Abstract:
A tonneau system for a cargo box of a vehicle having a support frame connectable to the cargo box. A cover spans the support frame and is positionable between a tensioned position and an untensioned position. A bow member is coupled to the cover and is moveable between a first position and a second position in response to the movement of the cover between the tensioned position and the untensioned position. A retaining member is then operably coupled to the support frame. The retaining member retains the bow member when the bow member is in the first position and releases the bow member when the bow member is in the second position.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention generally relates to coverings for pickup trucks and, more particularly, relates to a roll up tonneau cover system.  
       BACKGROUND OF THE INVENTION  
       [0002]     Tonneau covers have been used for a number of years to cover the cargo box of pickup trucks against dirt, debris, and other environmental contaminants and to improve the aesthetic quality thereof. Current tonneau covers often employ a VELCRO® hook-and-loop fastening system operably coupled between a soft tarp of the tonneau cover and the sidewalls of the cargo box of the pickup truck. This arrangement permits the tarp to be coupled to the cargo box to conceal the contents thereof or, alternatively, to be rolled up to reveal the contents of the cargo box of the pickup truck. The VELCRO® has disadvantages of wearing over time, pulling, and not allowing the fabric to move freely, which may result in a puckered and wrinkled appearance.  
         [0003]     A series of bows are typically coupled to the tarp and span the width of the cargo box. These bows serve to support and minimize accumulation of dirt, debris, and other environmental contaminants from collecting on top of the tarp. When the tarp is rolled up, these bows are often enclosed within the tarp bundle.  
         [0004]     Typically, these bows are cylindrical in cross-section and the ends thereof rest upon rails fixed to longitudinal sidewalls of the cargo box of the pickup truck. However, often times these bows fails to minimize the lifting action caused by aerodynamic forces during vehicle travel. That is, conventional soft or roll-up type tonneau covers often suffer from flapping at highway speeds, which can lead to premature failure.  
         [0005]     Accordingly, there exists a need in the relevant art to provide a tonneau cover system capable of overcoming the aerodynamic lifting forces caused during vehicle travel. Additionally, there exists a need in the relevant art to provide a tonneau cover system capable of reliably coupling the tonneau cover to the vehicle at various longitudinal locations. Still further, there exists a need in the relevant art to provide a tonneau cover system capable of overcoming the disadvantages of the prior art.  
       SUMMARY OF THE INVENTION  
       [0006]     According to the principles of the present invention, a tonneau system for a cargo box of a vehicle having an advantageous construction is provided. The tonneau cover system includes a support frame connectable to the cargo box. A cover spans the support frame and is positionable between a tensioned position and an untensioned position. A bow member is coupled to the cover and is moveable between a first position and a second position in response to the movement of the cover between the tensioned position and the untensioned position. A retaining member is then operably coupled to the support frame. The retaining member retains the bow member when the bow member is in the first position and releases the bow member when the bow member is in the second position.  
         [0007]     Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0008]     The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:  
         [0009]      FIG. 1  is a perspective view illustrating a pickup truck having a tonneau cover system according to the principles of the present invention;  
         [0010]      FIG. 2  is a perspective view illustrating the pickup truck having the tonneau cover system according to the principles of the present invention with portions removed for clarity;  
         [0011]      FIG. 3  is a cross sectional view illustrating the head rail assembly taken along line  3 - 3  of  FIG. 1 ;  
         [0012]      FIG. 4  is an enlarged perspective view illustrating the adjustment beam mechanism;  
         [0013]      FIG. 5  is an enlarge perspective view illustrating the rear frame rail assembly;  
         [0014]      FIG. 6  is a perspective view illustrating the pickup truck having the tonneau cover system with portions removed for clarity and the rear frame rail assembly in a raised position;  
         [0015]      FIG. 7  is an enlarged perspective view illustrating the bow member and retaining bracket;  
         [0016]      FIG. 8  is a side view illustrating the bow member and retaining block member in a released position;  
         [0017]      FIG. 9  is a side view illustrating the bow member and retaining block member in a retained position;  
         [0018]      FIG. 10  is an enlarged perspective view illustrating the retaining block member;  
         [0019]      FIG. 11  is an enlarged perspective view illustrating the bow member in the retained position;  
         [0020]      FIG. 12  is an enlarged perspective view illustrating the bow member in the released position;  
         [0021]      FIG. 13  is a cross section view illustrating the tonneau cover system of the present invention in the retained position employing a retaining bracket; and  
         [0022]      FIG. 14  is a cross section view illustrating the tonneau cover system of the present invention in the released position employing a retaining block member.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0023]     The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.  
