The plurality of rectangular elements can have opposite ends supportable by the first and second side walls, respectively. The rectangular elements can be pivotally connected together and moveable between a closed position in which the rectangular elements are in an extended configuration to cover the cargo box, and an open position in which the rectangular elements are in a retracted storage configuration to allow access to the cargo box. A first automatic latch can be coupled to a first rectangular element end at a first side of the tonneau cover. The first rectangular element end can be an end of any rectangular element intermediate the forward and rear rectangular elements. The first automatic latch can have a latched configuration in which the first automatic latch is latched to a first side wall of the cargo box, and an unlatched configuration in which the first automatic latch is unlatched from the first side wall. A first latch actuator can extend from the first latch to a first latch-rearward rectangular element. The first latch rearward element can be rearward of the first rectangular element end. Movement of the first latch-rearward rectangular element relative to the first rectangular element end, as the tonneau cover moves between the closed and open positions, can move the latch actuator which moves the first automatic latch between the latched and unlatched configurations, respectively.

In accordance with yet another aspect of the present disclosure, a tonneau cover system can be provided for a truck cargo box including a forward end and a rear end, and first and second side walls therebetween. The tonneau cover system can include a tonneau cover having a plurality of rectangular elements including a forward and a rear rectangular element, and a first and a second latch-rearward rectangular element. The plurality of rectangular elements can have opposite ends supportable by the first and second side walls, respectively. The rectangular elements can be pivotally connected together and moveable between a closed position in which the rectangular elements are in an extended configuration to cover the cargo box, and an open position in which the rectangular elements are in a retracted storage configuration to allow access to the cargo box. A first and a second automatic latch can be coupled to a first and a second rectangular element end at a first and a second side of the tonneau cover, respectively. The first and second rectangular element ends can each be an end of any rectangular element intermediate the forward and rear rectangular elements. Each of the first and second automatic latches can have a latched configuration in which each automatic latch is latched to the first and second side walls, respectively, of the cargo box, and an unlatched configuration in which each automatic latch is unlatched from the first and second side wall, respectively. A first and a second latch actuator can extend from the first and second latch, respectively, to the first and the second latch-rearward rectangular element, respectively. The first and the second latch-rearward rectangular element can be rearward of the first and second rectangular element end, respectively. Movement of the first latch-rearward rectangular element relative to the first rectangular element end, as the tonneau cover moves between the closed and open positions, can move the first latch actuator which moves the first automatic latch between the latched and unlatched configurations, respectively. Movement of the second latch-rearward rectangular element relative to the second rectangular element end, as the tonneau cover moves between the closed and open positions, can move the second latch actuator which moves the second automatic latch between the latched and unlatched configurations, respectively. During movement between the closed and the open positions, the first and second latch actuators can engage against the first and second latch-rearward rectangular elements, respectively, and the first and second latch-rearward rectangular elements can push against the first and second latch actuators, respectively, to move the first and second latch actuators which moves the first and second automatic latches from the unlatched to the latched configurations or vice versa.

DETAILED DESCRIPTION

FIGS. 1-12illustrate one example of a tonneau cover system30for a cargo box32of a truck34, such as a pick-up truck. The cargo box32can include a forward end wall36and a rear end wall or tailgate38, with a first side wall40and a second side wall42opposite the first side wall40. The first and second side walls40,42extend longitudinally between opposite ends or sides of the laterally or transversely extending forward and rear walls36,38.

A tonneau cover44can include a plurality of rectangular elements52including a forward rectangular element54and a rear rectangular element56, and respective latch-rearward rectangular elements78. The plurality of rectangular elements52have opposite ends supportable by the first and second side walls,40,42, respectively. The rectangular elements52are pivotally or hingedly connected together and moveable between a closed position (FIG. 1) and an open position (FIG. 3). In the closed position, the rectangular elements52are in an extended configuration (FIG. 1) covering the cargo box32. In the open position, the rectangular elements52are in a retracted storage configuration (FIG. 3) that allows access to the cargo box32.

As in this example embodiment, most or all of the rectangular elements52can be slats and the tonneau cover44can be a roll-up tonneau cover. The slats52can include a main extruded member98with an end cap or housing82provided along each end of the slat52, or each side of the tonneau cover44.

