Abstract:
A modular tailgate protector that is infinitely adjustable for accommodating vehicle storage beds having different widths includes a horizontal support bar having a first end, a second end, and a longitudinal axis, and a pair of vertical support columns adapted for sliding along the longitudinal axis of the horizontal support bar for adjusting the spacing between the vertical support columns. The modular tailgate protector includes locking elements coupled with the vertical support columns for selectively locking the vertical support columns at selected locations along the longitudinal axis of the horizontal support bar. The vertical support columns are insertable into stake post openings located at a rear end of a vehicle storage bed for spacing the horizontal support bar from a tailgate so that items loaded in the vehicle storage bed do not impact against the tailgate.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention generally relates to storage beds for trucks, and more specifically relates to tailgate protectors and load support systems for trucks. 
         [0003]    2. Description of the Related Art 
         [0004]    Pickup trucks have rear storage beds that are used for hauling and delivering items. Frequently, the items loaded in the rear beds of trucks are too long (e.g. ladders, wood beams, drywall, etc.), which requires the items to be placed atop a closed tailgate. Road conditions often cause the items supported by the top of the tailgate to bounce about with substantial force, which may dent, bend and/or damage the tailgate, and/or damage the latches and hinges connecting the tailgate to the truck bed.  FIG. 1  shows a conventional pickup truck having a bent and damaged tailgate. A bent or damaged tailgate will not only diminish the aesthetic appearance of a truck, but it may also make it extremely difficult or impossible to properly open and close the tailgate. 
         [0005]    There have been a number of efforts directed to protecting the tailgates of trucks. For example, referring to  FIG. 2A  of the present application, U.S. Pat. No. 4,389,067 to Rubio teaches that a rear portion  10  of a pickup truck includes sidewalls  12  and  14  and a tailgate  16  hinged along its lower edge  18  and latched at  20 . Disposed above and slightly forward of the tailgate  16  is a protective device  22 . Referring to  FIG. 2B , the protective device  22  includes an elongated support beam  24  and a pair of support legs  26  that are bolted or welded to the support beam  24 . The length of the beam  24  is selected to be approximately the same length as the outer width of truck sidewalls  12  and  14  while the lengths of legs  26  are selected to be substantially equal to or slightly larger than the depth of the load carrying compartment of the pickup truck. The ends of the beam  24  rest upon the sidewalls  12  and  14  of the truck  10 , however, the load carried by the beam  24  is primarily supported by the legs  26  rather than the sides of the truck. 
         [0006]    Referring to  FIGS. 2B and 2C , the Rubio device also includes a pair of L-shaped flanges  28  that are welded to the beam  24 , and a stiffening web  32  that is welded to both the L-shaped flange  28  and the beam  24 . The flange  28  has a horizontal leg  33  having a length that is slightly greater than the width of the top edge  36  of tailgate the  16  (shown in phantom) and a vertical leg  34  that extends outside the tailgate  16  and holds the unit in place by sandwiching the top of the tailgate between the support legs  26  and the vertical second leg  34 . 
         [0007]    U.S. Pat. No. 3,698,760 to Lane teaches a tailgate protector and load bar having a horizontal elongated bar that is secured to the top outside surface of the tailgate of a pickup truck. U.S. Pat. No. 6,247,742 to Boudreaux discloses a tailgate protecting device for protecting a tailgate from impact damage. The tailgate protecting device includes a plate having a top edge, a bottom edge, a front side and a back side. A panel is securely attached to and substantially covers the back side of the plate. A first pair of securing means removably attaches the top edge of the plate to a top edge of a tailgate. A second pair of securing means removably attaches the bottom edge of the plate to a bottom edge of the tailgate. 
         [0008]    Although the Rubio, Lane, and Boudreaux references discussed above teach providing protector devices for tailgates, all of the references teach that the protector devices should be directly coupled with the tailgate. As a result, bouncing loads may still apply impact forces on tailgates and the hinges and latches coupled with the tailgates, which may cause damage to the tailgates. 
