Abstract:
A frame can include front and back generally vertically and laterally extending frame members. The frame members can each have a generally trapezoidal configuration comprising a crossbeam portion extending generally laterally between two generally upwardly and laterally inwardly extending side leg portions. A rigid, non-collapsible shell can extend over the frame that is adapted to be supported on the truck body. The rigid, non-collapsible shell can include opposite side walls and a roof extending between the side walls. A plurality of posts can be attached to the frame through the roof, with each of the posts extending externally above the roof of the rigid, non-collapsible shell. A first rack can be attached to and can extend between at least two of the posts externally of the rigid, non-collapsible shell overlying the roof.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of U.S. patent application Ser. No. 14/602,325 filed on Jan. 22, 2015. The entire disclosure of the above application is incorporated herein by reference. 
     
    
     FIELD 
       [0002]    The present disclosure relates to truck caps and, in particular, to an outer shell in combination with an internal rigid frame and an exterior mounting rack able to support heavy loads. Even more particularly, the invention relates to such a truck cap in which the weight of the heavy load that is supported on an external rack is supported by the truck body through the internal frame concealed within the cap shell. 
       BACKGROUND 
       [0003]    A considerable number of pickup-type trucks are used by individuals for many types of business activities or just as a personal vehicle. These pickup trucks have an open rear bed or cargo area which is exposed to the weather. Various types of enclosures are used to protect this cargo area from the weather and to secure cargo, tools, etc. stored in the rear area from theft. These enclosures are referred to as a shell, canopy, topper, bed cap, box cap etc. and come in numerous configurations and sizes. These enclosures are usually attached to and supported by the side rails or frame of the truck body which form two sides of the open cargo area. Many of these enclosures are made of fiberglass, aluminum, wood etc., with fiberglass being the most common. 
         [0004]    Many of these pickup trucks are used in various industries and hold various types of tools and other equipment for use on a job site. However, due to the construction of the enclosure, usually of a lightweight material such as fiberglass, they are not able to support appreciable weight, even though it is desirable to mount ladders and other equipment on top of the enclosure. In order to be able to accommodate greater loads, the enclosure must be made of a more rigid material with internal reinforcing, which adds appreciable to the weight, size, and cost for the truck enclosure or have a type of support frame which extends externally about the weather-proof shell such as shown in U.S. Pat. No. 8,087,716. Although some of these prior art reinforced caps and external frames enable the external load to be heavier than heretofore possible, they increase the cost of the truck enclosure, increase the external size of the vehicle cap and detract from the appearance thereof. 
         [0005]    Therefore, there is a need for an improved truck enclosure or cap for the rear cargo area which is able to support greater loads externally of the enclosure adjacent the top thereof without detracting from the appearance of the vehicle while still providing weather-proof protection for the heretofore open truck bed or cargo area. 
       SUMMARY 
       [0006]    In one aspect of the present disclosure, a truck cap can include a frame for mounting on a truck body. The frame can include front and back generally vertically and laterally extending frame members. The frame members can each have a generally trapezoidal configuration comprising a crossbeam portion extending generally laterally between two generally upwardly and laterally inwardly extending side leg portions. A rigid, non-collapsible shell can extend over the frame that is adapted to be supported on the truck body. The rigid, non-collapsible shell can include opposite side walls and a roof extending between the side walls. A plurality of posts can be attached to the frame through the roof, with each of the posts extending externally above the roof of the rigid, non-collapsible shell. A first rack can be attached to and can extend between at least two of the posts externally of the rigid, non-collapsible shell overlying the roof. 