The forward rectangular element54can remain coupled to the side walls40,42in both the extended configuration (FIG. 1) and the retracted storage configuration (FIG. 3). The rear rectangular element56can have at least one manual latch72. The manual latch72can be latched or locked to one or both side walls40,42of the cargo box32when the tonneau cover44is in the extended configuration (FIG. 1). The manual latch72can be similar to the automatic latches62, and can similarly engage the latching flange60as described hereinafter. In some embodiments, the manual latch72can be a slam latch so that it automatically latches when the tonneau cover44is in the extended or closed configuration (FIG. 1). Instead of an automatic actuator, however, the manual latches72include a grasping portion74, which a user grasps and manipulates in order to individually or simultaneously move the manual latch(s)72of the rear slat56into an unlatched or unlocked position. This allows movement of the tonneau cover from the extended configuration (FIG. 1) toward the retracted storage configuration (FIG. 3) to be initiated from the rear slat56.

The tonneau cover system can include a first side rail46and a second side rail48. The first and second side rails46,48can be identical and are designed to be coupled to, and to extend longitudinally along, the first and second side walls40,42, respectively. For example, the side rails46,48can be clamped to the side walls40,42with a clamp59engaging a clamping flange58of the corresponding side rail46,48. Opposite ends of the plurality of rectangular elements52can be supported on respective support flanges50of the first and second side rails46,48. Thus, opposite ends of the plurality of rectangular elements52can be indirectly supported by the first and second side walls40,42via the side rails46,48.

The manual latch72can be latched or locked to one or both side walls40,42. Each side rails46,48can include a latching flange60positioned above the support flange50. The manual latch72can be indirectly latched to a respective side wall40,42by being latched to the respective side rails46,48. Similarly, the forward rectangular element54can be indirectly coupled to the side walls40,42by being coupled to the side rails46,48.

One or more automatic latches62can each be coupled to a corresponding rectangular element end64of the tonneau cover44. Each rectangular element end64having an automatic latch62can be an end of any rectangular element52intermediate the forward and rear rectangular elements54,56. Each automatic latch62can have a latched configuration (FIG. 8) in which the automatic latch62is latched or locked to a corresponding side wall40or42of the cargo box32. Each automatic latch62can have an unlatched configuration (FIG. 9in which the automatic latch62is unlatched or unlocked from the corresponding side wall40or42of the cargo box32). Each automatic latch62can be latched to the latching flange60of the corresponding side rail46,48in the latched configuration. Thus, each automatic latch62can be indirectly latched or locked to the corresponding side walls40,42via the side rails46,48. For example, the automatic latch62can have a latching surface100that is positioned adjacent to, and captured by, the latching flange60when the cover44is in the extended configuration and the automatic latch62is in the locked or latched position or configuration. As with this example embodiment, at least one automatic latch62can be provided on each of the opposite longitudinal sides of the tonneau cover44to help prevent unauthorized access to the cargo bed32by lifting either longitudinal side of the tonneau cover44.

A latch actuator76can extend from each automatic latch62to a corresponding latch-rearward rectangular element78, which is rearward of the rectangular element end64to which the corresponding automatic latch62is mounted. As in this example embodiment, the latch actuator76can include a coupling arm68, and a cable80. A biasing member66, such as the illustrated spring, can be provided to bias the automatic latch62and latch actuator76toward corresponding latched or locked positions (FIG. 8). The coupling arm68can engage a slot70of the automatic latch62to enable the coupling arm68to pull against the spring66to move the automatic latch62inward toward its unlatched or unlocked position (FIG. 9).

The automatic latch62and the coupling arm68can be supported by a housing82, which can include two housing components83,84. The housing82can include coupling flanges86, such as tabs, that engage into cooperating slots88of the slat52to couple the automatic latch62to the slat52. The cable80can extend from the coupling arm68and is anchored at its opposite end to the corresponding slat52via a terminal anchor90. The cable80can pass around an intermediate anchor92that operates as an actuator guide. The anchors90,92can each be similarly coupled to the corresponding slat52via flanges86, such as peripheral sides of a base plate94, that engage into cooperating slots88.

