Corner structure of container cover

Abstract

The invention relates to a corner structure for a container cover, in particular to a corner assembly for a container cover, which comprises a cover body and a base matched and jointed with the cover body. A patterned cut corner of a flexible cover having a generally rectangular shape is positioned and constrained between the cover and the base. The corner assembly omits the time and labor-intensive processes consumed by manufacturing the corners of the container cover by folding and manual sewing.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 448,112, filed on February 24, 2023, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present invention generally relates to a cargo bed cover for covering a pickup truck bed, and more particularly to a foldable cargo bed cover and its structure. Background Art

[0004] An advantage of a pickup truck is the ability to transport or store items in a cargo box or bed located behind the truck's passenger compartment (hereinafter referred to as the "cab"). The cargo box typically includes a pair of opposing side walls connected by a front wall or bulkhead and a rear wall or tailgate at the rear end.

[0005] One accessory used to cover the bed of a truck is commonly referred to as a bed cover. Bed covers are used to cover the bed of a pickup truck for a variety of reasons, including aesthetics, aerodynamics, and to protect any contents in the bed from being thrown out and from environmental elements such as rain, dust, snow, and debris.

[0006] There are various styles of cargo bed covers, generally including soft and hard bed covers. Soft bed covers typically utilize a frame defined by side frame members and transverse frame members extending between the side frame members. Additional transverse members, sometimes called arched cross members, may be positioned between the transverse frame members. A cover made of a flexible material is provided that extends over the entire foldable frame.

[0007] Soft bed covers can also come in a variety of styles and configurations, such as foldable, non-foldable, and roll-up bed covers. A foldable bed cover can be desirable because, when covering the entire pickup truck bed is not necessary, the bed cover can be folded toward the rear of the cab, leaving at least a portion of the bed uncovered. On the other hand, a non-foldable bed cover can be desirable due to its simplicity and lack of moving parts. Furthermore, a roll-up bed cover can be desirable due to its ease of bed access, affordability, and ease of installation.

[0008] Regardless of the configuration or style of a soft bed cover, one particularly complex and labor-intensive aspect of constructing the cover and attaching it to the frame is forming the cover's four corners. Conventional cover corners are composed of multiple components (e.g., tarpaulin, attachment strips, edge binding, and plastic reinforcements) and require complex stitching on a three-dimensional plane to properly form the corners, thus hindering manufacturing automation. Even after this complex and labor-intensive process, these soft tarpaulin corners are often the most susceptible locations for soft beds to damage, such as from fraying, curling, and folding, and they can cause various problems throughout the life of the bed cover.

[0009] From the above discussion, it can be seen that the conventional corner structure is complex and not durable enough. There is a need for a structure that can simplify the corner manufacturing and improve the durability of the corner of the cargo box cover. Summary of the Invention

[0010] To meet the aforementioned needs, and to overcome the enumerated shortcomings and other limitations of the related art, the present invention provides a corner assembly for a cargo box cover that eliminates the time-consuming and labor-intensive process of manufacturing cargo box cover corners by folding and hand-stitching.

[0011] Thus, in one aspect, the present invention is embodied in a corner assembly for a cargo box cover, the corner assembly being provided with a cover, a base matingly engaged with the cover, and a flexible cover having a generally rectangular shape and including at least one patterned cut corner positioned and captively retained between the cover and the base.

[0012] In another aspect, the present invention is embodied in a method of assembling a corner assembly for a cargo box cover, the method comprising the steps of providing a cover and a base; providing a flexible cover having a generally rectangular shape and including at least one patterned cut corner; positioning the patterned cut corner between the cover and the base; and matingly engaging the cover with the base to constrain the patterned cut corner between the cover and the base.

[0013] Other objects, features and advantages of the present invention will become apparent to those skilled in the art upon review of the following description (including the claims) and reference to the accompanying drawings, which are attached and constitute a part of this specification. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] For a more complete understanding of the present invention, reference should be made to the following detailed description taken in conjunction with the accompanying drawings, in which: Figure 1is a perspective view of a pickup truck with a bed cover installed showing the bed cover in an extended position covering the bed and in a collapsed position showing a portion of the bed uncovered in phantom.