         [0007]    In another aspect of the present disclosure, a truck cap for mounting on a truck having a cargo bed can include a rigid frame. The rigid frame can include front and back frame members. Each of the frame members can include a crossbeam portion extending generally laterally between two frame corners and a pair of generally upwardly and laterally inwardly extending side legs joining the two corners, respectively. The rigid frame can be designed to be supportable by the cargo bed of the truck to extend over the cargo bed. A rigid, non-collapsible shell can cover the rigid frame. The rigid, non-collapsible shell can include a shell roof extending between and joined to a pair of shell side walls at shell corners with each crossbeam portion of the frame extending adjacent the shell roof and each side leg of the frame extending adjacent the shell side walls, respectively. The rigid, non-collapsible shell being can be arranged about the frame such that the crossbeams are disposed below the roof and are spaced apart therefrom. A plurality of posts can be attached to the rigid frame through the shell roof between the shell corners. Each of the posts can extend externally above the roof of the rigid, non-collapsible shell. A first rack can be attached to and can extend between at least two of the posts externally of the rigid, non-collapsible shell overlying the roof. When a weight of a load is supported on the rack and the rack is mounted on the truck, the weight can be transferred to the truck through the rigid frame. 
         [0008]    In another aspect of the present disclosure, a truck cap for mounting on a truck having a cargo bed can include a rigid frame for mounting on the truck to overlie the cargo bed. The rigid frame can include front and back generally vertically and laterally extending frame members. The frame members can each have a generally trapezoidal configuration including a crossbeam extending generally laterally between two generally upwardly and laterally inwardly extending side legs. A rigid, non-collapsible shell can extend over the frame that is adapted to be supported on the truck to overlie the cargo bed. The rigid, non-collapsible shell can include opposite shell side walls and a roof extending between and joined to the shell side walls. The rigid, non-collapsible shell can extend over the rigid frame with each crossbeam of the rigid frame being spaced apart from the shell roof, and with each side leg of the rigid frame extending adjacent to one of the shell side walls. 
     
    
     
       DRAWINGS 
         [0009]    Sample embodiments of the invention are set forth in the following description, are shown in the drawings and are particularly and distinctly pointed out and set forth in the appended claims. 
           [0010]      FIG. 1  is a diagrammatic perspective view showing a usual pickup truck having the improved truck cap or enclosure of the present invention mounted thereon; 
           [0011]      FIG. 2  is a fragmentary rear view of the truck body with the tailgate removed and part of the shell broken away showing the rigid internal frame of the improved truck cap mounted thereon; 
           [0012]      FIG. 2A  is an enlarged view of the encircled portion of  FIG. 2 ; 
           [0013]      FIG. 3  is a perspective view of the internal frame of the truck cap of the present invention with a ladder rack attached prior to mounting on a pickup truck; 
           [0014]      FIG. 4  is a perspective view similar to  FIG. 3  showing another embodiment of the internal frame and with a pair of ladder racks attached thereto; 
           [0015]      FIG. 5  is an enlarged sectional view taken on line  5 - 5 ,  FIG. 3 ; 
           [0016]      FIG. 6  is an enlarged sectional view taken on line  6 - 6 ,  FIG. 3 ; and 
           [0017]      FIG. 7  is an internal rear view similar to  FIG. 2  showing a tool box mounted on the internal frame and an example of a tool supported therein. 
           [0018]    Similar numbers refer to similar parts throughout the drawings. 
       
    
    
     DETAILED DESCRIPTION 
       [0019]    The truck cap of the present invention is indicated generally at  1 , and is shown mounted on a usual vehicle  3  such as a pickup truck, having an open rear cargo area  5  ( FIG. 2 ). Vehicle  3  can have various configurations and will have some type of rear side rails or flanges  7  which extend along the top of vehicle side walls  9  and define cargo area  5 . Truck cap  1  includes a usual enclosure indicated generally at  11 , which preferably is made out of fiberglass, although it could be made out of wood, aluminum, or other types of material or combination thereof. Enclosure  11  is referred to hereinafter as a shell or cap although it is known by various other nomenclatures as discussed above. 
         [0020]    Shell  11  will have a usual construction with side walls  13  and an integral top wall or roof  15 . Side walls  13  usually will terminate in some type of inturned bottom flanges  17  which rest on and extend along side rails  7  of the vehicle body as shown in  FIGS. 2 and 2A . Bottom flanges  17  of shell  11  are usually secured to the truck body by C-clamps  20  or various other types of fasteners to removeably mount shell  11  on the vehicle body with the weight of the shell being supported on rails  7  of the vehicle body. If desired, shell  11  can be permanently attached by bolts, rivets, etc. to the vehicle body. 
