Patent Publication Number: US-10759261-B2

Title: Truck cargo box tonneau cover system including a side-locking lock bar locking multiple slats

Description:
FIELD 
     The present disclosure relates to truck cargo box tonneau cover systems including side locking or latching mechanisms. 
     BACKGROUND 
     This section provides background information related to the present disclosure which is not necessarily prior art. 
     Trucks such as pickups having an open top cargo box can be a quite popular type of vehicle because the cargo box enables objects of various sizes to be placed therein and transported. Tonneau cover systems can be used to cover the top of cargo box in a closed or extended configuration to protect the contents against dirt, debris, and other environmental contaminants, and to improve the aesthetic quality thereof. 
     In some cases, the tonneau covers can be formed of a plurality of rectangular elements in the form of slats that are hingedly coupled together so they can be rolled-up into a tubular compact, storage, open or retracted storage configuration at the front of the cargo box to allow access to the cargo box. In some cases, the tonneau covers can be formed of a plurality of rectangular elements in the form of sections that are hingedly coupled together so they can be folded-up into a stacked compact, storage, open or retracted storage configuration at the front of the cargo box. 
     Although a forward rectangular element or header and a rear rectangular element or header are typically coupled to the sides of the cargo box in the closed or extended configuration, additional protection against unauthorized access could potentially be provided by latching or locking the sides of the rectangular elements between the forward and rear headers to the side rails. One potential solution could involve providing movable latching components on each of the plurality of rectangular elements that engage the side rail. Disadvantages of such a solution can include significant additional parts, that increase assembly and manufacturing costs, and added complexity in locking and unlocking such a large number of latches. 
     Another potential solution could involve providing a single long movable latching component on each side rail that rotates between a locked position in which the latching component engages the rectangular elements and an unlocked position in which the latching component is rotated away from the rectangular elements. Disadvantages of such a solution can include the lack of a positive stop along the longitudinal length of the latching component to resist upward movement of the tonneau cover. 
     SUMMARY 
     This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features. 
     In accordance with one aspect of the present disclosure, a tonneau cover system is provided for a truck cargo box including a forward end and a rear end tailgate, and left and right side walls extending therebetween. Such a tonneau cover system can include left and right side rails supportable along the left and right side walls, respectively, of the cargo box. A lock bar can be slidably supported by each side rail. Each lock bar can extend longitudinally along a length of the side rail and can be laterally slidable between an unlocked position in which the lock bar is laterally recessed relative to the side rail, and a locked position in which the lock bar is laterally extended relative to the side rail. Each lock bar can define a lock bar plane. A tonneau cover can include a plurality of rectangular elements supportable on the left and right side rails and being hingedly coupled together and moveable between an open cover position in which the rectangular elements are in a longitudinally retracted storage configuration to allow access to the cargo box, and a closed cover position in which the rectangular elements are in a longitudinally extended configuration to cover the cargo box, and in which the plurality of rectangular elements define a tonneau cover plane. Each of the rectangular elements can include a locking surface. The lock bar can be engageable with, and movable by, the tailgate to slide the lock bar from the unlocked position to the locked position as the tailgate moves from an open tailgate position to a closed tailgate position. Movement of the lock bar between the locked position and the unlocked position can simultaneously interengage and disengage, respectively, with each of the locking surfaces of the plurality of rectangular elements. This interengagement can limit upward movement of the rectangular elements. In both the locked and unlocked positions of the lock bar, the lock bar plane can be substantially parallel to the tonneau cover plane. 
     In accordance with another aspect of the present disclosure, a tonneau cover system is provided for a truck cargo box including a forward end and a rear end tailgate, and left and right side walls extending therebetween. Such a tonneau cover system can include left and right side rails supportable along the left and right side walls, respectively, of the cargo box. Each side rail can include a lower inner longitudinal surface and a upper outer longitudinal surface along a length of the side rail. A lock bar can be slidably supportable by each side rail with each lock bar having a corresponding lock bar length extending longitudinally along the length of the side rail. The lock bar can be laterally slidable between an unlocked position in which the lock bar is laterally recessed relative to the side rail, and a locked position in which the lock bar is laterally extended relative to the side rail. Each lock bar can include an upper inner longitudinal margin and a lower outer longitudinal margin along the corresponding lock bar length. A tonneau cover can include a plurality of rectangular elements supportable on the left and right side rails. The plurality of rectangular elements can be hingedly coupled together and moveable between an open cover position in which the rectangular elements are in a longitudinally retracted storage configuration to allow access to the cargo box, and a closed cover position in which the rectangular elements are in a longitudinally extended configuration to cover the cargo box and in which the plurality of rectangular elements extend along the length of the side rail and the corresponding lock bar length. Each of the rectangular elements can include a locking surface. The lock bar can be engageable with, and movable by, the tailgate to slide the lock bar from the unlocked position to the locked position as the tailgate moves from an open tailgate position to a closed tailgate position. Movement of the lock bar between the locked position and the unlocked position simultaneously interengages and disengages, respectively, with each of the locking surfaces of the plurality of rectangular elements. This interengagement can limit upward movement of the plurality of rectangular elements. When the tonneau cover is in the closed cover position and the lock bar is in the locked position, upward movement of any of the plurality of rectangular elements and rotation of the lock bar about a longitudinal lock bar axis is limited by engagement of the upper inner longitudinal margin of the lock bar against the lower inner longitudinal surface of the side rail and engagement of the lower outer longitudinal margin of the lock bar against the upper outer longitudinal surface of the side rail. 
     Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 
    
    
     
       DRAWINGS 
       The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure. 
         FIG. 1  is a perspective view of one exemplary truck cargo box tonneau cover system in accordance with the present disclosure with the tonneau cover in a longitudinally extended or closed cover position. 
         FIG. 2  is a perspective view of the truck cargo box tonneau cover system of  FIG. 1  with the tonneau cover in an intermediate position. 
         FIG. 3  is a perspective view of the truck cargo box tonneau cover system of  FIG. 1  with the tonneau cover in a longitudinally retracted or open cover position. 
         FIG. 4  is a partial longitudinal cross-section of certain components of the tonneau cover system of  FIG. 1 . 
         FIG. 5  is a partial perspective view of the tonneau cover system of  FIG. 1 . 
         FIG. 6  is an exploded view of certain components of the tonneau cover system of  FIG. 1 . 
         FIG. 7  is a partial perspective view of the tonneau cover system of  FIG. 1  with the tonneau cover in its longitudinally extended or closed cover position, and the lock bar in its laterally extended or locked position and the lock bar correspondingly extending a first distance past the rear end of the side rail. 
         FIG. 8  is a rear plan view of the tonneau cover system of  FIG. 1  with the tonneau cover in its longitudinally extended or closed cover position, and the lock bar (minus the actuator component) in its laterally extended or locked position. 
         FIG. 9  is a partial perspective view similar to  FIG. 7 , but with the lock bar in its laterally retracted or unlocked position and the lock bar correspondingly extending a second distance past the rear end of the side rail that is greater than the first distance. 
         FIG. 10  is a partial perspective view similar to  FIG. 8  with the tonneau cover in its longitudinally extended or closed cover position, but with the lock bar (minus the actuator component) in its laterally retracted or unlocked position. 
         FIG. 11  is a simplified partial perspective view of another exemplary truck cargo box tonneau cover system in accordance with the present disclosure. 
         FIG. 12  is a partial rear plan view of the tonneau cover system of  FIG. 11  with the tonneau cover in its longitudinally extended or closed cover position, and the lock bar (minus its actuator component) in its laterally extended or locked position. 
         FIG. 13  is a partial perspective view similar to  FIG. 12  with the tonneau cover in its longitudinally extended or closed cover position, but with the lock bar (minus the actuator component) in its laterally retracted or unlocked position. 
     
    
    
     Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings. 
     DETAILED DESCRIPTION 
     Example embodiments will now be described more fully with reference to the accompanying drawings. 
       FIGS. 1-10  illustrate one exemplary tonneau cover system  20  for a truck cargo box  22  in accordance with the present disclosure. The truck cargo box  22  typically includes a forward end  24  and a rear end  26 , and left and right side walls  28 , extending between the forward and rear ends,  24  and  26 , respectively. The forward end  24  can include a front wall  30  and the rear end  26  can include a tailgate  32 . The tonneau cover system  20  can generally include side rails  34  slidably supporting lock bars  36 , and a tonneau cover  38  including a plurality of rectangular elements  40  hingedly coupled together. 
     The tonneau cover system  20  can include left and right side rails  34  that are supportable along the left and right side walls  28 , respectively. A lock bar  36  can be slidably supported by each side rail  34 . Each lock bar  36  can extend longitudinally along a length of the side rail  34  supporting it. Each lock bar  36  can be slidable relative to the side rail  34  between an unlocked position (e.g.,  FIGS. 9 and 10 ) in which the lock bar  36  is laterally recessed relative to the side rail  30  and a locked position (e.g.,  FIGS. 7 and 8 ) in which the lock bar  36  is laterally extended relative to the side rail  30 . 
