Patent Document

BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention relates to a lockable tonneau cover for use on a pickup truck which cover can double as a materials carrier. 
   2. Background of the Prior Art 
   The pickup truck is the workhorse of many tradesmen. The pickup truck is relatively small and nimble, allowing access to most work sites, even those that lack paved roads, yet has a bed that can carry a substantial load to the work site. The pickup truck bed can be loaded with a relatively sizable amount of material such as pipes, conduits, or lumber, or can carry needed tools to the site including compressors, generators, and a multitude of hand tools. One shortcoming experienced by pickup truck owners concerns the need to carry a diversified load. Many workers, such as framers and plumbers, need a wide assortment of hand tools as well as the needed supplies to carry out the job. While the materials are generally secured at a supply house that is frequented on the way to the job site, the tools remain with the worker from job to job. As these tools are relatively small and valuable, they must be protected from theft whenever the worker is away from the truck such as at the supply house, at lunch, or even at home after hours as unloading and the reloading a large amount of hand tools can be quite time-consuming and labor-intensive. 
   To address the need to secure hand tools, many pickup truck owners securely install some form of tool box within the pickup truck bed and lock the tool box as needed. Such boxes generally take one of two forms, either a large box that is bolted to the truck bed at its forward end or a tonneau cover that uses the truck bed&#39;s floor and four sides as part of the box with the cover forming the top of the box. In either case, the locks used with the tool box help prevent theft of the valuable tools from all but the most ardent of thieves. The problem created by the use of these tool boxes is that they, by necessity, take up valuable real estate within the pickup truck bed leaving less room to carry bulky supplies such as pipe or lumber. This results in the need to make multiple stops at the supply house which is time-consuming especially on a remote location site. Alternately, the tradesman has the supply house deliver the needed materials. However, this alternative can increase the costs to the tradesman from the delivery charges imposed by the supply house and can be time inefficient as the tradesman might be sitting idle at the job site waiting for the supply truck to arrive. Still a further solution is to have a second person help the tradesman get the supplies in this second person&#39;s truck. However, the problem with this method is that it is inefficient in requiring a second person and truck to accomplish the job, can still be problematic if the selected second person&#39;s truck lacks space due to the presence of a tool box within the truck, and the potential exists that no such second person is available. 
   To address such concerns, devices have been proposed that allow a pickup truck owner to carry a locked tool box while at the same time have sufficient room within the pickup truck to carry a relatively large supply of job materials. One type of such device is a truck rack that is bolted into the pickup truck bed and rises over the bed and oftentimes over the pickup truck cab. Any tool boxes are secured within the pickup truck bed in the usual way and materials are secured on the rack. While this type of device solves some of the tradesman&#39;s problems, these devices are not without shortcomings. Many of these devices, due to the structural struts used to form the racks, make access to the tool box within the bed awkward. Additionally, as such devices are fixedly attached to the pickup truck, movement of large objects, such as a refrigerator, tends to be difficult requiring the removal of the rack from the truck, which may be a very difficult and time-consuming undertaking. Furthermore, the rack clearly identifies the truck as a work truck which is undesirable to some workers who use the truck for personal purposes such as dating and do not want to use a “work truck” while others live in neighborhoods where the parking of work trucks may be restricted by restrictive covenants of the neighborhood. 
   Another type of device that is used is a convertible tonneau cover that covers the bed of the pickup truck and locks in place protecting the tools, yet also converts to a rack system that is capable of carrying needed supplies without the need to unload the tools. These devices allow a truck owner to carry tools securely and also carry a relatively large amount of material simultaneously while allowing the “removal” of the rack after the work day so as not to permanently mark the pickup truck as a work truck. The problem with such convertible tonneau covers is that many such devices are unduly complex in design. This makes such devices relatively expensive to obtain and also makes converting the device between standard tonneau cover and a rack-based system difficult and time-consuming. Additionally, many devices, due to the temporary nature of the rack to which the devices are converted, result in a rack that lacks the structural integrity of a fixed truck rack system. As a result, such systems are limited in the size of the load which can be placed upon the rack to which the device converts. 
   What is needed is a device that allows a worker to carry tools within the bed of a pickup truck with the ability to lock the tools whenever needed, while at the same time being able to carry a relatively large amount of supplies to a work site. Such a device must be of relatively simple design and construction so that it is not unduly expensive to produce and obtain and so that the device is capable of converting between a standard tonneau cover and a rack-based system in relatively short order. Such a device must be able to convert to a rack-based system that has substantial structural integrity so as to be able to handle relatively large material loads. Such a device must allow a user to be able to minimize the work truck look associated with the pickup truck. 
