Patent Document

BACKGROUND OF THE INVENTION 
     Pick-up trucks are typically produced with a cargo box having an open design with a tailgate which may be lowered or opened in some manner to allow access to the cargo box. Presently, there are many options and styles provided through the aftermarket to cover the open box to keep contents placed in the box out of the weather, more secure, or just to provide a more pleasing aesthetic. Varieties of box covers include both soft and hard tonneau covers and paneled tonneau covers which extend across the top of the box at the height of the box rails, and caps (or toppers) which sit on top of the box rails and extend over the box at a height of at least the height of the truck cab. Although some soft and paneled covers offer the ability to roll or remove the cover material entirely, the intended utility of the cover is typically limited to the dimensions defined by the cover itself. 
     Therefore, there is a need for a box cover that can transform to suit multiple load types and still protect the load from outside elements. 
     SUMMARY OF THE INVENTION 
     The present invention relates to a truck box cover system (i.e., a tonneau cover, topper, cap, etc.), and more particularly to a truck box cover system configured to transform to suit multiple load types and still protect the load from outside elements. The truck box cover system preferably raises and lowers and has pliable sides to maintain a closed configuration in all states. The truck box cover system is more preferably directed to a weatherproof soft tonneau cover that is convertible into a weatherproof cap with a soft top and sides. 
     One aspect of the present invention is directed to a truck box cover system with a first frame configured to attach to a truck box, a second frame, a plurality of telescopic assemblies operatively connected to the first frame and the second frame and configured to move the second frame relative to the first frame between two positions: a first position and a second position, a top comprising a first compliant material supported by the second frame, and a second compliant material supported by and extending from the first frame to the second frame; whereby the top is substantially removable from the second frame; whereby in the first position the first frame and the second frame are juxtaposed; and whereby in the second position the first frame and the second frame are spaced apart and the second compliant member is at least substantially taut, defining a first wall, a second wall, and a third wall. Further, the first and second compliant members may comprise weatherproof material and at least one of the first and second compliant members comprises a stretch tent textile. 
     The first frame of the truck box cover system may have a first rail member with a first rail member enclosure, and a second rail member, opposite the first rail member, with a second rail member enclosure; whereby in the first position the second compliant member is substantially retained within the first rail member enclosure and the second rail member enclosure. 
     The second frame of the truck box cover system may have a first cover member extending from a first end portion to a second end portion; a second cover member, opposite the first cover member, extending from a first end portion to a second end portion; a third cover member extending from the first end portion of the first cover member to the first end portion of the second cover member; and a fourth cover member extending from the second end portion of the first cover member to the second end portion of the second cover member; whereby the fourth cover member is detachably connected to the first and second cover members. 
     The first compliant material of the truck box cover system may have a first side and a second side opposite the first side; wherein a hook-and-loop material extends along the first and second sides of the first compliant material and a compatible hook-and-loop material extends along the first cover member from the first end portion to the second end portion and along the second cover member from the first end portion to the second end portion. 
     Additionally, or alternatively, the fourth cover member of the truck box cover system may include a pair of latches, wherein one latch is configured to interface with the second end portion of the first cover member and the other latch is configured to interface with the second end portion of the second cover member. Further, each of the pair of latches may have a spring-loaded rod. Additionally, a first cam member may be affixed to the second end portion of the first cover member and a second cam member may be affixed to the second end portion of the second cover member, whereby the first and second cam members are configured to interface with the spring-loaded rods of the pair of latches, respectively. 
     The first frame may have a first rail member extending from a first end portion to a second end portion; a second rail member, opposite the first rail member, extending from a first end portion to a second end portion; and a third rail member extending from the first end portion of the first rail member to the first end portion of the second rail member; whereby the second compliant material extends along and between the first frame and the second frame from the second end portions of the first rail member and the first cover member to the second end portions of the second rail member and the second cover member. Further, the truck box cover assembly may have a rear panel with a first side and a second side opposite the first side; whereby when the system is in the second position, the first side of the rear panel extends from the second end portion of the first cover member to the second end portion of the second cover member and the second side of the rear panel extends from the second end portion of the first rail member to the second end portion of the second rail member. 
