Abstract:
A vehicle tailgate enclosure can be adapted for rapid assembly and adjustable width. The enclosure includes two side sections and a center section. The center section is formed as an assembly of two portions. The side sections can each comprise beams which are advanced into recesses of the center section and retained. The width of the tailgate enclosure can be adjusted by the depth of advancement of the beams into the recesses of the center section. The center section can be constructed of a plastic material while the side sections can be metallic, thus leading to cost and weight savings. The tailgate enclosure can be easily and rapidly assembled by hand using a single tool.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is related to and claims priority to U.S. Provisional Patent Application No. 61/000,930, entitled “VEHICLE TAILGATE ENCLOSURE WITH ENHANCED ADJUSTMENT,” filed on Oct. 29, 2007, the entire application of which is hereby incorporated by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present application generally relates to a cargo tailgate enclosure for a pickup truck. 
         [0004]    2. Description of the Related Art 
         [0005]    Pick-up trucks are extremely popular. One of their primary advantages is the ability to haul loads in the storage bed located behind the cab of the vehicle. Unfortunately, often the storage bed is of an undesirable configuration for the load being transported. In particular, it is not unusual for the load to be larger than the truck bed, so that the tailgate of the truck needs to be lowered to enable the load to be adequately transferred. Unfortunately, this raises the risk that the load will fall out of the back of the truck, or that the load will need to be tied down, taking additional time. 
         [0006]    For this reason, various truck tailgate enclosures have been developed. Despite the great success and excellent functionality of previous tailgate enclosures, new areas exist in which to further improve the cargo tailgate enclosure. 
       SUMMARY OF THE INVENTION 
       [0007]    In some embodiments, a vehicle tailgate enclosure is configured to couple to a vehicle bed having a first side wall, a second side wall and a tailgate. The tailgate enclosure comprises a first side section or panel, a second side section or panel, and a center section or panel. The first side panel is desirably configured to couple to the first side wall of the vehicle bed. The second side panel is desirably configured to couple to the second side wall of the vehicle bed. The center panel is desirably configured to removably couple to the first side panel and the second side panel and to allow adjustable spacing therebetween. 
         [0008]    In other embodiments, a vehicle tailgate enclosure is configured to couple to a vehicle bed having a first side wall, a second side wall and a tailgate. The tailgate enclosure comprises a first side section or panel, a second side section or panel, and a center section or panel. The first side panel is composed of a first material. The second side panel is composed of the first material. The center panel extends between the first side panel and the second side panel. The center panel is composed of a second material different from the first material. The center panel is removably connected to the first and second side panels. 
         [0009]    In other embodiments, a tailgate enclosure comprises a first side section or panel, a second side section or panel, and a center section or panel. The first side panel comprises a plurality of beams. The second side panel comprises a plurality of beams. The center panel is configured to extend between the first side panel and the second side panel. The center panel comprises a first portion and a second portion. The second portion is configured to couple to the first portion. The coupling of the first portion and the second portion defines a plurality of recesses, each recess configured to receive one of the plurality of beams of the first and the second side panels. 
         [0010]    In other embodiments, a method of assembling a vehicle tailgate enclosure is provided. The method comprises assembling a center section or panel of the vehicle tailgate enclosure; advancing a plurality of beams of a first side section or panel into a corresponding plurality of recesses in the center panel; advancing a plurality of beams of a second side section or panel into a corresponding plurality of recesses in the center panel; and restraining the beams of the first side panel and the second side panel with respect to the center panel. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         [0011]      FIG. 1  is a perspective view of one embodiment of vehicle tailgate enclosure; 
           [0012]      FIG. 2  is a rear view of the vehicle tailgate enclosure of  FIG. 1 ; 
           [0013]      FIG. 3  is a front view of the vehicle tailgate enclosure of  FIG. 1 ; 
           [0014]      FIG. 4  is a top view of the vehicle tailgate enclosure of  FIG. 1 ; 
           [0015]      FIG. 5  is a cross-sectional view of the vehicle tailgate enclosure of  FIG. 1  taken along line  5 - 5  of  FIG. 2 ; 
           [0016]      FIG. 6  is a side view of the vehicle tailgate enclosure of  FIG. 1 ; 