         [0009]    U.S. Pat. No. 5,197,642 to Cortelli teaches a freight stacking support apparatus for supporting oversized freight above a tailgate of a pickup truck. The apparatus includes a support beam, a securing bracket with a locking mechanism, a triggering button for activating the locking mechanism, and a receiving bracket. The brackets are affixed to opposing top rear edges of the side walls of a pickup truck and the ends of the support beam are received in slots in the opposing brackets such that the support beam resides parallel to and above the tailgate. When the apparatus is in position, it allows the user to safely transport freight without damaging the tailgate. In addition, it permits user access to the contents of the pickup truck bed through the pivotable tailgate without lifting or removing the supported freight. Although Cortelli provides a device for supporting oversized freight above a tailgate, the device must be permanently secured to the truck bed. As a result, the device cannot be easily moved from one truck to another truck. In addition, the Cortelli device does not provide structure for easily tying down oversized loads to the support beam of the device. 
         [0010]    U.S. Pat. Nos. 6,213,530 and 6,343,826 to Bohannon teach an auxiliary load supporting apparatus for a vehicle having left and right sidewalls. The load supporting apparatus includes a first base mounted to the left sidewall and extending upwardly therefrom, a second base mounted to the right sidewall and extending upwardly therefrom, a first framework mounted to the first base and extending rearwardly therefrom away from the left sidewall, and a second framework mounted to the second base and extending rearwardly therefrom away from the right sidewall. The load is supported by the truck bed, the top of the tailgate, and by the top cross bar extending between the first framework and the second framework. 
         [0011]    In spite of the above advances, there remains a need for improved tailgate protectors that do not apply load to the tailgate, or the hinges and latches connecting the tailgate with the truck bed. There is also a need for improved tailgate protectors that may be easily coupled to a truck bed without requiring special tools or fasteners. There also remains a need for tailgate protectors that may be easily moved from one truck to another, and that may be used for a range of trucks having different bed widths. In addition, there remains a need for tailgate protectors that enable oversized items within the truck to be easily secured to a horizontal support bar overlying the tailgate so that the items do not move around during transit. There is also a need for tailgate protectors that do not extend beyond the rear of the truck so that the tailgate protector may remain connected to the truck when items are not being hauled. 
       SUMMARY OF THE INVENTION 
       [0012]    The present invention provides a tailgate protector that may be used on a wide range of trucks having various sizes. The tailgate protector is infinitely adjustable so that it may be used with trucks having different storage bed widths. The tailgate protector may be used with a wide variety of vehicles including trucks, pickup trucks and trailers. The tailgate protector of the present invention may also be easily switched from one vehicle to another without requiring special tools or a complicated transfer procedure. 
         [0013]    In one embodiment, a modular tailgate protector includes a horizontal support bar having a first end, a second end, and a longitudinal axis extending between the first and second ends, and a pair of vertical support columns having horizontal support bar openings adapted to receive the horizontal support bar, whereby the vertical support columns are adapted for sliding along the longitudinal axis of the horizontal support bar. The modular tailgate protector preferably includes a locking element coupled with each of the vertical support columns for selectively locking the vertical support columns at a desired location along the longitudinal axis of the horizontal support bar. The spacing between the first and second vertical support columns is infinitely adjustable for accommodating vehicle storage beds having different widths. 
         [0014]    In one embodiment, the vertical support columns preferably have lower ends adapted for insertion into stake post openings of a vehicle storage bed for spacing the horizontal support bar from a tailgate located at a rear end of the vehicle storage bed. Spacing the horizontal support bar from the tailgate will insure that items supported by the horizontal support bar will not contact and damage the tailgate and the hinges and latches associated with the tailgate. The horizontal support bar and the vertical support columns are preferably made of materials selected from the group consisting of steel, stainless steel, chrome, aluminum and alloys thereof. 
         [0015]    The modular tailgate protector preferably includes a pair of grommets insertable into the stake post openings, each grommet including a top covering flange and a central opening extending through the top covering flange. The central opening of the grommet is desirably adapted to receive and support the lower end of one of the vertical support columns upon insertion of the vertical support column into one of the stake post openings. The grommets preferably comprise polymer materials such as rubber or high density rubber. 
         [0016]    In one embodiment, the horizontal support bar openings are located adjacent upper ends of the vertical support columns. Each of the locking elements is preferably in communication with one of the horizontal support bar openings. In one embodiment, the locking elements are preferably moveable between a first position for allowing the vertical support columns to slide along the horizontal support bar and a second position for locking the vertical support columns in place on the horizontal support bar. 