     The rear panel may further have a third side extending from the first side to the second side and a fourth side opposite the third side; whereby the third and fourth sides are configured to be attached to the second compliant material. The attachment of the rear panel may be weatherproof. Further, the rear panel may be removable. 
     The truck box cover system may have a plurality of removable cover supports; whereby a first shelf extends from the first end portion to the second end portion of the first cover member and a second shelf extending from the first end portion to the second end portion of the second cover member; whereby the plurality of removable cover supports are configured to set upon and extend between the shelf of the first cover member and the shelf of the second cover member. 
     The movement of the second frame relative to the first frame by the telescopic assemblies may be electrically controlled. The electric control may be configured to be operated remotely. 
     The truck box cover system may further incorporate a rack system. The rack system may have a plurality of upstanding members and a plurality of cross members; whereby each of the plurality of upstanding members is configured to removably interface with the second frame; and whereby pairs of the plurality of upstanding members are positioned across from one another and each of the plurality of cross members is removably attached to one such pair of the plurality of upstanding members. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front perspective view of first embodiment of a truck box cover system in a first position according to the present invention. 
         FIG. 2  is a rear perspective view of the first embodiment system in the first position according to the present invention. 
         FIG. 3  is a perspective view of the first embodiment system in the first position installed in the box of a truck according to the present invention. 
         FIG. 4A  is a partial bottom perspective view of the first embodiment system in the first position according to the present invention. 
         FIG. 4B  is a partial rear perspective view of the first embodiment system in the first position according to the present invention. 
         FIG. 5A  is an end elevation view of a rail member and a cover member of the first embodiment system according to the present invention. 
         FIG. 5B  is an end elevation view of a rail member and a cover member of a second embodiment system according to the present invention. 
         FIG. 6  is a front perspective view of the first embodiment system transitioning between the first position and a second position according to the present invention. 
         FIG. 7A  is a rear perspective view of the first embodiment system shown in  FIG. 6  according to the present invention. 
         FIG. 7B  is a partial rear perspective view of a rail member of the first embodiment system shown in  FIG. 7A  according to the present invention. 
         FIG. 8  is a front perspective view of the first embodiment system in the second position according to the present invention. 
         FIG. 9  is a rear perspective view of the first embodiment system in the second position according to the present invention. 
         FIG. 10  is a rear perspective view of the first embodiment system in the second position installed in the box of the truck according to the present invention. 
         FIG. 11  is a partial rear perspective view of the first embodiment system in the second position according to the present invention. 
         FIG. 12  is a close-up perspective view of a cover latch mechanism of the first embodiment system according to the present invention. 
         FIG. 13  is a partial rear perspective view of the first embodiment system according to the present invention. 
         FIG. 14  is a rear perspective view of the first embodiment system in the second position according to the present invention. 
         FIG. 15  is a rear perspective view of the first embodiment system in the second position according to the present invention. 
         FIG. 16  is a front perspective view of the first embodiment system in the first position according to the present invention. 
         FIG. 17  is a perspective view of the first embodiment of the present invention. 
         FIG. 18  is a perspective view of the first embodiment with a rack system according of the present invention. 
         FIG. 19  is a perspective view of the first embodiment with the rack system according of the present invention. 
         FIG. 20  perspective view of the first embodiment with the rack system according of the present invention. 
         FIG. 21  is a perspective view of an upstanding member of the rack system according to the present invention. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structures. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims. 
       FIGS. 1-3  illustrate a first exemplary embodiment  100  of a truck box cover according to the present invention in a first position both independently and as installed in the box  12  of a truck  10 . The box  12  of a truck  10  typically comprises a box floor  14 , a first body panel  16  with a first box rail  18 , a second body panel  20  with a second box rail  22 , a box end panel  24  with a third box rail  26 , and a tailgate  28  (see also  FIGS. 10 and 11 ). 
