Abstract:
The present invention is directed to a tonneau cover incorporating a cable system which generates the proper amount of cross-car tension, and still provides for the tonneau cover to be rolled up and stowed when not in use. The present invention is directed to a tonneau cover for a vehicle that is moveable between a stowed position and a deployed position. The tonneau cover has at least one pocket extending along a side of the tonneau cover, and at least one cable disposed in the pocket such that a first end of the cable extends out of a first end of the pocket, and a second end of the cable extends out of a second end of the pocket such that when the tonneau cover is in the deployed position, the cable applies tension to the tonneau cover.

Description:
FIELD OF THE INVENTION 
     The present invention relates to a tonneau cover used for the bed of a pickup truck that is moveable between a stowed position and a deployed position, and incorporates a cable along the side of the tonneau cover to maintain proper tension when the tonneau cover is in the deployed position. 
     BACKGROUND OF THE INVENTION 
     Tonneau covers are a generally known device for covering the bed portion of a pickup truck. There are many different types of tonneau covers, some of which are a solid fiberglass panel which covers the entire bed of the pickup truck, and others are made of a foldable material which folds and is easily stowed away when not in use. The use of a tonneau cover may be to protect the various components inside the bed of the pickup truck from the surrounding environment, or provide an aesthetically pleasing appearance. 
     One particular type of tonneau cover, as mentioned above, is what is referred to as a “soft” tonneau cover made of a foldable material which facilitates ease of stowage. A soft tonneau cover typically is connected to a series of rails connected to the sides, tailgate, and front of the bed, respectively. One of the common ways to connect the tonneau cover to the rails along the sides of the bed, or side rails, is through a typical Velcro connection. A typical Velcro connection consists of two layers, a first layer having a series of hooks, and a second layer having a plurality of smaller loops. The hook layer may be disposed on the rail, and the loop layer may be disposed on the cover, or vice versa. Both layers of the Velcro connection typically extend along the length of the side rails. The use of a Velcro connection in prior art tonneau covers is considered desirable because the tonneau cover is easily removable from the side rails, allowing ease of access to the bed of the pickup truck, and allowing the cover to be rolled up and stowed at the front of the bed when not in use. 
     The Velcro connection also provides for the tonneau cover to be adjustable relative to the side rails. During installation, the Velcro connection may be adjusted to compensate for the tonneau cover becoming stretched over time. The cover is simply pulled tighter, and the Velcro connection is adjusted accordingly. However, during the life of the tonneau cover, dirt and other debris accumulate on the both the hook layer and the loop layer, reducing their effectiveness, thereby reducing the ability for the Velcro connection to maintain proper tension in the tonneau cover. 
     Accordingly, there exists a need for a tonneau cover which is able to be tensioned properly, and maintain the proper amount of tension over time, yet still have the functionality to be rolled up and stowed when needed. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to a tonneau cover incorporating a cable system which generates the proper amount of cross-car tension, and still provides for the tonneau cover to be rolled up and stowed when not in use. 
     The present invention is directed to a tonneau cover for a vehicle that is moveable between a stowed position and a deployed position. The tonneau cover has at least one pocket extending along a side of the tonneau cover, and at least one cable disposed in the pocket where a first end of the cable extends out of a first end of the pocket, and a second end of the cable extends out of a second end of the pocket such that when the tonneau cover is in the deployed position, the cable applies tension to the tonneau cover. 
     The present invention also includes a front rail connected to a set of side rails, and a rear rail that is connected to the side rails when the tonneau cover is in the deployed position. The tonneau cover is permanently connected to the front and rear rails. The rear rail includes at least one channel which receives a spring, and the spring is connected to the cable such that as the tonneau cover is placed in the deployed position, the spring applies tension to the cable, thereby applying tension to the tonneau cover, and achieving the proper amount of cross-car tension in the tonneau cover. 
     It is an object of this invention to provide a tonneau cover having a cable tensioning system which provides cross car tension when the tonneau cover is in the installed or deployed position. It is another object of this invention to provide a cable tensioning system which requires no secondary tensioning from the operator during the installation process. The cable system of the present invention automatically provides the proper tensioning of the cover when the tonneau cover is in a deployed position. 
     Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein: 
         FIG. 1  is a perspective view of a first side rail and a second side rail connected to the bed of a truck used for a tonneau cover, according to the present invention; 
         FIG. 2  is an exploded view of a tonneau cover, a first side rail, and a second side rail, according to the present invention; 
         FIG. 3  is an exploded view of a tonneau cover in a stowed position and the truck bed of a vehicle, according to the present invention; 
         FIG. 4  is first a perspective view of a tonneau cover in a stowed position and connected to the truck bed of a vehicle, according to the present invention; 
         FIG. 5A  is a first perspective view of a tonneau cover in a deployed position, according to the present invention; 
         FIG. 5B  is a perspective view of various positions of a tie-down strap used for maintaining a tonneau cover in a stowed position, according to the present invention; 
         FIG. 6  is a second perspective view of a tonneau cover in a stowed position and connected to the truck bed of a vehicle, according to the present invention; 
         FIG. 7  is a sectional side view of a side rail and a tonneau cover in a deployed position, according to the present invention; 
         FIG. 8  is an enlarged perspective view of a portion of a side rail and a portion of a rear rail used for a tonneau cover according to the present invention; 
         FIG. 9  is a bottom view of a portion of a side rail and a portion of a rear rail used for a tonneau cover according to the present invention; 
         FIG. 10  is a side view of a side rail used for a tonneau cover according to the present invention; 
         FIG. 11  is a top view of a side rail used for a tonneau cover according to the present invention; 
         FIG. 12A  is a front view of a connector used for a tonneau cover according to the present invention; 
         FIG. 12B  is a top view of a connector used for a tonneau cover according to the present invention; 
         FIG. 12C  is a side view of a connector used for a tonneau cover according to the present invention; 
         FIG. 13  is a bottom view of a tonneau cover removed from a truck bed, according to the present invention; 
         FIG. 14  is a sectional view taken along lines  14 - 14  of  FIG. 10 , according to the present invention; 
         FIG. 15A  is a front view of a back plate used for a connector of a tonneau cover, according to the present invention; 
         FIG. 15B  is a side view of a back plate used for a connector of a tonneau cover, according to the present invention; 
         FIG. 16A  is a side view of a washer used for a connector of a tonneau cover, according to the present invention; 
         FIG. 16B  is a front view of a washer used for a connector of a tonneau cover, according to the present invention; 
         FIG. 17A  is a side view of a side rail mount used for connection with the rear of a side rail for a tonneau cover, according to the present invention; 
         FIG. 17B  is a front view of a side rail mount used for connection with the rear of a side rail for a tonneau cover, according to the present invention; 
         FIG. 17C  is a top view of a side rail mount used for connection with the rear of a side rail for a tonneau cover, according to the present invention; 
         FIG. 18A  is a side view of a side rail mount used for connection with the front of a side rail for a tonneau cover, according to the present invention; 
         FIG. 18B  is a front view of a side rail mount used for connection with the front of a side rail for a tonneau cover, according to the present invention; 
         FIG. 18C  is a top view of a side rail mount used for connection with the front of a side rail for a tonneau cover, according to the present invention; and 
         FIG. 19  is a perspective view of a pickup bed having a tonneau cover in a deployed position, according to the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. 
     A truck bed incorporating a tonneau cover according to the present invention is shown in  FIG. 1  generally at  10 . Referring to the Figures generally, the tonneau cover  12  according to the present invention is attached to the truck bed  14  through the use of a first side rail  16  and a second side rail  18 . More specifically, the first side rail  16  is mounted on a first side wall  20  which is part of the bed  14 , and the second side rail  18  is mounted on a second side wall  22  which is also part of the bed  14 . 
     The tonneau cover  12  is selectively connected to each of the side rails  16 , 18 , and is permanently connected to a front rail  24 . During the installation of the tonneau cover  12  onto the truck bed  14 , the front rail  24  is connected to each of the side rails  16 , 18  such that the front rail  24  extends along a front wall  26  of the bed  14 . Each of the side rails  16 , 18  has a front connector  28  which is used to connect the side rails  16 , 18  to the front rail  24 . 
     The tonneau cover  12  is also permanently connected to a rear rail  30 , the rear rail  30  selectively connects to each of the side rails  16 , 18  through the use of rear connectors, or pivot mounts  32 . The tonneau cover  12  is made of a flexible material which is able to fold, and is also able to be rolled up as shown in  FIGS. 2 ,  3 , and  6 . More specifically, the tonneau cover  12  is movable between an installed, or deployed position, to a stowed position. The tonneau cover  12  includes a first pocket  34  and a second pocket  36 , each pocket has a first end  38  which is in proximity to the front rail  24  and a second end  40  which is in proximity to the rear rail  30 . Each of the pockets  34 , 36  extends along the sides of the tonneau cover  12 , almost the entire length of the tonneau cover  12 . Extending through each of the pockets  34 , 36  are cables  42 , 44 ; a first cable  42  extending through the first pocket  34 , and a second cable  44  extending through the second pocket  36 . A first end  46  of the first cable  42  extends out of the first end  38  of the first pocket  34 , and a second end  48  of the first cable  42  extends out of the second end  40  of the first pocket  34 . Additionally, the first end  46  of the second cable  44  extends out of the first end  38  of the second pocket  36 , and the second end  48  of the second cable  44  extends out of the second end  40  of the second pocket  36 . 