         [0017]    In one embodiment, each locking element includes a threaded opening extending through the vertical support column and being in communication with the horizontal support bar opening, and a threaded fastener adapted to be received in the threaded opening. The threaded fastener is preferably advanceable into the horizontal support bar opening for engaging the horizontal support bar. In one embodiment, the threaded fastener desirably includes a threaded eyebolt having an eye section and a threaded shaft. 
         [0018]    In one embodiment, the horizontal support bar has an outer surface having a tubular-shaped surface. In one embodiment, a horizontal support bar has a first substantially flat shoulder provided adjacent a first end of the horizontal support bar and a second substantially flat shoulder provided adjacent a second end of the horizontal support bar. The substantially flat shoulders preferably extend only part of the way around the circumference of the horizontal support bar, and only part of the way along the length of the horizontal support bar. The substantially flat shoulders desirably provide seating surfaces for fastening elements such as threaded eyebolts. In one embodiment, a threaded eyebolt may be tightened onto a vertical support column so that the distal end of a threaded eyebolt may abut against a substantially flat shoulder accessible at an outer surface of a horizontal support bar for locking the vertical support column in place relative to the horizontal support bar. 
         [0019]    In one embodiment, a modular tailgate protector is infinitely adjustable for accommodating vehicle storage beds having different widths. The modular tailgate protector preferably includes a horizontal support bar having a first end, a second end, and a longitudinal axis extending between the first and second ends, and a pair of vertical support columns adapted for sliding along the longitudinal axis of the horizontal support bar for adjusting the spacing between the vertical support columns. The modular tailgate protector also preferably includes locking elements coupled with the vertical support columns for selectively locking the vertical support columns at selected locations along the longitudinal axis of the horizontal support bar. The vertical support columns are preferably insertable into stake post openings located at a rear end of a vehicle storage bed for spacing the horizontal support bar from a tailgate. The locking elements are desirably moveable between a first position for allowing the vertical support columns to slide along the horizontal support bar and a second position for locking the vertical support columns in place on the horizontal support bar. 
         [0020]    In one embodiment, a modular tailgate protector includes a horizontal support bar having a first end, a second end, and a longitudinal axis extending between the first and second ends, and a pair of vertical support columns adapted for sliding along the longitudinal axis of the horizontal support bar for infinitely adjusting the spacing between the vertical support columns. The vertical support columns are preferably insertable into stake post openings on a vehicle storage bed for spacing the horizontal support bar from a tailgate located at a rear end of the vehicle storage bed. The modular tailgate protector preferably includes locking elements coupled with the vertical support columns for selectively locking the vertical support columns at selected locations along the longitudinal axis of the horizontal support bar. The spacing between the vertical support columns is desirably infinitely adjustable for accommodating vehicle storage beds having different widths. 
         [0021]    In one embodiment, the vertical support columns have lower ends that are sized and shaped to substantially conform to the stake post openings. In one embodiment, the stake post openings are square or rectangular in shape, and the lower ends of the vertical support columns conform to the shape of the stake post openings. 
         [0022]    These and other preferred embodiments of the present invention will be described in more detail below. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
         [0023]      FIG. 1  shows a rear view of a conventional pickup truck having a bent tailgate. 
           [0024]      FIGS. 2A-2C  show a prior art tailgate protector. 
           [0025]      FIG. 3  shows a tailgate protection system including a horizontal support bar, a pair of vertical support columns, a pair of threaded eyebolts, and a pair of grommets for the vertical support columns, in accordance with one embodiment of the present invention. 
           [0026]      FIG. 4A  shows a front view of the horizontal support bar shown in  FIG. 3 . 
           [0027]      FIG. 4B  shows a cross-sectional end view of the horizontal support bar shown in  FIG. 4A . 
           [0028]      FIG. 5A  shows a side view of one of the vertical support columns shown in  FIG. 3 . 
           [0029]      FIG. 5B  shows a cross-sectional view of the vertical support column shown in  FIG. 5A . 
           [0030]      FIG. 6  shows a threaded eyebolt for a tailgate protection system, in accordance with one embodiment of the present invention. 
