Abstract:
An active bed cover system having at least one deployable panel and at least one actuator. The deployable panel extends and retracts based on vehicle requirements and provides reduction in vehicle drag, thereby reducing emissions and improving fuel economy. Additionally, it allows for the system to retract within the tailgate and/or cargo bed liner allowing for access to the bed and improved usability and aesthetics. The active bed cover provides a fully deployable system with object detection, declutching of the actuator to help prevent damage, and communication with the vehicle to determine proper deployment and function.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a PCT International Application and claims benefit of U.S. Provisional Patent Application No. 61/968,438 filed Mar. 21, 2014. The disclosure of the above application is incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to an active bed cover assembly integrated into a tailgate system and/or cargo bed area for automotive applications. 
       BACKGROUND OF THE INVENTION 
       [0003]    There has been increasing desire to manufacture vehicles that meet or exceed environmental improvement requirements. However, there is a considerable loss of aerodynamic efficiency in vehicles, in particular, pickup trucks and other vehicles having a storage bed, due to the airflow into the bed and over the tailgate. 
         [0004]    Therefore, having parts with improved aerodynamics has become a well-received option typically effective toward helping to advance standards such as mileage requirements. There are also several other factors that must be considered including aerodynamic load, part weight, cost, complexity and durability. 
         [0005]    Typical systems, such as fixed panels, or motorized deployable panels, do not meet requirements. Known systems do not have a proper sealed and clutchable actuator with communication capability and life cycle durability, object detection, are not transparent to the vehicle when the tailgate is down, and are not durable and aerodynamically effective. Conventional systems also have the potential to break or be damaged due to sliding objects in the pickup cargo bed. Typical systems also do not have the ability to detect objects in the event there is cargo/objects in the way during deployment. 
         [0006]    Accordingly, there remains a need in the art to provide an automatically deployable structure under predetermined conditions that provides improved aerodynamics. 
       SUMMARY OF THE INVENTION 
       [0007]    The present invention is directed to an active bed cover assembly having at least one deployable panel that moves between at least a stowed position and a deployed position driven by at least one actuator, such as a sealed, clutchable actuator that has communication capability with the vehicle. The deployable panel improves aerodynamics and is part of a tailgate system/module and/or cargo bed lining that allows for a smooth, functional surface when the tailgate is down and does not limit access to the pickup bed or the available footprint. The assembly does not require manual deployment and is only utilized when necessary; at predetermined vehicle speeds under predetermined conditions with no bed cargo interference. 
         [0008]    When the deployable panel is in an extended or deployed position, the deployable panel improves airflow under predetermined conditions, e.g., vehicle speeds in the range of at least 30 miles per hour. When the deployable panel is in a retracted or stowed position, the deployable panel generally folds or otherwise moves out of the way within the tailgate and/or bed liner of the vehicle to improve pickup cargo bed clearance when the tailgate is down and prevent damage due to sliding objects in the pickup bed when the tailgate is up or down. The active bed cover assembly provides a fully deployable system with object detection, declutching to help prevent damage, e.g., to protect the deployable panel under higher predetermined loads, is flush when stowed for bed access and usability, has communication with the vehicle to determine proper deployment and function, and is suitable to meet automotive specifications and functionality. 
         [0009]    Utilization of the bed cover system that deploys and retracts based on vehicle requirements provides valuable reduction in vehicle drag, thereby reducing emissions and improving fuel economy. Additionally, it allows for the system to retract into the tailgate system/module/frame/bed liner so the vehicle can still meet cargo bed requirements and reduce or eliminate potential for damage due to sliding objects in the pickup bed. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein: 
           [0011]      FIG. 1  is a perspective view of a vehicle with a tailgate assembly in a closed position; 
           [0012]      FIG. 2  is a perspective view of the vehicle tailgate assembly incorporated with an active bed cover assembly shown in a deployed position, in accordance with one embodiment of the present invention; 
           [0013]      FIG. 3  is a perspective view of the vehicle tailgate assembly of  FIG. 2  in an open position and the active bed cover assembly in a stowed position; 
           [0014]      FIG. 4  is a perspective view of the vehicle tailgate assembly incorporated with an active bed cover assembly shown in a deployed position, in accordance with another embodiment of the present invention; 
           [0015]      FIG. 5  is a perspective view of the vehicle tailgate assembly incorporated with an active bed cover assembly shown in a deployed position, in accordance with yet another embodiment of the present invention; 