     Each lock bar  36  can define a lock bar plane. Each lock bar  36  can have a rectangular lateral or transverse cross-section (e.g.,  FIGS. 8 and 10 ), and an upper surface  44  of the lock bar  36  can define the lock bar plane. Each lock bar  36  can be mounted in a channel  46  of the respective side rail  34 , and can be slidable in the channel  46  laterally outwardly so the lock bar  36  becomes more recessed relative to the channel  46  and the respective side rail  34  and side wall  28 , and can be slidable in the channel  46  laterally inwardly so the lock bar  36  becomes more extended relative to the channel  46  and respective side rail  34  and side wall  28 . Thus, laterally inwardly or inner, and laterally outwardly or outer, in this context corresponds to movement or position toward and away from, respectively, the longitudinal center line of the truck  21 , cargo box  22 , and tonneau cover  38 . 
     Each side rail  34  can include a lower inner longitudinal or longitudinally extending surface  48  and a upper outer longitudinal or longitudinally extending surface  50  along a longitudinal length of the side rail  34 . Each lock bar  36  can include an upper inner longitudinal or longitudinally extending margin  52  and a lower outer longitudinal or longitudinally extending margin  54  along the corresponding longitudinal lock bar length. The upper inner margin  52  can be on the upper surface  44  of the lock bar  36 , and the lower outer margin  54  can be on the lower surface of the lock bar  36  opposite the upper surface  44 . As examples, the longitudinal length of the side rail  34  and the corresponding lock bar length can both be defined by the overall longitudinal length of the lock bar  36 , or can be defined by the overall length of the side rail  34 , or a length less than the overall length of the side rail  34  or of the lock bar  36 . The overall length of the lock bar  36 , however, is typically less than the overall length of the side rail  34  to avoid the tonneau cover  38  on the side rails  34  in the open position and the lock bar  36  interfering with each other. 
     The tonneau cover system  20  can include a tonneau cover  38  with a plurality of rectangular elements  40  supportable on the left and right side rails  28 . The rectangular elements  40  can be pivotably or hingedly coupled together so they are moveable between an open cover position ( FIG. 3 ) in which the rectangular elements  40  are in a longitudinally retracted storage configuration to allow access to the cargo box  22 , and a closed cover position ( FIG. 1 ) in which the rectangular elements  40  are in a longitudinally extended configuration to cover the cargo box  22 . In the closed cover position, the plurality of rectangular elements  40  can define a tonneau cover plane. For example, the upper surfaces of the rectangular elements  40  or of the cover material  62  in the closed cover position can define the tonneau cover plane. 
     As in the illustrated embodiment, the tonneau cover  38  can be a roll-up tonneau cover in which the rectangular elements are slats  40  and the tonneau cover  38  can be rolled up upon and can extend above the side rails  34  in the open cover position. The tonneau cover  38  can, e.g., alternatively be a fold-up tonneau cover in which the rectangular elements  40  are panels that can be folded together upon and can extend above the side rails  34  in the open cover position. 
     The rectangular elements  40  of the tonneau cover  38  can be pivotably or hingedly coupled together via hinge members  56 . As in the illustrated embodiment, each hinge member  56  can include intermediate components  57  separate from the rectangular elements  40 . The intermediate component  57  can be elastomeric or flexible and can include coupling projections  58  extending along opposite sides. The coupling projections  58  can be captured in cooperating coupling channels  60  extending along opposing sides of the adjacent rectangular elements  40 . In other embodiments, the hinge members  56  can include integral cooperating coupling channels or elements that directly hingedly couple with each other. These integral coupling elements can, for example, be extruded together with frame members or the main body  68  of the rectangular elements  40  and can extend along opposite sides of adjacent rectangular elements  40  that directly couple with each other. 
     The tonneau cover  38  can include a cover material  62  extending continuously over the plurality of rectangular slats  40 , for example, to help prevent moisture from penetrating the tonneau cover  38  and leaking into the cargo box  22 . The tonneau cover  38  can also include a seal member  63  extending along the lateral sides of the tonneau cover  38  to help prevent moisture from penetrating between the tonneau cover  38  and the side rails  34  and into the cargo box  22 . 