         [0021]    Referring to  FIGS. 2 and 3 , truck cap  1 , in addition to shell  11 , includes a rigid internal support frame indicated generally at  21 . Frame  21  includes front and rear frame members  23  and  25 , respectively, which are connected by a pair of spaced parallel side rails  27  which extend horizontally therebetween. In a first embodiment of frame  21 , front and rear frame members  23  and  25  are similar in size and configuration, each being a three-member generally trapezoidal configuration with a pair of side legs  29  and a horizontal cross beam  31 . Frame legs  29  are connected to cross beams  31  by angle plates  39  and a plurality of fasteners  40  such as rivets, bolts, T-slot fasteners or other types of well-known fasteners. Cross beams  31  may be a single member or could be two sections connected together by a fastening plate  41 . 
         [0022]    An angled steel plate  33  extends horizontally between the bottom ends  35  of each pair of legs  29  of the front and rear frame members ( FIGS. 2 and 3 ). Angled plates  35  will rest upon the top of shell flanges  17  and supported on side rails  7  of the vehicle body as shown in  FIGS. 2 and 2A . Plates  33  may be connected to frame legs  29  by rivets, bolts, welds, or other types of fasteners (not shown). Plates  33  preferably are secured to the vehicle body side rails by C-clamps  20  or other type fasteners well known in the truck cap industry. Preferably the frame members, and in particular frame legs  29 , cross beams  31 , and side rails  27  have a double slotted configuration referred to in the industry as double T-slotted members. This type of member is usually formed of an extruded aluminum and referring to side rails  27  in particular as shown in  FIG. 5 , has spaced outer parallel walls  27 A each formed with an aligned pair of slots  27 B for receiving fasteners  40  therethrough for engagement with T-slot nuts  40 A contained within elongated rectangular-shaped channels  32 . Each of the spaced ends of the T-rails  27  have T-shaped slots  34  formed therein. It is readily understood that other types of frame members can be used in forming frame  21  within the concept of the present invention, although the T-rail configuration of the frame members has advantages discussed further below. 
         [0023]    In accordance with a feature of the invention, a plurality of posts  43 , preferably four, are quadrilaterally placed in a rectangular configuration on the top of frame  21 , each being located generally adjacent the junction of side rails  27  with cross beams  31  ( FIG. 3 ). As shown in  FIG. 5 , each post  43  is connected to its respective side rail  27  by spaced pairs of fasteners  40  and T-slot nuts  40 A which sit inside of the elongated channels  32  of the cross beam. Each post  43  preferably is a hollow tubular member which extends vertically upwardly from a respective side rail  27  and extends through aligned holes  51  formed in top wall  15  of shell  11  terminating a short distance above the top of wall  15 . 
         [0024]    A sealing ring or grommet  59  is placed about the outer circumference of each post  43  within holes  51  to seal the post and shell  11  providing a weatherproof seal therebetween. These seals can be various types of elastomer rings or even some type of applied sealant. 
         [0025]    Various types of racks can be attached to the top ends of post  43 , one common type being a ladder rack as referred to in the vehicle rack industry, which is indicated generally at  52  and shown on  FIGS. 2, 3, and 5 . These racks consist of a pair of oval-shaped elongated rails  53  and have a generally oval shape with a longitudinally extending top slot or opening  54  and a pair of internal channels or voids  55  and  56  separated by a wall  49 . Rails  53  can be connected to top plates  57  which enclose the open tops of posts  43  by fasteners  58  and elongated nuts  58 A. Plate  57  may be attached to the open top of post  43  by welds  64  ( FIG. 6 ) or other type of attachment. It is readily understood that other types of rails or cargo supporting members can be attached to the tops of posts  43  without affecting the concept of the invention. 