     The truck box cover system  100  according to an exemplary first embodiment of the present invention preferably comprises a first frame  102 ; a second frame  124 ; a top  160  preferably comprising a first compliant material; a second compliant material  170  (see also  FIG. 6 ), a rear panel  70 , and a plurality of columns  190 . 
     The first frame  102  preferably comprises a first rail member  104 , a second rail member  114 , and a third rail member  120 . The first, second, and third rail members  104 , 114 , 120  are configured to follow the shape of the truck box  12 , specifically the first, second, and third box rails  18 , 22 , 26 , respectively. 
     The first, second, and third rail members  104 , 114 , 120  are preferably configured to be set upon the first, second, and third box rails  18 , 22 , 26  of the box  12 , respectively. Securing at least the first and second rail members  104 , 114 , to the first and second box rails  18 , 22  may be accomplished by clamping, bolting, and/or any other method now known or later developed. 
     Looking at  FIG. 5A  the first rail member  104  is shown in more detail. Preferably, the first rail member  104  comprises a first rail member retainer  106  and a first rail member enclosure  112 . Similarly, but not shown in this figure, the second rail member  114  preferably comprises a second rail member retainer  116  and a second rail member enclosure  118 . As discussed further below, the first and second rail member retainers  106 , 116  are configured to retain a first end portion  172  of the second compliant member  170 , and the first and second rail member enclosures  112 , 118  are configured to house at least a portion of the second compliant material  170  when the truck box cover system  100  is in the first position (see  FIG. 5 ). 
     Looking back to  FIG. 1 , the third rail member  120  is shown preferably comprising a third rail member retainer  122 , similar to the first and second rail member retainers  106 ,  116 . The third rail member  120  extends between the first and second rail members  104 , 114  and is configured to retain the first end portion  172  of the second compliant member  170 . 
     The second frame  124  is more easily seen in  FIGS. 6 and 7A . The second frame  124  preferably comprises a first cover member  126 , a second cover member  136 , a third cover member  146 , and a fourth cover member  150  (see  FIG. 4B ). Looking to  FIG. 5A  for a more detailed view, the first cover member  126  is shown preferably comprising a first cover member retainer  128 , a first cover member flange  130 , and a first cover member plate  132  extending inward from the first cover member retainer  128 . Hook-and-loop fastener material  30  is preferably provided along the first cover member flange  130 . The first cover member plate  132  preferably has a shelf  134  extending the length thereof and a first cam member  80  with a surface  82  is preferably provided thereupon. The first cover member retainer  128  is preferably configured to retain a second end portion  176  of the second compliant member  170 . 
     As shown in  FIG. 13 , the second cover member  136  is similar to the first cover member  126  and comprises a second cover member retainer  138 , a second cover member flange  140 , and a second cover member plate  142  extending inward from the second cover member retainer  138 . Hook-and-loop fastener material  30  is preferably provided along the second cover member flange  140  (see  FIG. 14 ). The second cover member plate  142  preferably has a shelf  144  and a second cam member  82  with a surface  84  is preferably provided thereupon. The second cover member retainer  138  is preferably configured to retain the second end portion  176  of the second compliant member  170 . 
     The third cover member  146  preferably comprises a third cover member retainer  148  and extends between the first and second cover members  126 , 136 . The third cover member  146  is configured to retain the second end portion  176  of the second compliant member  170  and a third side  166  of the first compliant member  160  (discussed further below). 
     Looking to  FIG. 4B , the fourth cover member  150  is shown. The fourth cover member  150  preferably comprises a fourth cover member retainer  152  (see  FIG. 2 ) and a pair of latches  154 . The pair of latches  154  are configured to removably engage with the first and second cover members  126 , 136 . 