     Reference in the description is now made to the function of the first cable  42  and first pocket  34 , as well as the first side rail  16 , however, the description also applies to the second cable  44 , the second pocket  36 , and the second side rail  18  since they are substantially symmetrical. The first end  46  of the cable  42  is connected to the front rail  24 , and connected to the second end  48  of the cable  42  is a tensioning member, such as a spring  50 . More specifically, the spring  50  is connected to the end  48  of the cable  42  that extends out of the pocket  34  toward the rear rail  30 . The spring  50  is connected to the rear rail  30  through the use of a hook  52  formed as part of the spring  50  and a latch (not shown) formed as part of the rear rail  30 . The spring  50  is disposed in a channel  54  formed as part of a base portion  56  of the rear rail  30 , and is located at an angle  58  relative to the side rail  16  as shown in  FIG. 9 . As mentioned above, the spring  50  is connected to the second end  48  of the cable  42 , and the cable  42  extends through a notch  60  formed in a wall portion  62 , and the wall portion  62  is formed as part of the base portion  56  in proximity to the channel  54 . While the spring  50  is shown to be a helical spring, other types of tensioning members or devices may be utilized to provide tensioning of the cable  42 . 
     The side rail  16  has a substantially triangular-shaped cross-section, best seen in  FIGS. 7 and 14 , and includes a base  64 , which is substantially horizontal, as well as a side wall  66 , which is substantially vertical and has an elongated aperture  68  which extends substantially the length of the rail  16 . The rail  16  also includes an angled wall portion  70  having an outer angled surface  72 . A portion of the tonneau cover  12  rests on the outer angled surface  72  when the tonneau cover  12  is in the deployed position, as shown in  FIG. 7 . The tonneau cover  12  includes a strip of material, or fabric  74  (preferably made of the same material as the remaining portion of the tonneau cover  12 ), which extends along the length of the side of the tonneau cover  12  to form the pocket  34 . The strip of fabric  74  is sewn to the tonneau cover  12  in this embodiment, but it is within the scope of the invention that the strip of fabric  74  may be connected to the tonneau cover  12  using other methods. There is also an outer clip  76  which surrounds an outer edge  78  of the tonneau cover  12  and an outer edge  80  of the strip of fabric  74 . The outer clip  76  has substantially U-shaped cross-section, and extends along the length of the pocket  34  and clamps the edges  78 , 80  together. However, while the outer clip  76  is shown, it is within the scope of the invention that other types of clips may be used, as long as they are flexible to allow the tonneau cover  12  to be placed in the stowed position shown in  FIGS. 2 ,  3 , and  6 . 
     The rear rail  30  is selectively connected to the rear connectors  32 . The rear connectors  32  include a recess  82  formed as part of a base  84 . The recess  82  of each connector  32  is capable of receiving a pivot rail  86  formed as part of the rear rail  30 . The recess  82  is substantially rounded, and corresponds to the shape of the pivot rail  86 . The pivot rail  86  is also shorter in height in relation to the base portion  56 , but the base portion  56  is substantially the same height as the side rail  18  to provide a smoother looking, more aesthetically pleasing appearance when the tonneau cover  12  is in the deployed position. 
     The connectors  28 , 32  also include a set of access apertures  88  and a set of through-apertures  90 , and a set of fasteners  92  are inserted into and through the apertures  88  and into the through-apertures  90 , through another set of threaded apertures  93  formed as part of a backing plate  94 . The backing plate  94  includes a shoulder portion  96  which is received by the elongated aperture  68 . The shoulder portion  96  prevents the backing plate  94 , and therefore the connectors  28 , 32 , from becoming displaced vertically relative to the side rails  16 , 18 . To connect the connectors  28 , 32  to the side rails  16 , 18 , the fasteners  92  are inserted through the through apertures  90  and the threaded apertures  93  formed as part of the backing plate  94  and are tightened, thereby applying pressure to an outer side wall  98  of the connectors  28 , 32 , and the side wall  66  of the side rail  16 , 18 , securing the connectors  28 , 32  to the rails  16 , 18 . To further secure the connectors  28 , 32  to the rails  16 , 18 , a rivet  100  is inserted through the base  64  and a bottom wall  102  of the side rails  16 , 18 , best shown in  FIG. 14 . The fasteners  92  are accessible for removal by extending a screwdriver, or the like, through the apertures  88 . 
     The outer side wall  98  and the bottom wall  102  of the connectors  28 , 32  along with an inner side wall  104  form a channel  106 , which is accessible through a transverse aperture  108 . There is an adjuster screw  110  which extends through the transverse aperture  108  and extends through a spacer  112 . The spacer  112  is also disposed in the transverse aperture  108  as well as an adjuster nut  114 . The adjuster screw  110  also extends through a pair of adjustment apertures  116 , through the spacer  112 , a washer  118 , and through the adjuster nut  114  as shown in the Figures. The adjuster screw  110  is partially threaded, and the threaded portion of the adjuster screw  110  is received by the adjuster nut  114 , which is also threaded. The adjuster nut  114  is prevented from rotating in the channel  106  because the sides of the adjuster nut  114  are in contact with the walls  98 , 104 , as shown in  FIG. 14 . 