[0015] Figure 2 yes Figure 1 A perspective view of the underlying frame of the cargo box cover is shown.

[0016] Figure 3 yes Figure 1 An enlarged view of a corner assembly of a cargo box cover is shown.

[0017] Figure 4 yes Figure 3 Exploded view of the structure of the corner assembly.

[0018] Figure 5 is used for Figure 1 A plan view of a cut piece of tarpaulin for the cargo box covering is shown.

[0019] Figure 6 yes Figure 5 An enlarged view of a cutout portion of a corner of a tarpaulin is shown.

[0020] Figure 7 is a top perspective view of a cover for a corner assembly of a cargo box cover.

[0021] Figure 8 yes Figure 7 A bottom perspective view of the cover is shown.

[0022] Figure 9 is a top perspective view of a base for a corner assembly of a cargo box cover.

[0023] Figure 10 yes Figure 9 Bottom perspective view of the base shown.

[0024] Figure 11 yes Figure 3 Bottom perspective view of the corner assembly shown.

[0025] Figure 12 The corner component is roughly along Figure 3 A cross-sectional view taken along line l2-l2 in FIG.

[0026] Other objects, features and advantages of the present invention will become apparent to those skilled in the art upon review of the following description (including the claims) and reference to the accompanying drawings, which are attached and constitute a part of this specification. DETAILED DESCRIPTION

[0027] In the following detailed description of the embodiments, reference will be made to the accompanying drawings, which form a part of this specification and show by way of illustration specific embodiments in which the invention may be practiced. It should be understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the invention. It should also be noted that while the drawings illustrate foldable cargo box covers, embodiments of the present invention may be used with any style of soft cargo box cover, as the present invention relates to corner assemblies of such cargo box covers for securing a flexible cover (e.g., fabric) to a frame.

[0028] Referring now to the accompanying drawings, Figure 1 A pickup truck 10 is generally shown in FIG. 1 having a foldable bed cover 12 attached to a bed 14 of the truck 10. The bed cover 12 is shown mounted to the bed 14 of the truck 10 to cover or enclose the bed 14. The bed 14 is positioned rearward of a passenger compartment ("cab") 16 of the truck 10 and includes a bottom wall 17 and a pair of opposed side walls 18 connected at front and rear ends by a front wall or bulkhead 20 and a rear wall or tailgate 22, respectively. The tops of the side walls are typically reinforced and define bed side rails 24. The bed cover 12 can be mounted to or rest on the bed side rails 24.

[0029] Figure 1 1 and 2. The bed cover 12 is shown in an extended position, wherein the sections 28 of the bed cover 12 are adjacent to each other and cover the bed 14. The bed cover 12 is foldable from the extended position to a folded position (shown in phantom) wherein the sections 28 are folded relative to each other toward the cab 16 or bulkhead 20 to expose at least a portion of the bed 14.

[0030] like Figure 1 As shown, the bed cover 12 has four sections 28. However, the bed cover 12 may have more or less than four sections 28, and for example, Figure 2 The illustrated frame 30 is provided in three sections, generally designated 28'.

[0031] The frame 30 is formed from a plurality of interconnected longitudinal side rails 32, transverse side rails or arched cross members 34, and end side rails 36. When mounted on the truck 10, the longitudinal side rails 32 generally define opposite sides of the bed cover 12 and are positioned above the bed side rails 24 of the bed 14. The end side rails 36 generally define opposite ends of the bed cover 12 and are positioned above the bulkhead 18 and tailgate 22. As discussed further below, at the four corners of the bed cover 12, the longitudinal side rails 32 and end side rails 36 of the tailgate and bulkhead sections 28 are connected to each other via corner connectors, which may be interference fit with the longitudinal sections or secured by mechanical fasteners, such as screws. The entire frame 30, and the bed cover 12 as a whole, is secured to the bed side rails 24 or other portions of the bed 14 by clamps 38, which may be supported by the transverse side rails 34.

