Patent Publication Number: US-2011049316-A1

Title: Hinge for tonneau cover and mounting assembly

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to a hinge for a tonneau cover and a mounting assembly. 
     It has become more common nowadays that pickup truck users mount a tonneau cover over the truck bed of their pickup truck to protect the carried cargoes from the environment, such as rain, dust, etc. There are many types of tonneau covers available in the market, for example, fiber-glass tonneau covers and twin sheet plastic tonneau covers molded by the vacuum thermoforming process. The hinge for the tonneau cover and the mounting assembly has already been known from the U.S. Pat. No. 6,109,681 by Edwards et al. The hinge according to the Edwards patent uses a beam in mounting the hinge. The length of the beam covers the distance from the left truck bed wall to the right truck bed wall. This is a waste of material and results in the increase in the manufacturing cost. In addition, the beam is of the fixed length for one model of a pickup truck and is, therefore, not compatible with another model of which width is different. It is, therefore, necessary to provide a hinge for the tonneau cover and the mounting assembly that can eliminate these aforementioned drawbacks. 
     BRIEF SUMMARY OF THE INVENTION 
     The hinge for the tonneau cover and the mounting assembly according to the present invention comprises a right hinge, a left hinge, four connectors, a first clamping device, and a second clamping device. The first clamping device is attached to the right edge of the truck bed, while the second clamping device is attached to the left edge of the truck bed. The first two connectors are attached to the first clamping device, while the remaining two connectors are attached to the second clamping device. The right hinge comprises an upper plate having the first end and the second end, wherein the first end is attached to the tonneau cover, the second end is rotatably attached to the first end of the front plate. The front plate having the first end and the second end, wherein the first end is rotatably attached to the upper plate, the second end includes the downward plate extending therefrom, wherein during the mounting the first end rests over the upper edge of front truck bed wall. The downward plate extends from the front plate in the downward direction, at the right edge of the downward plate includes a lateral plate extending therefrom. A lateral plate extends from the downward plate in the direction toward the rear end of the truck after being assembled, wherein the lateral plate is attached to the two connectors that have been attached to the first clamping device. The left hinge comprises the upper plate having the first end and the second end, wherein the first end is attached to the tonneau cover, the second end is rotatably attached to the first end of the front plate. The front plate has the first end and the second end, wherein the first end is rotatably attached to the upper plate, the second end includes the downward plate extending therefrom, wherein during the mounting the first end rests over the upper edge of front truck bed wall. The downward plate extending from the front plate in the downward direction, at the left edge of the downward plate includes a lateral plate extending therefrom. The lateral plate extends from the downward plate in the direction toward the rear end of the truck after being assembled, wherein the lateral plate is attached to the two connectors that have been attached to the second clamping device. 
     One object of the present invention is to provide the hinge for the tonneau cover and mounting assembly having a mounting means without drilling the truck bed. 
     Another object of the present invention is to provide the hinge for the tonneau cover and mounting assembly having low cost of manufacturing and being compatible with various models of pickup trucks. 
     Yet another object of the present invention is to provide the hinge for the tonneau cover and mounting assembly that can be mounted in the pickup trucks with or without the bed liner. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       The foregoing summary, as well as the following detailed description of the invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there are shown in the drawings embodiments which are presently preferred. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown. 