           [0016]      FIG. 6  is a top plan view of the vehicle tailgate assembly incorporated with the active bed cover assembly of  FIG. 5  in the deployed position; 
           [0017]      FIG. 7  is an exploded view of an exemplary actuator with internal clutching for deploying/stowing the active bed cover assembly, in accordance with the present invention; 
           [0018]      FIG. 8  is a perspective view of the actuator of  FIG. 7  without the housing for clarity; 
           [0019]      FIG. 9  is a perspective view of a tailgate assembly with an active bed cover assembly including an integrated slide out panel shown in a deployed position, in accordance with a fourth embodiment of the present invention; 
           [0020]      FIG. 10A  is a front perspective view of a tailgate assembly with an active bed cover assembly including a rollable panel shown in a deployed position, in accordance with a fifth embodiment of the present invention; 
           [0021]      FIG. 10B  is a broken-away side view schematic of the assembly of  FIG. 10A  illustrating stages of deployment of the rollable panel from a stowed position to the deployed position; 
           [0022]      FIG. 11  is a perspective view of a vehicle with an active bed cover assembly including integrated side flip out panels shown in a partially deployed position, in accordance with a sixth embodiment of the present invention; 
           [0023]      FIG. 12A  is a perspective view of a vehicle with an active bed cover assembly including integrated side flip out panels shown in a deployed position, in accordance with a seventh embodiment of the present invention; 
           [0024]      FIG. 12B  is a rear elevation schematic of the assembly of  FIG. 12A  illustrating stages of deployment of the side flip out panels from a stowed position to the deployed position; 
           [0025]      FIG. 13A  is a perspective view of a tailgate assembly with an active bed cover assembly including an integrated folding panel shown in a deployed position, in accordance with an eighth embodiment of the present invention; 
           [0026]      FIG. 13B  is a broken-away side view of the cover assembly of  FIG. 13A  illustrating the folding panel in a stowed position; 
           [0027]      FIG. 13C  is a broken-away side view of the assembly of  FIG. 13A  illustrating pivotal movement of the folding panel from a stowed position toward the deployed position; 
           [0028]      FIG. 13D  is a broken-away side view of the assembly of  FIG. 13A  illustrating the folding panel in the deployed position; 
           [0029]      FIG. 14A  is a perspective view of a tailgate assembly with an active bed cover assembly including an integrated stacking panel shown in a deployed position, in accordance with a ninth embodiment of the present invention; 
           [0030]      FIG. 14B  is a broken-away side view of the cover assembly of  FIG. 14A  illustrating the folding panel in a stowed position; 
           [0031]      FIG. 14C  is a broken-away side view of the assembly of  FIG. 14A  illustrating rotational movement of the stacking panel from a stowed position toward the deployed position; 
           [0032]      FIG. 14D  is a broken-away side view of the assembly of  FIG. 14C  illustrating the stacking panel slidably extended to the deployed position; 
           [0033]      FIG. 15A  is a perspective view of a tailgate assembly with an active bed cover assembly including a tambour door panel shown in a partially deployed position, in accordance with a tenth embodiment of the present invention; 
           [0034]      FIG. 15B  is a broken-away side view of the assembly of  FIG. 15A  illustrating the tambour door panel uncoiling and slidably extending toward the deployed position; 
           [0035]      FIG. 16  is a perspective view of a vehicle with an active bed cover assembly including an integrated floor panel shown in a deployed position, in accordance with an eleventh embodiment of the present invention; 
           [0036]      FIG. 17  is a perspective view of a vehicle with an active bed cover assembly including a scissor hinge panel shown in a deployed position, in accordance with a twelfth embodiment of the present invention; 
           [0037]      FIG. 18  is a perspective view of a vehicle with an active bed cover assembly including a hinged sail panel shown in a deployed position, in accordance with a thirteenth embodiment of the present invention; 
           [0038]      FIG. 19  is a perspective view of a vehicle with an active bed cover assembly including an inflatable bladder panel shown in a deployed position, in accordance with a fourteenth embodiment of the present invention; and 
           [0039]      FIG. 20  is a perspective view of a vehicle with an integrated active bed cover assembly, in accordance with a fifteenth embodiment of the present invention; 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0040]    The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. 
         [0041]    Referring to  FIGS. 1-3  generally, in accordance with the present invention, there is provided an active bed cover assembly generally shown at  10  for a vehicle  12 . The vehicle  12  includes a cargo bed generally indicated at  14  with side walls  16 ,  18 , and a tailgate assembly generally shown at  20 . 
         [0042]    The active bed cover assembly  10  includes at least one deployable panel  22  rotatably connected to the vehicle  12 . Typically, the panel  22  is moveable between at least a deployed position and a stowed position. However, depending on the application the deployable panel  22  is slidable, extendable, articulatable, stackable, pivotable, rollable, elevatable, inflatable, foldable, combinations thereof or otherwise connected and deployable in the cargo bed  14  area depending on the application. 
