Patent Publication Number: US-11027603-B1

Title: Latching structure of tonneau cover

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the priority to and benefits of Chinese Patent Application No. 202021773296.8, filed on Aug. 21, 2020, entitled with “Framework for Tonneau Cover,” and Chinese Patent Application No. 202010849997.3, filed on Aug. 21, 2020, entitled with “Framework for Tonneau Cover,” which are incorporated herein by reference in their entireties for all purposes. 
     BACKGROUND OF THE INVENTION 
     Truck cover system are often used to protect cargo beds of pickup trucks. Cover systems often cover all or a portion of the cargo bed such that any items stored and/or hauled in the cargo bed are protected from outside elements, as well as theft. Many conventional cover systems are releasably latched at the tailgate to a side rail of the truck to keep the cover in a tensioned configuration. To facilitate access to the cargo bed, the latching structure of the cover system may be easily released. Conventional cover systembi involves many inadequacies. Improved cover systems are desired. 
     BRIEF SUMMARY OF THE INVENTION 
     A truck cover system is proposed according to some embodiments of the present invention. The truck cover system includes: a rail coupled to a wall of the truck, wherein the rail includes a channel on a top portion of the rail and a latching slot at a side of the rail, wherein the channel extends along a longitudinal direction of the rail and is configured to couple to a cover, and the latching slot extends along the longitudinal direction of the rail. The truck cover system further includes a latching insert inserted in the latching slot, wherein the latching insert includes a first through hole and a positioning hole. The truck cover system includes a latching positioner fastened to the latching insert, wherein the latching positioner includes a second through hole aligned with the first through hole and a positioning pin aligned with the positioning hole. The truck cover system further includes a latching housing releasably latched to the latching positioner. 
     According to some embodiments, the first through hole and the positioning hole are disposed along a longitudinal direction of the latching insert and are spaced apart from each other. 
     According to some embodiments, the first through hole and the positioning hole are disposed along a direction perpendicular to a longitudinal direction of the latching insert and are spaced apart from each other. 
     According to some embodiments, the latching insert comprises a plurality of the first through holes and a plurality of the positioning holes. 
     According to some embodiments, the truck cover system further includes a bolt passing through the first through hole and the second through hole, and a nut engaging with the bolt. 
     According to some embodiments, the positioning hole comprises a through hole. 
     According to some embodiments, the positioning hole comprises a blind hole. 
     According to some embodiments, the positioning hole has a diameter different from that of the first through hole. 
     According to some embodiments, the positioning hole has the same diameter as that of the first through hole. 
     According to some embodiments, wherein the latching slot comprises an upper lip and a lower lip defining an opening therebetween, wherein the bolt passes through the opening. 
     According to some embodiments, the lower lip extends along a vertical direction, and the upper lip slants from the vertical direction. 
     According to some embodiments, the latching positioner comprises a slant engaging surface that engages with the upper lip of the latching slot. 
     According to some embodiments, the latching housing comprises a latching end, and the latching positioner comprises a latching surface at an end of the latching positioner, wherein the latching end engages the latching surface. 
     According to some embodiments, the latching end comprises a finger engaging the latching surface. 
     According to some embodiments, the latching surface comprises a protrusion at a top portion thereof. 
     According to some embodiments, the latching surface comprises a concave surface. 
     According to some embodiments, the latching housing comprises a latching tongue releasably engaged in the latching slot of the rail. 
     According to some embodiments, the latching insert comprises a recess to receive the latching tongue. 
     According to some embodiments, the latching housing comprises a latching pin coupled to the latching tongue through a spring. 
     According to some embodiments, the first through hole comprises a countersink to receive a head of the bolt. 
     Numerous benefits are achieved by way of the present invention over conventional techniques. For example, embodiments of the present invention provide a truck cover system that can improve the releasably latching of the cover in the extended configuration. For some embodiments, the cooperation between the latching housing and the latching positioner may be conveniently adjusted to vary the tension applied to the cover. The latching surface of the latching positioner can prevent the latching housing from slipping off in operation. For some embodiments, the positioning pin can make sure the latching housing and the latching positioner to be readily aligned. These and other embodiments of the invention along with many of its advantages and features are described in more detail in conjunction with the text below and attached figures. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings form a part of the present disclosure, that describe exemplary embodiments of the present invention. The drawings together with the specification will explain the principles of the invention. The following diagrams are merely examples, which should not unduly limit the scope of the claims herein. One of ordinary skill in the art would recognize many other variations, modifications, and alternatives. It is also understood that the examples and embodiments described herein are for illustrative purposes only and that various modifications or changes in light thereof will be suggested to persons skilled in the art and are to be included within the spirit and purview of this process and scope of the appended claims. 
