Abstract:
A cargo box inner ( 12 ) for a vehicle ( 10 ) is provided. The cargo box inner ( 12 ) is comprised of a series of interconnected composite panels ( 22, 24   a,    24   b,    26 ) that form a cargo bed ( 14 ). One or more pairs of these panels ( 22, 24   a,    24   b,    26 ) are each joined together for forming a storage bin ( 40   a,    40   b,    42 ) adjacent to the cargo bed ( 14 ). Each storage bin ( 40   a,    40   b,    42 ) is selectively covered by a lid ( 50, 64 ), which is movable between an open position and a closed position.

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S)  
       [0001]     The present application claims priority to U.S. provisional patent application 60/712,947 filed Aug. 31, 2005, and is related to U.S. non-provisional application no. ______ filed on Oct. 19, 2005, and entitled “D-PILLAR STRUCTURE FOR A REAR VEHICLE BODY STRUCTURE” (Attorney Docket No. 81123725/FGT-2067), the disclosure of which is incorporated by reference herein. 
     
    
     TECHNICAL FIELD  
       [0002]     The present invention relates generally to vehicles, and more particularly to a cargo box inner that enhances the storage capacity of a vehicle.  
       BACKGROUND  
       [0003]     Cargo box inners (“cargo boxes”) typically are mounted to a vehicle frame between substantially vertical rear fenders or quarter panels. These cargo boxes usually define an open-top bed behind a passenger cabin of a truck. Accordingly, cargo boxes are also known as pickup boxes, truck boxes, pickup truck boxes, and truck bed boxes.  
         [0004]     Traditional cargo boxes were comprised of up to forty (40) steel components, including panels with a thermoformed plastic liner. These steel components typically were welded together for defining a bed floor, two sidewalls, and a headboard.  
         [0005]     Automotive manufacturers later developed a cargo box having a one-piece composite construction, which could be produced more quickly and at significantly lower costs than its steel counterpart. In addition, the composite box is substantially lightweight and has improved resistance to dents and corrosion.  
         [0006]     Existing one-piece cargo boxes do not have additional storage bins or other compartments integrally formed therein adjacent to the bed.  
         [0007]     Also, the typical one-piece box includes a floor portion and two sidewall portions that extend somewhat outboard from the floor portion. In this way, the cargo box can be removed from a mold after the box has been fabricated. Also, in this regard, the largest width of the cargo box typically is measured between the top ends of the opposing sidewall portions. In other words, the floor portion does not extend across as much of the available space between the outer sidewall fenders as the top ends of the sidewall portions. It is understood that a larger-sized floor portion can increase the storage capacity of the vehicle.  
         [0008]     It would therefore be desirable to provide a cargo box having a robust construction with an enhanced storage capacity and a low manufacturing cost associated therewith.  
       SUMMARY OF THE INVENTION  
       [0009]     A cargo box inner for a vehicle is provided. The cargo box inner is comprised of a series of interconnected composite panels that form a cargo bed. Two or more of these panels define a storage bin adjacent to the cargo bed. Each storage bin is selectively covered by a lid that is movable between an open position and a closed position.  
         [0010]     One advantage of the invention is that a cargo box inner is provided that increases the storage capacity of a vehicle.  
         [0011]     Another advantage of the invention is that a cargo box inner is provided that has generally fewer components and is thus manufactured within shorter cycle times and at substantially lower costs.  
         [0012]     Yet another advantage of the invention is that a cargo box inner is provided that has a modular construction with components that can be efficiently packaged for storing and/or shipping large volumes of the components at lower costs.  
         [0013]     Still another advantage of the invention is that a cargo box inner is provided that has a modular construction that can be quickly repaired with minimized costs associated therewith.  
         [0014]     Yet another advantage of the invention is that a cargo box inner is provided that has a lightweight construction for improving the fuel economy of a vehicle.  
         [0015]     Still another advantage of the invention is that a cargo box inner is provided that has a robust construction for supporting high-load cargo and resisting dents and corrosion.  
         [0016]     Other advantages of the present invention will become apparent upon considering the following detailed description and appended claims, and upon reference to the accompanying drawings. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0017]     For a more complete understanding of this invention, reference should now be made to the embodiments illustrated in greater detail in the accompanying drawings and described below by way of the examples of the invention:  
         [0018]      FIG. 1  is a rear perspective view of a vehicle having a cargo box inner, according to one advantageous embodiment of the claimed invention.  