         [0026]    A modified cargo-supporting frame is shown in  FIG. 4  and is indicated generally at  65 , and will be used with taller end cap shells. Frame  65  will have front and rear frame member  66  and  67  respectively, each having a three member trapezoid configuration. Front frame member  66  will have upwardly angled legs  68  and a horizontal cross beam  69 . Rear frame member  67  will have upwardly angled legs  70  and a cross beam  71 . Front frame member  66  will be taller than rear frame member  67  and is connected thereto by parallel side rails  72  and a pair of downwardly sloped side rail sections  73  and a connecting cross beam  74 . 
         [0027]    This modified frame  65  enables a taller inside storage area, yet enables a usual tailgate and window to be installed adjacent the shorter rear frame member  67 . This is in contrast to frame  21  discussed above wherein the front and rear frame members are equal in size and configuration. 
         [0028]    A usual ladder rack  52  similar to the ladder rack discussed above and attached to frame  21  having two spaced rails  53 , can be attached to posts  43  and may have a second ladder rack  79  mounted on ladder rack  52 . Rack  79  may be the same as or very similar to ladder rack  52  and have a pair of racks  78  connected to elongated rails  53  by a pair of fasteners or bolts  80  and nuts  81 . The spaced pair of rails  78  of ladder rack  79  will extend transversely across rails  53  of ladder rack  52 , as shown in  FIGS. 1, 4, and 6 . 
         [0029]    Again, as with the embodiment of  FIGS. 2, 3, and 5 , this modified frame construction will transfer all of its supported weight onto the truck body through frame  65  and not be placed on the shell which will cover and conceal internal support frame  65 . The frame members of frame  65  preferably are formed of the same single or double T-slot members as that of frame  21 . 
         [0030]    The forming of frame members  27 ,  29 , and  31  of frame  21  and the frame members  68 ,  69 ,  70 ,  71 ,  73  and  74  of frame  65  of a T-slot configuration or even a double T-slot configuration as shown in the drawings, provides numerous locations within the cargo storage area, such as shown in  FIG. 7 , in which various types of hangers  85  can be secured in one or more of the T-shaped grooves for supporting various types of tools or equipment, such as a cable or wire  86  as an example shown in  FIG. 7 . This provides numerous locations completely along the length and width of the storage area in which to attach various brackets or other supporting hardware for the storage of tools or other equipment. Also, as shown in  FIG. 7 , an interior tool box  87  can be suspended on one of the side rails and attached to one of the front and rear rails which would be readily accessible either from the interior of the truck cap or through an external door in the covering shell well-known in the art. 
         [0031]    Thus, the truck cap of the present invention provides a rigid internal frame which is easily mounted within the truck cargo area by supporting it on the side rails or flanges of the truck body, in combination with a lightweight external shell, which also is supported on the side flanges of the frame of the truck body. This provides a complete weather enclosure to the open cargo area of the truck while providing access thereto by a usual rear gate, rear window, or even side opening windows and doors. The support posts which extend through openings in the top roof of the shell can have various racks or other cargo-supporting structures attached thereto for supporting or containing any type of external load. Most importantly, the weight of any external load or cargo supported on the roof rack is transmitted by the posts to the internal frame directly onto the side walls or flanges of the vehicle body. This avoids any of the load being supported in any manner by the lighter, flexible, outer weather-proof shell. Furthermore, the seals between the posts and holes formed in the shell prevent any water or weather from entering the cargo storage area and causing damage to the stored contents. 
         [0032]    It is readily understood that the truck cap of the present invention can be constructed as a combination consisting of the rigid internal frame with the posts extending through and sealed to the outer shell, or can be installed as a retrofit internal frame requiring only four holes to be drilled in the top wall of the shell for insertion of the four posts therethrough, after which seals can be placed in or formed about the post once the frame is properly positioned with respect to the shell. 
         [0033]    In the foregoing description, certain terms have been used for brevity, clearness, and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed. 
         [0034]    Moreover, the description and illustration set out herein are an example and the invention is not limited to the exact details shown or described.