Abstract:
A clamp assembly is disclosed for a tonneau cover for a vehicle wherein the clamp assembly includes a plurality of spacers disposed therein to facilitate installation thereof on a variety of vehicle types and styles.

Description:
[0001]    This application claims priority to a provisional patent application, Ser. No. 60/592,106, entitled CLAMP SYSTEM, filed July  29 ,  2004 . The invention relates to a clamp assembly and more particularly to a clamp assembly for a truck cap, tonneau cover, and the like for a vehicle wherein the clamp assembly includes a plurality of spacers to facilitate an adjustment of the clamp assembly. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    A number of accessories, such as truck caps, tonneau covers, light bars, utility boxes, and the like, can be added to a pickup truck or other vehicle for functional and decorative purposes. These accessories are typically secured to the truck by fasteners, aluminum extruded clamps, or “C” clamps. 
         [0004]    Tonneau covers are typically made of a relatively soft, flexible fabric, approximately the size and shape of the cargo area to be covered. Alternatively, the cover can be constructed of a rigid and durable material such as fiberglass. The cover can include a mechanism disposed along the edge of the cover for securing the cover to the vehicle. In one known type of cover, holes are drilled in the vehicle and one portion of a snap is secured in each hole. The corresponding snap portions are secured about the perimeter of the cover. To secure the cover to the vehicle, the fabric is placed over the cargo area and the snaps are engaged. 
         [0005]    In another known type of cover, a plurality of rails is clamped about the periphery of the cargo area. The rails include snaps, slots, or other features that engage corresponding features secured to the periphery of the cover. 
         [0006]    The existing clamps can be problematic since the areas surrounding the drilled openings and any areas damaged by the clamps are susceptible to corrosion. Additionally, if a particular accessory is removed, the openings and the damaged areas remain in the truck bed side rails, thus detracting from the appearance of the vehicle. 
         [0007]    It would be desirable to produce a clamp assembly which can be adapted to fit a variety of vehicles and wherein the clamp assembly militates against damage to the vehicle. 
       SUMMARY OF THE INVENTION 
       [0008]    Consistent and consonant with the present invention, a clamp assembly which can be adapted to fit a variety of vehicles and wherein the clamp assembly militates against damage to the vehicle, has been discovered. 
         [0009]    In accordance with one aspect of the present invention, a clamp assembly adapted to slidingly connect to an associated rail system includes a main body portion, the main body portion comprising a front side, a back side, multiple concave portions located on the back side, a top, a rounded bottom, an inset portion within which is inset an elongate aperture, a serrated portion on the back side, the serrated portion running along the length of the elongate aperture, multiple spacers, the spacers comprising a front side, a back side, a top, a rounded bottom, an open-ended slot, with the open end at the top, a first serrated portion on the front side of the spacers, the first serrated portion adapted to fit the serrated portion on the back side of the main body portion, a second serrated portion on the back side of the spacers, adapted to fit the first serrated portion on the front side of the spacers, multiple protuberant portions on the front side of the spacers, the protuberant portions adapted to fit in the concave portions on the back side of the main body portion, receiving portions on the back side of the spacers, the receiving portions adapted to receive the protuberant portions, a fastener, the fastener adapted to fit through the elongate apertures, and a clamp jaw, the clamp jaw comprising a front side, a back side, a bolt-receiving aperture, an outer top surface, a groove, the groove adapted to receive the second serrated portion, a pin, the pin adapted to enter the slot, and a rubber inlay, the rubber inlay fitting over the outer top surface. 
         [0010]    In accordance with another aspect of the present invention, a clamp assembly includes a main body portion, the main body portion having an aperture adapted to receive a fastener and a fastener-receiving portion, the bolt-receiving portion having an anti-rotation portion. 
         [0011]    In accordance with another aspect of the present invention, the assembly includes at least one spacer, the spacer having an open-ended slot, the spacer fitting between the main body portion and the fastener-receiving portion. 
         [0012]    In accordance with another aspect of the present invention, the main body portion further includes an anti-rotation portion to coincide with the anti-rotation portion of the fastener-receiving portion. 
         [0013]    In accordance with another aspect of the present invention, the fastener-receiving portion is a clamp jaw, and the anti-rotation portion of the main body portion is a serrated portion, and the anti-rotation portion of the clamp jaw is a groove designed to fit the serrated portion. 
         [0014]    In accordance with another aspect of the present invention, the at least one spacer has a serrated portion on at least one side, the serrated portion designed to fit with the serrated portion of the main body portion and the groove of the clamp jaw. 