         FIG. 1  is a perspective view of an embodiment of a truck with a cover system according to embodiments of the present invention. 
         FIG. 2  is a partial rear perspective view of a latching system according to embodiments of the present invention. 
         FIG. 3  shows a partially exploded view of a latching system according to embodiments of the present invention. 
         FIG. 4  is a perspective view of the latching positioner according to embodiments of the present invention. 
         FIG. 5  is a partial perspective view of the latching system according to embodiments of the present invention. 
         FIG. 6  is a partial perspective view of the latching system according to embodiments of the present invention. 
         FIG. 7  is a partial rear perspective view of the latching system according to embodiments of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention is directed to truck bed cover systems. 
     One or more specific embodiments of the present invention will be described below. These embodiments are only exemplary of the present invention. Additionally, in an effort to provide a concise description of these exemplary embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers&#39; specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure. 
       FIG. 1  is a perspective view of an embodiment of a truck  10  with a truck cover system  12 . As illustrated, the cover system  12  covers the compartment  14  formed by the truck bed  16  to protect an interior of the truck bed  16  and items that may be stored in the compartment  14 . For example, the cover system  12  may block dirt and precipitation from entering the truck bed  16 . 
     The cover system  12  includes a cover  18  (e.g., flexible cover) that extends over the compartment  14 . The cover  18  may be made out of a variety of materials including fabric, plastic (e.g., vinyl), etc. The cover  18  couples to the truck bed  16  with rails  20  that in turn couple to truck walls  22  (e.g., truck bed walls). To block removal of the cover  18  and/or access to the truck bed  16 , the cover system  12  includes one or more latch systems  24 . For example, the cover system  12  may include two latch systems  24  one at each corner of the truck bed  16  next to the tailgate  26 . In operation, the latch systems  24  couple to the rails  20  to tension/pull the cover  18  into an extended position (e.g., tensioned configuration) that facilitates the flow of precipitation off of the cover system  12  as well as enhancing the aesthetic appearance of the cover system  12 . 
       FIG. 2  is a partial rear perspective view of the latch system  24  according to some embodiments. It should be noted that  FIG. 2  shows rail  20  used as the left rail if viewing in the driving direction of the truck. In some embodiments, the right rail of the cover system is a mirror image of rail  20  shown in  FIG. 2 . As shown in  FIG. 2 , rail  20  extends in a longitudinal direction for a predetermined length. It should be noted that the longitudinal direction may refer to the direction parallel with the longitudinal direction of the truck. In some embodiments, rail  20  may include a channel  210  disposed on the top portion of rail  20 . In some embodiments, channel  210  extends in the longitudinal direction of rail  20 . In some embodiments, channel  210  is inclined outward away from the horizontal direction. In this case, the inner side (adjacent to the compartment  14  of the truck bed  16 ) of the channel  210  is higher than the outer side of channel  210 , which facilitates the falling off of the precipitation on the cover attached to rail  20 . In some embodiments, channel  210  may include retaining members  212  disposed on the opposite sides thereof. In some embodiments, channel  210  is configured to couple to cover  18  (not shown). In some embodiments, a fastening system (e.g., a hook and loop fastening system) may be disposed in channel  210  to secure cover  18  (not shown) in the extended configuration. In this case, a corresponding fastening system may be attached to cover  18  to fasten cover  18  to rail  20 . 
     As shown in  FIG. 2 , rail  20  may include a latching slot  220  also extending in the longitudinal direction of rail  20 . In some embodiments, latching slot  220  may include an upper lip  222  and a lower lip  224 , for example, at the side adjacent to compartment  14 . In some embodiments, upper lip  222  is disposed to incline away from the hollow inner portion of latching slot  220 . For example, upper lip  222  is inclined toward the inner side of the truck bed. In some embodiment, the inclined upper lip  222  may engage a corresponding inclined surface  254  on a latching insert  250  (which is described below in detail) to improve the engagement. In some embodiments, lower lip  224  may extend vertically to improve positioning between rail  20  and latching positioner  250 . It should be noted that the horizontal and/or vertical direction refers to the horizontal and/or direction when the truck is in normal operation. For example, the horizontal direction refers to a direction that is parallel with a driving surface on which the truck is driven, while the vertical direction refers to a direction perpendicular to the driving surface. In some embodiments, latching slot  220  defines an opening  223  between upper lip  222  and lower lip  224 . The dimension of the opening  223  between upper lip  222  and lower lip  224  is reduced compared with the dimension of the cross-section of latching slot  220  due to the opposite extension of upper lip  222  and lower lip  224 , thereby providing a retaining structure for latching positioner  250 . In this case, latching slot  220  can secure latching system  24  in position to tension cover  18  (not shown) in the extended configuration. 