           [0017]      FIG. 7  is an exploded assembly view of the vehicle tailgate enclosure of  FIG. 1 ; 
           [0018]      FIG. 8  is a perspective view of another embodiment of vehicle tailgate enclosure; 
           [0019]      FIG. 9  is a rear view of the vehicle tailgate enclosure of  FIG. 8 ; 
           [0020]      FIG. 10  is a front view of the vehicle tailgate enclosure of  FIG. 8 ; 
           [0021]      FIG. 11  is a top view of the vehicle tailgate enclosure of  FIG. 8 ; 
           [0022]      FIG. 12  is a cross-sectional view of the vehicle tailgate enclosure of  FIG. 8  taken along line  12 - 12  of  FIG. 2 ; 
           [0023]      FIG. 13  is a side view of the vehicle tailgate enclosure of  FIG. 8 ; 
           [0024]      FIG. 14  is an exploded assembly view of the vehicle tailgate enclosure of  FIG. 8 . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0025]    Vehicle Tailgate Enclosure 
         [0026]    With reference to  FIGS. 1-7  one embodiment of vehicle tailgate enclosure  2  is illustrated. The tailgate enclosure  2  can be configured to coupled to a bed of a vehicle such as a pick up truck having a first side wall, a second side wall, a cargo floor, and a tailgate. In some embodiments, the tailgate enclosure  2  can be rotatably coupled to a vehicle bed and define a first position in which the tailgate enclosure is positioned substantially over the tailgate in an open position such that the tailgate enclosure defines an extended cargo area. The tailgate enclosure  2  can define a second position in which the tailgate enclosure is positioned substantially over the cargo floor to define a partitioned cargo area.  FIG. 1  illustrates a perspective view of the vehicle tailgate enclosure  2 . In the illustrated embodiment, the tailgate enclosure  2  comprises a first side panel  10 , a second side panel  20 , and a center panel  30  extending between the first side panel  10  and second side panel  20 . 
         [0027]    Side Panels 
         [0028]    With reference to  FIG. 1 , in the illustrated embodiment, the first and second side panels  10 ,  20  each comprise an endcap  12 ,  22 , and a plurality of beams  14 ,  24 . In some embodiment, the endcaps  12 ,  22  can be configured to couple directly to sidewalls of the vehicle bed. In other embodiments, the endcaps  12 ,  22  can be configured to couple to a latch positioned on the sidewalls of the vehicle bed. In various embodiments, the coupling between the endcaps  12 ,  22  and the vehicle bed can be rotatable, while in other embodiments, the coupling can be rotationally fixed. 
         [0029]    With continued reference to  FIG. 1 , in the illustrated embodiments, each of the beams  14 ,  24  comprises a generally rectangular tubular member having rounded corners. In other embodiments, the beams  14 ,  24  can comprise other types of members such as generally cylindrical tubular members, square tubes, or members having oval-shaped cross-sections. Advantageously, squared tubes such as the illustrated beams  14 ,  24  can be relatively easily retained within a housing, as relatively flat side surfaces can be clamped by the housing. Also advantageously, it can be desirable to have rounded tubular members with rounded edges to facilitate gripping and movement of the tailgate enclosure by one of the beams  14 ,  24 . 
         [0030]    In some embodiments, the beams  14 ,  24  comprise a metallic material. Desirably, the beams  14 ,  24  can be formed of an aluminum composition such as aluminum or an aluminum alloy. Advantageously, aluminum materials can have relatively high strength and low weight characteristics. In other embodiments, the beams  14 ,  24  can comprise other metallic compositions or alloys, or non-metallic compositions, such as plastic or composite materials. 
         [0031]    With reference to  FIG. 1 , in the illustrated embodiment, the first and second side panels  10 ,  20  each comprise three beams  14 ,  24 . Desirably, these beams  14 ,  24  are sized and spaced to span approximately a height of the sidewalls of a vehicle bed and to prevent passage of relatively large objects between the beams  14 ,  24 , thus providing a substantial enclosure for an extended vehicle bed when the tailgate enclosure is in the first position. In other embodiments, the side panels  10 ,  20  of the tailgate enclosure  2  can each have more or fewer than three beams  14 ,  24 , such as, for example two or four or more beams  14 ,  24 . 
         [0032]    With reference to  FIG. 1 , each of the beams  14 ,  24  can include a bed extending portion  16 ,  26  in which, when positioned in a vehicle bed, the bed extending portion  16 ,  26  is substantially parallel to the sidewalls of the bed. As illustrated, each of the beams  14 ,  24  can also include a bend portion  18 ,  28 , and an enclosure portion  19 ,  29 . In the illustrated embodiments, the bend portion  18 ,  28  comprises a radiused curve of approximately ninety degrees, although in other embodiments, other curve amounts and geometries are possible. The enclosure portion  19 ,  29  can extend from the curved portion  18 ,  29  to the center panel  30  of the tailgate enclosure  2 . 