         [0043]    A pair of hinges  24  are connected toward an upper edge  26  of the tailgate  20  to the first end  28  of the deployable panel  22 . The panel  22  is adapted for attachment to the pair of hinges  24  which can be any hinge arrangement suitable for predetermined cycling and durability requirements. Typically, the upper edge  26  region has a ‘U’ shaped cross-section, cutout or notch and each hinge is fastened in the region, e.g., directly or by way of a fastener or pin going through diverging side walls of the cutout. However, depending on the application hinges are bolted, screwed, welded, riveted, secured with adhesive and/or epoxy, combinations thereof or otherwise connected to the panel  22  and tailgate  20  and/or side walls  16 ,  18  depending on the application. Alternatively, molded-in panel features which are used to attach to opposing vehicle features and/or in combination with at least one fastener for each hinge or the like may be used to pivotally secure the panel  22  to the vehicle  12  and allow deployment of the panel  22 . 
         [0044]    At least one actuator  30  is connected to a respective drive shaft  32  operably coupled to the deployable panel  22  and embedded within the tailgate  20  to flip the panel  22  up/down. Typically, the actuator  30  and drive shaft  32  are enclosed within the tailgate assembly  20  between an inner panel  38  and an outer panel  40  of the tailgate  20 , generally centrally located toward the upper end of the tailgate  20  (See  FIG. 3  indicated in phantom). Preferably, one actuator  30  and a single driving rotating shaft is used and rotates the panel  22  up/down. Optionally, access panels may be provided for servicing and maintenance of the actuating arrangement. 
         [0045]    The actuator  30  rotates the drive shaft  32  to drive the panel  22  upward during deployment of the panel  22  to the deployed position (see  FIG. 2 ). When the active bed cover assembly  10  is in the extended/up or deployed position, the deployable panel  22  improves airflow. 
         [0046]    The actuator  30  also rotates the drive shaft  32  in the opposite direction to move the panel  22  downward out of the way to the stowed position. When the active bed cover assembly  10  is in the retracted/down or stowed position, the deployable panel  22  nests within a depression  36  or recess having a predetermined depth formed into the inner panel  38  of the tailgate  20  which depression is sized to receive the full panel  22  within the depression  36 . Thus, whether the tailgate assembly  20  is in the closed or open position ( FIG. 3  open position) the stowed panel  22  is substantially flush to the inner panel  38  allowing for a smooth, functional surface when the tailgate  20  is down, helping to prevent damage to the stowed panel  22  from sliding or moving cargo, and does not limit access to the pickup bed or the available footprint. 
         [0047]    The actuator  30  is a rotary actuator, e.g., with feedback options, hex-type, screw-type drive, higher speed actuator, electric, mechanical, linear, e.g., with current override circuits, declutching, hydraulic, pneumatic, extending, power lift actuator, or any other actuators and combinations thereof depending on the application and predetermined vehicle needs. 
         [0048]    In a preferred embodiment, the actuator  30  has internal clutching that reacts to certain conditions by de-clutching or disengages gears allowing the deployable panel  22  to stop deployment to help prevent damage to the active deployable panel  22 . Upon impact to the deployable panel  22 , e.g., by a sliding object in the pickup bed, the actuator  30  will clutch to disengage the gearing so that the deployable panel  22  can move freely out of the way. The actuator  30  itself does not move out of the way upon impact to the deployable panel  22 . In the event there is cargo/objects in the way during deployment of the panel  22 , the actuator  30  can clutch to disengage the gearing or the actuator  30  can retract the deployable panel  22  back to the stowed position. Typically, the actuator  30  senses current spikes and causes the actuator  30  to react to certain conditions, e.g., sensing of objects in the cargo bed hitting the deployable panel  22  induces the actuator  30  to disengage the gearing. 
         [0049]    The actuator  30  is typically sealed and has communication capability with the vehicle  12 . The actuator  30  and the vehicle  12  also communicate to deploy and retract the deployable panel  22  based upon predetermined conditions such as vehicle speed, wind direction, e.g., average wind direction is unfavorably about 5° yaw, etc. By way of example, the deployable panel  22  is embedded in the tailgate  20  of the vehicle  12  and when the vehicle  12  reaches a predetermined speed, e.g., about 30-40 mph, the deployable panel  22  folds upward to the deployed position and stays up until the vehicle drops back down to below the predetermined speed or other predetermined conditions for continued deployment are no longer met. 
         [0050]    When the deployable panel  22  is up in the deployed position it is extended to partially cover the vehicle bed  14 . Generally, covering about one third to one half of the cargo bed. Typically, covering less than one third of the cargo bed. Preferably, extending 6 inches to 30 inches. More preferably, extending at least 22 inches. Most preferably, extending about 30 inches. 