         [0015]    In accordance with another aspect of the present invention, the assembly includes a selectively adjustable fastener, the fastener passing through the aperture of the main body portion, the slot of the spacer, and into the clamp jaw. 
         [0016]    In accordance with another aspect of the present invention, the assembly includes a rail insert, the rail insert attached to the main body portion, the rail insert adapted to slidably engage at least one associated rail. 
         [0017]    In accordance with another aspect of the present invention, the assembly includes protuberant portions, the protuberant portions located on the spacer, concave portions, the concave portions located on the back of the main body portion, and receiving portions on the back side of the spacer. 
         [0018]    In accordance with another aspect of the present invention, the aperture in the main body portion is an elongate aperture. 
         [0019]    In accordance with another aspect of the present invention, the assembly includes an inset portion in the main body portion and a cover plate, the cover plate fitting inside the inset portion. 
         [0020]    In accordance with another aspect of the present invention, the main body portion and the spacers have a substantially rounded bottom. 
         [0021]    In accordance with another aspect of the present invention, the assembly is adapted to be removed with an associated tonneau cover. 
         [0022]    In accordance with another aspect of the present invention, a method for adjusting a clamp assembly on an associated rail system includes the steps of attaching a main body portion to the rail system by inserting a fastener through an aperture in the main body portion into a groove in the rail system, abutting a clamp jaw to the bottom of the rail system, and attaching the clamp jaw to the main body portion via a selectively adjustable fastener. 
         [0023]    In accordance with another aspect of the present invention, the method includes inserting a spacer between the main body portion and the clamp jaw. 
         [0024]    In accordance with another aspect of the present invention, prior to inserting a spacer between the main body portion and the clamp jaw, the method includes loosening the selectively adjustable fastener. 
         [0025]    In accordance with another aspect of the present invention, inserting a spacer between the main body portion and the clamp jaw further includes inserting multiple spacers between the main body portion and the clamp jaw and tightening the selectively adjustable fastener. 
         [0026]    In accordance with another aspect of the present invention, inserting a spacer between the main body portion and the clamp jaw, wherein the spacer has an open-ended slot and a serrated portion, further includes inserting the open-ended slot over the fastener, between the main body portion and the clamp jaw and aligning the serrated portion of the spacer with a serrated portion on the main body portion. 
         [0027]    In accordance with another aspect of the present invention, the method further includes removing an associated tonneau cover and resting the tonneau cover on an associated surface, wherein the bottom of the main body portion is contacting the associated surface, thereby holding the tonneau cover above the associated surface. 
         [0028]    In accordance with another aspect of the present invention, the clamp jaw has a rubber inlay, which includes a center portion that is angled at approximately a 45 degree angle with respect to the clamp jaw and multiple ribs on the surface of the inlay. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0029]    The above, as well as other advantages of the present invention will become readily apparent to those skilled in the art from the following detailed description of at least one embodiment when considered in the light of the accompanying drawings in which: 
           [0030]      FIG. 1  is an exploded perspective view of a clamp assembly, along with a cooperating rail system, according to one embodiment of the invention; 
           [0031]      FIG. 2  is a perspective view of the front and back sides of the main body portion of the clamp assembly; 
           [0032]      FIG. 3  is a side and sectional view of the main body portion of the clamp assembly; 
           [0033]      FIG. 4  is a perspective view of the front and back of the clamp jaw without the rubber inlay, and without the hex nut; 
           [0034]      FIG. 5  is a perspective view of the front and back of one embodiment of the spacer; 
           [0035]      FIG. 6  is a perspective view of a vehicle with a tonneau cover in place; 
           [0036]      FIG. 7  is a perspective view of a T-nut; 
           [0037]      FIG. 8  is a perspective view of the front and back of the cover plate; 
           [0038]      FIG. 9  is a side view of three connected spacers; 
           [0039]      FIG. 10  is a perspective view of another embodiment of the clamp jaw; 
           [0040]      FIG. 11  is a perspective view of the clamp assembly attached to the rail system; and, 
           [0041]      FIG. 12  is a side view of the clamp assembly attached to the rail system. 
       
    
    
     DESCRIPTION OF THE INVENTION 
       [0042]    The following detailed description and appended drawings describe and illustrate various exemplary embodiments of the invention. The description and drawings serve to enable one skilled in the art to make and use the invention, and are not intended to limit the scope of the invention in any manner. 
