Abstract:
A cap and cover assembly is for use with a pick up truck having a truck box. The cap and cover assembly includes a top panel and opposing sides. Each side has a flexible side portion hingeably attached to a rigid side portion. The flexible side portion has one side attached to the top panel. The opposing sides are releasably attached to the truck box. The opposing sides have a cap configuration where the sides are in a stowed portion and a cover configuration when the sides are generally upright. In one embodiment the cap and cover assembly also includes a spring loaded lift arm adapted to aid in the cover to cap conversion. In another embodiment the sides are arranged such that in the stowed position the sides create a “keystone” arrangement.

Description:
FIELD OF THE INVENTION 
   This invention relates to pick-up truck covers and in particular pick-up truck covers that are convertible from a cap mode to a cover mode. 
   BACKGROUND OF THE INVENTION 
   Covers for the boxes of pick-up trucks are well known. There tends to be two types of covers generally in use. One type of cover typically extends from one sidewall of the truck box to the other. Alternatively the other cover or cap is typically at the same height as the truck cab and is particularly useful when hauling large material. In some designs the cap is higher than the truck cab. 
   Efforts have been made to incorporate both the cover and the cap in one designs. The challenge is to provide a cover that can readily be converted into a cap and vice versa. A further challenge is to ensure that both configurations or modes are sturdy and stable. 
   Some of the prior art cap/cover assemblies include assemblies wherein the cover is made from flexible sheet material. An example of such a design is shown in U.S. Pat. No. 4,789,196 issued to Fields on Dec. 6, 1988. Another type of cap/cover assembly is where the extension walls are attachable and detachable. An example of such a design is shown in U.S. Pat. No. 5,316,357 issued to Schroeder on May 31, 1994. Other assemblies include sides that are hingeably attached to the top and cab. An example of such assemblies is shown in U.S. Pat. No. 4,768,824 issued to Andonian on Sep. 6, 1988. 
   There are advantages and disadvantages associated with each of these assemblies and therefore improvements may be made with each of these assemblies. Accordingly it would be advantageous to provide a cap/cover assembly wherein a portion of the sides is a flexible sheet such that a cap/cover assembly can easily be changed from the cap to the cover configuration. Further it would be advantageous to provide a cap/cover assembly that has a “keystone” arrangement when the assembly is in the stowed or cover configuration. Still further it would be advantageous to provide a cap/cover assembly that includes a spring loaded lift arm to aid the user in moving the assembly from the cover to the cap configuration. 
   SUMMARY OF THE INVENTION 
   The present invention is to a cap and cover assembly for use with a pick up truck having a truck box. The assembly includes a top panel and opposing sides. Each side has a flexible side portion hingeably attached to a rigid side portion. The flexible side portion has one side attached to the top panel. The opposing sides are releasably attached to the truck box. The opposing sides have a cover configuration where the sides are in a stowed portion and a cap configuration when the sides are generally upright. 
   In one embodiment the top panel has a center rail that extends downwardly from the underside of the top panel and the center rail includes a center portion and a sloped side portion. The rigid side portion is generally L-shaped in cross section with an elongate side portion and a bottom rail portion and wherein the bottom rail portion is releasably attached to the truck box when the sides are in the cap configuration. The center rail is sized such that when the assembly is in the cover configuration the bottom rail portion of the rigid side portion is in a keystone arrangement and tensions the flexible side portions. 
   In another aspect of the invention a cap and cover assembly is for use with a pick up truck having a truck box. The cap and cover assembly includes a top panel, opposing sides and a spring loaded lift arm. Each side is hingeably attached to the top panel and releasably attachabe to the truck box and wherein the opposing sides have a cover configuration where the sides are in a stowed portion and a cap configuration when the sides are generally upright. The spring loaded lift arm is operably connected to the top panel and is adapted to aid in converting the cap and cover assembly from the cover configuration to the cap configuration. 