As in this example embodiment, the cable80can have an initial or first portion, between the automatic latch62and the intermediate anchor92, that extends in a first direction that is substantially parallel to a longitudinal direction of the slats52. This first direction is also substantially parallel to the transverse or lateral direction of the tonneau cover44and cargo box32. This first direction is also substantially transverse to the longitudinal direction of the tonneau cover44and cargo box32. In addition, the cable80can have a second or terminal section, between the automatic latch62and the intermediate anchor92, that extends in a second direction that is substantially perpendicular to the first direction. It is worth noting that any apparent kinks in the cable80of the drawings are merely drawing artifacts, and are not actually present in the physical cable80.

As the tonneau cover44moves between the closed and open positions, the relative hinging movement of the latch-rearward slats78relative to the slat end64to which the respective automatic latch62is mounted results in the terminal anchor90effectively moving away from the intermediate anchor92and from the automatic latch62. Thus, the relative hinging movement of the slats52while rolling-up the tonneau cover44causes the respective latch-rearward slats78to pull the cable80and the automatic latch62, moving them into corresponding unlatched or unlocked positions or configurations. Thus, there is no need to separately manually operate the automatic latches. The act of rolling up the tonneau cover44alone automatically unlatches each automatic latch62. Similarly, the act of unrolling the tonneau cover44alone can automatically latch each automatic latch62. In some embodiments, the automatic latches62can be slam latches so that they automatically latch when the tonneau cover44is in the extended or closed configuration (FIG. 1).

In some embodiments, there is at least one intermediate automatic latch62on each of the opposite sides of the tonneau cover44. Each of these automatic latches62can have separate cables80that are independently anchored to the corresponding latch-rearward rectangular elements78. In some embodiments, the rectangular element ends64for these opposite automatic latches62can be opposite ends of the same rectangular element52. In some embodiments, multiple automatic latches62can share the same corresponding latch-rearward rectangular element78, which in the illustrated embodiment carries the terminal anchor90.

As in the illustrated embodiment, the rectangular elements or slats52can have lower surfaces96upon which the tonneau cover44rests when in a closed or extended configuration (FIG. 1) covering the cargo box32. As in this embodiment, these lower surfaces96can rest upon the upper surface of the support flanges50. In addition, each automatic latch62can have a latching surface100. The latching surface100can be positioned higher than the lower surfaces96of the slats52. As in this embodiment, the latching surface100of the automatic latches62can engage against the lower side or surface of the latching flange60when the tonneau cover44is in the extended configuration and the automatic latches62are in the latched configuration or position.

Each automatic latch62can have the characteristics of a slam latch, including a slam surface102. As each slat52moves into its closed position or extended configuration, the slam surface102can engage the latching flange60of the side rail46. This engagement of the slam surface102against the side rail46causes the automatic latch62to move inward against the outward biasing force of the spring66. When the automatic latch62passes the latching flange, the biasing force of the spring66moves the automatic latch62outward into the latched configuration with the latching surface100adjacent to, and captured by, the latching flange60.

The slats52can include a main extruded member98and an end cap provided by the housing82. Each automatic latch62can extend outward from the main extruded member through the end cap of the housing82. Additionally or alternatively, each latch automatic62can be slidably supported within a channel of the main extruded member98and can extend from a distal end of the channel. In some embodiments, the latch can be mounted to extend through an end cap of an extruded slat52, or can simply be mounted in a channel of an extruded slat52.

The manual latch or latches72of the rear slat56can be slam latches that are identical to those of the automatic latches62described above. For example, a manual latch72can be provided on each end of the rear slat56. A manual latch actuator can include the cable80extending between the coupling arms68of the two manual latches72. The grasping portion74can be provided by the cable80itself, or by a separate extension coupled to the cable80. The cable can extend through two intermediate anchors spaced adjacent one side of the cargo box32, so that a user can simultaneously unlatch both manual latches72from a single location adjacent the side of the cargo box32. Then, as the slats52are moved toward their open position, and the tonneau cover44is moved toward its retracted storage configuration, the automatic latches62move into their unlatched position without requiring any other manual action by the user.

