Abstract:
A cover for the bed of a pickup truck provides a front rigid panel fastened to the front wall of the pickup bed, at least one intermediate rigid panel attached to the front rigid panel by a first transverse hinge, and a rear rigid panel attached to the intermediate rigid panel by a second transverse hinge. The rear rigid panel has a tailgate locking lip flaring downwardly and outwardly to prevent the tailgate from opening. In the fully covering position, the pickup bed cover provides a water-resistant, locked cargo area. In the partially covering position, the rear rigid panel and, optionally, the intermediate rigid panel fold forward to permit access to the cargo bed. Another pickup bed cover according to the applicant&#39;s invention provides a frontmost rigid panel fastened to a toolbox mounted in the pickup bed, at least one intermediate rigid panel attached to the front rigid panel by a first transverse hinge, and a rearmost rigid panel attached to the intermediate rigid panel by a second transverse hinge.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     This application is a continuation-in-part of application Ser. No. 10/891,398 filed Jul. 14, 2004, for which application U.S. Pat. No. 6,899,372 issued on May 31, 2005. This invention relates to pickup bed covers and the like and, more particularly, to a multi-section folding pickup bed cover which is capable of being partially opened to permit use of some or all of the pickup bed. The cover is sufficiently rigid to support at least 100 pounds on top of the cover without bending. When unfolded to cover the entire pickup bed, locks engage the rearmost stake pockets in the pickup bed side rails. The cover folds against the pickup cab to permit use of the entire pickup bed.  
         [0003]     Pickups with open beds experience reduced fuel economy due the drag created by the tailgate and the open bed generally. Like other pickup bed covers in the prior art, the pickup bed cover according to the present invention improves fuel economy.  
         [0004]     2. Discussion  
         [0005]     Pickup trucks are used for business and pleasure. Trucks may haul merchandise during business hours and camping equipment on weekends. It is sometimes necessary to transport cargo under cover, while at the same time transporting cargo which extends upward past the side rails of the pickup bed.  
         [0006]     In the prior art, pickup beds have been covered by a tonneau type cover which is formed of cloth or synthetic material and attached to the sidewall of the pickup bed by snaps. The tonneau type cover can be rolled up in the manner of a window blind or folded into a series of pleats. The tonneau type cover, although widely used, can be easily removed and does not prevent access to the bed. Moreover, installation of the tonneau cover requires drilling of the sidewall for installation of the snaps. The tonneau type cover is not capable of supporting substantial weight on top of the cover.  
         [0007]     U.S. Pat. No. 4,252,362, Campbell, discloses a pickup bed cover characterized by a multi-channeled track having a first pair of parallel rails leading out of a storage area horizontally along the ends thereof down to the floor of the bed. A rollable or otherwise storable fabric or slatted canopy is drawn from the storage area across the parallel rails. The storage area uses valuable cargo space, and the fabric cover cannot support substantial weight.  
         [0008]     The pickup bed cover of the present invention provides secure storage area and improved fuel economy when deployed in a position to fully cover the pickup bed. In addition, the pickup bed cover of the present invention provides the convenience of use of some or all of the pickup bed for transporting cargo which does not fit in the fully covered bed.  
       SUMMARY OF THE INVENTION  
       [0009]     A cover for the bed of a pickup truck provides a front rigid panel fastened to the front wall of the pickup bed, at least one intermediate rigid panel attached to the front rigid panel by a first transverse hinge, and a rear rigid panel attached to the intermediate rigid panel by a second transverse hinge. Another pickup bed cover according to the applicant&#39;s invention provides a frontmost rigid panel fastened to a toolbox mounted in the pickup bed, at least one intermediate rigid panel attached to the front rigid panel by a first transverse hinge, and a rearmost rigid panel attached to the intermediate rigid panel by a second transverse hinge. The rear rigid panel has a tailgate locking lip flaring downwardly and outwardly to prevent the tailgate from opening. In the fully covering position, the pickup bed cover provides a water-resistant, locked cargo area. In the partially covering position, the rear rigid panel and, optionally, the intermediate rigid panel fold forward to permit access to the cargo bed.  
         [0010]     An object of the present invention is to provide a pickup bed cover which can be folded forward toward the cab to provide either partial or full access to the pickup bed.  
         [0011]     Yet another object of the present invention is to provide a pickup bed cover whose rigid panels will support at least 100 pounds without bending or deforming.  
         [0012]     An object of the present invention is to provide a pickup bed cover which can be folded forward toward the toolbox to provide either partial or full access to the pickup bed.  