   Further features of the invention will be described or will become apparent in the course of the following detailed description. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The invention will now be described by way of example only, with reference to the accompanying drawings, in which: 
       FIG. 1  is a perspective view of the convertible cap/cover assembly for a pick-up truck constructed in accordance with the present invention and shown in the cover configuration; 
       FIG. 2  is a perspective view of the convertible cap/cover assembly for a pick-up truck constructed in accordance with the present invention and shown in the cap configuration; 
       FIG. 3  is a side sectional view along the centre line of the convertible cap/cover assembly in the cap configuration; 
       FIG. 4  is an end sectional view of the convertible cap/ cover taken along line A—A of  FIG. 3  showing the cap/cover assembly in the cap configuration; 
       FIG. 5  is an enlarged sectional view of the flexible panel of the convertible cap/cover assembly; 
       FIG. 6  is a sectional view similar to that shown in  FIG. 4  but showing the convertible cap/cover assembly in the cover configuration; 
       FIG. 7  is an enlarged detail of the stake pocket cam locks shown in the unlocked position; 
       FIG. 8  is an enlarged detail of the stake pocket cam locks of  FIG. 7  but shown in the locked position; 
       FIG. 9  is a back sectional view of the truck cap rear panel showing the convertible cap/cover assembly in the cap configuration; 
       FIG. 10  is a side sectional view of a truck cap rear panel showing the convertible cap/cover assembly in the cap configuration; 
       FIG. 11  is an enlarged view of the truck cap rear panel taken along line B—B of  FIG. 9 ; 
       FIG. 12  is an enlarged detail of the truck cap rear panel showing the hatch frame detail of A in  FIG. 10 ; 
       FIG. 13  is an enlarged detail of the truck cap rear panel showing the T-handle latch detail of C in  FIG. 10 ; 
       FIG. 14  an enlarged detail of the truck cap rear panel showing the attachment to the hinge tube of the side panel detail of D in  FIG. 9 ; 
       FIG. 15  is a back sectional view of the truck cover rear panel showing the convertible cap/cover assembly in the cover configuration; 
       FIG. 16  is a side sectional view of a truck cover rear panel showing the convertible cap/cover assembly in the cover configuration; 
       FIG. 17  is a front sectional view of the truck cap front panel showing the convertible cap/cover assembly in the cap configuration; 
       FIG. 18  is a side sectional view of a truck cap rear panel showing the convertible cap/cover assembly in the cap configuration; 
       FIG. 19  is an enlarged detail of the truck cap front panel showing the front bottom attachment detail of F in  FIG. 18 ; 
       FIG. 20  is an enlarged detail of the truck cap front panel showing the front top attachment detail of G in  FIG. 18 ; 
       FIG. 21  is a front sectional view of the truck cover front panel showing the convertible cap/cover assembly in the cover configuration; 
       FIG. 22  is an enlarged sectional view of the truck cover front panel taken along line A—A in  FIG. 21 ; 
       FIG. 23  Is a side sectional view of the three bar link of the convertible cap/cover assembly showing the three bar link in the stowed and partially raised positions in phantom; 
       FIG. 24  is a back sectional view of the three bar link of the convertible cap/cover assembly; 
       FIG. 25  is an enlarged detail of attachment of the three bar link to the top panel of the convertible cap/cover assembly of the detail B from  FIG. 24 ; 
       FIG. 26  is a side sectional view of the convertible cap/cover assembly, showing the cap/cover assembly in the cover configuration; 
       FIG. 27  is a side sectional view of the convertible cap/cover assembly, showing the cap/cover assembly in the first stage of the transition from the cover to the cap configuration; 
       FIG. 28  is a side sectional view of the convertible cap/cover assembly, showing the cap/cover assembly in the second stage of the transition from the cover to the cap configuration; 
       FIG. 29  is a side sectional view of the convertible cap/cover assembly, showing the cap/cover assembly in the cap configuration; 