   SUMMARY OF THE INVENTION 
   The convertible tonneau cover of the present invention addresses the aforementioned needs in the art. The convertible tonneau cover fits onto a pickup truck bed and allows a worker to carry tools within the bed of a pickup truck with the ability to lock the tools whenever needed. The convertible tonneau cover also allows the pickup truck to carry a relatively large amount of supplies to a work site. The convertible tonneau cover is of relatively simple design and construction so that it is relatively inexpensive to produce thereby making it affordable to a large number of tradesmen. The present invention is capable of converting between a standard tonneau cover and a rack-based system in relatively short order. The convertible tonneau cover is able to convert to a rack-based system that has substantial structural integrity allowing the device to be able to handle relatively large material loads. The convertible tonneau cover lacks the hardcore tell-tale signs of a work truck and allows an owner to be able to minimize the work truck look associated with the pickup truck. 
   The convertible tonneau cover of the present invention is comprised of a base frame that is attached to an upper periphery of a pickup truck bed in outlining relationship with the upper periphery of the bed, the base frame having a longitudinal midline that extends between the head of the pickup truck bed and the tailgate thereof. A first door assembly is pivotally attached to the base frame on a first side of and adjacent to the midline of the base frame such that the first door assembly is capable of opening and closing with respect to the base frame. A plurality of first kickstands is pivotally attached to the first door assembly such that each of the plurality of first kickstands extends between the first door assembled and the base frame whenever the first door assembly is open. A second door assembly is pivotally attached to the base frame on a second side of and adjacent to the midline of the base frame such that the second door assembly is capable of opening and closing with respect to the base frame. A plurality of second kickstands is pivotally attached to the second door assembly such that each of the plurality of second kickstands extends between the second door assembly and the base frame whenever the second door assembly is open. A first bracket is attached to the first door assembly and to the second door assembly whenever the first door assembly is open and the second door assembly is open while a second bracket is attached to the first door assembly and to the second door assembly whenever the first door assembly is open and the second door assembly is second open. The base frame has a first handle and the first door assembly has a second handle that is aligned with the first handle whenever the first door assembly is closed and the base frame has a third handle and the second door assembly has a fourth handle that is aligned with the third handle whenever the second door assembly is closed. This allows locking of the two door assemblies. Each of the plurality of first kickstands is received within a respective first gusset attached to the base frame whenever the first door assembly is open and each of the plurality of second kickstands is received within a respective second gusset attached to the base frame whenever the second door assembly is open. The first door assembly has a first frame assembly and a first cover attached to a first top of the first frame assembly while the second door assembly has a second frame assembly and a second cover attached to a second top of the second frame assembly. The base frame has a brace that extends along a length of the midline. The base frame has a first end and an opposing second end joined by a first side and an opposing second side such that the longitudinal midline extends between the first end and the second end and the first door assembly is pivotally attached to the first end and to the second end on the first side of the midline and the second door assembly is pivotally attached to the first end and to the second end on the second side of the midline. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of the convertible tonneau cover of the present invention. 
       FIG. 2  is a perspective view of the base frame used with the convertible tonneau cover. 
       FIG. 3  is a detail view of the gusseted portion of the base frame noted in  FIG. 2 . 
       FIG. 4  is a detail view of the portion of the base frame noted in  FIG. 2 . 
       FIG. 5  is a perspective view of the door frame with the kickstands stored. 
       FIG. 6  is a perspective view of the door assembly, 
       FIG. 7  is a perspective view of the door assembly mounted within the base frame. 
       FIG. 8  is a perspective view of the front and back of the pair of rack brackets. 
       FIG. 9  is a perspective view of an alternate embodiment of the convertible tonneau cover of the present invention. 
       FIG. 10  is a detail view of the base frame of the tonneau cover of  FIG. 9 . 
       FIG. 11  is a detail view of the gussets noted in  FIG. 10 . 
       FIG. 12  is a perspective view of the convertible tonneau cover is use on a pickup truck in a rack configuration. 
       FIG. 13  is a perspective view of the convertible tonneau cover in use on a pickup truck in a cover configuration. 
       FIG. 14  is a perspective view of a single rack bracket. 
       FIG. 15  is a sectional view of the rack bracket taken along line  15 — 15  in  FIG. 14 . 
   

   Similar reference numerals refer to similar parts throughout the several views of the drawings. 