         [0033]    Center Panel 
         [0034]    With continued reference to  FIG. 1 , a center panel  30  extends between the first side panel  10  and the second side panel  20  of the tailgate enclosure  2 . In the illustrated embodiment, the center panel  30  comprises two uprights  32  extending transversely to the beams  14 ,  24  of the side panels  10 ,  20 . The uprights  32  each comprise stops  38  that can be composed of a rubber or polymeric material to cushion the tailgate enclosure  2  when it is rested on the cargo floor or tailgate of the vehicle bed. The center panel further comprises a plurality of beams  36  extending generally parallel to the enclosure portions  19 ,  29  of the beams  14 ,  24  of the side panels  10 ,  20 . 
         [0035]    In some embodiments, the center panel  30  can be formed of a material that is different from the material of the side panels  10 ,  20 . For example, in some embodiments, as discussed in further detail below, the center panel  30  can be formed of a molded thermoplastic material. In other embodiments, the center panel  30  can be formed of a polymeric material, a composite material such as a carbon fiber composite or a glass fiber composite, or a metallic material. In some embodiments, desirably the use of a plastic material in the center panel  30  can reduce the total weight of a vehicle tailgate enclosure as compared to a similar tailgate enclosure that is comprised substantially entirely of metallic materials. 
         [0036]    In some embodiments, the center panel  30  can be configured to be removably coupled to the side panels  10 ,  20 . Advantageously, this removable coupling allows the tailgate enclosure  2  to be stored in a relatively small shipping box, thus facilitating distribution of a tailgate enclosure  2  in an unassembled state. 
         [0037]    As discussed below, the center panel  30  can be configured to retain the side panels such that the assembly of the center panel  30  and side panels  10 ,  20  allows an adjustable width of the end caps  12 ,  22  of the side panels  10 ,  20  relative to one another. Thus, desirably one tailgate enclosure  2  can be adapted to fit vehicle beds having various different widths. In some embodiments, the tailgate enclosure  2  can have a width adjustment range (that is, the difference between a maximum width of the tailgate enclosure and a minimum width thereof) of approximately 2 inches, while in other embodiments, the width adjustment range can be approximately 4 inches and in still other embodiments, the width adjustment range can be approximately 6 inches. 
         [0038]    With respect to  FIGS. 2-4  and  6 , various views of the tailgate enclosure  2  are illustrated.  FIGS. 5 and 7  illustrate a cross sectional and exploded assembly view of the tailgate enclosure  2  showing the assembly of one embodiment of center panel  30 . In the illustrated embodiment the center panel  30  comprises a first portion  40  and a second portion  50  coupled with fasteners  36 . In the illustrated embodiment, the first and second portions  40 ,  50  are substantially identically configured, each comprising a portion of the uprights  32  and beams  38 . When the portions  40 ,  50  are positioned in opposite orientations (that is, the first portion  40  is rotated 180 degrees with respect to the second portion), the first and second portions can be coupled with fasteners  36  such as screws. In other embodiments, other fastener types can be used to couple the first portion  40  to the second portion  50 . In still other embodiments, the first and second portions  40 ,  50  can be configured with mating interference surfaces such that they snap together. As illustrated, the first portion defines a first lateral outer surface  44  of the center panel  30 , and the second sidewall defines a second lateral outer surface  54  of the center panel  30 . Advantageously, a center portion formed of two substantially identical portions  40 ,  50  can reduce manufacturing costs as a single tooling setup can be used to create both portions  40 ,  50 . It can also advantageously reduce inventory costs as a single part can be maintained in inventory. It can also facilitate ease of assembly of the center panel  30 . 
         [0039]    With continued reference to  FIGS. 5 and 7 , coupling the first portion  40  to the second portion  50  forms the center panel  30 . The center panel  30  comprises a plurality of recesses  42  each configured to receive a beam  14 ,  24  of the first and second side panels  10 ,  20 . When the first and second portions  40 ,  50  are coupled, the beams  14 ,  24  are retained in the recesses  42 . Width adjustment of the tailgate enclosure  2  can be provided by a depth, D, of the recesses  42 . Accordingly, to adjust the width of the tailgate enclosure, the beams  14 ,  24  can be advanced varying amounts into the recesses  42  such that the end caps  12 ,  22  are a desired width apart, then retained at a desired width by securely coupling the first portion  40  to the second portion  50 . In some embodiments, the center panel  30  can include a plurality of lock or set screws to retain the beams  14 ,  24  at a desired depth in the center panel  30 . 
         [0040]    Advantageously, in the illustrated embodiment, the two portion  40 ,  50  coupling of the center panel  30  provides a relatively rigid center panel  30  that resists twisting of one upright  32  relative to another, while having a low total parts count for a tailgate enclosure  2 . In other embodiments, the center panel  30  can be formed of more than two portions, or can be formed of a single, unitary panel. 