         [0013]     Other objects, features, and advantages of the present invention will become clear from the following description of the preferred embodiment when read in conjunction with the accompanying drawings and appended claims. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]      FIG. 1  is a view of applicant&#39;s pickup bed cover according to the present invention installed on a short-bed pickup.  
         [0015]      FIG. 2  is a side view of the pickup bed cover shown in  FIG. 1 .  
         [0016]      FIG. 3  is a side view of the pickup bed cover shown in  FIG. 1  wherein a rear section of the pickup bed cover has been folded forward across an intermediate section to permit access to the portion of the pickup bed near the tailgate.  
         [0017]      FIG. 4  is a side view of the pickup bed cover shown in  FIG. 1  wherein the rear section and the intermediate section have been folded forward across a front section to permit access to the rearmost approximately two-thirds of the pickup bed.  
         [0018]      FIG. 5  is a side view of the pickup bed cover shown in  FIG. 1  wherein the rear section, the intermediate section, and the front section have been folded forward against the back of the cab to permit access to the entire pickup bed.  
         [0019]      FIG. 6  is an enlarged view of the pickup bed cover shown in  FIGS. 1-5 .  
         [0020]      FIG. 7  is a detailed view of the pickup bed cover shown in  FIGS. 1-5 , wherein a lateral extension of the pickup bed cover is shown in conjunction with the pickup rail and a locking lip portion of the pickup bed cover extends downwardly to the rear of the tailgate.  
         [0021]      FIG. 8  is a view, partially cut away, of the underside of a section of the pickup bed cover shown in  FIGS. 1-5 .  
         [0022]      FIG. 9  is an enlarged side view of a double hinge panel shown in  FIG. 6 .  
         [0023]      FIG. 10  is another view of the double hinge panel shown in  FIGS. 6 and 9  illustrating the of the rear section and the intermediate section forward across the front section.  
         [0024]     FIG. 11  is another view of the double hinge panel shown in  FIGS. 6, 9 , and  10  further illustrating the folding of the rear section and the intermediate section forward across the front section.  
         [0025]      FIG. 12  is side view showing the attachment of the rear section to the intermediate section in  FIG. 6 .  
         [0026]      FIG. 13  is a detailed enlarged view of the pickup bed cover shown in  FIG. 4 .  
         [0027]      FIG. 14  is a detailed enlarged view of the pickup bed cover shown in  FIG. 5 .  
         [0028]      FIG. 15  is a view of a pickup bed cover according to the present invention used in conjunction with a tool box in a short-bed pickup.  
         [0029]      FIG. 16  is a view of a pickup bed cover according to the present invention installed on a long-bed pickup.  
         [0030]      FIG. 17 , similar to  FIG. 15 , is a view of a pickup bed cover according to the present invention attached to a tool box in a short-bed pickup.  
         [0031]      FIG. 18  is a view of a pickup bed cover according to the present invention attached to a tool box in a long-bed pickup.  
         [0032]      FIG. 19  is a side view of the pickup bed cover shown in  FIG. 18  wherein a rear section of the pickup bed cover has been folded forward across an intermediate section to permit access to the portion of the pickup bed near the tailgate.  
         [0033]      FIG. 20  is an enlarged detail showing the attachment of the pickup bed cover to the toolbox shown in  FIGS. 17, 18  and  19 .  
         [0034]      FIG. 21  is an another view of the pickup bed cover shown in  FIGS. 18 and 19 . 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0035]     In the following description of the invention, like numerals and characters designate like elements throughout the figures of the drawings.  
         [0036]     Referring generally to the drawings and more particularly to  FIGS. 1 and 2 , a folding pickup bed cover  50  in accordance with the present invention covers the bed  52  of a pickup  54 . The bed  52  of the pickup truck includes sidewalls  56 , a front wall  58 , and a rear wall  60 . The rear wall  60  is a tailgate.  
         [0037]     The pickup bed cover  50  is formed by substantially rigid panels  62   a,    62   b,    62   c,    62   d,  and  62   e  which extend transversely across the pickup truck bed  52 . The rigid panels are also referred to herein as rigid sections. The rigid panels are hinged together by hinges  64   a,    64   b,    64   c,  and  64   d.  The rearmost rigid panel  62   a  includes a tailgate locking lip  66  which flares downwardly and outwardly along the tailgate  60  to prevent the tailgate  60  from opening when the cover  50  is locked in the closed position illustrated in  FIGS. 1 and 2 . The frontmost rigid panel  62   e  is attached to the front wall  58  of the pickup bed  52  adjacent the cab  68  (See  FIG. 6 ). The rigid panels can be formed from aluminum, stainless steel, or other suitable material. The rigid panel  62   c  is sometimes referred to as a double-hinge panel.  