   DESCRIPTION OF THE PREFERRED EMBODIMENT 
   Referring now to the drawings, it is seen that the convertible tonneau cover of the present invention, generally denoted by reference numeral  10 , is comprised of base frame  12  that is generally rectangular in shape and that has a first end  14 , an opposed second end  16 , a first side  18  that connects the first end  14  and the second end  16 , and an opposed second side  20  that also connects the first end  14  and the second end  16 . As seen a first gusset plate  22  with a first opening  24  connects the first end  14  with the first side  18 , a second gusset plate  26  with a second opening  28  connects the first side  18  with the second end  16 , a third gusset plate  30  with a third opening  32  connects the second end  16  with the second side  20 , and a fourth gusset plate  34  with a fourth opening  36  connects the second side  20  with the first end  14 . A brace  38  extends between the first end  14  and the second end  16  along the longitudinal midline of the base frame  12 . As seen, the brace  38  is an inverted T with the leg  40  of the T being on the longitudinal midline and dividing the base frame into a first half and a second half. A first opening  42  is located on the first end  14  on one side of the leg  40  of the brace  38  while a second opening  44  is located on the first end  14  on the opposite side of the leg  40  of the brace  38 . A third opening  46  is located on the second end  16  on one side of the leg  40  of the brace  38 , this third opening  46  facing the first opening  42  on the first end  14 , while a fourth opening  48  is located on the second end  16  on the opposite side of the leg  40  of the brace  38 , this fourth opening  48  facing the second opening  44  on the first end  14 . A first handle  50  is located on the first side  14  of the base frame  12  while a second handle  52  is located on the second side  20  of the base frame  12 . The base frame  12  is made from an appropriate and sturdy material such as metal including aluminum. 
   A door assembly  54  has a generally rectangular-shaped door frame  56  that has a first end  58  and a second end  60  opposite the first end  58 , while a first side  62  connects the first end  58  and the second end  60  and a second side  64  also connects the first end  58  with the second end  60 , the second side  64  being opposite the first side  62 . A first pin  66  extends outwardly from the first end  58  of the door frame  56  and is longitudinally aligned with the second side  64  of the door frame  56 , while a second pin  68  extends outwardly from the second end  60  of the door frame  56  and is aligned with the first pin  66 . One or more cross braces  70  extend between the first side  62  and the second side  64  of the door frame  56  in order to give the door frame  56  structural rigidity. A first kickstand  72  is pivotally connected to the first side  62  of the door frame  56  proximate the first end  58 , the first kickstand  72  having a pin  74  extending from its distal end, while a second kickstand  76  is pivotally connected to the first side  62  of the door frame  56  proximate the second end  60 , the second kickstand  76  having a pin  78  extending from its distal end. The first kickstand  72  and the second kickstand  76  can each be pivoted to a tucked position wherein each kickstand  72  and  76  is flush against the first side  62  of the door frame  56 , as best seen in  FIG. 5  and an extended position wherein each kickstand  72  and  76  extends downwardly from the door frame  56  as best seen in  FIGS. 1 ,  6 , and  12 . One or more openings  80  are located along a length of the second end  60  of the door frame  56  while a corresponding series of openings (not illustrated) are located along a length of the first end  58  of the door frame  56 . A cover  82  is attached to the top of the door frame  56 , which cover  82  can have any appropriate design thereon such as the illustrated diamond-plate. A handle  84  extends upwardly from the cover  82 . The door assembly  54  is made from the same or similar material as the material used to make the base frame  12 . 