[0032] Each section 28 of the cargo bed cover 12 is pivotally attached to the adjacent section 28 of the cargo bed cover 12. The section 28 of the cargo bed cover located near the tailgate 22 (in the extended position), i.e., the "tailgate" section 28a, is pivotally attached to the middle section 28b via a hinge mechanism 40 (i.e., a hinge, flexible substrate, or similar connection). This is achieved by positioning the hinge mechanism 40 between the middle section 28b and the corresponding longitudinal side rail 32 of the tailgate section 28a. When the tailgate section 28a is moved toward the folded position, the tailgate section 28a folds about the hinge mechanism 40 so that the top surface of the tailgate section 28a is adjacent to the top surface of the middle section 28b.

[0033] The intermediate section 28b is also pivotally attached to the second intermediate section 28b ( Figure 1 ) or connected to the section 28 located near the partition 18 ("partition" section 28c; see generally Figure 2 A hinge mechanism 42 provides this pivotal attachment and is positioned between respective longitudinal side rails 32 of adjacent segments 28 .

[0034] As the cargo box cover 12 moves further into the folded position, the tailgate section 28a and the intermediate section 28b fold together around the hinge mechanism 42 onto the bulkhead section 28c. To accommodate the combined thickness of the tailgate and intermediate sections 28a, 28b, the hinge mechanism 42 can be configured as a double hinge mechanism with a spacer or enlarged flexible member. Such hinge mechanisms 40, 42 are well known in the art and need not be discussed further herein.

[0035] Covering the frame 30 and secured to the longitudinal side rails 32 and the end side rails 36 is a tarpaulin or cover 44 made of a flexible fabric material, such as vinyl. The cover 44 is preferably provided as a single piece of material and extends over substantially all of the sections 28 of the bed cover 12. Thus, a section 28 is generally defined as the portion of the bed cover 12 that extends between the end side rails 36 and the hinge mechanisms 40, 42, or between adjacent hinge mechanisms 40, 42. In one embodiment, the cover 44 is cut from a single piece of base material 46 and has an overall rectangular shape having sides 48 and ends 50. However, as discussed further below, the corners of the cover 44 are not cut at right angles.

[0036] Each side 48 and end 50 of the cover 44 is coupled to a plastic edge strip (not shown) by, for example, sewing. The edge strip (which may be formed by extrusion) preferably includes integral fasteners (not shown) for securing the sides 48 and ends 50 of the cover 44 to the longitudinal and end rails 32 and 36 of the frame 30. While various configurations are possible, in one embodiment, the fasteners are configured as protrusions with enlarged tips or heads, giving the overall shape of a Christmas tree-shaped fastener. The longitudinal and end rails 32 and 36 of the frame 30 (which may be aluminum extrusions) may be formed with slots having a reduced-width entrance opening that faces generally outward when positioned on the bed rails 24. To secure the cover 44 to the frame 30, the fasteners are inserted into the slots. When the fasteners are inserted into the slots, the enlarged heads are elastically deformed by the reduced-width entrance openings (which are smaller than the head). Once through the inlet opening, the resilience of the head causes it to return to its original shape, snapping the raised head into the slot and securing the sides 48 and ends 50 of the cover 44 to the frame 30 .

[0037] Typically, in the traditional manufacture of soft cargo box covers, the cover corners are one of the most labor-intensive features of construction. Conventional corner construction typically involves placing a molded plastic reinforcement beneath the cover's lower surface, precisely folding the cover over the reinforcement, and applying multiple rows of stitching along a three-dimensional contour, followed by hemming around the corner stitch edges, all of which require manual labor. The corner assembly 62 disclosed herein eliminates this complex process and structure.

[0038] like Figures 3 and 4 As shown, corner assembly 62 includes three main components: a cover 64, a base 66, and a patterned cut corner 68 of cover 44. Cover and base 64, 66 are configured to matingly engage and clamp, hold, and / or constrain the cut corner 68 therebetween.