     In some embodiments, latching system  24  may include a latching housing  230 , a latching insert  240  inserted into latching slot  220 , and a latching positioner  250  fastened to latching insert  240  through latching slot  220 . In some embodiments, at least a part of latching insert  240  slides from one end of rail  20  into latching slot  220 . For example, a part of latching insert  240  slides from the rear end of rail  20  adjacent to the tailgate of the truck into latching slot  220 . 
     Latching positioner  250  is fastened to latching insert  240  using fasteners. In some embodiments, latching positioner  250  also provides alignment indicia to facilitate alignment of the latching positioners  250  at the two corners of the truck bed, whereby evenly tensioning cover  18 . In some embodiments, latching positioner  250  also provides adjustment to the position of the end portion of cover  18 , whereby providing different tensioning to cover  18 . The details of the structures of latching positioner  250  and latching insert  240  are described below. 
     As shown in  FIG. 2 , latching positioner  250  may include a latching surface  252  at one end thereof, which receives an end of the latching housing  240  to provide a tensioning effect to cover  18  (not shown). In some embodiments, the upper portion of latching surface  252  may include a small protrusion  259  (shown in  FIG. 4 ) to improve the latching effect with latching housing  230 . Latching positioner  250  may include an inward inclined surface  254  on a side engaging latching slot  220 . For example, the side engaging latching slot  220  may be the outer side distant from the compartment  14  of the truck bed  16  (shown in  FIG. 1 ). The inward inclined surface  254  may engage upper lip  222  of latching slot  220  in the assembled state of the latching system  24 . 
     As shown in  FIG. 2 , latching housing  230  may include a latching tongue  232  driven by a latching pin  233 . In some embodiments, a spring (not shown) is sleeved on the latching pin  233  to provide a driving force to latching pin  233 . It should be noted that  FIG. 2  shows the latching system  24  in the unlatched position, where the latching tongue  232  is driven by the spring to an extended position. Latching tongue  232  may snap into latching slot  220  to retain latching housing  230  in position when tensioning cover  18  (not shown) to the extended configuration to prevent unintentional release of the latching housing  230  from latching positioner  250 . When it is desired to release latching housing  230  from latching positioner  250  in order to store cover  18  in a stowed position, one can drive latching pin  233  to retract latching tongue  232  out of latching slot  220 . 
     As shown in  FIG. 2 , latching housing  230  may include a latching end  234 , which may engage latching surface  252  of latching positioner  250 . For example, latching end  234  may be the front end of latching housing  230 . In some embodiments not shown, latching end  234  may include a finger on the top portion thereof, which may facilitate the latching effect between latching end  234  and latching surface  252 . In some embodiments, the latching effect is further improved when latching end  234  includes the finger, and latching surface  252  includes the protrusion  259  (shown in  FIG. 4 ). 
       FIG. 3  shows a partially exploded view of latching system  24 , illustrating latching positioner  250  and latching insert  240 . As shown in  FIG. 3 , latching insert  240  may include an end plate  242  at one end thereof, and an insert body  244  extending from end plate  242 . For example, end plate  242  may be disposed at the rear end of latching insert  240 , while insert body  244  may extend in the longitudinal direction of rail  20  (shown in  FIG. 2 ). In some embodiments, end plate  242  may cover the end of rail  20  to prevent debris or other foreign materials from entering into latching slot  220  of rail  20 . In some embodiments, latching insert  240  may be formed as a one-piece structure to improve its strength. In some other embodiments, end plate  242  and insert body  244  may be formed separately. Then end plate  242  and insert body  244  may be coupled together using adhesive or glue. In some embodiments, endplate  242  and insert body  244  may also be coupled together using welding or soldering processes. In some embodiments, additional components may be disposed on end plate  242  to provide additional functions. For example, a reinforcing stub  241  may extend from end plate  242 , which may slide into a corresponding slot disposed in rail  20  to provide additional structural reinforcement. In some embodiments, the cross-section of insert body  244  may conform with the cross-section of latching slot  220  (shown in  FIG. 2 ) and can fit in the latching slot  220 . Insert body  244  may include an engaging surface  245  that may engage upper lip  222  and lower lip  224  of latching slot  220  when insert body  244  slides into latching slot  220 . 