     As shown in  FIGS. 12 and 13 , each of the latches  154  preferably has a spring-loaded rod  156  with a pin  157  configured to interface with the first and second cover member plates  132 , 142  of the respective first and second cover members  126 , 136  when in an engaged position. The interface with the first and second cover member plates  132 , 142  may be made through the respective first and second cam members  80 , 84 . To disengage the fourth cover member  150  from the first and second cover members  126 , 136 , the spring-loaded rods  156  are moved inward toward each other until clear of the first and second cover member plates  132 , 146  and potentially the first and second cam members  80 , 84 , then the fourth cover member  150  is free to move relative to the first and second cover members  126 , 136 . The spring-loaded rods  156  may be maintained in the disengaged position by placing the pin  157  against a catch  158 . 
     To engage the fourth cover member  150  with the first and second cover members  126 , 136 , the reverse of the disengaging procedure is performed; however, the spring-loaded rods  156  may be in the engaged position prior to engaging with the first and second cover members  126 , 136 . In that case, during the process of lowering the fourth cover member  150  into position between the first and second cover members  126 , 136 , each of the spring-loaded rods  156  will follow the surfaces  82 , 86  of the respective first and second cam members  80 , 84 . Through the biased nature of the spring-loaded rods  156 , the spring-loaded rods  156  will engage with the first and second cover member plates  132 , 142  when they are below the most inwardly extending portion of the first and second cam members  80 , 84 . 
     Looking back to  FIG. 5A , one method of securing the second compliant material  170  is shown with respect to the first rail member retainer  106  of the first rail member  104 . The first end portion  172  of the second compliant material  170  is preferably fed into the first cover member retainer  106  through a slot  108  creating a loop  178  in the first end portion  172 . Preferably, a dowel  50  is then inserted into the loop  178  along the length of the first rail member retainer  106 . The diameter  52  of the dowel  50  is preferably greater than the width  110  of the slot  108 , thereby retaining the first end portion  172  of the second compliant material  170  within the first rail member retainer  106 . Clips (not shown) may further secure the free end  174  of the first end portion  172  of the second compliant member  170  to the first cover member retainer  106 ; however, as shown with respect to a second embodiment  200  of the cover system shown in  FIG. 5B , the loop  178  may be formed by sewing (or otherwise attaching) the free end  174  back to the second compliant material. The same retention method is preferably provided for the second compliant material  170  within at least the second rail member  114 , the third rail member  120 , the first cover member  126 , the second cover member  136 , and the third cover member  146 , and the first compliant material  160  within at least the fourth cover member  150 . 
     The second frame  124  is preferably sized and configured to be positioned adjacent to and substantially over the first frame  102 , whereby the first cover member  126 , the second cover member  136 , and the third cover member  146  of the second frame  124  are positioned substantially directly above the first rail member  104 , the second rail member  114 , and the third rail member  120  of the first frame  102 , respectively, when the truck box cover system  100  is in the first position (see  FIGS. 1, 2, and 5 ). 
     Additionally, as depicted in  FIGS. 1-5 , when in the first position, the second compliant material  170  along and between the first rail member  104  and the first cover member  126  is preferably substantially positioned within the first rail member enclosure  112  and the second compliant material  170  along and between the second rail member  114  and the second cover member  136  is preferably substantially positioned within the second rail member enclosure  118 . 
     The second embodiment  200  of the cover system shown in  FIG. 5B  preferably comprises a first frame  202  with a first rail member  204  and a second frame  224  with first cover member  226 . In the second embodiment  200 , it should be understood that the second rail member (not shown) of the first frame  202  and the second cover member (not shown) of the second frame  224  are mirror images of the respective first rail member  204  and the first cover member  226 . The first rail member  204  comprises a first rail member retainer  206  with a slot  208  and a first rail member enclosure  212 . The first cover member  226  comprises a first cover retainer  228 , a first cover member flange  230 , and a first cover member plate  232  with a shelf  234 . Preferably, a hook-and-loop fastener material  30  is provided on the inside surface of the first cover member flange  230 . 