[0039] like Figure 3 、 Figure 4 、 Figure 7 and Figure 8 As shown, the cover body 64 includes a generally flat top 70 from which extends a tapered skirt portion 72 outwardly and downwardly. The skirt portion 72 defines approximately ninety degrees in the circumferential direction. The flat top 70 and skirt portion 72 generally form a partial frustoconical shape. Optionally, in the assembled corner configuration, extending from the sides of the skirt portion 72 and overlying the cover member 44 (specifically, the sides 48 or the ends 50) are tabs 74 that can be used for branding purposes.

[0040] The underside or bottom side of the cover 64 includes a plurality of features that help engage the cover 64 with the base 66 and securely hold the cut corner 68 therebetween. These features include a first pair of locating pins 76 extending downwardly from the skirt portion 72, a second pair of locating pins 78 extending downwardly from the flat top 70, a first mounting boss 80 extending from the skirt portion 72, and a second mounting boss 82 extending from the flat top 70. Also shown is a ribbed or grooved surface 83 provided as the lower surface of the flat top 70.

[0041] like Figure 4 、 Figure 9 and Figure 10 As shown, base 66 has a shape corresponding to cover 64 and includes features corresponding to those of cover 64. Generally, base 66 is defined by a wedge- or scallop-shaped body 84, which includes a generally flat top 86 (with a ribbed or grooved surface 87) and a tapered outer surface 88 extending downwardly and outwardly from top 86. Similar to cover 64, flat top 86 and outer surface 88 generally form a partial frustoconical shape that corresponds to and fits within the frustoconical shape of flat top 70 and skirt portion 72 of cover 64. Support members 90 extend from side 91 of body 84 (generally opposite outer surface 88). Support members 90 are configured to mate with and be inserted into the ends of longitudinal side rails 32 and end side rails 36 of tailgate and bulkhead sections 28a, 28c of frame 30. As previously mentioned, and without limiting the attachment method, this engagement may be an interference fit and may further be secured by friction, adhesive, and / or mechanical means.

[0042] Corresponding features of the base 66 include a first pair of locating holes 92 defined in the tapered outer surface 88 of the body 84, a second pair of locating holes 94 defined in the flat top 86, a first mounting hole 96 defined in the tapered outer surface 88, and a second mounting hole 98 defined in the flat top 86. In the corner assembly 62, the first and second pairs of locating holes 92, 94 receive the first and second pairs of locating pins 76, 78, respectively, and the first and second mounting holes 96, 98 receive the first and second mounting bosses 80, 82, respectively.

[0043] The mounting bosses 80, 82 include threaded portions 100 therein, which can be provided by insert molding an internally threaded barrel 102 with the cover 64 (and more specifically, with each mounting boss 80, 82). To retain and secure the cover 64 to the base 66, a threaded fastener 103 can be inserted into the opening in the mounting holes 96, 98 and engage with the threaded portions 100 of the mounting bosses 80, 82.

[0044] As described above, when the cover 64 and base 66 are fastened together, the cut corner 68 of the cover 44 is clamped between the cover 64 and base 66. To facilitate the engagement of the cut corner 68 with the cover and base 64, 66, the cut corner 68 is not provided at the ninety-degree intersection of the side 48 and the end 50 of the cover 44. Instead, as Figures 4 to 6 As shown, each cut corner 68 is defined along its edge by a convex portion 104 that is recessed relative to the sides 48 and end 50 of the cover 44 by a step 105. During the sewing process, the step 105 can be folded over the plastic member and sewn to the edge strip (not shown). Preferably, the convex portion 104 is formed as an approximately ninety-degree arc segment. Alternatively, the convex portion 104 is not recessed relative to the sides 48 and end 50, but rather is formed to smoothly transition from these sides 48 and end 50 (i.e., without the step 105).

[0045] A notch 106 is formed on the edge of the cut corner 68 near the center or midpoint of the convex portion 104. The notch 106 may be V-shaped and may extend to a depth greater than half the radius of curvature of the convex portion 104. It should be noted that the notch may take any shape as long as the cut corner 68 can be secured between the cover 64 and the base 66 without any gaps or openings in the overall corner structure.