         [0019]      FIG. 2  is a partially exploded view of the vehicle shown in  FIG. 1 , illustrating the cargo box inner attached to a vehicle frame between a pair of rear fenders.  
         [0020]      FIG. 3  is a fully exploded view of the cargo box inner shown in  FIG. 1 , illustrating the cargo box inner having a modular construction comprised of individual composite panels.  
         [0021]      FIG. 4  is a cross-sectional view of the vehicle shown  FIG. 1 , as taken along line  4 - 4 , illustrating the cargo box inner having a side bin.  
         [0022]      FIG. 5  is cross-sectional view of the cargo box inner shown in  FIG. 1 , as taken along line  5 - 5 , illustrating the cargo box inner having a forward bin.  
         [0023]      FIG. 6  is a top view of the cargo box inner shown in  FIG. 1 , illustrating the cargo box inner having a forward bin extending substantially across a width of the box.  
         [0024]      FIG. 7A  is a perspective cross-sectional view of the forward bin shown in  FIG. 5  illustrating the load-bearing structure of the lid.  
         [0025]      FIG. 7B  is an enlarged view of the piano hinge shown in  FIG. 7A , as taken within circle  7 B.  
         [0026]      FIG. 8  is a perspective view of the cargo box inner shown in  FIG. 1 , as taken along arrow  8 , illustrating a sidewall panel having a handle mounted therein for opening a storage bin.  
         [0027]      FIG. 9  is a rear perspective view of the vehicle shown  FIG. 1 , illustrating the vehicle with a cover attached thereon for covering the cargo box inner and securing cargo therein. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0028]     In the following figures, the same reference numerals are used to identify the same components in the various views.  
         [0029]     The present invention is particularly suited for a cargo box inner (“cargo box”) for an open-top bed of a vehicle, such as a sports utility vehicle (“SUV”). Accordingly, the embodiments described herein employ structural features where the context permits.  
         [0030]     However, various other embodiments are contemplated having different combinations of the described features, having additional features other than those described herein, or even lacking one or more of those features. For instance, the cargo box can be integrated within a pickup truck having an open-top bed, a luxury SUV having an enclosed rear cargo bay, an SUV having a retractable roof over its cargo bay, or other suitable vehicles. Thus, the claimed invention can be carried out in a variety of other modes and utilized for other suitable applications as desired.  
         [0031]     Referring now to  FIG. 1 , there is shown a perspective view of an SUV  10  having a cargo box  12 , according to one advantageous embodiment of the claimed invention. As detailed below, the cargo box  12  provides a substantially large cargo bed  14  and a series of storage compartments  16  for enhancing the storage capacity of the SUV  10 .  
         [0032]     As shown in  FIG. 2 , the cargo box  12  is mounted to a vehicle frame  18  of the SUV  10  between a pair of vertical rear fenders  20 . In this regard, the rear fenders  20  define the width of the packaging constraints within which the cargo box  12  can be installed.  
         [0033]     Referring to  FIG. 3 , there is shown a fully exploded view of the cargo box  12  illustrated in  FIG. 2 . This cargo box  12  has a modular construction comprised of individual composite panels. The composite panels primarily include a floor panel  22 , a pair of sidewall panels  24   a ,  24   b , and a headboard panel  26 . This construction is beneficial at least for the reason that a damaged panel can be repaired or replaced within a substantially short period of time and at generally low costs.  
         [0034]     Further, each composite panel is comprised of sheet molding compound (“SMC”). In that regard, it will be appreciated that the cargo box  12  has a substantially strong and lightweight construction that is resistant to corrosion and dents. However, the composite panels can be comprised of various other suitable materials as desired so long as they fulfill the purposes of the present invention.  
         [0035]     Also, one or more of these composite panels has structures therein, which could not otherwise be formed in a one-piece composite box. For instance, the headboard panel  26  has substantially thick reinforcement ribs  90  and a series of recesses  92  for displaying the name of a vehicle trim level. It is understood that all of the composite panels can have the ribs  90  formed therein. Also, one or more of the panels can have recesses or other suitable structures for displaying a symbol, a word, a letter, a number, or a trademark as desired.  