     Attached to each end of the side rails  16 , 18  are side rail mounts  120 , each of which includes an extension  122  having a recess  124 . Each extension  122  is received into an end of the side rails  16 , 18  as shown in the Figures, such that the recess  124  is exposed in the elongated aperture  68 , and a portion of the front rail  24  is disposed between the side rail mounts  120  and the front connector  28 . Each extension  122  also receives a screw  126  in the recess  124 , and when the screw  126  is tightened, the side rail mounts  120  are then secured to the side rails  16 , 18 . 
     Referring now to  FIGS. 10 and 11 , the rear connector  32  associated with the second side rail  18  also includes a release mechanism, generally shown at  128 . The release mechanism  128  includes latch  130 , a handle  132 , and a spring  134 . The spring  134  is disposed between the extension  122  of the side rail mount  120  connected to the rear of the second side rail  18 , and biases the latch  130  forward, the function of which will be described later. 
     The tonneau cover  12  is first assembled to the front connectors  28 . The front rail  24  also includes a pivot rail  86  (which is similar to the pivot rail  86  of the rear rail  30 ) which is received into the recess  82  of the front connectors  28 ; the front rail  24  is then pivoted about the pivot rail  86  such that the front rail  24  is on top of the front wall  26 , and disposed substantially between the side rails  16 , 18  as shown in  FIGS. 4 ,  5 A, and  6 . The side rail mounts  120  are then connected to the side rails  16 , 18  as described above, securing the front rail  24  to the side rails  16 , 18 . 
     The tonneau cover  12  is maintained in the stowed position by a plurality of tie-down straps  136 . To change the tonneau cover  12  to the deployed position, the straps  136  are released, and the cover  12  is rolled toward the rear of the bed  14  as shown in  FIGS. 5A and 19 . Once the cover  12  is rolled out, best shown in  FIGS. 5A ,  8 - 9 , and  19 , the rear rail  30  is then connected to the rear connectors  32 . The pivot rail  86  of the rear rail  30  is first inserted into the recess  82  (shown in  FIG. 10 ) of the rear connectors  32 , and the rear rail  30  is then rotated about the pivot rail  86  until the rear rail  30  is in the position shown in  FIGS. 8-9 . As this occurs, pressure is applied to the rear rail  30  to cause the release mechanism  128  to lock the rear rail  30  into position. As the rear rail  30  is placed in the position shown in  FIGS. 8 and 9 , the tension is increased in the cables  42 , 44  such that the cables  42 , 44  position the outer edges of the tonneau cover  12  across the outer angled surface  72  of the side rails  16 , 18 . The cables  42 , 44  are of a length that when in the deployed position, the springs  50  apply tension to the cables  42 , 44 , thereby creating tension in the tonneau cover  12  and ensuring the tonneau cover  12  fits properly in relation to the side rails  16 , 18 , the front rail  24 , and the rear rail  30 . More specifically, the cables  42 , 44  provide the proper cross-car tension in the tonneau cover  12 . 
     To change the tonneau cover  12  to the stowed position as shown in  FIGS. 2-3  and  6 , thereby allowing access to the bed  14 , the handle  132  is simply pulled to move the latch  130  against the force of the spring  134 , thereby releasing the rear rail  30  from the release mechanism  128 . The release mechanism  128 , latch  130 , handle  132 , and spring  134  are best seen in  FIGS. 10-12C . This allows the tonneau cover  12  to be rolled up as shown in  FIGS. 2-3  and  6 . The tonneau cover  12  is maintained in the stowed position by the tie down straps  136 , if desired. 
     The present invention has the advantage that the springs  50  maintain the proper tension on the tonneau cover  12  over the life of the tonneau cover  12 , even as the tonneau cover  12  is exposed to various temperatures and weather conditions or may become worn. The springs  50  also maintain the edges of the tonneau cover  12  in contact with the outer angled surface  72  of the side rails  16 , 18  when the tonneau cover  12  is in the deployed position, preventing moisture, dirt, and other debris from entering the bed  14 . Additionally, because the tension in the cables  42 , 44  is automatically generated by the springs  50  and the edges of the tonneau cover  12  are automatically properly positioned onto the outer angled surfaces  72  of the side rails  16 , 18 , the additional step of attaching the cover  12  to the side rails  16 , 18  (as with previous designs) is eliminated, reducing the time needed to change the cover between the stowed position and the deployed position. 
     The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the essence of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.