[0046] A series of holes are also formed in the cut corner 68. Two oval holes 108 are formed generally adjacent to the lateral extents of the convex portion 104, and three circular holes 110 are distributed in a generally semicircular pattern centered at the apex of the recess 106. It should be noted that the holes may be of any shape that ensures a secure fit between the cover 64 and the base 66 while preventing tearing due to stretching once the corner is fully assembled.

[0047] When assembling the components of the corner assembly 62, the base 66 is mounted to the longitudinal side rails 32 and the end side rails 36 of the frame 30. The cut corner portion 68 of the cover 44 is then positioned over the base 66 so that the oblong hole 108 is positioned over the locating hole 92 and the convex portion 104 covers the tapered outer surface 88 of the base 66. At this point, the hole 110 surrounding the apex of the notch 106 is positioned over the locating hole 94 and the mounting hole 98. Providing the notch 106 in the cut corner portion 68 allows the cover 44 to be positioned over the base 66 without requiring folding or additional positioning on the base 66.

[0048] With the cut corners 68 positioned over the base 66 (with the corresponding holes aligned), the cover 64 is mounted to the base 66 by passing the locating pins 76, 78 and mounting bosses 82 through the corresponding oval holes 108 and hole 110 of the cover 44, and through the locating holes 92, 94 and mounting hole 98 of the base 66. The cover 64 and base 66 can then be fastened together using fasteners 103 through the corresponding mounting bosses and holes 80, 82, 96, 98. It should be noted that the mounting bosses 80 of the cover 64 and the mounting holes 96 of the base 66 are positioned within the recesses 106 of the cover 44. Therefore, there are generally no holes in the cover 44 associated with the mounting bosses / holes 80, 96. When the lid 64 and base 66 are fastened together, the cover 44 is captured between the lid 64 and base 66, and in particular, between the lower surface of the flat top 70 of the lid 64 and the upper surface of the flat top 86 of the base 66. The ribbed bottom surface 83 of the lid 64 and the ribbed top surface 87 of the base 66 cooperate to hold the cover 44 in the corner assembly 62, increasing friction and keeping the cover 44 taut against the frame 30. The ribbed surfaces 83, 87 also help direct water in the corner assembly 62 outward and away from underneath the cargo box cover 12.

[0049] It should also be noted that in some embodiments, the attachment features of the cover 64 and base 66 can be reversed, such that the locating pins and mounting bosses are located on the base 66, while the locating holes and mounting holes are located on the cover 64. This may be desirable so that the cover 44 can be stretched and tightened onto the base 66 (without physically maintaining their alignment) until the cover 64 is positioned on top of the base 66. In other alternative embodiments, the cover 64 and base 66 can have a mixture of these features, such as the cover 64 having locating pins and mounting holes while the base 66 has locating holes and mounting bosses. In alternative embodiments of the patterned cut corner 68, its various features (convex portion 104, concave step 105, notch 106, and hole 108) can be used alone or in combination with one or more other features. Any combination of these features is contemplated herein.

[0050] As can be seen from the above description, the corner assembly 62 of the bed cover 12 allows for the construction of corners with minimal complexity and manual labor compared to conventional bed cover corner formation methods. Thus, time and cost savings can be achieved in bed cover production.

[0051] Although the present invention has been described with reference to certain specific embodiments incorporating its principles, those skilled in the art will readily appreciate that the present invention is susceptible to modification, variation, and alteration without departing from the true spirit and fair scope of the invention as defined by the claims that follow. Therefore, the scope of the claims should not be limited by the preferred embodiments, but should be given as broad an interpretation as possible consistent with the overall description. The terms used herein are therefore intended to be interpreted as words of description rather than of limitation.

[0052] It is also to be understood that the following claims are intended to cover all generic and specific features of the invention described herein and all statements which, as a matter of language, might be construed as intervening therebetween as to the scope of the invention.

Claims

1. A corner assembly for a cargo bed cover, the cargo bed cover having a frame configured to be at least partially disposed on or along a side wall, bulkhead, and / or tailgate of a pickup truck's cargo bed, the corner assembly comprising: Cover body; a base in mating engagement with the lid and configured to be positioned at a corner of a pickup truck's bed, wherein at least one of the lid and the base is configured to engage the frame of the bed cover; and A flexible cover having a generally rectangular shape and including at least one patterned cut corner positioned and constrainedly retained between the cover and the base, wherein the flexible cover is configured to cover the cargo box of the pickup truck.