         [0051]    When the deployable panel  22  is up in the deployed position it is generally between the side walls  16 ,  18  extending horizontally. Accordingly, the deployable panel  22  extends generally flat along the same plane as the top of the side walls  16 ,  18  of the cargo bed  14 , and prevent air from swirling within the storage bed and reduce drag. Alternatively, the panel  22  is angled up, e.g., generally, zero to 60 degrees over horizontal, typically, five to thirty degrees over horizontal, preferably, fifteen to thirty degrees over horizontal, most preferably, five to fifteen degrees maximum over horizontal. In accordance with a most preferred embodiment, the panel  22  is not at an angle when in the deployed position. 
         [0052]    When the deployable panel  22  is up in the deployed position it is possible to angle the panel  22  with the cargo load in the cargo bed  14 , e.g., about 85 to 90 degrees, without departing from the scope of the invention. 
         [0053]    The sides  34  of the formed panel  22  are angled with the proximal end of the panel  22  being widest. 
         [0054]    Referring to  FIG. 4  generally, in accordance with another embodiment of the present invention, an active bed cover assembly generally shown at  110  for a vehicle  112  is identical to the first embodiment except that the deployable panel  122  as a different profile. The sides  134  are substantially straight and a cutout  136  is located along the leading edge of the panel  22  away from the proximal end forming a central cutout  136  with side wings or side extensions. 
         [0055]    Referring to  FIGS. 5-6  generally, in accordance with another embodiment of the present invention, an active bed cover assembly generally shown at  210  for a vehicle  212  is identical to the first embodiment except that the deployable panel  222  as a different profile in that the sides are straight and the distal end of the panel  222  extends substantially from one side wall  16  to the other 18. 
         [0056]    The deployable panel  22 ,  122 ,  222  is made of a composite plastic in these particular embodiments. However, depending on the particular application, it is also within the scope of the invention to manufacture the deployable panel  22 ,  122 ,  222  of different materials such as steel or aluminum, painted carbon fiber, extruded rubber, or other suitable impact resistant material to withstand a predetermined load without departing from the scope of the invention. Additionally, the deployable panel  22 ,  122 ,  222  may consist of a single piece, e.g., of molded composite plastic, or multiple pieces assembled together. 
         [0057]    Referring generally to  FIGS. 7-8 , the actuator  30  used in any embodiment can be declutchable. An exemplary actuator assembly with internal clutching is shown generally at  310 , comprising a clutch system, generally shown at  312 , as will be explained in further detail below. Generally, there is provided a sealed actuator with internal clutching assembly in accordance with the present invention which provides desirable higher cycle durability and capability combined with a water tight arrangement for use, by way of example, in underbody environments exposed to the elements. The sealed actuator with internal clutching assembly further provides a safety override clutch system which allows the actuator to rotate under predetermined conditions, e.g., predetermined high loads, to help protect a motor and other components of the actuator with internal clutching assembly, as will be explained in greater detail below. When subjected to abnormal loads or a predetermined amount of force or other predetermined conditions, the actuator with internal clutching assembly will move features out of the way to help prevent damage thereto. 
         [0058]    Referring to  FIG. 9  generally, in accordance with a fourth embodiment of the present invention, an active bed cover assembly generally shown at  410  for a vehicle  412  is identical to the first embodiment except that a slide out panel  440  is slidably connected to the deployable panel  422  to slide in/out. Just as with the first embodiment, the deployable panel  422  is rotated up/down by the at least one actuator between a deployed position and stowed position. However, the slide out panel  440  is slidable received within or under, most preferably within, the deployable panel  422  such that when stowed, the slide out panel  440  is not seen when the deployable panel  422  is stowed flush within the inner panel of the tailgate  420 . When the active bed cover assembly  410  is in the extended/up or deployed position, the deployable panel  422  and slide out panel  440  improve airflow. To deploy the assembly the panels  422 ,  440  are rotated upward as a unit and the slide out panel  440  is then slide outward to the fully extended position by the same or an additional actuator. To stow the assembly, the slide out panel  440  slides into the deployable panel  422  and the panels  422 ,  440  are rotated downward as a unit into the tailgate depression. 