FIGS. 13-26illustrate another example of a tonneau cover system30for a cargo box32of a truck34, such as a pick-up truck. Corresponding elements of this embodiment use the same reference numbers as those used with respect to the prior example embodiment, regardless of whether the corresponding elements are identical or not. For brevity, aspects in common between the two embodiments will not necessarily be repeated below.

The tonneau cover44of the tonneau cover system30can include a plurality of rectangular elements52pivotably or hingedly coupled together in series. In some embodiments, the pivotable coupling or hinge between any of the adjacent rectangular elements52can include a flexible member coupled between adjacent rectangular elements52. In some embodiments, the pivotable coupling or hinge between any of the adjacent rectangular elements52can additionally or alternatively include cooperating interlocking rigid elements (not shown) of adjacent rectangular elements52that engage each other.

The tonneau cover44can include a plurality of rectangular elements52including a forward rectangular element54and a rear rectangular element56, and respective latch-rearward rectangular elements78. The plurality of rectangular elements52have opposite ends supportable by the first and second side walls,40,42, respectively. The rectangular elements52are pivotally or hingedly connected together and moveable between a closed position (FIGS. 13 and 14) and an open position (FIG. 16). In the closed position, the rectangular elements52are in an extended configuration (FIGS. 13 and 14) covering the cargo box32. In the open position, the rectangular elements52are in a retracted or storage configuration (FIG. 13) that allows access to the cargo box32.

As in this example embodiment, most or all of the rectangular elements52can be panels or sections and the tonneau cover44can be a fold-up tonneau cover44. In some cases, each panel52can comprise a central rigid panel and can include rigid frame elements bounding its periphery. In some cases, each section52can comprise a rigid rectangular frame that can be covered by a flexible sheet material.

The forward rectangular element54can remain coupled to the side walls40,42in both the extended configuration (FIG. 1) and the retracted storage configuration (FIG. 3). The rear rectangular element56can have at least one manual latch72. The manual latches72can be latched or locked to one or both side walls40,42of the cargo box32when the tonneau cover44is in the extended configuration (FIGS. 13 and 14) as generally described above. Also as generally described above, one or more automatic latches62can each be coupled to a corresponding rectangular element end64of the tonneau cover44. Each rectangular element end64having an automatic latch62can be an end of any rectangular element52intermediate the forward and rear rectangular elements54,56.

As in this embodiment, any manual latches72and any automatic latches62can have many aspects in common. For example, each of the manual latches72and the automatic latches62can comprise an elongate member. The elongate member latches62,72can include a plurality of angled slots70therein. The latch actuator76can include an elongate arm80, which can have a corresponding plurality of pins69that ride within the slots70. Each latch62,72and the latch actuator76can be supported within a housing82, which can include an elongate extruded member84. The housing82can include fixed end caps83,85that effectively prevent longitudinal movement of each latch62,72with its respective housing82. Each latch62,72, however, is supported within the housing82so that it is permitted to move laterally between its latched configuration (FIGS. 21 and 22) and its unlatched configuration (FIGS. 19 and 20).

In contrast, the latch actuator arm80is supported within the housing82so that it is essentially prevented from moving laterally, but is permitted to move longitudinally between its corresponding latched position or configuration (FIGS. 21 and 22) and its corresponding unlatched position or configuration (FIGS. 19 and 20). A biasing member or spring66can be provided, e.g., between the forward fixed end cap83and the latch actuator arm80, to bias the arm80toward its unlatched configuration. This, in turn, biases the latch62,72into its corresponding unlatched configuration, due to the interaction of the pins69and the slots70.

The manual latches72ofFIG. 17can be mounted to and carried by the rear rectangular element56and can include a grasping portion or handle74. The grasping portion74can be coupled to a fixed base104and to a slider106via a link108. The biasing member66can bias the latch actuator arm80against a foot110of the slider106. Movement of the grasping portion74can cause longitudinal sliding movement of the slider110and, therefore, of the latch actuator80and manual latch72between the corresponding latched and unlatched configurations.

