Patent ID: 12221072

IV. DETAILED DESCRIPTION

Reference is now made to the drawings wherein the showings are for purposes of illustrating embodiments of the article only and not for purposes of limiting the same, and wherein like reference numerals are understood to refer to like components.

FIGS.4A1,4A2,4B1,4B2,5A,5B,6A,6B,7and8depict steps and interim product states in a method of fabricating a backpack truck box in accordance with the present invention. FIGS.4A1,4A2,4B1and4B2depict an initial interim product state of forming first and second patterned members100a,100bfrom sheet material, which can be sheet metal, stainless steel sheet (SST), carbon steel or alum. The patterned members100a,100bare pre-cut into a pattern which can be formed though a subsequent process into final panels, which are then assembled into the final backpack truck box, as will be described in detail hereinbelow. The patterned members100a,100bcan be pre-cut using a metal saw or a laser in a computer numerical control (CNC) or by a stamping operation or other suitable operation without departing from the invention.

As also shown in FIGS.4A1,4A2,4B1and4B2, each of the patterned members100a,100bare formed with a plurality of edges110sa,110sb,110pa,110pbhaving opposing tabs112sa,112sb,112pa,112pbformed contiguously on opposing edges of each of the first and second panels. In an exemplary embodiment of FIGS.4A1and4B1, the step of forming the first and second patterned members110a,100bincludes forming each panel120a,120binto a two-dimensional shape known from geometry as a “semi-truncated rectangle,” being of a generally rectangular shape but having two corners (e.g., the top-most comers) cut off or truncated. The pairs of the opposing tabs112sa,112sb,112pa,112pbare preferably rectangular in shape. Upon final assembly, these panels result in a backpack truck housing having a three-dimensional shape known from geometry as a “semi-truncated rectangular prism,” which is to say, a figure that extends linearly between the two panels120a,120beach having the shape of a semi-truncated rectangle. However, as shown in the alternate embodiment of FIGS.4A2and4B2, these panels can also result in a solid rectangular shape, where it is appreciated that similar reference numerals refer to similar elements, in these figures and in the other figures throughout the present disclosure. It is to be further appreciated that the panels120a,120bcould alternatively be formed from any other suitable shape without departing from the invention.

With continuing reference to FIGS.4A1,4A2,4B1and4B2, the plurality of edges110sa,110sb,110pa,110pbof each panel120a,120binclude first and second opposing parallel edges110pa,110pband first and second opposing sloped edges110sa,110sb. The sloped edges110sa,110sbare formed along the edges of the truncated corners of the rectangle while the parallel edges110pa,110pbare formed along the remaining portions of the rectangular sides. The area bounded by these edges110sa,110sb,110pa,110pband along with a top edge114and a bottom edge116defines the two-dimensional semi-truncated rectangular shape of each panel120a,120b, while the rectangular shaped panels are formed without sloped edges.

With ongoing reference to FIGS.4A1,4A2,4B1and4B2, the pairs of rectangular opposing tabs112sa,112sb,112pa,112pbincludes sloped edge tabs112sa,112sbformed respectively on opposing sloped edges110sa,110sband parallel edge tabs112pa,112pbformed respectively on opposing parallel edges112pa,112pb. In the preferred embodiment, the pairs of rectangular opposing tabs112sa,112sb,112pa,112pbare mirror symmetrical with each other, as are the respective plurality of sloped and parallel edges110sa,110sb,110pa,110pbof each panel120a,120b.

With specific reference to FIGS.4B1,4B2,5A,5B,6A,6B, and7, further steps of the present method include performing one or more bending operations upon each of the pairs of opposing tabs112sa,112sb,112pa,112pbto form first and second side portions130sa,130sb,130pa,130pbextending at a predetermined angle from each of the first and second panels120a,120b. The side portions130sa,130sb,130pa,130pbare generally flat portions that extend along the entire length of each of the respective edges110sa,110sb,110pa,110pb. The side portions130sa,130sb,130pa,130pbare defined by wider portions of the opposing tabs112sa,112sb,112pa,112pb, as explained hereinbelow. The steps of performing the bending operations includes forming the side portions130pa,130pbrespectively along the first and second opposing parallel edges110pa,110pband also forming the side portions130sa,130sbalong the first and second opposing sloped edges110sa,110sb.

In one exemplary embodiment, the bending operations can be performed by forming dies or on a traditional press brake. However, it is to be appreciated that the bending operations can alternatively be formed by any other suitable device or process.