         [0059]    Referring to  FIGS. 10A-10B  generally, in accordance with a fifth embodiment of the present invention, there is provided an active bed cover assembly generally shown at  610  for a vehicle  612  movable between the deployed position (See  FIG. 10A ) and the stowed position. The deployable panel  622  and a track arrangement  642  embedded in the depression  636  formed in tailgate  620  and toward the upward inner edge of the side walls  616 ,  618  forms a garage door style panel system. A first set of rollers or the like are connected toward the first end of the panel  622  to follow the track (slide or roll) in an upward/downward direction ( FIG. 10B ) when the panel is driven by the actuator. A second set of rollers or the like are connected toward the second end of the panel  622  to follow the track (slide or roll) in an outward/inward direction ( FIG. 10B ) when the panel is driven by the actuator.  FIG. 10B  illustrates stages of deployment of the rollable panel from a stowed position to the deployed position and back. Typically, the tracks  642  have a ‘U’ shaped cross-section and are bolted in the base of the ‘U’ to the tailgate  620  and side walls  616 ,  618 . However, depending on the application tracks  624  are welded, riveted, secured with adhesive and/or epoxy or otherwise connected depending on the application. Optionally, each track includes a first end and a second end with respective stop features in the second end. When the actuator drives the panel  622  to the stowed position the panel  622  is embedded within the depression  636  of the tailgate such that the panel  622  is flush with the tailgate. 
         [0060]    Referring to  FIG. 11  generally, in accordance with a sixth embodiment of the present invention, there is provided an active bed cover assembly generally shown at  510  for a vehicle  512 . At least two panels  522  are pivotally connected to the upward inner edge of the side walls  516 ,  518 . Each panel  522  has at least one hinge, the same or different than the first embodiment, to connect the panels to the side walls  516 ,  518 . The panels  522  rotate independently upward to a deployed position, using the same or different actuator and drive shaft as the first embodiment. Depending on the application the panels  522  deploy simultaneously. The actuators rotate each panel  522  down to the stowed position into the bed liner of the cargo bed (against the side walls  516 ,  518 ). 
         [0061]    Referring to  FIGS. 12A-12B  generally, in accordance with a seventh embodiment of the present invention, there is provided an active bed cover assembly generally shown at  710  for a vehicle  712 . At least two panels  722  form integrated flip out panels, each slidably disposed within a respective cavity  744  of the cargo bed  714 . Each panel  722  is also pivotally connected toward the upward inner edge of a respective side wall  716 ,  718 . Each panel  722  has at least one hinge, the same or different than the first embodiment, to connect the panels to the side walls  716 ,  718 . At least one actuator drives the panels  722  upward to clear the cavity  744  and then rotates each panel  722  independently down to a deployed position ( FIG. 12A ), using the same or different actuator and drive shaft as the first embodiment. Depending on the application the panels  722  deploy simultaneously. The panels  722  in the deployed position form a single horizontal panel over the cargo bed to improve aerodynamics. The actuators rotate each panel  722  up and then slide the panels  722  into each cavity  744  to the stowed position. Each cavity  722  is formed in the respective side of the bed liner of the cargo bed, and, alternatively, in the space between the bed liner and vehicle  712  outer side panel. 
         [0062]    Optionally, the cavity  744  can include a mechanism, e.g., including ball bearings, tracks, or other mechanism, used to move the panel  722  about the ball bearings when the assembly  710  is being changed from the stowed position to a partially deployed position or vice versa. When the panel  722  is in the partially deployed position, the panel  722  slides along the surface of the cavity  744  so that the top of the panel  722  is at a greater height than the top of the side walls  716 ,  718  before rotating downward to the fully deployed position horizontal to the cargo bed floor. 
         [0063]    Referring to  FIGS. 13A-13D  generally, in accordance with an eighth embodiment of the present invention, there is provided an active bed cover assembly generally shown at  810  for a vehicle  812 . At least two panels form an integrated folding panel indicated generally at  822  comprised of a first panel  848  connected to a second panel  850  by at least one joint  852 . Each panel has a first end and a second end. The proximal end  854  of the first panel  848  is pivotally connected to the tailgate  820  toward the top of a depression  836  formed in the tailgate. Preferably, the sides of the first end  854  are adapted to form the pivotable connection. The second end of the first panel  848  is pivotally connected to the first end of the second panel  850  at joint  852 . Generally, the second end  856  of the second panel  850  is free floating. Typically, the second end  856  of the second panel  850  is slidably connected to the side walls  816 ,  816  of the cargo bed. Preferably, the sides of the second end  856  are adapted to slide or roll within tracks formed in or connected to the side walls  816 ,  818 . At least one actuator drives the integrated folding panel  822  to the deployed position ( FIGS. 13A, 13D ), using the same or different actuator and drive shaft as the first embodiment. When the actuator drives the integrated folding panel  822  to the stowed position ( FIG. 13B ), the panels  848 ,  850  fold downward upon one another and are embedded within the depression  836  of the tailgate such that the second panel  850  is flush with the tailgate. The assembly  810  could be jointed or hinged in the opposite direction without departing from the scope of the invention. 