     Each of the rectangular elements  40  can include a locking surface  42 . As in this illustrated embodiment, each rectangular element  40  can include a main body  68  and an end cap  64 , and the end cap  64  of each slat  40  can form the locking surface  42 . For example, a recess  66  of the end cap  64  can form the locking surface  42 . In other embodiments, the locking surface  42  can be provided by another portion of the end cap  64 , such as an upper surface thereof, or by the main body  68 , or by another component (not shown) that is coupled to the main body  68  of the rectangular element  40 . As used herein, each of the plurality of rectangular elements  40  can be all of the plurality of rectangular elements  40  that make up the tonneau cover  38 , or some subset thereof. For example, each of the rectangular elements can be a subset of rectangular elements that are coupled in immediate succession with each other, or a subset of rectangular elements coupled together with intervening rectangular elements of the tonneau cover therebetween (e.g., alternating rectangular elements  40  of the tonneau cover  38 ), or any combination of the above subsets. 
     The lock bar  36  can include a lock bar main body  102  and a separate actuator component  72  coupled to the main body  102  of the lock bar  36 . For example, the actuator component  72  can be a simple bumper or extension that is rigidly coupled to a rear end of the main body  102  and positioned to engage the tailgate as the tailgate moves from an open position to a closed position. Alternatively, the actuator component  72  can be movably coupled to the lock bar main body  102 . In the retracted or unlocked position, the lock bar  36  can extend a first distance rearward of the rear end  104  of the side rail  34 . In the extended or locked position, the lock bar  36  can extend a second distance rearward of the rear end  104  of the side rail  34  that is less than the first distance. 
     Each lock bar  36  can have a rear end  74  that is engageable with, and movable by, the tailgate  32  as the tailgate  32  moves from the open tailgate position to the closed tailgate position. As the tailgate  32  moves to the closed tailgate position, the tailgate  32  engages and moves the actuator component  72  of the rear end  74  of the lock bar  36  to engage and slide the lock bar  36  from the retracted or unlocked position to the extended or locked position. Movement of the lock bar  36  between the locked position and the unlocked position can simultaneously interengage and disengage, respectively, the lock bar  36  with the locking surfaces  42  of each of the plurality of rectangular elements  40  of the tonneau cover  38 . This interengagement limits upward movement of the rectangular elements  40 . 
     When the tonneau cover  38  is in the closed cover position ( FIG. 1 ) and the lock bar  36  is in the locked position (e.g.,  FIGS. 7 and 8 ), upward movement of any one of the plurality of rectangular elements  40  and rotation of the lock bar  36  about its longitudinal axis can both be limited by engagement of the upper inner longitudinal margin  52  of the lock bar  36  against the lower inner longitudinal surface  48  of the side rail  34  and engagement of the lower outer longitudinal margin  54  of the lock bar  36  against the upper outer longitudinal surface  50  of the side rail to  34 . In both the locked and unlocked positions of the lock bar, the lock bar plane can be substantially parallel to the tonneau cover plane (in the extended or closed cover position). A slight gap can be provided, e.g., between the upper inner longitudinal margin  52  of the lock bar  36  and the lower inner longitudinal surface  48  of the side rail  34 , to account for manufacturing tolerances, or to facilitate sliding action, or both. 
     This engagement of the upper inner longitudinal margin  52  of the lock bar  36  against the lower inner longitudinal surface  48  of the side rail  34 , or of the lower outer longitudinal margin  54  of the lock bar  36  against the upper outer longitudinal surface  50  of the side rail to  34 , or of both, can occur simultaneously along the length of the side rail  34  and the corresponding lock bar length. Separately, the engagement of the upper inner longitudinal margin  52  of the lock bar  36  against the lower inner longitudinal surface  48  of the side rail  34 , or of the lower outer longitudinal margin  54  of the lock bar  36  against the upper outer longitudinal surface  50  of the side rail to  34 , or of both, can occur continuously along the length of the side rail  34  and the corresponding lock bar length. The corresponding lock bar length can be the overall length of the lock bar  36 , or a portion thereof. 
     The tonneau cover  38  can include a front header  88  and a rear header  90 . The front header  88  and the rear header  90  can be coupled to the plurality of rectangular elements  40  at the forward end and a rearward end, respectively, of the tonneau cover  38 . The front header  88  can be coupled to the side rails  34 , side walls  28 , or both, in both the open and closed cover positions. A slam latch  92  can be coupled to each lateral side of the rear header  90  of the tonneau cover  38  to selectively latch the rear header  90  to the side rails  34 . An actuator  94 , such as the illustrated cable, can extend between the slam latches  92  and can enable operation of both slam latches  92  via a single action, such as pulling on the actuator cable  94 . Such slam latches  92 , for example, can sufficiently couple the rear header  90  to the side rails  34  to permit the truck  21  to be driven with the tonneau cover  38  in the closed position and the tailgate  32  down or open. 