         [0038]     Referring now to  FIGS. 3-5 , the pickup bed cover  50  is shown in progressively folded configurations. In  FIG. 3 , the rearmost rigid panel  62   a  is folded along the hinge  64   a  so the rigid panel  62   a  rests atop the rigid panel  62   b  and the top rear portion of the left side rail  70  of the sidewall  18  is exposed. With rigid panel  62   a  folded over rigid panel  62   b,  a rear portion  72  of the pickup bed  52  is open. The folding of rigid panel  62   a  over rigid panel  62   b  along the hinge  64   a  is shown in detail in  FIG. 12 .  
         [0039]     Referring now to  FIG. 4 , the pickup bed cover  50  is folded along hinges  64   b  and  64   c  so the rearmost rigid panel is disposed between the rigid panel  62   b  and the rigid panel  62   d.  The rigid panel  62   c  is substantially vertical. With the rigid panels  62   a,    62   b,  and  62   c  folded forward as shown in  FIG. 4 , both the rear portion  72  and the intermediate portion  74  of the pickup bed  52  are accessible. The folded configuration of the pickup bed cover  50  as represented by  FIG. 4  is shown in detail in  FIG. 13 .  
         [0040]     Referring now to  FIG. 5 , the pickup bed cover  50  is folded forward once again along the hinge  64   d  so rigid panels  62   a,    62   b,    62   c,  and  62   d  are adjacent the cab  68  and supported by the frontmost rigid panel  62   e.  With the rigid panels  62   a,    62   b,    62   c,  and  62   d  folded forward as shown in  FIG. 5 , the rear portion  72 , the intermediate portion  74 , and the front portion  76  of the pickup bed  52  are accessible. The folded configuration of the pickup bed cover  50  as represented by  FIG. 4  is shown in detail in  FIG. 14 .  
         [0041]     Referring now to  FIGS. 4 and 5 , a latch pin  78  extends through mating bores in rigid panels  62   a,    62   b,  and  62   d  to maintain the pancake-style stack of rigid panels in a tight bundle. As shown in  FIG. 5 , a support  80  is attached to a support connection  82  on rigid panel  62   d  and to a convenient attachment point  84  on the inside of the side rail  70 . The latch pin  78  and the support  80  are shown in greater detail in  FIGS. 13 and 14 .  
         [0042]     Referring now to  FIG. 6 , the rearmost rigid panel  62   a  is foldably attached to the rigid panel  62   b  by the hinge  64   a.  The rigid panel  62   b  is foldably attached to the rigid panel  62   c  by the hinge  64   b.  The rigid panel  62   c  is foldably attached to the rigid panel  62   d  by the hinge  64   c.  The rigid panel  62   d  is foldably attached to the rigid panel  62   e  by the hinge  64   c.  The rigid panel  62   f  includes bores  82 . The bores  82  in the frontmost rigid panel  62   f  permit attachment of the frontmost rigid panel  62   f  to the front wall  58  of the pickup bed  52 . In the presently preferred embodiment, the hinges  64   a,    64   b,    64   c,  and  64   d  are of the type commonly referred to as piano hinges. A rotary lock  96  secures each corner of the rearmost rigid panel  62   a  to the rear stake pocket in each side rail  70 .  
         [0043]     Referring now to  FIG. 7 , each rigid panel  62   a,    62   b,    62   c,    62   d,  and  62   e  includes, on each side where the panel contacts the side wall  56 , a lateral extension  90 . The lateral extension  90  extends outwardly across the side rail  70  of the side wall  56 . A lateral extension seal  92  extends along the length of each side rail  70  beneath the lateral extension  90  of each rigid panel. The lateral extension seal  92  prevents rubbing of the lateral extension  90  against the side rails  70 , deters water and other substances from entering the pickup bed  52  when the cover  50  is deployed as illustrated in  FIGS. 1 and 2 , and contributes to sound reduction. The lateral extension  90  flares downwardly from the main portion of the rigid panel to form an angle A of about 87 degrees with respect to a vertical reference line  94 .  
         [0044]     Referring now to  FIG. 8 , each rigid panel  62   a,    62   b,    62   c,    62   d,  and  62   e  includes at least one hinge lip  100  for attachment of the hinges to adjacent rigid panels. The hinge lip  100  includes a series of bores  102  for attachment of the piano hinges.  