         [0036]     By way of another example, the floor panel  22  has tire-tread texture  94  formed therein. However, one or more panels can have the tire tread texture  94  or various other surface textures including a coarse-grain texture and a fine grain texture.  
         [0037]     The floor panel  22  has a front portion  28 , a rear portion  30 , and a pair of opposing side portions  32   a ,  32   b . The front portion  28  of the floor panel  22  is attached to a bottom portion  34  of the headboard panel  26 . Moreover, the opposing side portions  32   a ,  32   b  of the floor panel  22  are attached to lower portions  36   a ,  36   b  of the opposing sidewall panels  24   a ,  24   b . This construction is secured by a series of bolt fasteners and adhesive bonding. However, other suitable fastening means can be utilized as desired.  
         [0038]     The floor panel  22  has a substantially wide construction for enhancing the storage capacity of the cargo box  12 . Specifically, as exemplified in  FIG. 4 , each sidewall panel  24   a ,  24   b  extends substantially perpendicularly from the floor panel  22 . In that regard, the floor panel  22  is sized substantially wide within the packaging constraints defined by the rear fenders  20   a ,  20   b . In other words, the cavity  38  between each sidewall panel  24   a ,  24   b  and its respective fender  20   a ,  20   b  is minimized for increasing the width of the floor panel  22 .  
         [0039]     One skilled in the art will appreciate that otherwise extending the sidewall panels  24   a ,  24   b  outboard from the floor panel  22  can increase the width of the cavity  38 . Accordingly, this construction would decrease the width of the floor panel  22  and the storage space within the predetermined packaging restraints.  
         [0040]     As introduced in  FIG. 1 , the cargo box  12  further includes one or more storage bins  16  for enhancing the storage capacity of the SUV  10 . In this embodiment, the storage bins  16  include a pair of side bins  40   a ,  40   b  (as exemplified in  FIG. 4 ) and a forward bin  42  (as exemplified in  FIG. 5 ). However, it is contemplated that the cargo box  12  can instead have more or less than three storage bins that are located in a variety of suitable locations.  
         [0041]     With specific attention to  FIG. 4 , the side bin  40   a  is defined by the floor panel  22  and the sidewall panel  24   a . In particular, the floor panel  22  and the sidewall panel  24   a  each have a side-bin structure  44   a ,  44   b  respectively formed therein for joining together and forming the side bin  40   a . It is understood that the side-bin structures  44   a ,  44   b  can be recesses within the respective panels  22 ,  24   a  or other suitable structures as desired.  
         [0042]     In this embodiment, each side-bin structure  44   a ,  44   b  includes a recessed seat  46   a ,  46   b  with a seal member  48  attached thereon. The recessed seats  46   a ,  46   b  are utilized for receiving and supporting a lid  50  pivotally attached to the sidewall panel  24   a  via a hinge member. For example, the lid  50  has an extruded rubber living hinge  52  extending therefrom for snap-fitting into an aperture  52 ′ formed in the sidewall panel  24   a . The lid  50  is movable between an open position and a closed position, in which the lid  50  sealingly covers the side bin  40   a  with the seal member  48  sandwiched between the lid  50  and the recessed seats  46   a ,  46   b.    
         [0043]     Furthermore, each lid  50  is a load floor or load-bearing structure and thus provides additional surface area upon which cargo can be stored. Specifically, in the closed position, the lid  50  extends outboard from a periphery of the floor panel  22  and therefore increases the storage capacity of the SUV  10 .  
         [0044]     Moreover, as shown in  FIG. 2 , each side bin  40   a ,  40   b  and wheel housing  54  are offset from a longitudinal reference line  56  of the cargo box  12  by a substantially equal distance. In this respect, it is understood that the lid  50  is less likely to support higher-load cargo placed within the bed  14 .  
         [0045]     Referring now to  FIGS. 5 and 6 , the forward bin  42  is defined by forward-bin structures  58   a ,  58   b ,  58   c ,  58   d  respectively formed in the headboard panel  26 , the floor panel  22  and the sidewall panels  24   a ,  24   b . The forward-bin structures  58   a ,  58   b ,  58   c ,  58   d  are recesses but can instead be various other suitable structures as desired. Also, as best shown in  FIG. 6 , this forward bin  42  extends substantially across the width of the cargo box  12 . It is contemplated that the forward bin  42  can have various suitable constructions.  