       FIG. 30  is an enlarged detail of  FIG. 7  of the lift arm of the convertible cap/cover assembly, showing the cap/cover assembly in the cover configuration; 
       FIG. 31  is an enlarged detail of  FIG. 8  of the lift arm of the convertible cap/cover assembly, showing the cap/cover assembly in first stage of the transition from the cover to the cap configuration; 
       FIG. 32  is an enlarged detail of  FIG. 9  of the lift arm of the convertible cap/cover assembly, showing the cap/cover assembly in second stage of the transition from the cover to the cap configuration; 
       FIG. 33  is an enlarged detail of  FIG. 10  of the lift arm of the convertible cap/cover assembly, showing the cap/cover assembly in the cap configuration; 
       FIG. 34  is a sectional view of the convertible cap/ cover taken along line B—B of  FIG. 3  showing the cap/cover assembly in the cap configuration; 
       FIG. 35  is an end view of the convertible cap/cover assembly showing the cap/cover assembly in the cap configuration but showing the side panels in the tucked position; 
       FIG. 36  is a side sectional view of the convertible cap/cover assembly showing the cover in a propped up position; 
       FIG. 37  is an enlarged detail of  FIG. 16  of the lift arm end of the convertible cap/cover assembly, showing the cap/cover assembly in a propped up position; and 
       FIG. 38  shows a detail of the stake pocket cam locks in which the stake cam includes a lever and a plurality of stake cams along one side are ganged together. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Referring to figures, the cap/cover assembly is shown generally at  10 . The cap/cover assembly  10  is adapted to be attached to a truck which includes a truck box  11  and a truck cab  15 . The cap/cover assembly  10  includes a top panel  12 , a pair of sides  14 , a front cap panel  16  and a rear cap panel  18 . Each side  14  includes a flexible side panel  20  and rigid side panel  22 , as best seen in  FIGS. 4 to 6 . The cap/cover assembly has a cover configuration shown in  FIG. 1  and a cap configuration shown in  FIG. 2 . 
   Referring to  FIGS. 4 to 8 , the flexible side panel  20  is hingeably attached to the rigid side panel  22 . Each flexible side panel  20  includes a flexible sheet  24 , a longitudinal lower sheet rail  26  and a longitudinal upper outer rail  28 , as best seen in  FIG. 5 . The flexible sheet  24  is anchored between the longitudinal lower sheet rail  26  and the rigid side panel  22 . A plurality of screws  30  attach the rigid side panel to the longitudinal lower sheet rail  26 . Similarly a plurality of screws  30  attach the longitudinal upper outer rail to the top panel  12 . The lower sheet rail  26  has a hinge tube  32  attached thereto with a plurality of sheet metal straps  34 . 
   Referring specifically to  FIGS. 7 ,  8  and  38 , the rigid side panel  22  is generally L-shaped with an elongate side portion  36  and an integrally attached bottom rail portion  38 . Stake pocket locks  40  are used to lock the rigid side panel  22  in place in the cap configuration. Stake pocket locks  40  are positioned in stake pockets  42 . Details of stake pocket locks  40  are shown in  FIGS. 7 and 8 . The stake pocket locks  40  include a rectangular stake cam  44  which is positioned with a lever  46 . A master lever  48  is connectable to the lever  46  with a connecting rod  50 . The stake pocket  42  has rectangular slot  52  for receiving the rectangular stake cam  44 . A rubber seal  54  is positioned at one end of the rigid side panel  22  such that when in position there is provided a seal between the rigid side panel  22  and the truck box  11 . In use the stake locks  40  are ¼ turn type fasteners. A plurality of stake cams  44  through the attached levers  46  may be ganged together so that they can be operated by a master lever  48  located at the rear stake pocket  42 . The levers  46  are normal to the cap side when the locks are free and the master lever  48  is pushed into an over-center position (just past parallel to the truck side) in the locked position. It will be appreciated by those skilled in the art that the number of stake locks  40  that are required will depend on the length of the truck box  11 . For long truck boxes typically three stake locks  40  per side will be adequate and for short truck boxes two stake locks  40  per side will be adequate. 