     Each lock bar  36  can include a plurality of angled recesses or slots  96  and each side rail  34  can include a plurality of pins  98 . For example, the pins can be mounted in recesses or apertures  97  in the side rail  34  engaging the angled slots  96  to guide the lock bar  36  between its locked and unlocked positions. The slots  96  can be angled so that longitudinal movement of the lock bar  36  in a forward direction or toward the forward end  24  of the cargo box  22  and of the tonneau cover  38  moves the lock bar  36  laterally inwardly relative to the side rail  34  and toward the unlocked position. Similarly, the slots  96  can be angled so that longitudinal movement of the lock bar  36  in a rearward direction or toward the rear end  26  of the cargo box  22  and the tonneau cover  38  moves the lock bar  36  laterally outward relative to the side rail  34  and toward the locked position. 
     A lock bar biasing member  100  can bias the rear end  78  of the lock bar  36  longitudinally in a rearward direction or toward the rear end  24  of the cargo box  22  and of the tonneau cover  38  and toward the recessed or unlocked position of the lock bar  36 . Such a lock bar biasing member  100  can also bias the rear end  74  of the lock bar  36  toward the tailgate  32 . 
     In an alternative embodiment, the actuator component  72  can be movable along the longitudinal axis of the lock bar  36  relative to the lock bar main body  102 . An actuator biasing member (not shown) between the lock bar main body  102  and the actuator component  72  can bias these components  102 ,  72  away from each other along the longitudinal axis of the lock bar  36 . This actuator biasing member can exert a biasing force that is greater than the biasing force of the lock bar biasing member  100 . Thus, the actuator component  72  can move without moving the lock bar main body  102  in cases where the tailgate  32  is closed, for example, while the tonneau cover  38  is in an intermediate position, which might otherwise damage the tonneau cover  38  or locking system. As examples, the biasing member can include a spring or an elastic compound. 
     A pin (not shown) can be provided at a distal end of a spring arm (not shown) extending rearwardly from the lock bar main body  102 . As the rear end of the lock bar main body  102  enters the channel  46  of the side rail  34 , the side rail  34  can push the spring arm down, causing the pin to engage a cooperating recess (not shown) in the actuator component  72  and prevent further longitudinal movement of the components relative to each other. Thus, an intruder would not be able to move the lock bar main body  102  of the lock bar  36  from its locked position without opening the tailgate  32 . 
       FIGS. 11-13  illustrate another exemplary tonneau cover system  20  for a truck cargo box  22  in accordance with the present disclosure. To avoid unnecessary duplication, some common features are not illustrated and repeated below. Instead, the discussion below about this embodiment focuses primarily on differences between this embodiment and the other embodiments and alternatives hereof. Accordingly, the same reference numerals are used for all embodiments to indicate like elements, even if the elements are not identical, and the entirety of the discussion of the other embodiments and alternatives herein, is likewise applicable to this embodiment unless it is irreconcilable with the description of this embodiment below. 
     Similar to the prior embodiments, each lock bar  36  can be supported in a channel  46  of the side rail  34 . Pins  98  of the side rails  34  can extend into angled recesses or slots  96  of the lock bar  36  to guide the lock bar  36  between the locked position ( FIG. 12 ) and the unlocked position ( FIGS. 11 and 13 ). 
     The rectangular elements  40  can include a locking surface  42 . The locking surface  42  can be an upper locking surface of the end caps  64  of the rectangular elements  40 . Each lock bar  36  can include a lower inner longitudinally extending cooperating locking surface  106  that engages the locking surfaces  42  of the rectangular elements  40  in the locked position. 
     The lock bar  36  can include one or more longitudinally extending sealing members  108  that can engage upper sealing surfaces  110  of the rectangular elements  40 . As in this example, the upper sealing surfaces  110  can be provided by the main body  68  of the rectangular elements  40 . As other examples, the sealing surfaces  110  can be provided by a continuously extending cover material  62 , or by the end caps  64 . 
     U.S. patent application Ser. No. 15/642,593, filed on Jul. 6, 2017, entitled “Tonneau Cover System with Intermediate Automatic Latching,” and naming Chad Carter, et al. as inventors; and U.S. patent application Ser. No. 16/213,058, filed on Dec. 7, 2018, entitled “Truck Cargo Box Tonneau Cover System Including a Side-Locking Lock Bar Locking Multiple Slats,” and naming Michael Spencer as inventor; are both incorporated herein by reference in their entirety. 
     Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. Similarly, the features, or combinations of features, or alternatives thereto, of one embodiment can be combined with features or combinations of features, or alternatives thereto, of other embodiments. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. 
     Although the terms first, second, third, etc., may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments. 
     The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.