       In the drawings: 
         FIG. 1  is a perspective view of a portion of a truck bed of a pickup truck in accordance with a preferred embodiment of the present invention; 
         FIG. 2  is a sectional view from the line  2 - 2  in  FIG. 1  of an upper edge of a right truck bed wall; 
         FIG. 3  is a perspective view of a right hinge and a mounting assembly according to a preferred embodiment of the present invention; 
         FIG. 4  is a perspective view of a left hinge and the mounting assembly according to a preferred embodiment of the present invention; 
         FIG. 5  is a perspective view of holes at a right bed liner wall; 
         FIG. 6  is a perspective view of a first clamping device that has already been mounted to the upper edge of the right truck bed wall; 
         FIG. 7  is the sectional view from the line  7 - 7  in  FIG. 1  of the right hinge mounted to the truck bed that has already been mounted with the bed liner; 
         FIG. 8  is the sectional view from the line  7 - 7  in  FIG. 1  of the right hinge mounted to the truck bed without bed liner; 
         FIG. 9  is the sectional view from the line  7 - 7  in  FIG. 1  of the right hinge mounted to the truck bed mounted with the bed liner as indicated by the solid line in comparison with the right hinge mounted to the truck bed without the bed liner as indicated by the dotted line; and 
         FIG. 10  is a sectional view from the line  2 - 2  in  FIG. 1  of the right hinge mounted to the truck bed that has already been mounted with the bed liner. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Certain terminology is used in the following description for convenience only and is not limiting. The words “right,” “left,” “lower,” “upper,” “front” and “rear” designate directions in the drawings to which reference is made. The word “inwardly” refers to a direction toward the geometric center of the device, and designated parts thereof, in accordance with the present invention. Unless specifically set forth herein, the terms “a,” “an” and “the” are not limited to one element, but instead should be read as meaning “at least one.” The terminology includes the words noted above, derivatives thereof and words of similar import. 
     Referring to the drawings in detail, wherein like numerals indicate like elements throughout the several views,  FIG. 1  shows a pickup truck  20  according to a preferred embodiment of the present invention. The pickup truck  20  preferably includes a passenger cabin  21 , a truck bed  22 , a front truck bed wall  23 , a right truck bed wall  24 , an upper edge  25  of front truck bed wall, a horizontal edge  26  of the right truck bed wall and a downward edge  27  of the right truck bed wall.  FIG. 2  shows an enlarged view of the horizontal edge  26  and the downward edge  27 . 
     The hinge for the tonneau cover and mounting assembly according to the a preferred embodiment of the present invention comprises a right hinge  30  as shown in  FIG. 3 , a left hinge  31  as shown in  FIG. 4 , four connectors  46 , a first clamping device and a second clamping device. The first clamping device is attached to the right edge of the truck bed  22 , while the second clamping device is attached to the left edge of the truck bed  22 . The first two connectors  46  are attached to the first clamping device and the remaining two connectors  46  are attached to the second clamping device. 
       FIG. 3  shows the right hinge  30  comprising an upper plate  32 , a front plate  35 , a downward plate  38 , and the lateral plate  40  as explained in detail below. The upper plate  32  includes a first end and a second end, wherein the first end is attached to the tonneau cover  29  and the second end is rotatably attached to the first end  36  of the front plate  35  with a rotating axis A acting as the a rotating axis of the hinge. The front plate  35  includes a first end  36  and a second end  37 , wherein the first end  36  is rotatably attached to the upper plate  32  and the second end  37  includes the downward plate  38  extending therefrom, wherein during the mounting the first end  36  rests over the upper edge  25  of front truck bed wall. The downward plate  38  extends from the front plate  35  in the downward direction, at the right edge of the downward plate includes a lateral plate  40  extending therefrom, and the lateral plate  40  extending from the downward plate  38  in the direction toward the rear end of the truck after being assembled, wherein the lateral plate  40  is attached to the two connectors  46  that have been attached to the first clamping device. 
       FIG. 4  shows the left hinge  31  comprising an upper plate  32 L, a front plate  35 L, a downward plate  38 L, and a lateral plate  40 L to be later described. The upper plate  32 L includes a first end and a second end, wherein the first end is attached to the tonneau cover  29  and the second end is rotatably attached to the first end  36 L of the front plate  35 L with a rotating axis A acting as the a rotating axis of the hinge. The front plate  35 L includes a first end  36 L and a second end  37 L, wherein the first end  36 L is rotatably attached to the upper plate  32 L and the second end  37 L includes the downward plate  38 L extending therefrom, wherein during the mounting the first end  36 L rests over the upper edge  25  of front truck bed wall. The downward plate  38 L extends from the front plate  35 L in the downward direction, at the left edge of the downward plate includes a lateral plate  40 L extending therefrom, and the lateral plate  40 L extending from the downward plate  38 L in the direction toward the rear end of the truck after being assembled, wherein the lateral plate  40 L is attached to the two connectors  46  that have been attached to the second clamping device. 