   The top panel  12  has a top center rail  56  along the center thereof. Center rail  56  has sloped side portions  58  a center portion  60  which is spaced downwardly from the top panel  12 . The sloped sides  58  engage the bottom rail portion  38  of the rigid side panel  22  when the cap/cover  10  is in the cover configuration as shown in  FIG. 6 . 
   In the cover configuration shown in  FIG. 6  the bottom rail portion  38  of the rigid side panels  22  make contact with the sloped side portions  58  of center rail  56  and the weight of the top panel  12  forces the angled rails down between the side panels, pushing them outward (the ‘keystone’ principle or arrangement). This outward movement is resisted by tension in the flexible panels  20  and the assembly is held in a generally rigid configuration. The outward movement and the depth of engagement of the keystone feature is limited by stops  62 . Stops  62  are attached to the underside of the top panel  12  proximate to the sloped side portions  58  of the centre rail  56 , as best seen in  FIG. 4 . Front and rear covers are attached as described in more detail below. 
   In the cover configuration the sides are folded under the top panel with the flexible panel  20  wrapped around a hinge tube  32  that defines the outer edge of the cover. In the cover configuration, the rear edges of the side panels  14  rest on a rear lateral bar  64  and a front lateral bar  66 , shown in  FIG. 6 . The rear lateral bar  64  is fixed just below the top lip of the pick-up truck box  11  at the rear and similarly the front lateral bar  66  is fixed just below the forward edges. A seal  57  (shown in  FIG. 5 ) is provided along the upper edge of the rigid side panel  22  to seal the assembly when it is in the cover configuration. The seal  57  will be compressed onto the top edge of the truck box  11  when in the cover configuration. 
   The back of the cap/cover assembly  10  is covered with one of the rear cap panel  18  or a rear cover panel  86  depending on whether it is in the cap configuration or the cover configuration. The cap configuration is shown in  FIGS. 9 through 14  and the cover configuration is shown in  FIGS. 15 and 16 . 
   Referring to  FIGS. 9 through 14 , the truck cap rear panel  18  consists of a hatch frame  70  and a hatch  72 . The top portion of the hatch frame  70  snaps into groove  74  formed in the trailing edge of the rigid top panel  12  as best seen in  FIG. 12 . A seal  76  is provided between the groove  74  and the hatch frame  70 . Similarly grooves are provided in the rigid side panels  22 . A bottom seal  77  is provided between the hatch  72  and the tail gate of truck box  11  as best seen in  FIG. 13 . Brackets  78  hook over the rear lateral bar  64  as best seen in  FIG. 11 . The rear cap panel  18  is secured to hinge tube  32 . It may be secured to hinge tube  32  with a hinge tube lock  80  such as SPAE-NAUR part #D-141KA (best seen in  FIG. 14 ). Hinge tube  32  is provided with a slot and lock  80  is rotated to lock so that it engages the slot and secures the rear cap panel  18  to the hinge tubes  32 . The hatch  72  has a continuous hinge  82  along the top edge and latch  84  to secure it to the tail gate of the truck box  11 . Preferably latch  84  is similar to the SPAE-NAUR part #096-240. To lock latch  84  to the tail gate of the truck box  11  the tee handle is turned ¼ turn and the latch engages behind the top lip of the tail gate of the truck box  11  as best seen in  FIG. 13 . 
   In the cover configuration shown in  FIGS. 15 and 16 , the rear cover panel  86  is retained in a similar manner to the rear cap panel  18 . The top edge of the rear cover panel  86  snaps into the groove  74  in the rigid top panel  12 . The rear cover panel  86  is secured to the hinge tubes  32 . Preferably similar cam latches lock the rear cover panel  86  into the ends of the hinge tube  32  as described above. The tee handled latch  88  for the rear cover panel  86  is slightly different from that described above since it latches into a slot in the top of the rear lateral bar  64  to prevent the rear of the cover from being raised. 