     As shown in  FIG. 3 , a through hole  246  is disposed in insert body  244  that is opened from engaging surface  245 . In some embodiments, through hole  246  may extend horizontally in a crosswise direction when latching system  24  is in operation. In some embodiments, a positioning hole  247  is disposed in insert body  244 . In some embodiments, positioning hole  247  is disposed side by side with through hole  246  along the longitudinal direction of latching insert  240 , that is along the longitudinal direction of rail  20 , and spaced apart from each other. In some embodiments not shown, positioning hole  247  may be disposed side by side with through hole  246  along a direction perpendicular with the longitudinal direction of latching insert  240  and are spaced apart from each other. It should be noted that the relative position between through hole  246  and positioning hole  247  may vary as appropriate according to particular applications, and it should not be limited to the positions as shown in  FIG. 3 . 
     In some embodiments, positioning hole  247  may be designed as a through hole. In some other embodiments, positioning hole  247  may be designed as a blind hole opened from engaging surface  245 . In some embodiments, positioning hole  247  may have a diameter different from that of through hole  246 . In some other embodiments, positioning hole  247  may have the same diameter as that of through hole  246 . In some embodiments, the distance of through hole  246  from end plate  242  may be designed according to the particular applications. In some embodiments not shown, insert body  244  may include a plurality of through holes  246  spaced apart from each other along the longitudinal direction of latching insert  240 . In such case, insert body  244  provide different positioning for latching positioner  250  along the longitudinal direction of rail  20 . In some embodiments not shown that includes a plurality of through holes  246 , one through hole  246  may be used as the positioning hole for the adjacent through hole  246 , provided the distance between through holes  246  remain the same. In some embodiments not shown that includes a plurality of through holes  246 , insert body  244  may also include a plurality of positioning holes  247 . In such case, each through hole  246  may have its own positioning hole  247 . In such case, a pair of through hole  246  and positioning hole  247  may be disposed side by side along the direction perpendicular to the longitudinal direction of latching insert  240 . In such case, the distance between adjacent through holes  246  may not be designed evenly, rather varies as appropriate according to particular applications. 
     As shown in  FIG. 3 , insert body  244  may include a recess  243  opened from surface  245 . In some embodiments, recess  243  may receive latching tongue  232  of latching housing  230  (shown in  FIG. 2 ) when latching housing  230  engages latching positioner  250 . 
     As shown in  FIG. 3 , latching positioner  250  may include a through hole  256  extending in the same direction as through hole  246  in insert body  244 . For example, through hole  256  is aligned with through hole  246 . A bolt  260  may pass through hole  256  and through hole  246  and engage with a nut  262  to fasten the latching positioner  250  with insert body  244  when insert body  244  slides into latching slot  220  of rail  20 . In this case, bolt  260  also passes through the opening  233  defined in latching slot  220 , with upper lip  222  and lower lip  224  interposed between latching positioner  250  and latching insert  240 . In some embodiments, through hole  256  may include a countersink hole. In such case, the head of bolt  260  may remain level with a side surface  251  of latching positioner  250  that is adjacent to the compartment  14  of the truck bed  16 . The cooperation between bolt  260  and nut  262  may provide the desired latching effect between latching positioner  250  and rail  20  while avoiding excessive fastening pressure applied to rail  20  that causes deformation thereof. 
     In some embodiments, insert body  244  may include a notch  248  on a side surface  249  opposite side surface  245 . Notch  248  can receive nut  262 . In some embodiments, latching positioner  250  may include a positioning pin  257  extending from a side surface  253  opposite side surface  251 . In some embodiments, positioning pin  275  is aligned with positioning hole  247  in insert body  244 . Positioning pin  257  may insert into positioning hole  247  in insert body  244  when latching positioner  250  engages with insert body  244 . In some embodiments, positioning pin  257  may improve the positioning between latching positioner  250  and rail  20 . 