         [0045]     Referring now to  FIGS. 9-11 , the lip  100  of rigid panel  62   b  is attached to one lip  100  of rigid panel  62   c  by hinge  64   b.  A hinge seal  101  is disposed between the lip  100  of the rigid panel  62   b  and the adjacent hinge element of the hinge  64   b.  Another hinge seal  101  is disposed between the lip  100  of the rigid panel  62   c  and the adjacent hinge element of the hinge  64   b.  Another hinge seal  101  is adhesively attached to one of the hinge elements of the hinge  64   b  so as to provide a seal between the hinge elements. A second lip  100  of the rigid panel  62   c  is attached to a lip  100  of the adjacent rigid panel  62   d  by the hinge  64   c.  Three hinge seals  101  promote water resistance and reduce vibration and noise.  
         [0046]     In  FIG. 9 , the pickup bed cover  50  is shown in a horizontal position, i.e., wherein the pickup bed cover  50  covers the bed entirely as shown in  FIGS. 1, 2 , and  6 .  
         [0047]     In  FIG. 10 , the pickup bed cover  50  is shown in an intermediate position between the configuration shown in  FIG. 2  and the configuration shown in  FIG. 4 . An arrow B shows the direction of folding of the rigid panel  62   b  in counterclockwise fashion at the hinge  64   b.  An arrow C shows the direction of folding of the rigid panel  62   c  in counterclockwise fashion at the hinge  64   c.    
         [0048]     In  FIG. 11 , the rigid panels  62   a  and  62   b  are lying generally horizontally across the rigid panel  62   d.  Rigid panel  62   c,  which is hingedly connected between rigid panel  62   b  and rigid panel  62   b  is in a substantially vertical position.  
         [0049]     Referring now to  FIG. 12 , the rigid panel  62   a  folds across rigid panel  62   b  at hinge  64   a  to accomplish a change from the configuration shown in  FIG. 2  to the configuration shown in  FIG. 3 .  
         [0050]     In  FIG. 13 , the pickup bed cover  50  according to the present invention is configured as shown in  FIG. 4 . The latch pin  78  is disposed through mating bores  110 ,  112 , and  114  in rigid panels  62   a,    62   b,  and  62   d,  respectively. When the latch pin  78  is in place as shown in  FIG. 13 , the rigid panels  62   a,    62   b,    62   c,  and  62   d  are fixedly attached and move together along arrow D to achieve the configuration shown in  FIGS. 5 and 14 . As the rigid panel  62   d  folds upwardly at the hinge  64   d,  the support  80  extends and further stabilizes the pickup bed cover  50  in a vertical position against the cab  68  (See  FIGS. 5 and 14 ).  
         [0051]     It will be understood by one skilled in the art that the support  80  can be pneumatic, hydraulic, or mechanical. Pneumatic and hydraulic supports are well known in the art for hatchbacks, trunks, and hoods of various vehicles. Because they are well known in the art, it is not necessary to explain their operation except as it relates to the present invention.  
         [0052]     Referring now to  FIG. 14 , the pickup bed cover  50  is shown in a fully folded position as in  FIG. 5 . The latch pin  78  holds rigid panels  62   a,    62   b,    62   c,  and  62   d  in fixed relationship. The support  80  holds the combination of panels  62   a,    62   b,    62   c,  and  62   d  in an essentially vertical position against the cab  58  of the pickup  54 .  
         [0053]     Referring now to  FIG. 15 , a shorter pickup bed cover  350  is shown covering a portion of the pickup bed  52  of a short-bed pickup wherein a toolbox  152  has been mounted. The rearmost rigid panel  62   a  folds across the rigid panel  64   b.  The rigid panel  62   b  is foldably attached to a frontmost rigid panel  62   h  by hinge  64   d.  The frontmost rigid panel  62   h  includes a substantially vertical lip  63  (See  FIG. 20 ). Bores  83  (not shown) in the substantially vertical lip  63  permit attachment of the frontmost rigid panel  62   h  to the toolbox  152 . The combination of rigid panels  62   a  and  62   b,  held in fixed relationship by a latch pin  78  (See  FIGS. 4, 5 ,  13 , and  14 ), then swings counterclockwise around the hinge  64   d  to a vertical position behind the tool box  152  (See  FIGS. 13 and 14 ).  
         [0054]     Referring now to  FIG. 16 , a pickup bed cover  250  according to the present invention is formed by substantially rigid panels  62   a,    62   b,    62   c,    62   d,    62   e,    62   f,  and  62   g  which extend transversely across the pickup truck bed  52 . The rigid panels are hinged together by hinges  64   a,    64   b,    64   c,    64   d,    64   e,  and  64   f.  The rearmost rigid panel  62   a  includes a tailgate locking lip  66  which flares downwardly and outwardly along the tailgate  60  to prevent the tailgate  60  from opening when the cover  250  is locked in the closed position illustrated in  FIGS. 1 and 2 . The frontmost rigid panel  62   e  is attached to the front wall  58  of the pickup bed  52  adjacent the cab  68  (See  FIG. 6 ). The rigid panel  62   f  is a second double-hinge panel. Like double-hinge panel  62   c,  the double-hinge panel  62   f  accommodates folding of multiple layers of rigid panels in pancake fashion.  