         [0024]     With reference to  FIGS. 1 and 2 , a pickup truck  10  is shown having a roll up tonneau system  12  which is attached to a cargo box  13  according to the present invention. Cargo box  13  has a front wall  14 , a left sidewall  16 , a right sidewall  18 , and a rear wall or tailgate  20 . Roll up tonneau system  12  includes a flexible, stretchable fabric cover  22  that is drawn tightly over a substantially rigid rail support system  24  and removably attached to rail support system  24 . Rail support system  24  is comprised of a number of frame rails that are attached to one another to form a rectangular frame. The frame rails included are a front frame rail or head rail assembly  26 , a left side frame rail assembly  28 , a right side frame rail assembly  30 , and a rear frame rail assembly  32 . Rail support system  24  is aligned with and coupled to the top of sidewalls  16  and  18  of cargo box  13  as well as the top of front wall  14  and tailgate  20 , according to one of many method. A clamping system or fastening system may be used to fasten the rail assemblies  26 ,  28 ,  30 , and  32  to the sidewalls  16  and  18  of pickup truck  10 . An example of a clamping system can be found in commonly-assigned U.S. patent application Ser. No. 10/331,711, entitled “Roll Up Tonneau Cover System.” The disclosure of this application is incorporated herein by reference. Stretchable fabric cover  22  is support cross-vehicle via a plurality of cross bows  301 , which each selectively engage corresponding retaining members coupled to left side frame rail assembly  28  and right side frame rail assembly  30 , which will be discussed in detail below.  
         [0025]     It should be understood that right sidewall  18  and left sidewall  16  of pickup truck  10  and the corresponding right side frame rail assembly  30  and left side frame rail assembly  28  are identical in construction, yet arranged in mirrored symmetry. Accordingly, in the interest of brevity, only one side will be discussed in detail below unless noted otherwise.  
         [0026]     Still referring to  FIGS. 1 and 2 , right side frame rail assembly  30  is coupled to right sidewall  18  of cargo box  13  of pickup truck  10 . As can be seen, sidewall  18  of cargo box  13  includes a generally horizontal top surface  34  and a downwardly extending inside wall  36 . However, it should be appreciated that generally horizontal top surface  34  and downwardly extending inside wall  36  may have any one of a number of configurations, which are dependent upon styling and functionality determined by the vehicle manufacturer. Hence, it should be understood that the particular shape of these surfaces/walls may vary, along with the specific shape of those corresponding components of frame rail assembly  30 .  
         [0027]     Turning now to  FIG. 3 , head rail assembly  26  will now be described in detail. As can be seen in the figure, head rail assembly  26  generally includes an extruded front bracket member  40 . Extruded front bracket member  40  is preferably made of a light-weight, corrosion resistant material, such as aluminum. Extruded front bracket member  40  includes a gasket channel  42  extending longitudinally along a forward portion  44  of extruded front bracket member  40 . Gasket channel  42  is sized to receive a corresponding channel feature  46  of a flexible gasket member  48  such that flexible gasket member  48  is coupled with and supported by extruded front bracket member  40 . Gasket member  48  is positionable such that it engages and forms a fluid seal between a nose portion  50  of gasket member  48  and front wall  14  of pickup truck  10 . In this regard, water and other environmental contaminants are prevented from entering cargo box  13  of pickup truck  10 . During assembly, channel feature  46  of flexible gasket member  48  is slid into gasket channel  42 .  
         [0028]     Extruded front bracket member  40  further includes cover retaining slot  52  extending longitudinally along forward portion  44  of extruded front bracket member  40 . Cover retaining slot  52  is sized to receive a corresponding rod member  54 . Preferably, rod member  54  is received within a channel  56  sewn or otherwise formed in stretchable fabric cover  22 . In this regard, stretchable fabric cover  22  is reliably retained in connection with extruded front bracket member  40 . During assembly, rod member  54  is first slid into channel  56  of stretchable fabric cover  22  and the two are slid into cover retaining slot  52 .  
         [0029]     Still referring to  FIG. 3 , extruded front bracket member  40  further includes a tip support  60  extending along forward portion  44 . Tip support  60  is adapted to be received between a fold-back portion  62  of stretchable fabric cover  22  and provides support to stretchable fabric cover  22 . Tip support  60  permits stretchable fabric cover  22  to extend forward from extruded front bracket member  40  to bridge a gap between extruded front bracket member  40  and front wall  14  and to further conceal gasket member  48 . Tip support  60  may be received within a support channel  64  formed in extruded front bracket member  40 . However, it should also be understood that tip support  60  may be integrally formed with extruded front bracket member  40  or may be part of a separate polymer extrusion to which the stretchable fabric cover  22  is sewn. This extrusion would be slidably engaged with bracket member  40 .  