   Referring to  FIGS. 17 through 20 , the truck front cap panel  16  is similar in concept to the rear cap panel  18 . The front cap panel  16  is secured to the hinge tubes  32  using cam latches in a fashion similar to the rear cap panel  18 . A ¼ turn of the cam latches lock the front cap panel into the ends of the hinge tubes  32 . Front cap panel brackets  90  hook over a bar  92  that is attached to the lift arm hinge brackets  124  which is described in more detail below. The lift arm hinge bracket  124  is attached to the front lateral bar  66 . The outer edge of the front cap panel  16  is formed into a lip  96  which fits over the cap/cover assembly and latches over ridges  98  on the outside of the rigid top panel  12  (as best seen in  FIG. 20 ) and sides  14 . 
   The front cover panel  100  is retained in a somewhat similar fashion. The outer edge  102  (shown in  FIG. 22 ) of the front cover panel  100  extends over the top panel  12  but the top panel is free to move rearwardly therefrom as the first step in changing the assembly from the cover to the cap. Front cover brackets  104  hook over bar  92  as described above. 
   Preferably the sides  14  include further support for example a three bar link support  106 . Referring to  FIGS. 23 to 25  the three bar link support  106  consists of two rotating links  108  with a connecting link  110 . A pivot point  111  for the three bar link support  106  is located on the bottom rail portion  38  of the rigid side panel  22  shown in  FIG. 24 . In the cover configuration it is stowed horizontally along the bottom rail of the rigid side panel as shown in phantom at arrow  112  in  FIG. 23 . After raising the cap/cover assembly and before the retractable prop  130  (shown in  FIGS. 34 and 35 ) is removed, the three bar link  106  is raised until the connecting link  110  contacts the underside of the top panel outer rail. Arrow  114  shows the three bar link support  106  in a partially raised position. Once the three bar link  106  is raised it is lodged behind retention blocks  116  attached to the outer rail  28  further rearward movement of the rotating links lifts the outer rail creating a tension in the flexible side panel  20 . The three bar link is latched back to the rear edge of the rigid panel at anchor point  117  using an over center latch  119  similar to the SPAE-NAUR part #096-640. 
   Referring to  FIG. 30 , the lift arm  94  consists of two parallel square section tubes  118  connected by a channel section  120 . The lift arm  94  pivots on a lift arm hinge  122 . Lift arm hinge  122  is mounted in lift arm hinge brackets  124  on the front lateral bar  66  which is located immediately behind the front wall of the truck box  11 . Torsion springs  126  are located on the lift arm hinge  122  with the load arm attached to the square tubes  118 . A friction guide pad or conveyor strip  127  is provided on the underside of the top panel  12 . 
   In the cap configuration the lift arm  94  is vertical and supports the front edge of the cap, the spring load is zero. In the cover configuration the lift arm  94  is horizontal and a latch bar  128  mounted between the top panel center rails  56  interacts with it in two ways. Specifically, when the cover is closed, the latch bar  128  is lodged under the lift arm  94  close to the hinge point, locking the front of the cover to the lift arm  94 . This holds the front of the cover down but allows the rear to be lifted (pivoting about the lift arm hinge  122  for access to the truck box. In the transition from cover to cap, discussed in more detail below, when the cover is pulled rearwards the latch bar  128  slides along under the lift arm  94  until it engages in the channel section  120 . This links the front of the cover to the end of the lift arm  94 . At this point the torsion spring load is a maximum and is tending to lift the front of the cover. By pushing downwards and forwards the cover follows the lift arm  94  as it rotates into the vertical position. 