         [0046]     With attention to  FIG. 5 , the forward-bin structure  58   b  of the floor panel  22  is a substantially thick recessed portion of the floor panel  22  for attachment to the vehicle frame  18  via a series of bolt fasteners  60 . It is understood that other portions of the floor panel  22  or other composite panels can have localized thickened portions as desired.  
         [0047]     In addition, the forward-bin structures  58   b ,  58   c ,  58   d  each have a recessed seat  62   b ,  62   c ,  62   d  for receiving and supporting a lid  64  pivotally attached to the headboard panel  26 . The lid  64  is movable between an open position and a closed position, in which the lid  64  sealingly covers the forward bin  42  with the seal member  66  sandwiched between the lid  64  and the recessed seats  62   b ,  62   c ,  62   d.    
         [0048]     Furthermore, the lid  64  is a load floor or load-bearing structure that is sufficiently strong for supporting cargo thereon. In this embodiment, as best shown in  FIG. 7A , the lid  64  has a top side  65   a  and a bottom side  65   b  with gussets  67  integrally formed therein. It is understood that the lid  64  can instead have other suitable reinforcement members or lack the same as desired.  
         [0049]     In addition, referring to  FIGS. 5 and 6 , the lid  64  strengthens the overall front-end portion of the cargo box  12 . Namely, the periphery of the lid  64  in its closed position is sandwiched between the floor panel  22 , the sidewall panels  24   a ,  24   b , and the headboard panel  26 . In this way, the lid  64  bears a load transferred between the composite panels and stabilizes the cargo box  12 . For example, in this embodiment, the lid  64  is pivotally attached to the headboard panel  26  substantially across its width via one or more piano hinges  100 . The piano hinge  100  is comprised of opposing leaf plates  102   a ,  102   b  and a pin  104  coupled therebetween. Accordingly, the lid  64  in its closed position transfers a load through the leaf plates  102   a ,  102   b  and evenly distributes the load across a substantial portion of the headboard panel  26 . In this embodiment, the piano hinge  100  also has a seal member  106  attached thereon for preventing water and other moisture in the bed  14  from seeping into the hinge  69  and the forward bin  42 . It will be appreciated that the lid  64  can instead be pivotally attached to the headboard panel  26  and transfer loads thereto by various other suitable constructions.  
         [0050]     Referring now to  FIGS. 4 through 6 , the cargo box  12  further includes a latch mechanism  68  (shown in  FIG. 4 ) and a detent mechanism  70  (shown in  FIGS. 5 and 6 ) for operating the respective lids  50 ,  64 .  
         [0051]     For instance, with respect to the side bin  40   a  shown in  FIG. 4 , the cargo box  12  includes a latch mechanism  68  comprising a rotatable locking arm  72  extending from the lid  50  and a hole  74  formed in the floor panel  22  for receiving the arm  72  and locking the lid  50  in a closed position. It is understood that the latch mechanism  68  can instead be other suitable latch mechanisms.  
         [0052]     Regarding the forward bin  42  exemplified in  FIGS. 5 and 6 , the cargo box  12  includes a detent mechanism  70  which holds the lid  64  in its existing position whether the lid  64  is opened or closed. In this embodiment, the detent mechanism  70  is a gas strut device. However, it will be appreciated that the detent mechanism  70  can instead be other suitable devices.  
         [0053]     Moreover, the lid  64  for the forward bin  42  is attached to a pawl cable latch  76  schematically shown in  FIG. 3  for selectively releasing the lid  64  from the closed position. This pawl cable latch  76  is operated via a cable  78  attached to a handle  80  (shown in  FIG. 8 ) that is mounted to the sidewall panel  24   a.    
         [0054]     Referring now to  FIG. 9 , there is shown the SUV  10  shown in  FIG. 1  with a tonneau cover  82  secured across the top of the cargo box  12  and the tailgate  84  moved to a closed position. It will be appreciated that the storage bins are sufficiently positioned on the cargo box  12  for concealing and otherwise preventing access thereto when the cover  82  is installed on the cargo box  12 . This construction is beneficial for safely storing possessions in the storage bins and minimizing the risk of theft.  
         [0055]     While particular embodiments of the invention have been shown and described, it will be understood, of course, that the invention is not limited thereto since modifications may be made by those skilled in the art, particularly in light of the foregoing teachings. Accordingly, it is intended that the invention be limited only in terms of the appended claims.