         [0030]     Referring now to  FIGS. 3 and 4 , tonneau system  12  further includes an adjustment beam mechanism  100  engagable with extruded front bracket member  40 . Adjustment beam mechanism  100  is provided for maintaining a constant tensional force on stretchable fabric cover  22  to a desired tightness. Adjustment beam mechanism  100  includes a cantilever beam member  102  having a first end  104  and a second end  106 . First end  104  of cantilever beam member  102  is fixedly mounted to extruded front bracket member  40  via conventional fasteners  109  and a mounting bracket  110 . Mounting bracket  110  is slidably engaged in slot  112  of extruded front bracket member  40 . Mounting bracket  110  is preferably sized to permit simple positioning of mounting bracket  110  and cantilever beam member  102  relative to extruded front bracket member  40  when the fasteners are loosened. However, on the other hand, mounting bracket  110  should preferably frictionally engage flanges  114  when the fasteners are tightened.  
         [0031]     As best seen in  FIGS. 2-4 , adjustment beam mechanism  100  further includes a finger member  120 , which is operably coupled to frame rail assembly  30 . Finger member  120  is sized to extend upward from frame assembly  30  in a generally L-shaped configuration. An end  122  of finger member  120  is engagable with second end  106  of cantilever beam member  102 . Such engagement of finger member  120  against the biasing force of cantilever beam member  102  cause extruded front bracket member  40  to be urged forward (relative to the vehicle) to draw stretchable fabric cover  22  tightly over rail support system  24 .  
         [0032]     It should be understood that cantilever beam member  102  may be pre-bent to tailor a desired biasing force. It is generally desired that adjustment beam mechanism  100  is disposed on each side of the vehicle bed to provide equal tensioning thereabout. Specifically, it is desired that adjustment beam mechanism  100  is arranged to provide about 15 to 10 pounds of tensioning force on each side.  
         [0033]     Turning now to  FIG. 5 , rear frame rail assembly  32  will be described in detail. Rear frame rail assembly  32  generally includes an extruded rear bracket member  200 . Rear bracket member  200  is similar in construction to front bracket member  40 ; however, rear bracket member  200  includes a rounded bull nose portion  202 . Rear bracket member  200  further includes a receiving channel  56 ′ for receiving rod member  54  coupled to fabric cover  22  similarly as mentioned above. Rear frame rail assembly  32  still further includes a latching system, such as that described in commonly-assigned U.S. patent application Ser. No. 10/331,711, entitled “Roll Up Tonneau Cover System.” 
         [0034]     With continued reference to  FIG. 5 , rounded bull nose portion  202  of rear bracket member  200  is sized to be pivotally received within a concave portion  204  of a corresponding rear pivot block  206 . In this regard, rear frame rail assembly  32  may pivot upward about the interface between rounded bull nose portion  202  and concave portion  204  into a raised position (see  FIG. 6 ). In this raised position, the tension in fabric cover  22  is released. However, in a lowered position, the tension is then again exerted upon fabric cover  22  according to the biasing force of adjustment beam mechanism  100 . Rear pivot block  206  is fixedly coupled to frame rail assembly  30  via conventional means, such as fasteners. It should be appreciated that as rear bracket member  200  is lowered into a down position, fabric cover  22  is drawn rearward against the biasing force of adjustment beam mechanism  100 . During this operation, fabric cover  22  is translated rearward a predetermined distance. This translation distance will be used to effect an additional retaining features that will be described in detail below. During an opposition operation, namely the raising or pivoting of rear bracket member  200  causes the tension in fabric cover  22  to be released, which causes fabric cover  22  to translate forward in response to the biasing forces of adjustment beam mechanism  100 .  
         [0035]     Still referring to  FIG. 5 , rear bracket member  200  further includes a strip member  212  extending along rearward portion  210 . Strip member  212  is adapted to be sewn into fabric cover  22  and provides support to stretchable fabric cover  22 . Strip member  212  may be received within a support channel  214  formed in rear bracket member  200 . However, it should also be understood that strip member  212  may be integrally formed with rear bracket member  200 .  
         [0036]     Turning now to  FIGS. 6 and 7 , it can be seen that tonneau system  12  further includes a retaining system  300  for retaining sections of fabric cover  22  located between head rail assembly  26  and rear frame rail assembly  32 . As best seen in  FIG. 6 , retaining system  300  includes a plurality of cross vehicle bow members  301  operably coupled with fabric cover  22  and engaging retaining brackets  302  fixedly coupled to frame rail assembly  28 ,  30 . Retaining brackets  302  may be of any shape or design; however, two possible configurations will be discussed herein.  