The automatic latches62ofFIG. 18can be mounted to a rectangular element end64of a rectangular element between the forward and rear rectangular elements54and56, respectively. The automatic latches62can have many components in common with the manual latches72, as described above. Instead of the grasping portion74and related components, however, the latch actuator76of the automatic latches62can include a bumper112fixed to a rearward end of the latch actuator arm80for movement therewith.

The biasing member66, such as the illustrated spring, can bias the automatic latch62and arm80of the latch actuator76toward corresponding unlatched or unlocked positions (FIGS. 25 and 26). The latch actuator76can extend from the automatic latch62to the respective latch-rearward rectangular element78. As each latch-rearward rectangular element78is rotated or pivotably hinged toward the folded or storage configuration, the biasing member66causes the arm80to push against the latch-rearward rectangular element78and to extend from the housing82of the respective automatic latch62and toward its unlatched configuration. In some cases, the arm80including bumper112can extend outward from and past the rearward edge or periphery of the rectangular element end64, and can extend to a position within the periphery of the corresponding latch-rearward rectangular elements78, in its unlatched configuration.

Thus, there is no need to separately manually operate the automatic latches. The act of folding up each latch-rearward rectangular element78of the tonneau cover44alone, without any other manual manipulation, automatically unlatches each automatic latch62of each rectangular element end64prior to needing to pivot the corresponding rectangular element52itself toward the folded or storage configuration (FIG. 16).

Similarly, the act of unfolding the tonneau cover44alone can automatically latch each automatic latch62. During unfolding, each rectangular element52having a rectangular element end64carrying an automatic latch62can be moved into its unfolded, closed, or extended position against the side rails46,48while the automatic latch62and latch actuator arm80is held in its unlatched or unlocked position by the spring66. Then, as the corresponding latch-rearward rectangular element78is pivoted into its unfolded position against the side rails46,48, the fixed forward end cap83of the latch-rearward rectangular element78can engage against the bumper112to push against the latch actuator76, moving arm80and automatic latch62into their corresponding latched configurations (FIGS. 23, and 24).

As discussed above, the latch actuator76can engage against the corresponding latch-rearward rectangular element78during pivotable movement of the latch-rearward element78relative to the corresponding rectangular element end64as the latch-rearward element78is moved between its closed and open positions. The engagement during this relative pivotable movement need not be throughout the entirety of this relative pivotable movement.

As in this embodiment, each rectangular element end64and respective latch-rearward rectangular element78can be comprised of an adjacent pair of rectangular elements52. In addition, a first automatic latch62can be coupled to a first element end64at a first side of the tonneau cover44. A second automatic latch62can be coupled to a second element end64at a second, opposite side of the tonneau cover44. The first and second rectangular element ends64can be opposite ends of the same one of the rectangular elements52and the corresponding latch-rearward rectangular elements78can be an adjacent one of the rectangular elements52. Alternatively, the first and second rectangular element ends64can be ends of different rectangular elements52and the respective latch-rearward rectangular elements78can comprise different adjacent pairs of the rectangular elements52.

As in this embodiment, a manual latch72with a grasping portion74can be provided on opposite ends of the rear rectangular element56. In some cases, a single manual latch can be provided. To fold up the tonneau cover44from the extended configuration ofFIG. 13, the manual latches72are manually moved into their unlatched configurations using the handle74. This permits the rear rectangular member56to be folded onto the adjacent rectangular member57. To the extent the rear rectangular member56is a latch-rearward rectangular member78for automatic latches62of opposite rectangular element ends64of the adjacent rectangular element57, this operation alone unlatches these automatic latches62as described above.

With any automatic latches62of the adjacent rectangular element57unlatched, the rectangular element57can be folded onto next adjacent rectangular element55as illustrated inFIG. 15. Similarly, to the extent the adjacent rectangular member57is a latch-rearward rectangular member78for automatic latches62of opposite rectangular element ends64of the next adjacent rectangular element55, this operation alone unlatches these automatic latches62, as described above. With any automatic latches62of the next adjacent rectangular element55unlatched, the rectangular element55can be folded onto the next adjacent or forward rectangular element54or pivoted into a raised position that can correspond to the final open or retracted storage configuration as illustrated inFIG. 16.