           [0031]      FIG. 7A  shows a top plan view of one of the support grommets shown in  FIG. 3 . 
           [0032]      FIG. 7B  shows a side view of the support grommet shown in  FIG. 7A . 
           [0033]      FIG. 8  shows a right side of a bed of a pickup truck including a pair of stake post openings. 
           [0034]      FIG. 9A  shows the tailgate protection system of  FIG. 3  coupled with a pair of rear stake post openings, in accordance with one embodiment of the present invention. 
           [0035]      FIG. 9B  shows the tailgate protection system of  FIG. 9A  with items supported by the horizontal support bar, in accordance with one embodiment of the present invention. 
           [0036]      FIG. 9C  shows a second end of the tailgate protection system shown in  FIG. 9B . 
           [0037]      FIG. 10A  shows a front view of a horizontal support bar of a tailgate protector system, in accordance with one embodiment of the present invention. 
           [0038]      FIG. 10B  shows a cross-sectional view of the horizontal support bar shown in  FIG. 10A . 
       
    
    
     DETAILED DESCRIPTION 
       [0039]    Referring to  FIG. 3 , in one embodiment, a tailgate protection system  100  includes a horizontal support bar  102 , a pair of vertical support columns  104 A,  104 B that receive the ends of the horizontal support bar  102 , a pair of grommets  106 A,  106 B that are assembled with the vertical support columns  104 A,  104 B, and a pair of threaded eyebolts  108 A,  108 B that are threadable into the upper ends of the vertical support columns  104 A,  104 B. 
         [0040]    Referring to  FIG. 4A , in one embodiment, the horizontal support bar  102  has a first end  110  and a second end  112  opposite the first end. The horizontal support bar  102  preferably has an elongated central opening  114  that extends from the first end  110  to the second end  112 . In one embodiment, the horizontal support bar  102  is made from a durable material such as metal. In a more preferred embodiment, the horizontal support bar  102  is made of stainless steel. In a highly preferred embodiment, the horizontal support bar  102  is made of aluminum or alloys thereof. 
         [0041]    The horizontal support bar  102  preferably has a length L 1  that spans from the first end  110  to the second end  112 . The length L 1  is preferably long enough to span the width of a truck bed. In one embodiment, the length L 1  is between about 5-7 feet, and more preferably about 6 feet. The horizontal support bar  102  has a diameter D 1  of about 1-3 inches and more preferably about 1.5 inches. 
         [0042]    Referring to  FIG. 4B , in one embodiment, the elongated central opening  114  of the horizontal support bar  102  has a diameter D 2  of about 0.50-1.00 inches and more preferably about 0.75 inches. In one embodiment, the horizontal support bar preferably has a thickness T 1  of about 0.25-0.50 inches and more preferably about 0.375 inches. 
         [0043]    Referring to  FIG. 5A , in one embodiment, a vertical support column  104  has an upper end  120  and a lower end  122 . In one embodiment, the vertical support column  104  desirably has a length L 2  of about 6.00-12.00 inches and more preferably about 9.00 inches. In one embodiment, the upper end  120  defines a top surface  124  such as a curved, convex surface. The upper end  120  of the vertical support column  104  preferably includes a horizontal support bar opening  126  adapted to receive one of the ends of the horizontal support bar  102  ( FIG. 3 ). The horizontal support bar opening  126  preferably has a diameter D 3  that closely matches the outer diameter D 1  of the horizontal support bar  102 . In one embodiment, the horizontal support bar opening  126  has a diameter D 1  of about 1.00-3.00 inches and more preferably about 1.50 inches. In one embodiment, the ends of the horizontal support bar are adapted to slide into the horizontal support bar opening  126 . 
         [0044]    The vertical support column  104  desirably includes a threaded opening  128  that preferably extends along the longitudinal axis of the vertical support column from the top surface  124  thereof to the horizontal support bar opening  126 . In one embodiment, the threaded opening  128  has a length L 3  of about 0.25-0.75 inches and more preferably about 0.50 inches. In one embodiment, the threaded opening has a diameter D 4  of about 0.25-0.50 inches and more preferably about 0.375 inches. 