       FIG. 4  is a perspective view of latching positioner  250  according to some embodiments. As shown in  FIG. 4 , latching positioner  250  may include a latching surface  252 , which is structured as a concave surface. In some embodiments, latching positioner  250  may include a side plate  255  extending along side surface  251 . In some embodiments, side plate  255  is disposed at an inner side of latching positioner  250 , which is adjacent to compartment  14  when latching positioner  250  is assembled with rail  20  (shown in  FIG. 2 ). Side plate  255  may stop latching end  234  (shown in  FIG. 2 ) of latching housing  230  (shown in  FIG. 2 ) from falling laterally out of engagement with latching surface  252 . In some embodiments, latching positioner  250  may include protrusion  259  disposed at the upper portion of latching surface  252 . In some embodiments, protrusion  259  may have a thickness of 3 mm at the end thereof. Protrusion  259  may stop latching end  234  of latching housing  230  from disengaging upwardly from latching surface  252  in order to improve latching effect with latching housing  230 . In some embodiments, latching positioner  250  may include a ramp surface  258  extending slantly downward from latching surface  252 . Ramp surface  258  may facilitate retaining the engagement between latching end  234  of latching housing  230  and latching surface  252  of latching positioner  250  by preventing latching end  234  from moving downwardly. 
       FIG. 5  is a partial perspective view of latching system  24 , illustrating latching housing  230  and latching positioner  250  in the latched position. For clarification of illustration, latching insert  240  is omitted from  FIG. 5 . As shown in  FIG. 5 , latching end  234  of latching housing  230  engages latching surface  252  of latching positioner  250 . In some embodiments, latching end  234  may have a thickness of 8 mm to provide sufficient stiffness for latching end  234 . In some embodiments, latching end  234  may have a round contour to facilitate latching end  334  sliding over protrusion  259  of latching positioner  250  and get into engagement with latching surface  252  of latching positioner  250 . As shown in  FIG. 5 , latching housing  230  may include latching tongue  232  driven by latching pin  233  (shown in  FIG. 2 ). In some embodiments, latching housing  230  may include an opening  235  disposed at a side from which latching tongue  232  may pass through and extend out of latching housing  230 . In some embodiments, the upper surface  237  of latching tongue  232  is a planer surface, and the lower surface  236  of latching tongue  232  is a ramp that inclines downwardly from the upper surface  237 . The ramp facilitates the snapping of latching tongue  232  into engagement with latching slot  220  (shown in  FIG. 2 ), while the planer surface of upper surface  237  may prevent latching tongue  232  from accidentally disengaging from latching slot  220 . In some embodiments, lower surface  236  may include a round contour. 
       FIG. 6  is a partial perspective view of latching system  24 , illustrating latching housing  230 . As shown in  FIG. 6 , latching system  24  may include an end rail  30  in some embodiments. In some embodiments, a latching housing  230  may be disposed at each end of end rail  30 . In some embodiments, latching housing  230  may include a cord  238  attached to latching pin  233 . When it is desired to release latching housing  230  from latching positioner  250  in order to store cover  18  in a stowed position, one can drive latching pin  233  by drawing cord  238  to retract latching tongue  232  out of latching slot  220 . In some embodiments, end rail  30  may include an anchor structure  302  to which cord  238  is attached. In some embodiments, latching housing  230  may include a plurality of cords  238  disposed between the two latching housings  230  at both ends of end rail  30 . End rail  30  may include a plurality of anchor structures  302  to anchor the plurality of cords  238 . When it is desired to release latching tongue  232 , one may draw any section of cords  238  away from end rail  30  in a direction substantially perpendicular to the longitudinal direction of end rail  30 . 
       FIG. 7  is a partial rear perspective view of latching system  24 , illustrating latching housing  230  and latching positioner  250  in the latched position. As shown in  FIG. 7 , latching end  234  of latching housing  230  engages latching surface  252  of latching positioner  250 . In some embodiments, latching surface  252  of latching positioner  250  may be structured as a planer surface. Thanks to the latching tongue  232  (shown in  FIG. 6 ) snaping into latching slot  220  (shown in  FIG. 2 ), latching end  234  of latching housing  230  could not disengage unintentionally from latching surface  252  of latching positioner  250 . 
     While the above is a full description of the specific embodiments, various modifications, alternative constructions and equivalents may be used. Therefore, the above description and illustrations should not be taken as limiting the scope of the present disclosure which is defined by the appended claims.