         [0064]    Referring to  FIGS. 14A-14D  generally, in accordance with a ninth embodiment of the present invention, there is provided an active bed cover assembly generally shown at  910  for a vehicle  912 . A plurality of panels form an integrated stacking panel indicated generally at  922 . At least three panels are shown, including a first panel  948  pivotably connected to the tailgate, a second panel  950  operably slidably connected to the first panel  948 , and a third panel  958  which is operably slidably connected to the second panel  950 . When in the stowed position ( FIG. 14B ) the integrated stacking panel  922  are folded or stacked up to one another and are embedded within the depression  936  of the tailgate such that the third panel  958  is flush with the tailgate. 
         [0065]    Each panel  948 ,  950 ,  958  has a first end and a second end. The proximal end  954  of the first panel  948  is pivotally connected to the tailgate  920  toward the upper outer edge of a depression  936  formed in the tailgate. Preferably, the sides of the first end  954  are adapted to form the pivotable connection. When the actuator drives the integrated stacking panel  922  to the deployed position ( FIGS. 14A, 14D ), the panel  922  is first rotated upward to a partially deployed position ( FIG. 14C ). Typically, the actuator drives rotation of the first panel  948  and all three panels move upward as a unit. The actuator then drives the second and third panels  948 ,  958 , either consecutively or simultaneously, to extend, e.g., slidably extend, outward to the deployed position ( FIG. 14D ). Thus, adjacent panels track with one another such that as one is driven outward the other is pushed or pulled outward, and as one is driven in the other direction the other is pushed or pulled toward the same direction. Typically, at least one of the panels  848 ,  950 ,  958  is adapted to track in a respective track connected to or formed in the side walls  916 ,  918  of the cargo liner. Optionally, stops are incorporated with the second end of both the first and second panel  948 ,  950  to stop panels from extending further than desired. The panels could be stacked in the opposite orientation such that the first panel  948  is below the second panel  950  which is below the third panel  958  without departing from the scope of the invention. 
         [0066]    Referring to  FIGS. 15A-15B  generally, in accordance with a tenth embodiment of the present invention, there is provided an active bed cover assembly generally shown at  1010  for a vehicle  1012  movable between a stowed position and a deployed position (partially deployed depicted in  FIG. 15A ). A deployable panel  1022  forms a tambour door-type panel slidably connected to tracks  1042  formed in or connected to the side walls  1016  and  1018  of the vehicle. When driven to the stowed position ( FIG. 15B ) the panel  1022  is rolled  1060  such that the rolled up panel  1022  becomes embedded within a depression  1036  formed in the tailgate  1020  so that the roll  1060  is flush with the tailgate. As the actuator drives the panel to the deployed position the panel  1022  unrolls and the leading side edges translate along the tracks  1042  to the deployed position. Typically, the tracks  1042  have a ‘U’ shaped cross-section and are bolted in the base of the ‘U’ to the upper side walls  1016 ,  1018 . However, depending on the application tracks  1042  are welded, riveted, secured with adhesive and/or epoxy or otherwise connected depending on the application. Optionally, each track includes a second end with respective stop features. 
         [0067]    Referring to  FIG. 16  generally, in accordance with an eleventh embodiment of the present invention, there is provided an active bed cover assembly generally shown at  1110  for a vehicle  1112  movable between a stowed position and a deployed position ( FIG. 16 ). A deployable panel  1122  forms an integrated floor panel that rests horizontally on the floor of the cargo bed, e.g., within a depression  1136  such that the panel  1122  is flush with the floor. At least one actuator drives the entire horizontal panel  1122  to lift upward, e.g., floor elevator lift-type system incorporating a track conveyor and/or track mechanism, to the deployed position and down to the stowed position. 
         [0068]    Referring to  FIG. 17  generally, in accordance with an twelfth embodiment of the present invention, there is provided an active bed cover assembly generally shown at  1210  for a vehicle  1212  movable between a stowed position and a deployed position ( FIG. 17 ). A deployable panel  1222  forms a scissor hinge panel. The panel is formed of a flexible and/or soft material, e.g., fabric, vinyl or other material, and is framed in semi-rigid or rigid material along at least the front edge, rear edge and diagonally. Typically, a screw drive and higher speed actuator is employed. The ends of the front frame bar  1262  can be adapted such that when driven to the stowed position the bar  1262  slides rearward within tracks  1242  formed in or connected to the side walls  1216 ,  1218  of the cargo bed. 