         [0043]    With reference now to  FIGS. 1-10 , the figures depict a clamp assembly  10  according to one embodiment of the invention. The clamp assembly  10  includes a main body portion  12 , spacers  14 , and a clamp jaw  16 . The main body portion  12  has a first side or front side  18 . An inset portion  20  is formed in the front side  18 . An elongate aperture  22  is formed at a bottom portion of the inset portion  20  and is surrounded by an annular surface  24 . The annular surface  24  is adapted to receive a bolt plate  26  therein. The elongate aperture  22  allows the fastener  30  and the clamp jaw  16  to be adjusted to the proper height. The bolt plate  26  includes a pair of apertures  28  adapted to receive a threaded fastener  30  therein. An aperture  32  is formed in the upper portion of the inset portion  20  and is adapted to receive a threaded fastener  34  therein. The inset portion  20  receives a snap-in cover plate  36  to hide the threaded fasteners  30 ,  34  after installation. The cover plate  36  has a front side  88 , a back side  90 , top connecting tabs  84 , and bottom connecting tab  86 . Connecting tabs  84 ,  86  snap into tab receiving portions  94 ,  108 . A back side  38  of the main body portion  12  includes a serrated portion  40  extending outwardly therefrom. 
         [0044]    The spacers  14  are generally U-shaped having a pair of upright arms  42  with a slot  44  disposed therebetween. As shown in the drawings, spacers  14  having different thicknesses can be used as desired. The slot  44  of the spacers  14  is aligned with the elongate aperture  22  of the main body portion  12  to allow the threaded fastener  30  to pass therethrough. A first serrated portion  46  is formed on a first side of the spacers  14  on each of the arms  42 . A second serrated portion  48  is formed on a second side of the spacers  14  on each of the arms  42 . The first serrated portion  46  of the spacers  14  is adapted to mesh with the serrated portion  40  of the main body portion  12  or the second serrated portion  48  of an adjacent spacer  14 . A protuberant portion  50  is formed on a periphery of the first side of each of the spacers  14  and is adapted to be received in a concave portion  92  formed in the main body portion  12  or receiving portions  98  on an adjacent spacer  14  (although it is to be understood that on some embodiments of the spacers  14 , in particular the thinner spacers  14 , there are no receiving portions  98 ). The protuberant portion  50  of the first spacer  14  is received within concave portion  92  of the main body portion  12 , thereby preventing slipping. 
         [0045]    The clamp jaw  16  is generally C-shaped. The top portion includes an outer surface  52  adapted to abut an undersurface of a truck rail (not shown). In the embodiment shown, a rubber inlay  54  is provided to be disposed between the outer surface  52  and the undersurface of the truck rail. A groove  56  is provided at a bottom portion of the clamp jaw  16  and cooperates with the second serrated portion  48  of one of the spacers  14 , or the serrated portion  104  of the main body portion  12 , to militate against rotation or spinning of the clamp jaw  16 . An aperture  58  is formed in the clamp jaw  16  to permit the fastener  30  to pass therethrough and be joined with a nut  60 . The clamp jaw  16  also has a pin  100  that is adapted to fit within the slot  44  and/or elongate aperture  22 . The pin  100 , like the groove  56  helps prevent rotation or spinning of the clamp jaw  16 . If additional spacers  14  are needed, the fastener  30  is loosened, and the clamp jaw  16  is moved far enough away from the main body portion  12  to allow insertion of an additional spacer(s)  14 . The spacer  14 , using slot  44  is slid around the fastener  30  and the protuberant portions  50  of the second spacer  14  are fit within the receiving portions  98  of the first spacer  14 , and the groove  56  of the clamp jaw  16  is fit against the second serrated portion  48  on the second spacer  14 . The fastener  30  is then re-tightened until the clamp assembly  10  is securely fastened. 
         [0046]    In use, the clamp assembly  10  cooperates with an extruded rail system  62  to be fastened to the truck rail  106 . When the clamp assembly  10  is used with a truck cap (not shown), the clamp assembly  10  may be adapted to cooperate with a rail portion of the truck cap. The clamp assembly  10  is assembled by placing the rail  62  on top of the truck rail  106 . The outer surface  52  and the rubber inlay  54  are held adjacent the undersurface of the truck rail  106 . The fastener  34  is inserted through washer  68 , and then through the aperture  32  to be received in a rail insert  70  disposed in a first slotted portion  64  of the rail  62 . The rail insert  70  allows for easy movement of the clamp assembly  10  along the slotted portion  64 . It is to be understood that the clamp assembly  10  can either be slidably engageable with the rail system or fastened in place. The fastener  30  is inserted through one of the apertures  28  formed in the bolt plate  26 , the elongate aperture  22 , the aperture  58  formed in the clamp jaw  16 , and received in the nut  60 . The desired number of spacers  14  is placed between a downwardly extending rail flange  15  of the tonneau cover  78  or truck cap (not shown) and a corresponding flange (not shown) of the truck rail  106 . In this way, the tonneau cover  78  or truck cap (not shown) may be appropriately centered on the truck bed  82 , and secured to the truck bed  82 . The slot  44  allows the spacers  14  to be inserted and removed as desired without completely disassembling the clamp assembly  10 . Once the desired number of spacers  14  has been inserted, the clamp assembly  10  can be positioned as desired and the fasteners  30 ,  34  tightened to hold the clamp assembly  10  in place. In one embodiment of the invention, a plurality of the clamp assemblies  10  is used to hold the rail  62  in place on the truck rail  106 . Snaps or other conventional fasteners (not shown) disposed in a second slotted portion  66  of the rail  62  cooperate with snaps or other conventional fasteners (not shown) in the tonneau cover  78  to hold the tonneau cover  78  in place. 