     The first compliant material  160  preferably comprises a first side  162 , a second side  164 , a third side  166 , and a fourth side  168 . The first and second sides  162 , 164  preferably comprise hook-and-loop fastener material (see  FIG. 14 ) therealong and are configured to be removably attachable to the first and second cover member flanges  130 , 140  of the second frame  124 , respectively. The third side  166  of the first compliant material  160  is preferably retained within the third cover member retainer  146  of the third cover member  146  and the fourth side  168  is preferably retained within the fourth cover member retainer  150  of the fourth cover member  150 . The first compliant material  160  is shown as being removably attached by the hook-and-loop fastener material  30 , however, additional or alternative fastening configurations, such as snaps, are contemplated. 
     Looking at  FIGS. 11 and 14 , a plurality of removable cover supports  60  are shown. The plurality of cover supports  60  are preferably provided positioned on the shelves  134 , 144  of the first and second cover members  126 , 136  and extend therebetween. 
     Each of the plurality of columns  190  preferably comprises a telescopic assembly  192  with a base  194 , a telescopic portion  196  (see  FIG. 11 ), and an actuator  198  (see  FIG. 4A ) preferably located within, or at least substantially within, the base  194  and configured to actively engage with the telescopic portion  196 . The base  194  is preferably attached to at least one of the floor  14  of the truck box  12  and the first frame  102 . The telescopic portions  196  are preferably attached to the second frame  124 . Even more preferably, the telescopic portions  196  are attached to the first and second cover member plates  132 , 142  of as shown in  FIG. 5A . 
     Looking to  FIGS. 6-7B , the cover system  100  is shown in an intermediate state as it is being raised from the first, lowered, position to a second, raised, position. Extension of the telescoping portions  196  is performed by activation of the actuators  198  through a switch (not shown) in electrical communication therewith. The switch (not shown) is preferably operated through a remote (not shown). Upon activation, the second frame  124  is raised relative to the first frame  102 . As shown in  FIGS. 7A and 7B , the second compliant material  170  is unfurled from the first and second rail member enclosures  112 , 118 . The second compliant material  170  is preferably a continuous un-interrupted piece of material and made from a pliable and weather-resistant material such as a stretch tent textile. 
     The second frame  124  continues the upward assent until reaching the second position shown in  FIGS. 8-11 . In the second position, the second compliant member  170  is preferably made taught between the first frame  102  and the second frame  124  and provides a first wall  180 , a second wall  182 , and a third wall  184 . 
     To return the second frame  124  to the first position, the actuators  198  are activated by the switch (not shown) in the reverse direction. 
     The actuators  198  are preferably hydraulically driven but a pneumatic system is also within the purview of the present invention. Activation of the actuators  198  to extend the telescoping portions  196  is preferably a one-touch activation, whereas the retraction of the telescoping portions  196  to lower the second frame  124  from the second position to the first position preferably requires constant activation of the switch (not shown) by a user (not shown). This is done to reduce the chance of user injury, damage to the cover  100 , and/or the load (not shown) being carried in the truck box  12  by accidental activation; however, this functionality should not be viewed as limiting the invention. Additionally, or alternatively, a manually operated switch (not shown) may be included which must be manually closed prior to activation of the actuators  198 . 
     Turning now to  FIG. 17  in which the rear panel  70  is shown as installed. The rear panel  70  preferably comprises a first rod (hidden) provided along a first side  72  and a second rod (hidden) provided along a second side  74 , a third side  76 , and a fourth side  78 . With reference to  FIG. 13 , the first rod (hidden) is receivable within the recesses  92  of a pair of upper brackets  90  attached to the first and second cover members  126 , 136  and the second rod (hidden) is receivable within the recesses  96  of a pair of lower brackets  94  attached to the first and second rail members  104 , 114 . The third and fourth sides  76 , 78  are preferably configured to be secured in a weatherproof manner to the second compliant member  170 . The weatherproof connection may be made through hook-and-loop material or any other method now known or later developed. The rear panel  70  is preferably formed from a compliant material, such as a stretch tent textile, and is configured to be rolled up and stored when not in use. 