         [0037]     With reference to  FIGS. 6 and 7 , retaining bracket  302  is illustrated as a generally sheet-like member shaped to define a generally planar section  304  and a receiving section  306 . Planar section  304  is disposed adjacent frame rail assembly  28 ,  30  and fastened thereto via conventional means, such as fasteners. Receiving section  306 , however, is shaped to receive a corresponding portion of vehicle bow member  301 . That is, in the embodiment illustrated in  FIGS. 6 and 7 , vehicle bow member  301  is generally cylindrical in cross-section. Accordingly, receiving section  306  is generally cylindrical, concave in shape to readily receive and retaining vehicle bow member  301  therein. Receiving section  306  extends upward to an end  308 , which is positioned relative to vehicle bow member  301  to generally prevent vehicle bow member  301  from disengaging with retaining bracket  302  in a vertical direction.  
         [0038]     Vehicle bow member  301  is generally cylindrical in cross-section. Vehicle bow member  301  may define an enclosed tubular member or may be constructed of rolled aluminum, or other material. Preferably, vehicle bow member  301  further includes an optional paddle-shaped bow end  310  extending outwardly from vehicle bow member  301 . Paddle-shaped bow end  310  overlaps a portion of frame rail assembly  28 ,  30 . Paddle-shaped bow end  310  serves to push outwardly in a lateral direction (in the cross-vehicle direction) keeping the stretchable fabric cover  22  taunt. Paddle-shaped bow end  310  further biases the periphery of stretchable fabric cover  22  down to seal against frame rail assembly  28 ,  30 . Frame rail assembly  28 ,  30  have alternating high and low sections that act as a labyrinthian seal.  
         [0039]     Alternatively, as seen in  FIGS. 8-12 , retaining bracket  302  may be made as a block member, generally indicated at  302 ′. Retaining block member  302 ′ is preferably made of a Nylon or other plastic material and is injection molded. Retaining block member  302 ′ is preferably fastened to frame rail assembly  28 ,  30  via a fastener  303  extending through an aperture  350  formed in retaining block member  302 ′. Fastener  303  engages a sliding bracket  305  received within frame rail assembly  28 ,  30 . Retaining block member  302 ′ further includes a tab member  352  that is sized to be slidably received within a channel  354  of frame rail assembly  28 ,  30 . Tab member  352  and channel  354  cooperate to prevent, or at least, minimize rotation of retaining block member  302 ′ to ensure proper positioning of retaining block member  302 ′. Retaining block member  302 ′ further includes a receiving section  356 , which is shaped to receive a corresponding portion of vehicle bow member  301 . That is, in the embodiment illustrated in  FIGS. 8-12 , vehicle bow member  301  is generally cylindrical in cross-section. Accordingly, receiving section  356  is generally cylindrical, concave in shape to readily receive and retaining vehicle bow member  301  therein. Receiving section  356  extends upward to an end  358 , which is positioned relative to vehicle bow member  301  to generally prevent vehicle bow member  301  from disengaging from retaining block member  302 ′ in a vertical direction. More particularly, as seen in  FIG. 10 , end  358  may terminate at a single finger  360 , if desired.  
         [0040]     Turning now to  FIGS. 13 and 14 , it can be seen that vehicle bow member  301  is engaged and retained within receiving section  356  when rear bracket member  200  is lowered (see  FIG. 13 ), while conversely vehicle bow member  301  is released and free to be raised when bracket member  200  is raised (see  FIG. 14 ). It is worth noting that this operating is illustrated in  FIGS. 13 and 14  in connection with retaining bracket  302  and retaining block member  302 ′.  
         [0041]     As best seen in  FIGS. 8 and 9 , vehicle bow member  301  is coupled to fabric cover  22  through a coupling system  400 . Coupling system  400  includes a rod or cord member  402  slidably received within a bow channel  404  extending longitudinally through vehicle bow member  301 . Cord member  402  captures a portion  406  of fabric cover  22  simply by routing fabric cover  22  around cord member  402 . The shape of bow channel  404  retaining cord member  402  therein, thereby preventing fabric cover  22  from disengaging from vehicle bow member  301 . Most preferably, portion  406  of fabric cover  22  is sewn into fabric cover  22  to prevent migration of fabric cover  22  relative to cord member  402 . It should be understood that this positive coupling of fabric cover  22  to vehicle bow member  301  (and the corresponding coupling of vehicle bow member  301  to either retaining bracket  302  or retaining block member  302 ′) serves to retain and prevent raising of fabric cover  22  during vehicle travel.  
         [0042]     The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.