     From the above description, those of ordinary skills in the art will appreciate that the hinge for the tonneau cover  29  and mounting assembly according to the present invention can be mounted without drilling the truck bed  22  due to the use of the clamping device in the mounting and compatible with various models since the right hinge  30  and the left hinge  31  are separated. These devices can, therefore, be mounted to pickup trucks  20  having different widths of the truck bed  22 . 
     The mounting assembly further comprises a bracket  49  for use with the right hinge  30  as shown in  FIG. 3 . The bracket  49  is adjustably attached to the downward plate  38  of the right hinge  30 . During the mounting, one end of the bracket  49  will be in the position abutting the front truck bed wall  23  to prevent the right hinge  30  from moving to the front of the truck bed  22  when the user opens/closes the tonneau cover  29 . The abutting distance of the bracket  49  is adjustable by inserting the threaded shaft of the bracket through the nut  48 . The bracket  49  is then fastened into the threaded hole  39 . After the bracket  49  is fastened to the proper abutting distance, the nut  48  is then tightened. 
     The mounting assembly further comprises a bracket  49  for use with the left hinge  31  as shown in  FIG. 4 . The bracket  49  is adjustably attached to the downward plate  38 L of the left hinge  31 . During the mounting, one end of the bracket  49  will be in the position abutting the front truck bed wall  23  to prevent the left hinge  31  from moving to the front of the truck bed  22  when the user opens/closes the tonneau cover  29 . The abutting distance of the bracket  49  is adjustable by inserting the threaded shaft of the bracket through the nut  48 . The bracket  49  is then fastened into the threaded hole  39 L. After the bracket  49  is fastened to the proper abutting distance, the nut  48  is then tightened. 
     In addition, the present invention also provides other components as described below to be mounted in the pickup truck with or without the bed liner. Specifically, the lateral plate  40  of the right hinge  30 , as shown in  FIG. 3 , includes two notches  41 , wherein those notches  41  extend from the lower edge of the lateral plate  40 . This allows the installer to mount the notch  41  to the threaded shaft  52  by sliding the lateral plate  40  in the downward direction to couple the notch  41  to the threaded shaft  52 . The lateral plate  40 L of the left hinge  31 , as shown in  FIG. 4 , includes two notches  41 L, wherein those notches  41 L extend from the lower edge of the lateral plate  40 L. 
     The outer plate  44  of the first clamping device, as shown in  FIG. 3  includes two threaded shafts  59 . The first clamping device is attached to the right edge of the truck bed by screwing the bolt  47  until the inner plate  45  exerts the force onto the outer plate  44  with the downward edge  27  of the truck bed resting therebetween. The outer plate  44  of the second clamping device, as shown in  FIG. 4 , includes two threaded shaft  59 . The second clamping device is attached to the left edge of the truck bed by screwing the bolt  47  until the inner plate  45  exerts the force onto the outer plate  44  with the downward edge of truck bed resting therebetween. Each connector  46  comprises two ends, as shown in  FIGS. 3 and 4 . One end is the threaded shaft  52  and the other end includes the threaded hole  53 . During the mounting, the threaded hole  53  of the connector  46  is fastened to the threaded shaft  59  of the outer plate  44 . 
     The mounting assembly further comprises the cover plate  42  for use with the right hinge  30 , as shown in  FIG. 3 . The cover plate  42  includes the upper protrusion  60  extending therefrom and includes the lower protrusion  61  extending therefrom in the same direction as the upper protrusion. The cover plate  42  includes two lower holes  55  and two upper holes  56 , wherein the upper holes  56  are located in the higher position than the lower holes  55  for the distance X of at least equal to the thickness of the bed liner, as shown in  FIG. 7 . The thickness of the bed liner  28  is represented by the distance Y. The lower holes  55  are used in the attachment to the pickup truck mounted with the bed liner  28 . The upper holes  56  are used in the attachment to the pickup truck  20  without the bed liner  28 . The reason that the distance X is at least equal to the thickness of the bed liner  28  is described as follows. In case the distance X is equal to the thickness of the bed liner  28 , during the mounting of the bed liner  28  using the lower holes  55 , the front plate  35  rests in direct contact with the upper edge  64  of the front bed liner wall  62  as shown in  FIGS. 7 and 9 . During the mounting without the bed liner  28  using the upper hole  56 , the front plate  35  will rest in direct contact with the upper edge  25  of the front truck bed wall  23  as shown in  FIGS. 8 and 9 . In case the distance X is greater than the thickness of the bed liner  28  and the bed liner  28  installed which using the lower hole  55 , the front plate  35  rests above the upper edge  64  of the front bed liner wall  62  for a certain distance. It can be seen that the mounting is possible. However, it may be necessary to provide additional members to prevent the permeation of the water and to provide efficient usage. 