         [0055]     According to the present invention, the only alterations to the pickup bed  52  are the holes in the front wall  58  for attachment of the front rigid panel  62   e,  together with a point of attachment of the support  80  in one side wall  56 .  
         [0056]     Referring now to  FIG. 17 , (similar to  FIG. 15  with a callout to  FIG. 20 ) a pickup bed cover  350  is shown covering the pickup bed  52  of a short-bed pickup where a toolbox  152  has been mounted. The rearmost rigid panel  62   a  is foldably attached to the rigid panel  62   b  by hinge  64   a.  The rigid panel  62   b  is foldably attached to the rigid panel  62   h  by hinge  64   d.  The frontmost rigid panel  62   h  includes a substantially vertical lip  63  (See  FIG. 20 ). Bores  83  in the substantially vertical lip  63  of the frontmost rigid panel  62   h  permit attachment of the frontmost rigid panel  62   h  to the toolbox  152 . The combination of rigid panels  62   a  and  62   b  is held in fixed relationship by a latch pin  78  (See  FIGS. 4, 5 ,  13 , and  14 ), then swings counterclockwise around the hinge  64   d  to a vertical position behind the tool box  152 .  
         [0057]     Now referring to  FIG. 18 , a pickup bed cover  450  is shown covering the pickup bed  52  of a long-bed pickup wherein a toolbox  152  has been mounted. The rearmost rigid panel  62   a  is foldably attached to the rigid panel  62   b  by the hinge  64   a.  The rigid panel  62   b  is foldably attached to a relatively narrower rigid panel  61  by the hinge  64   b.  Relatively narrower rigid panel  61  is foldably attached to the rigid panel  62   d  by the hinge  64   c.  The rigid panel  62   d  is foldably attached to the rigid panel  62   h  by the hinge  64   d.  The rigid panel  62   h  includes a substantially vertical lip  63  (See  FIG. 20 ). Bores  83  in the substantially vertical lip  63  of the frontmost rigid panel  62   h  permit attachment of the frontmost rigid panel  62   h  to the toolbox  152 .  
         [0058]     Now referring to  FIG. 19 , the pickup bed cover  450  is shown covering a portion of a pickup bed  52  of the long-bed pickup wherein the toolbox  152  has been mounted. The rearmost rigid panel  62   a  is folded along the hinge  64   a  so the rigid panel  62   a  rests atop the rigid panel  62   b  and the top rear portion of the left side rail  70  of the sidewall  18  is exposed. With rigid panel  62   a  folded over rigid panel  62   b,  the rear portion  72  of the pickup bed  52  is open. The folding of rigid panel  62   a  over rigid panel  62   b  along the hinge  64   a  is shown in detail in  FIG. 12 .  
         [0059]     Now referring to  FIG. 20 , the rigid panel  62   d  is foldably attached to the frontmost rigid panel  62   h  by the hinge  64   d.  The frontmost rigid panel  62   h  includes the substantially vertical lip  63 . Bores  83  permit bolts  86 , washers  88 , and nuts  89  to attach the frontmost rigid panel  62   h  to the toolbox  152 . The seal  101  is adhesively attached between the substantially vertical lip  63  of the frontmost rigid panel  62   h  and the toolbox  152 . The seal  101  promotes water resistance and reduces vibration and noise.  
         [0060]     Now referring to  FIG. 21 , the rearmost rigid panel  62   a  is foldably attached to the rigid panel  62   b  by the hinge  64   a.  The rigid panel  62   b  is foldably attached to the relatively narrower rigid panel  61  by the hinge  64   b.  The relatively narrower rigid panel  61  is foldably attached to the rigid panel  62   d  by the hinge  64   c.  The rigid panel  62   d  is foldably attached to the frontmost rigid panel  62   h  by the hinge  64   d  (See  FIGS. 9 and 12 ). The frontmost rigid panel  62   h  includes a substantially vertical lip  63 . Bores  83  in the substantially vertical lip  63  of the frontmost rigid panel  62   h  permit attachment of the frontmost rigid panel  62   h  to the toolbox  152  (See  FIG. 20 ). A rotary lock  96  secures each corner of the rearmost rigid panel  62   a  to the rear stake pocket in each side rail  70 .  
         [0061]     The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the invention and its practical application, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto and their equivalents.