   A prop  130  is a swinging frame that is hinged to the rear ends of the top panel center rails  56 , it is stored between the center rails  56  in a horizontal position. Prop  130  swings down and locates on the rear lateral bar  64  to support the rear edge of the top panel  12  during the folding and unfolding procedure prior to the transition from cap to cover configuration and vice versa. To lower the folded assembly into the cover configuration, the bottom edge of the prop  130  is pushed forwards off the lateral bar  64  and as the rear edge of the cover moves backwards and downwards the prop is once again folded into the horizontal position. 
   Referring to  FIGS. 26 to 29  and the details of these figures found in  FIGS. 30 to 37 , to convert to the cap configuration, the cover assembly is raised with the aid of the lift arm  94  and supported at the rear by a retractable prop  130 . The sides  14  are unfolded by releasing the cables  132  and are attached to the pick-up box sides using stake pocket locking mechanisms  40  that latch into the stake pockets  42 . The three bar link support mechanism  106  is raised on both sides to create a rigid connection between the outer rail  28  of the top panel and the bottom rail portion  38  of the side panel, again creating a tension in the flexible panels  20 . The rear prop  130  is retracted and front and rear covers attached. 
   To convert from the cap to the cover configuration, the sequence of events of are reversed. The retractable prop  130  is lowered to support the rear of the cover, the stiffening mechanisms or three bar link mechanism  106  are collapsed, the stake pocket locks  40  are released and the sides are raised. The forward end of the side panels are raised by pulling on cables  132 , initially by hand and then by attaching the free ends of the cables to tensioning levers  135  which are rotated into an over-center lock position. Pulleys  133  are attached to the underside of the top panel  12  to ease the use of cables  132 . The rear end of the side panels are raised by hand and latched at  137  into the cover configuration by short lanyards  134  that engages in slots in the rear ends of the side panel bottom rail portions  38 . Lifting the rear edge of the cover releases the prop  130  and the cover is then lowered and pulled rearwards. The front edge of the cover is still locked to the lift arm  94  which rotates downwards as the cover moves rearwards. The torsion springs  126  wind up and act as a shock absorber to cushion the drop of the cover. Finally the cover is pushed forward, riding on conveyor strips  127 , until the latch bar  128  is locked under the lift arm  94  as shown in  30 . 
   After raising the cap and before the retractable prop  130  is removed, the three bar link  106  is raised until the connecting link  110  contacts the underside of the top panel outer rail  28  and is lodged behind retention blocks  116  attached to the outer rail  28 . Further rearward movement of the rotating links  108  lifts the outer rail  28  creating a tension in the flexible panel  20 . The three bar link  106  is latched back to the rear edge of the rigid side panel  22  using an over-center latch similar to SPAE-NAUR part #096-640. 
   The transition from cover to cap and vice versa could be motorized using high torque motors to drive the lift arm  94  and to raise and lower the sides, again depending on the degree of sophistication and cost that the market will bear. 
   The method of construction shown is only intended for demonstrating the novel concepts involved. The rigid top and sides will have a covering. A production version may be made from fiberglass with a honeycomb core. 
   The reinforcement in the flexible panel  20  may vary from the single ply fabric, as used in the prototype, to multiple plies, kevlar or steel mesh depending on the degree of security required and the cost that the market will bear. 
   The invention may be adapted for use as a camping trailer cover by increasing the height of the rigid side panels  22 . However, the method of raising and lowering would have to be modified as the span of the lift arm  94  and prop  130  would be significantly reduced resulting in the folded assembly being unstable. 
   As used herein, the terms “comprises” and “comprising” are to be construed as being inclusive and opened rather than exclusive. Specifically, when used in this specification including the claims, the terms “comprises” and “composing” and variations thereof mean that the specified features, steps or components are included. The terms are not to be interpreted to exclude the presence of other features, steps or components. 
   It will be appreciated that the above description related to the invention by way of example only. Many variations on the invention will be obvious to those skilled in the art and such obvious variations are within the scope of the invention as described herein whether or not expressly described.