         [0047]    After installation, the clamp assembly  10  provides a safe and aesthetically pleasing clamp assembly  10  since the fasteners  30 ,  34  are hidden from view by the cover plate  36 . Additionally, the rubber inlay  54  provided on the outer surface  52  of the clamp jaw  16  militates against skidding, sliding, or moving of the clamp assembly  10 . In this embodiment, the rubber inlay  54  also has ribs  102  along the surface in order to further prevent skidding, sliding, or moving of the clamp assembly  10 . Additionally, the serrated portions  40 ,  46 ,  48 , groove  56 , the protuberant portions  50 , and cooperating receiving portions  98  militate against a relative movement between the main body portion  12 , the spacers  14 , and the clamp jaw  16 . The spacers  14  allow the clamp assembly  10  to be used on a variety of vehicles  76  having truck rails  106  of varying widths. It is to be understood that as may spacers  14  can be used as desired to accommodate the different widths of truck rails  106 . 
         [0048]    With reference now to  FIGS. 7 and 10 ,  FIG. 7  shows a T-nut  110 , which has a similar function to the clamp jaw  16 . T-nut  110  has a groove  56 ′ for preventing rotation, and aperture  58 ′ for receiving the fastener  30 .  FIG. 10  shows another embodiment of the clamp jaw  16 ′, which, for this particular embodiment, is modified for a specific vehicle application. Clamp jaw  16 ′ has a groove  56 ″ and a pin  100 ′ for preventing rotation, aperture  58 ″ for receiving the fastener  30 , and rubber inlay  54 ′ for preventing slipping. 
         [0049]    In this embodiment, the serrated portions  40 ,  46 ,  48  have individual teeth that engage with each other to form a slip-free connection. It is to be understood, however, that the serrated portions  40 ,  46 ,  48  are merely embodiments of the invention and are not intended to limit the invention in any manner. It is to be understood that any means of preventing rotation could be used, as long as chosen using sound engineering judgment. For example, the following anti-rotation devices could be used—pins and holes, flexible press fit, clips, and any other male/female combination devices. It is also to be understood that the placement of the serrated portions is not intended to limit the invention. The serrated portions could be located anywhere on the main body portion  12  and spacers  14 , as long as chosen using sound engineering judgment. For example, the serrated portions could be located on the inside of the slots. 
         [0050]    The attachment of the clamp assembly  10  allows for easy removal of the tonneau cover  78 , and allows the clamp assembly  10  to remain attached to the tonneau cover  78 . In this embodiment, the clamp assembly  10  has a rounded bottom, so that the tonneau cover  78  can be placed on the ground using the clamp assembly  10  as support. So, when the tonneau cover  78  is removed and placed on the ground, the clamp assemblies  10  hold the tonneau cover  78  up off of the ground. 
         [0051]    With reference now to  FIGS. 11 and 12 , the clamp assembly  10  is shown attached to the rail system  62 . In this particular embodiment, the clamp assembly  10  is fixedly attached to the rail flange  15 .  FIG. 12  shows the clamp assembly  10  with multiple spacers  14 . In one embodiment, the clamp jaw  16  has an angled outer surface  52  and rubber inlay  54 . This angle allows the clamp jaw  16  to fit more securely within the rail system  62 . As can be seen in  FIG. 12 , the rubber inlay  54  fits within bend  112  in the rail system  62 . In this particular embodiment, the angle is approximately 45 degrees, but it is to be understood that any angle, chosen using sound engineering judgment, could be used. 
         [0052]    From the foregoing description, one ordinarily skilled in the art can easily ascertain the essential characteristics of this invention and, without departing from the spirit and scope thereof, can make various changes and modifications to the invention to adapt it to various usages and conditions.