         [0041]    Center Panel Comprising Two Dissimilar Portions 
         [0042]    With reference to  FIGS. 8-14 , another embodiment of tailgate enclosure  2 ′ is illustrated. The illustrated tailgate enclosure  2 ′ comprises first and second side panels  10 ,  20  substantially as described above with respect to  FIGS. 1-7 . Tailgate enclosure further comprises a center panel  30 ′. 
         [0043]      FIGS. 12 and 14  illustrate a cross sectional and exploded assembly view of the tailgate enclosure  2 ′ showing the assembly of one embodiment of center panel  30 ′. In the illustrated embodiment the center panel  30 ′ comprises a first portion  40 ′ and a second portion  50 ′ coupled with fasteners  36 . In the illustrated embodiment, the first and second portions  40 ′,  50 ′ are not substantially identically configured. Rather, the first portion  40 ′ defines an outer portion defining two lateral outer surfaces  44 ′. When the second portion  50 ′ is positioned within the lateral outer surfaces  44 ′, the first and second portions  40 ′,  50 ′ can be coupled with fasteners  36  such as screws. In the illustrated embodiment, the second portion  50 ′ can include holes for the fasteners, while the first portion  40 ′ has threaded inserts to receive the fasteners  36 . Accordingly, in some embodiments, no fasteners or fastener holes are visible from one side of the tailgate enclosure  2 ′, thus presenting a sleek look in certain orientations. In other embodiments, other fastener types can be used to couple the first portion  40 ′ to the second portion  50 ′. In still other embodiments, the first and second portions  40 ′,  50 ′ can be configured with mating interference surfaces such that they snap together. 
         [0044]    With continued reference to  FIGS. 12 and 14 , coupling the first portion  40 ′ to the second portion  50 ′ forms the center panel  30 ′. The center panel comprises a plurality of recesses  42 ′ each configured to receive a beam  14 ,  24  of the first and second side panels  10 ,  20 . When the first and second portions  40 ′,  50 ′ are coupled, the beams  14 ,  24  are retained in the recesses  42 ′. In some embodiments, the center panel  30 ′ can include a plurality of lock or set screws to retain the beams  14 ,  24  in the center panel  30 ′. 
         [0045]    Method of Assembly 
         [0046]    Advantageously, vehicle tailgate enclosures  2 ,  2 ′ described herein can be easily transported in relatively small shipping packages such as boxes. Accordingly, shipping costs should be relatively low as compared to pre-assembled tailgate enclosures. Additionally, assembly can be relatively quick and easy to perform by an end-user, a distributor, or a retailer. Further savings can be obtained with the tailgate enclosures  2 ,  2 ′ described herein as the vehicle tailgate enclosures  2 ,  2 ′ can be adjustable in width, thereby reducing the need to maintain inventory of separate make and model specific vehicle tailgate enclosures. 
         [0047]    For example, the vehicle tailgate enclosures  2 ,  2 ′ can be easily assembled using a method comprising assembling a center panel assembling a center panel  30 ,  30 ′ of the vehicle tailgate enclosure  2 ,  2 ′, advancing a plurality of beams  14  of a first side panel  10  into a corresponding plurality of recesses  42 ,  42 ′ in the center panel  30 , advancing a plurality of beams  24  of a second side panel  20  into a corresponding plurality of recesses  42 ,  42 ′ in the center panel  30 ,  30 ′ and restraining the beams  14 ,  24  of the first side panel  10  and the second side panel  20  with respect to the center panel  30 ,  30 ′. Advantageously, in some embodiments, the entire assembly method can be performed with a single tool, used to couple the first portion  40 ,  40 ′ of the center panel  30 ,  30 ′ to the second portion  50 ,  50 ′ to form the housing  30 ,  30 ′. 
         [0048]    Although the cargo tailgate enclosure  2 ,  2 ′ has been disclosed in the context of certain preferred embodiments and examples, it will be understood by those skilled in the art that the cargo tailgate enclosure extends beyond the specifically disclosed embodiments to other alternative embodiments and/or users of the invention and obvious modifications and equivalent thereof. In particular, while the present cargo tailgate enclosure has been described in the context of a particularly preferred embodiment, a skilled artisan will appreciate in view of the present disclosure that certain advantages, features and aspects of the cargo tailgate enclosure may be realized in a variety of other applications, many of which have been noted above. Additionally, it is contemplated that various aspects and features of the invention described can be practiced separately, combined together, or substituted for one another, and that a variety of combinations and sub-combinations of the features and aspects can be made and still fall within the scope of the inventions. Thus, it is intended that the scope of the present invention herein disclosed, should not be limited by the particular disclosed embodiments described above but should be determined only by a fair reading of the claims.