         [0045]    As is well known to those skilled in the art, the rear storage beds of pickup trucks typically have first and second sidewalls that define the left and right borders of the storage bed. The tops of the side walls typically have stake post openings formed therein. A conventional pickup bed may include a first sidewall having a front stake post opening and a rear stake post opening, and a second sidewall having a front stake post opening and a rear stake post opening. Referring to  FIG. 5B , in one embodiment, the vertical support column  104  has an outer surface  130  that is sized and shaped to fit within one of the stake post openings in the storage bed of a truck. In one embodiment, the vertical support column  104  has a cross-sectional shape that is square or rectangular. In one embodiment, the vertical support column  104  has a width W 1  of about 1.75-2.50 inches and more preferably about 2.125 inches, and a thickness T 1  of about 1.00-2.00 inches and more preferably about 1.375 inches. 
         [0046]    Referring to  FIG. 6 , in one embodiment, a fastening device  108 , such as a threaded eyebolt, is adapted to be inserted into the threaded opening  128  at the top of the vertical support column  104 . The threaded eyebolt  108  preferably has an eye  132  and a threaded shaft  134  projecting from the eye. The threaded shaft  134  preferably has a length L 4  that is at least equal to and preferably greater than the length L 3  of the threaded opening  128 . The threaded opening  128  is preferably adapted to receive the threaded shaft  134  of the fastening device  108  for securing the horizontal support bar  102  ( FIG. 3 ) relative to the vertical support column  104  ( FIG. 5A ). 
         [0047]    Referring to  FIG. 6 , in one embodiment, the fastening device includes a washer  135  that is adapted for being positioned at a proximal end of the threaded shaft  134  for abutting against a shoulder adjacent the eye  132 . The washer  135  is preferably made of a compliant material such as a polymer, nylon, or polypropylene. In one embodiment, when the fastening element  108  is tightened, the washer  135  is positioned between the shoulder adjacent the eye  132  and the top surface  124  of the vertical support column  104 . In a preferred embodiment, the washer  135  is a nylon washer that is about a ⅜″ screw size. The washer  135  preferably has an outer diameter of about 0.750″ and a thickness of about 0.057″-0.067″. In one embodiment, a nylon washer is used because it is a durable material and because it effectively functions as a tightening cushion. 
         [0048]    In one embodiment, the ends of the horizontal support bar are adapted to slide into the vertical support column opening  126 . The spacing between the two vertical support columns is preferably determined by the spacing between the two rear stake post openings on the opposing sidewalls of the storage bed. The horizontal support bar is preferably centered between the two vertical support columns and the threaded eyebolts  108  are tightened for securing the horizontal support bar to the vertical support columns. 
         [0049]    Referring to  FIG. 7A , in one embodiment, the tailgate protection system includes a grommet  106  having a grommet opening  136  that is adapted to receive the shaft of the vertical support column  104  shown in  FIGS. 5A and 5B . The grommet opening  136  preferably has a width W 2  and a thickness T 2  that substantially match the respective width W 1  and the thickness T 1  of the shaft of the vertical support column  104 . 
         [0050]    Referring to  FIG. 7B , in one embodiment, the grommet  106  includes a grommet flange  138  having a top surface  140  and a bottom surface  142 , whereby the grommet opening  136  extends between the top and bottom surfaces  140 ,  142  of the flange. The grommet  106  also preferably includes a plug  144  projecting from the bottom surface  142  of the flange  138 . The plug  144  preferably has an inner surface  146  that closely matches the size and shape of the vertical support column  104  ( FIG. 5A ) and an outer surface  148  that conforms to the size and shape of a stake post opening in the bed of a truck. 
         [0051]      FIG. 8  shows a right side wall  150  of a truck bed. The right side wall  150  includes a forward stake post opening  152  and a rear stake post opening  154 . In one embodiment, the stake post openings  152 ,  154  preferably define rectangular-shaped openings. As will be described in more detail below, the rear stake post opening  154  is adapted to receive one of the grommets  106  shown in  FIGS. 7A and 7B , with one of the vertical support columns  104  ( FIG. 5A ) being insertable in the opening  136  of the grommet  106 . 