         [0069]    Referring to  FIG. 18  generally, in accordance with a thirteenth embodiment of the present invention, there is provided an active bed cover assembly generally shown at  1310  for a vehicle  1312  movable between a stowed position and a deployed position ( FIG. 18 ). A deployable panel  1322  forms hinged sail panel comprising a first panel  1364  over a second panel  1366 . The panel  1322  is formed of a flexible material, e.g., fabric, vinyl or other material, and is driven outward to the extended deployed position and inward toward the tailgate to the stowed position. 
         [0070]    Referring to  FIG. 19  generally, in accordance with an fourteenth embodiment of the present invention, there is provided an active bed cover assembly generally shown at  1410  for a vehicle  1412  movable between a stowed position and a deployed position ( FIG. 19 ). A deployable panel  1422  forms an inflatable bladder panel. The panel is formed of a material suitable for inflating. At least the front of the panel  1422  is connected to a semi-rigid or rigid bar  1462 . The ends of the front frame bar  1462  are adapted such that as the panel  1422  is inflated either the panel moves the bar  1462  along tracks  1442  or the bar  1462  is driven outward toward the deployed position pulling the panel  1422  with it. For stowing, the bar  1462  is driven to slide rearward within the tracks  1442  formed in or connected to the side walls  1416 ,  1418  of the cargo bed to the stowed position against the tailgate. 
         [0071]    Referring to  FIG. 20  generally, in accordance with a fifteenth embodiment of the present invention, there is provided an active bed cover assembly integrated with the back panel of the tailgate assembly  1520  for a vehicle  1512  movable between a stowed position and a deployed position. A linkage assembly indicated generally at  1564  connects the back panel  1520  toward the top inner edge of the cargo bed side walls  1516 ,  1518  of the vehicle. A lift assist mechanism, e.g., gas struts, generally indicated at  1566  is provided on both sides of the panel  1522 . Lift assist mechanism  1566  includes a gas cylinder and actuation shafts received in compressed air assist type pneumatic cylinder bodies. When the tailgate/panel  1522  is driven to the deployed position, the cylinder applies force to the linkage  1564  assisting the tailgate/panel in a deployed direction until the tailgate/panel  1522  is horizontal. When the tailgate/panel  1522  is driven to the stowed position, the cylinder provides force assistance in a stowed direction until the tailgate/panel  1522  is vertical. Thus, the entire tailgate  1520  rotates up and down and improves aerodynamics when in the up/horizontal position. 
         [0072]    Referring generally to  FIGS. 7-8 , an exemplary actuator assembly with internal clutching is shown generally at  310 , provided with a clutch system shown generally at  312 , where the actuator  310  is employable with any embodiment described herein. At least one actuator  310  with internal clutching is used or other actuator and/or in combination with any additional actuator(s) is/are used in the system. 
         [0073]    The clutch system  312  comprises a housing portion indicated generally at  312 , an output shaft  316  which is received within and holds an output detent ring  318  and a moving detent ring  320 . 
         [0074]    During normal operation of the active bed cover assembly  10 , etc, the actuator assembly  310  provides power to drive and move the at least one panel  22 , etc between at least the stowed position and deployed position. Also connected to the actuator assembly  310  is a rotatable drive shaft, e.g., drive shaft  32 , that is operably connected to the at least one panel  22 , etc and the output shaft  316  of the actuator assembly  310 . The drive shaft  32  functions to deploy the at least one panel  22 , etc in the event of predetermined conditions sensed by the actuator assembly  310  in order to move the at least one panel  22 , etc to a fully extended deployed position for improved aerodynamics. 
         [0075]    The output detent ring  318  is free to rotate on the output shaft  316  about a portion of the output shaft  316  that is not splined. The moving detent ring  320  is able to move axially to the output shaft  316  but is locked radially by a plurality of interlocking splines  322 ,  324  on both components. The output shaft  316  has interlocking splines  322  that are arranged parallel to the longitudinal axis and operably spaced about an outer surface located on a lower half of the output shaft  316 . The moving detent ring  320  has outer interlocking splines  324  forming complementary channels to slidably interlock with the interlocking splines  322  for controlled axial movement of the moving detent ring  320 . The interlocking splines  322  of the output shaft  316  terminate at an integrally formed projecting ring  326  having an abutting surface  328 , lying transverse to the axis, against which the output detent ring  318  engages. The output detent ring  318  abuts against this surface  328  on the output shaft  316  and does not move axially. 
         [0076]    An output gear  330  is in mesh with the output detent ring  318  for transmitting torque. The output gear  330  has spaced circumferential segments  332  that are generally square teeth like shaped held in place within opposing recesses  334  of the output detent ring  318  for transmitting the torque. 
         [0077]    The output and moving detent rings  318 ,  320  have first and second intermeshing ramped teeth, generally shown at  336 ,  338 , respectively, that are held together in mesh by the biasing force of a wave spring  340 . The wave spring  340  is received on the outer output shaft  316  and provides a biasing force against the moving detent ring  320  in the direction of the output detent ring  318 . 