     Turning now to  FIGS. 18-21  a rack system  300  according to the present invention is shown. The rack system  300  is preferably configured to interface with the cover system  100 , 200 . The rack system  300  comprises a plurality of upstanding members  302  and a plurality of cross-members  320 . 
       FIG. 21  provides a view of an exemplary embodiment of an upstanding member  302  according to the present invention. The upstanding member  302  preferably comprises a pillar  304 , with a through-hole  306 , extending from a base  308 , and an arm  310  extending alongside at least a portion of the pillar  304  and below the base  308 . The arm  310  has an upturned end  312 . 
     Each upstanding member  302  is configured to interface with the first and second cover members  126 , 136 . As shown in  FIGS. 18 and 19  with respect to placement of an upstanding member  302  on the second cover member  136 , the upstanding member  302  is positioned with the upturned end  312  received within the second cover member  136  between the second cover member retainer  138  and the second cover member flange  140  with the remainder of the arm  310  that is below the base  308  abutting the outside of the second cover member flange  140 . The base  308  is positioned atop the second cover member  136 . This arrangement allows for increased versatility as the plurality of upstanding members  302  may be placed at any location along the first and second cover members  126 , 136 . 
       FIG. 20  illustrates the plurality of cross-members  320  attached to and extending between opposing upstanding members  302 . Here, the plurality of cross-members  320  have through-holes (hidden) at opposing end portions  322 , 324  which are configured to be alignable with the through-holes  306  of the pillars  304 . The plurality of cross-members  320  are preferably removably attached to the upstanding members  302  with pins  330  extending through the aligned upstanding member through-hole  306  and the cross-member through-hole (hidden), however, other methods of removable attachment are contemplated, such as by a threaded fastener (not shown). It should also be noted that the placement of the plurality of cross-members  320  on the plurality of upstanding members  302  may be adjustable. 
     The rack system  300  is configured to be incorporated and usable with both cover system  100 , 200  in both the first position and the second position.  FIGS. 18-20  illustrate thus with the cover system  100 . 
     A method for raising and lowering a truck box cover is also contemplated according to the present invention and is describes with respect to the first embodiment of the truck box cover assembly  100 . The method preferably comprises the steps of: providing a first frame  102  and a second frame  124 ; providing a plurality of telescopic assemblies  192  operably connected to the first frame  102  and the second frame  124 , whereby the second frame  124  is configured to be movable relative to the first frame  102  through activation of the plurality of telescopic assemblies  192  between two positions: a first position and a second position; whereby in the first position the first frame  102  and the second frame  124  are juxtaposed and in the second position the first frame  102  and the second frame  124  are spaced apart; providing a first compliant member  160  supported by and extending across the second frame  124 ; providing a second compliant material  170  supported by and extending between the first frame  102  and the second frame  124 ; whereby, when in the first position, activating the plurality of telescoping assemblies  192  to move the second frame  124  to the second position wherein the second compliant material  170  is taut; and whereby when in the second position, activating the plurality of telescoping assemblies  192  to move the second frame  124  to the first position. The method further comprises the step of actively monitoring the truck box cover system  100  when moving from the second position to the first position. Active monitoring may include, but should not be limited to, constantly maintained activation of the plurality of telescopic assemblies  192  by a user (not shown) and/or pressure sensors (not shown) monitoring force applied in a direction different than the downward movement of the second frame  124 . The method may further comprise the step of tucking the second compliant member  170  into a first rail member retainer  112  and a second rail member enclosure  118  of the first frame  102  when moving the second frame  124  from the second position to the first position. 
     The foregoing is considered as illustrative only of the principles of the invention. Furthermore, because numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.

Technology Category: 7