         [0052]    Referring to  FIG. 9A , in one embodiment, a truck bed  150  includes a first rear stake post opening  154 A formed in a left side wall of a truck bed and a second rear stake post opening  154 B formed in a right side wall of the truck bed. The tail gate protector  100  shown in  FIG. 3  is inserted into the stake post openings  154 A,  154 B by inserting the first vertical support column  104 A into the first stake post opening  154 A and the second vertical support column  154 B into the second stake post opening  154 B. The first and second grommets  106 A,  106 B surround the shafts of the vertical support columns  104 A,  104 B and cover the tops of the stake post openings. The ends of the horizontal support bar  102  are preferably received in the openings  126  of the vertical support columns  104 A,  104 B, and eyebolts  108 A,  108 B are preferably threaded into the threaded openings in the vertical support columns for locking the position of the horizontal support bar  102  relative to the vertical support columns  104 A,  104 B. 
         [0053]    The horizontal support bar  102  preferably extends over the top of the tailgate when the tailgate is in the closed position, thereby preventing items stored in the truck bed  150  from contacting the top of the tailgate, which will prevent damage to the tailgate. 
         [0054]      FIG. 9B  shows the tailgate protector  100  inserted into the rear stake post openings of the truck bed for protecting the tailgate. As shown in  FIG. 9B , the tailgate may be opened and closed with the tailgate protector  100  in place, and the tailgate protector  100  will not interfere with the operation of the tailgate when it is installed on the truck bed. As shown in  FIG. 9B , long objects such as a ladder or wood may be positioned atop the horizontal support bar  102 . The bar  102  prevents the long objects from contacting the tailgate so that the tailgate will not be damaged by the objects during transit. The threaded eyebolts  108 A,  108 B are preferably threaded into the threaded openings at the tops of the vertical support columns and the eyebolts are tightened for securing the position of the horizontal support bar  102  relative to the vertical support columns  104 A,  104 B. The ability of the horizontal support bar to slide within the vertical support column openings before the horizontal support bar is locked in place desirably enables the tailgate protector system to be used with truck beds having different widths. For a wider bed, the vertical support columns will be wider apart. For a narrower bed, the vertical support columns will be closer together. The eyebolts  108 A,  108 B preferably enable tie-down elements such as a rope or a bungee cord to be passed through the openings of the eyebolts for quickly and effectively tying down items stored in the truck bed and supported by the horizontal support bar. 
         [0055]      FIG. 9C  shows the right grommet  106 B secured in the second rear stake post opening. The flange  138  of the grommet  106 B covers the edges of the stake post opening, and the vertical support column is inserted into the central grommet opening  136  ( FIG. 7A ). The second end  112  of the horizontal support bar  102  is passed through the opening  126 B adjacent the upper end  120  of the vertical support column. The threaded shaft of the eyebolt  108 B may be threaded into the threaded opening of the vertical support column  104 B for securing the horizontal support bar  102  in place relative to the vertical support column  104 . A tie-down element such as a bungee cord  160  may be passed through the opening of the eyebolt  108  for tying down items over the tailgate protector  100 . 
         [0056]    Referring to  FIGS. 10A and 10B , in one embodiment, a horizontal support bar  202  has a tubular shaped outer surface. In one embodiment, the horizontal support bar  202  has a first end  210  with a first substantially flat shoulder  216 A provided adjacent the first end, and a second end  212  with a second substantially flat shoulder  216 B provided adjacent the second end. The substantially flat shoulders  216 A,  216 B preferably extend only part of the way around the circumference of the horizontal support bar  202 , and only part of the way along the length of the horizontal support bar. The shoulders  216 A,  216 B preferably do not extend all the way to the ends of the horizontal support bar but only a portion of the length of the horizontal support bar. The substantially flat shoulders  216 A,  216 B desirably provide seating surfaces for fastening elements such as threaded eyebolts. In one embodiment, a threaded eyebolt may be tightened onto a vertical support column so that the distal end of a threaded eyebolt may abut against one of the substantially flat shoulders  216 A,  216 B accessible at an outer surface of a horizontal support bar for locking the vertical support column in place relative to the horizontal support bar. Although the present invention is not limited by any particular theory of operation, it is believed that providing a substantially flat shoulder area on an outer surface of a horizontal support bar will enhance locking forces between a fastening element and the horizontal support bar. 
         [0057]    While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. As such, the scope of the present invention is to be limited only as set forth in the appended claims.