With continued reference to FIGS.4B1,4B2,5A,5B,6A,6B, and7, the steps of performing the bending operations includes performing the bending operations upon each of the pairs of opposing tabs112sa,112sb,112pa,112pbto form perpendicular side portions130sa,130sb,130pa,130pbformed at right angles to the panels120a,120b. In this manner, the perpendicular side portions130sa,130sb,130pa,130pbeach define a partial perimeter into an internal volume of the backpack truck box housing upon final assembly. An additional plurality of bending operations are also performed to produce perpendicularly-extending rectangular gutters132sa,132sb,132pa,132pb, formed at right angles to the to the side portions130sa,130sb,130pa,130pband extending outwardly away therefrom. The gutters132sa,132sb,132pa,132pbare formed from portions of the opposing tabs112sa,112sb,112pa,112pbthat are narrower than the side portions130sa,130sb,130pa,130pb, so that the partial perimeters resulting from each of the gutters132sa,132sb,132pa,132pbhave a smaller extent than the side portions130sa,130sb,130pa,130pb. However, it is further contemplated that the gutters could be optionally substituted with a section of gasket material, without departing from the invention.

With additional reference to FIGS.4B1,4B2,5A,5B,6A,6B, and7, the gutters132sa,132sb,132pa,132pbcan be formed by creating a perpendicular bend along a boundary portion where the gutters132sa,132sb,132pa,132pbadjoin the130sa,130sb,130pa,130pb, and another perpendicular bend formed along the middle of the narrow portions of the opposing tabs112sa,112sb,112pa,112pb. The resulting structure of the gutters132sa,132sb,132pa,132pbare oriented so that an outer edge is angled in a direction back toward the respective outer surfaces of the first and second panels120a,120b. In this manner, the gutters132sa,132sb,132pa,132pbdefine the partial perimeters that will form the openings into the interior of the backpack truck box.

As specifically indicated in FIGS.4A1,4A2,4B1and4B2the bottom edge116of the panels120a,120bcan be formed with a ledge134to provide a mounting surface. This ledge134can be formed in the pattern and bending operations described hereinabove. However, in an alternative embodiment, as shown inFIG.5, the bottom edge116can be notched during the pattern operation to omit this ledge134.

As specifically indicated in FIGS.4B1,4B2, and8, the method further includes steps of welding together the side portions130sa,130sb,130pa,130pbof the first panel120ato respective corresponding side portions130sa,130sb,130pa,130pbof the second panel120bto produce a welded backpack truck box housing140. Specifically, the welding steps include welding a middle portion142between the side portions130sa,130sb,130pa,130pbto define a width of the backpack truck box housing. As indicated inFIG.8, the middle portion142can also include a middle gutter144for also defining a partial perimeter contiguous with the partial perimeters formed by the gutters132sa,132sb,132pa,132pb.

As also shown inFIG.8, the principal welds can be formed between the middle portion142and along the joint between the sloped side portions130sa,130sband the parallel side portions130pa,130pb. However, the middle portion142can be omitted in embodiments with only one door. With the present method, it is no longer necessary to perform welds along the sloped and parallel edges of each panel20a,20bas was done in the prior art. Thus, the present method considerably reduces the number of welds in the finished backpack truck box140, greatly reducing manufacturing time and resources and the resulting costs, while also providing a smoother, more uniform and regular aesthetic appearance to the finished product.

As also shown in FIGS.4B1and4B2, a top portion146is welded onto the panels120a,120bof the assembled backpack truck box housing to provide an enclosure to a top surface of the backpack truck box140. The bottom edge of the top portion144cooperates with the gutters132sa,132sb,132pa,132pb,144to define a continuous perimeter for openings150into the internal volume of the backpack truck box140. Shelves152are optionally assembled or welded within the interior volume of the backpack truck box housing140Doors can then be attached to each of the partial perimeters formed by the gutters132sa,132sb,132pa,132pb,144for enclosing the internal volume of the backpack truck box housing140.

FIGS.9A,9B,9C,9D,9E, and9Fshow various views of all sides of the semi-truncated embodiment of the assembled backpack truck box140formed in accordance with the method of the present invention.FIGS.11A,11B,11C,11D,11E, and11Fsimilar depict the rectangular embodiment. These views respectively show the first and second panels120a,120bthe side portions130sa,130sb,130pa,130pb, with the middle portion142with the top portion146and all the openings150formed therefrom. It is to be appreciated that the backpack truck box140as shown and described herewith is mirror symmetrical and any features not explicitly shown by any reference numerals in any of the views should be understood to identically correspond to mirror symmetrical features that are explicitly shown, as would be understood by those having skill in the art.

FIGS.10A and10Brespectively show a completed backpack truck box of the “semi-truncated rectangular prism” embodiment, configured to receive doors122a,124athat allow access to the interior compartments of the truck box.FIGS.12A and12Brespectively show a backpack truck box of the rectangular box embodiment, also configured to receive doors122a,124athat allow access to the interior compartments of the truck box.

Numerous embodiments have been described herein. It will be apparent to those skilled in the art that the above methods and apparatuses may incorporate changes and modifications without departing from the general scope of this invention. It is intended to include all such modifications and alterations in so far as they come within the scope of the appended claims or the equivalents thereof.