     The mounting assembly further comprises the cover plate  42 L for use with the left hinge  31 , as shown in  FIG. 4 . The cover plate  42 L includes the upper protrusion  60 L extending therefrom and includes the lower protrusion  61 L extending therefrom in the same direction as the upper protrusion. The cover plate  42 L includes two lower holes  55 L and two upper holes  56 L, wherein the upper hole  56 L is located in the higher position than the lower hole  55 L for the distance of at least equal to the thickness of the bed liner  28 . The lower hole  55 L is attached to the pickup truck  20  mounted with the bed liner  28 . The upper hole  56 L is attached to the pickup truck  20  without the bed liner  28 . The reason that the upper hole  56 L is higher than the lower hole  55 L for the size of at least equal to the thickness of the bed liner  28  is the same as that of the cover plate  42  as described above. 
     The lateral plate  40  of the right hinge  30 , as shown in  FIG. 3 , is attached to the connector  46  by engaging two notches  41  of the lateral plate to the threaded shaft  52  of the connector  46 . The cover plate  42  is then mounted to the lateral plate  40  by coupling the upper protrusion  60  to the upper edge of lateral plate  40  and coupling the lower protrusion  61  to the lower edge of the lateral plate  40  and engaging the lower hole  55  or the upper hole  56  of the cover plate with the threaded shaft  52  of the connector. The nut  48  accompany anti-loosing means is then tightened, which, in the present invention, the spring washer  67  is used for anti-loosing. The cover plate  42  prevents the lateral plate  40  from vertically sliding. That is, if the cover plate  42  is not provided but the lateral plate  40  is engaged with the threaded shaft  52  using only the nut  48 , the notch  41  of the lateral plate may be vertically slidable. On the other hand, if the cover plate  42  is engaged before the nut is fastened, the cover plate  42  is thus tightened to the threaded shaft  52 . This will prevent the cover plate  42  from moving up and down or rotating due to the fact that the upper protrusion  60  and lower protrusion  61  will retain the lateral plate  40  in the fixed position. The upward and downward movement is therefore impossible. 
     The lateral plate  40 L of the left hinge  31 , as shown in  FIG. 4 , is attached to the connector  46  by engaging two notches  41 L of the lateral plate to the threaded shaft  52  of the connector  46 . The cover plate  42 L is then mounted to the lateral plate  40 L by coupling the upper protrusion  60 L to the upper edge of lateral plate  40 L and coupling the lower protrusion  61 L to the lower edge of the lateral plate  40 L and engaging the lower hole  55 L or the upper hole  56 L of the cover plate with the threaded shaft  52  of the connector. The nut  48  accompany anti-loosing means is then tightened. 
       FIG. 9  shows the comparison of the position of the right hinge  30  in case of being mounted to the truck bed  22  with the bed liner  28  as indicated by the solid line compared with the right hinge  30  mounted to the truck bed  22  without the bed liner  28  as indicated by the dotted line. It can be seen that, when the bed liner  28  is not mounted, the front plate  35  of the hinge will rest against the upper edge  25  of the front truck bed wall. On the other hand, when the bed liner  28  is mounted, the front plate  35  of the hinge will rest against the upper edge  64  of the front bed liner wall. But in both cases, the distance from the hinge to the front edge of the truck bed  22  as shown by the distance B must be the same. This will allow the tonneau cover  29  to tightly cover the truck bed  22 . In case the hinge is mounted in the position away from the front edge of the truck bed  22  by the distance of greater than the distance B, the rear edge of the tonneau cover  29  will be located beyond the truck bed  22 . However, in case the hinge is mounted in the position away from the front edge of the truck bed  22  by the distance of less than the distance B, the rear edge of the tonneau cover  29  will be located inwardly next to rear of the truck bed  22 . That is, the tonneau cover  29  is not tightly closed. It can be seen that, the mounting method of the hinge for the tonneau cover  29  and the mounting assembly according to the present invention can be changed from the case where the pickup truck  20  is mounted with or without the bed liner  28  by only properly selecting the upper hole or the lower hole of the cover plate  42 . 