   A bracket  86  has a generally isosceles trapezoid shape and has an upper leg  88  that may have upwardly extending wings  90  on either end, a lower leg  92  that is parallel with the upper leg  88 , a first diagonal leg  94  that extends diagonally between the upper leg  88  and the lower leg  92  and a second diagonal leg  96  that also extends diagonally between the upper leg  88  and the lower leg  92  at a complementary angle relative to the first diagonal leg  94 . As seen, the first diagonal leg  94  has a series of openings  98  thereon, while the second diagonal leg  96  also has a series of openings  100  therein 
   The base frame  12  is attached to the upper periphery of a pickup truck T bed B so that the base frame  12  outlines this outer periphery (many pickup truck beds B are not precisely rectangular for aerodynamic purposes and the base frame  12  is similarly not precisely rectangular so that the base frame  12  properly outlines the upper periphery of the pickup truck bed B) and the base frame  12  is secured in place in any desired manner such as by passing screws (not illustrated) through the base frame  12  and the bed B at strategic points. The door assembly  54  is installed within the base frame  12  by positioning the door assembly  54  within one of the halves of the base frame  12  as delineated by the leg  40  of the brace  38  of the base frame  12 . The first pin  66  of the door frame  56  is received within the first opening  42  of the first end  14  of the base frame  12  while the second pin  68  of the door frame  56  is received within the third opening  46  of the second end  16  of the base frame  12 . The door assembly  54  is sized to just fit within the half of the base frame  12  and pivot along the longitudinal midline of the base frame  12 . A second door assembly  54  is installed on the other side of the longitudinal midline of the base frame  12  is similar fashion. Once each door assembly  54  is installed, each door assembly  54  is capable of pivoting between a raised position and a lowered position. In the lowered position, best seen in  FIGS. 7 and 13 , the door assembly  54  is generally flush with base frame  12  with the kickstands  72  and  76  in a tucked position. The handle  84  on the door assembly  54  aligns with its respective handle  50  or  52  on the base frame  12  allowing a lock to be passed through the two handles  84  and  50  or  52  in order to lock the door assembly  54  in place and prevent access into the interior of the pickup truck bed B. In this lowered position, the door frame  56  rests on the gusset plates  22  and  26  or  30  and  34  of that half of the base frame  12 . In the raised position, best illustrated in  FIGS. 1 and 12 , each door assembly  54  is pivoted upwardly and its kickstands  72  and  76  are pivoted to their untucked positions. The door assembly is pivoted until the pin  74  of the first kickstand  72  is able to be received within the first opening  24  of the first gusset plate  22  (or the fourth opening  36  of the fourth gusset plate  34 ) and the pin  78  of the second kickstand  76  is able to be received within the second opening  28  of the second gusset plate  26  (or the third opening  32  of the third gusset plate  30 ). Each door assembly  54  is so positioned so that the two open door assemblies  54  form a V. A first bracket  86  is positioned down into the V such that the openings  98  of the first diagonal leg  94  align with the openings  80  on the second end  60  of one of the door assemblies  54  and the openings  100  on the second diagonal leg  96  align with the openings  80  on the second end  60  of the other door assembly  54 . Bolts  102  are passed through the aligned opening pairs  98 - 80  and  100 - 80 . Similarly, a second bracket  86  is positioned on the opposite side of the device  10  such that the openings  98  and  100  align with their corresponding openings on the first end  58  of the door frame  54  and are similarly bolted. The convertible tonneau cover is now in a rack configuration and is capable of carrying material M on the two brackets  86  while maintaining standard cargo capacity within the bed B of the truck T. When use of the rack is no longer needed, the bolts  102  are removed from the various aligned opening pairs, each kickstand  72  and  76  is removed from its respective gusset opening, and each door assembly  54  is pivoted back to its closed position and locked as needed. 
   As seen in  FIGS. 10 and 11 , the device  10  can be made to be more readily disassembleable. In such an embodiment, each end of the first end  14 ′, the second end  16 ′, the first side  18 ′ and the second side  20 ′ would have its own gusset plate  104  thereon, each gusset plate  104  having a first opening  106  and a second opening  108 . When the base frame  12 ′ is assembled, as each of the four legs of the base frame  12 ′ are brought together, the two gusset plates  104  on the end of each leg overlap one another such that each first opening  106  on the overlapped gusset plates  104  aligns as does each second opening  108 . A bolt  110  is passed through the aligned first openings  106  in order to hold the two overlapped gusset plates  104  together and thus form the base frame  12 ′. The pins  74  and  78  of the two kickstands  72  and  76  respectively are received within the aligned second openings  108  on the overlapped gusset plates  104 . Additionally, instead of using a brace  38 , a pair of pins  112  extend outwardly from the first end  14 ′ of the base frame  12 ′ toward the second end  16 ′ of the base frame  12 ′, each of the two pins  112  being on opposing sides of the longitudinal midline of the base frame  12 ′. A second pair of pins  114  extends outwardly from the second end  16 ′ of the base frame  12 ′ toward the first end  14 ′ each of the second pins  114  aligned with a respective one of the first pins  112 . Additionally, each door assembly  54 ′ has an opening  116  that receives one each of the first pin  112  and the second pin  114  in order to achieve pivotal attachment to the base frame  12 ′. In all other respects the two embodiments are equivalent. 
   While the invention has been particularly shown and described with reference to an embodiment thereof, it will be appreciated by those skilled in the art that various changes in form and detail may be made without departing from the spirit and scope of the invention.

Technology Category: b