         [0078]    The components of the clutch system  310  (e.g., output shaft  316 , output gear  330 , output detent ring  318 , moving detent ring  320 , and wave spring  340 ) are held together by first and second locking rings  342 ,  344  located toward respective ends the output shaft  316  of the clutch assembly  312 . 
         [0079]    A motor  346  selectively provides torque suitable for particular applications. Suitable electontronics  348 , most preferably, a shut off printed circuit board (PCB) with connector contacts  350  correlate with vehicle communication networks for commanding the motor  46  based upon predetermined conditions, e.g., commanding energizing of the motor correlating with predetermined vehicle speed ranges. The PCB electronics senses current spike for override, which allows the clutch to disengage the drive system allowing it to rotate freely. 
         [0080]    The motor  346  has a worm gear, shown generally at  352 , which causes a main gear, shown generally at  354 , to rotate. The main gear  354  has a gear and a helix angle portion  358 . The worm gear  352  has a shaft, e.g., a threaded shaft, which engages the teeth of the gear  356 , which causes the gear  356  of the main gear  354  to rotate as the worm gear  352  rotates. Rotation of the gear  356  causes the helix angle portion  358  of the main gear  354  to also rotate. The helix angle portion  358  rotatably engages the output gear  330 . The gear ratio range of the gear  356  to helix angle portion  358  is operably suitable for transmitting torque from the motor/worm gear  346 / 352  to the output gear  330 . The first and second intermeshing ramped teeth  336 ,  338  of the output and moving detent rings  318 ,  320  when held together by the biasing force of the wave spring  340  lock and allow the output shaft  316  to rotate and transmit the torque of the motor  346  through the main gear  354  and output gear  330  to the outside of the housing portion  314 . The output shaft  330  is operably coupled to the drive shaft  32  for selectively rotating, folding or otherwise moving at least one panel  22  etc between at least the stowed position and the deployed position. The wave spring  340  allows for a more compact structure while meeting biasing and predetermined load requirements. 
         [0081]    The housing portion  314  comprises a first half  360  and a second half  362 . The first half  60  has a first clutch assembly cavity  364  and a first motor cavity  366 . The second half  362  has a second clutch assembly cavity  368 , a main gear cavity  370 , and a second motor cavity. The clutch system  312  fits fully inside the first and second halves  360 ,  362  of the housing (within the first and second clutch assembly cavities  364 ,  368 ), as well as the motor  346  and electronics  348 / 350  (within the first motor cavity  366  and second motor cavity), and main gear  354  (within the main gear cavity  370 ). The first and second halves  360 ,  362  of the housing portion  314  are joined together, and connected with fasteners, and first and second seals added  372 ,  374  onto the output shaft  316  to form a weathertight housing. The housing  314  may be formed in the tailgate module  20 , etc. without departing from the scope of the invention. 
         [0082]    In operation, the first and second intermeshing ramped teeth  336 ,  338  of the output and moving detent rings  318 ,  320 , that when held together by the biasing force of the wave spring  340 , lock together and allow the output shaft  316  to rotate. This allows torque transmission from the motor  346 /worm gear  352  through the main gear  354  and output gear  330  to the outside of the housing portion  314  via the output shaft  316  to the drive shaft  32 . During a predetermined level of high load, the first and second intermeshing ramped teeth  336 ,  338  create an axile force that overcomes the load from the wave spring  340 . This allows the moving detent ring  320  to disengage and allow the output shaft  316  to rotate freely, thereby preventing damage to the sealed actuator internal clutching assembly  310 . 
         [0083]    Thus, there is provided a sealed actuator with internal clutching assembly  310  which can drive in both directions, but when stopped will hold its position without back driving when subjected to a predetermined load, e.g., a load many times greater than its dynamic range. The actuator  310  also protects itself from damage from predetermined loads, e.g., very high loads, by means of the clutch that will disengage the drive system allowing it to rotate (e.g., allowing the output shaft  316  to rotate freely). The sealed actuator with internal clutching assembly  310  is in a waterproof housing and can rotate in both directions for as many revolutions as needed. The clutch is fully self contained in the housing. The actuator has an output passthrough drive structure, e.g., output shaft  316  arrangement, allowing it to drive a shaft, e.g., drive shaft  32 , or part from either side or both sides. The actuator  310  can be mounted to a fixed part with the only external moving part is the drive shaft  32 . The clutch system  312  of the sealed actuator with internal clutching assembly  310  also does not change shape or height when it clutches, which is yet another significant advantage. 
         [0084]    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.