     The bracket  50 , as shown in  FIG. 3 , is used with the first clamping device. The bracket  50  is placed in the position that abuts the right truck bed wall  24 , as shown in  FIG. 10 . This will allow the outer plate  44  to rest in the substantially vertical position. The bracket  50  is used in connection with the nut  48  and the threaded hole  54 . 
     The bracket  50 , as shown in  FIG. 4 , is used with the second clamping device. The bracket  50  is placed in the position that abuts the left truck bed wall. This will allow the outer plate  44  to rest in the substantially vertical position. The bracket  50  is used in connection with the nut  48  and the threaded hole  54 . 
     The hinge for tonneau cover  29  and mounting assembly according to the present invention comprises the mounting method in case the pickup truck is mounted with the bed liner as follows. In case the truck bed  22  has already been mounted with the bed liner  28 , first, the installer preferably must remove the bed liner  28  from the truck bed  22 . The installer then preferably drills the hole  66  in the predetermined position, as shown in  FIG. 5 , at the right bed liner wall  63  and the left bed liner wall. The installer then mounts the clamping device comprising the outer plate  44  and the inner plate  45 , as shown in  FIGS. 3 and 4 , to the downward edge on the left and the right sides of the truck bed  22  in the position close to the front of the truck bed  22 . This can be done by inserting the bolt  47  through the spring washer  67 , the washer  33 , and the hole  57  at the outer plate. The bolt  47  is then fastened to the threaded hole  58  at the inner plate  45 . This will allow the outer plate  44  to exert a force to the inner plate  45  with the downward edge resting therebetween. This will allow the outer plate  44  to be attached to the truck bed  22  wherein  FIG. 6  shows the first clamping device mounted to the right truck bed wall  24 . 
     The bed liner  28  is then placed on the truck bed  22  where the position of the drilled hole  66  corresponds to the threaded shaft  59 . The connector  46  is to be mounted to the outer plate  44  by inserting the connector  46  through the hole  66  at the lateral bed liner wall. The connector  46  is then fastened to the threaded shaft  59  of the outer plate  44 . The right hinge  30  and left hinge  31  are to be mounted to the tonneau cover  29  by inserting the bolt  51  through the spring washer  67 , the washer  33 , and the hole  34  of the right hinge and fastening to the threaded hole at the tonneau cover  29 . The bolt  51  is inserted through the spring washer  67 , the washer  33 , and the hole  34 L of the left hinge  31  and then fastened to the threaded hole at the tonneau cover  29 . 
     The right hinge  30  and left hinge  31  are to be mounted to the truck bed  22 . In case of the mounting of the right hinge  30 , the installer must engage the notch  41  to the threaded shaft  52 . The cover plate  42  is then engaged with the lateral plate  40  by engaging the lower hole  55  to the threaded shaft  52 . The washer  33  and the spring washer  67  are then mounted and fastened by the nut  48 . Once the mounting is completed, the result will be as shown in  FIGS. 7 and 10 . The mounting method of the left hinge  31  is done is the similar way. As can be seen from  FIG. 10 , the upper edge  65  of the right bed liner wall rests on the outer plate  44 . 
     In case the truck bed  22  is not mounted with the bed liner  28 , the mounting steps of the hinge for the tonneau cover  29  and the mounting assembly are similar to the steps as previously described, but the steps related to the bed liner  28  are omitted and, in the mounting steps for the cover plate, the installer must engage the upper holes  56 ,  56 L to the threaded shaft  52 . 
     It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the appended claims.