2. The corner assembly according to claim 1, wherein: The cover defines a first shape, and the base defines a second shape that corresponds to and fits within the first shape.

3. The corner assembly according to claim 1, wherein: The cover includes one or more first attachment features and the base includes one or more second attachment features, wherein at least some of the first and second attachment features define mating portions of the cover and the base.

4. The corner assembly according to claim 1, wherein The one or more first attachment features and the one or more second attachment features include at least one of: locating pins and locating holes corresponding to each other, and / or mounting bosses and mounting holes corresponding to each other.

5. The corner assembly according to claim 1, wherein The one or more first attachment features include at least one locating pin and / or mounting boss extending from a surface of the cover toward the base.

6. The corner assembly according to claim 5, wherein: The one or more second attachment features include at least one locating hole and / or mounting hole provided in a surface of the base opposite the cover and corresponding to the at least one locating pin and / or mounting boss of the one or more first attachment features.

7. The corner assembly according to claim 1, wherein: The one or more first attachment features include a first grooved surface provided in the cover, and the one or more second attachment features include a second grooved surface provided in the base, wherein the first grooved surface and the second grooved surface engage the flexible cover therebetween.

8. The corner assembly according to claim 1, wherein: The at least one patterned cut corner of the flexible cover comprises one or more holes formed in the cover, wherein the one or more holes correspond to the one or more first attachment features and the one or more second attachment features of the cover and the base.

9. The corner assembly according to claim 8, wherein: The patterned cut corners also include V-shaped notches.

10. The corner assembly according to claim 1, wherein The patterned cut corners include V-shaped notches.

11. The corner assembly according to claim 1, wherein: The patterned cut corners of the flexible cover include convex portions extending between sides and ends of the cover.

12. The corner assembly according to claim 11, wherein The convex portion is recessed relative to the side and the end of the cover member by a step.

13. The corner assembly according to claim 11, wherein: A V-shaped notch is centrally provided in the convex portion.

14. The corner assembly according to claim 13, wherein: The patterned cut corners include one or more holes formed in the cover, wherein the one or more holes correspond to the one or more first attachment features of the cover and the one or more second attachment features of the base.

15. The corner assembly of claim 1, wherein: The cover includes a tapered skirt portion defining a partial frustoconical shape and a generally flat top portion, The base includes a tapered skirt portion defining a partial frustoconical shape and a generally flat top, and The partial frustoconical shape of the base corresponds to and fits within the partial frustoconical shape of the cover.

16. A method of assembling a corner assembly of a cargo box cover, the method comprising the steps of: providing a cover; Provide a base; providing a flexible cover having a generally rectangular shape and including at least one patterned cut corner; positioning the patterned cut corner between the cover and the base; as well as The cover is matingly engaged with the base to constrain and retain the patterned cut corners between the cover and the base.

17. The method according to claim 16, wherein The cover and the base include one or more retaining features, and the patterned cut corners include one or more holes provided in the cover, the method further comprising the step of positioning the one or more holes corresponding to the one or more retaining features before mating the cover with the base.

18. The method according to claim 17, wherein The step of positioning the one or more holes corresponding to the one or more retention features includes passing one or more of the retention features through the one or more holes.

19. The method according to claim 16, wherein The cover and the base each include a tapered skirt portion defining a partially truncated cone shape and a generally flat top, the patterned cut corner includes a convex portion and a recess centrally disposed in the convex portion, and the method further includes the step of closing the recess so that the patterned cut corner is mated with the cover and subsequently engaging the base without any gap or opening.

20. A cargo box cover assembly, comprising: a frame configured to be disposed at least partially on or along a sidewall, bulkhead, and / or tailgate of a pickup truck's cargo box; a flexible cover having a generally rectangular shape and configured to be attached directly or indirectly to the frame; Corner assembly, including: Cover body; a base, mating and engaging with the cover; At least one of the cover and the base is engaged with the frame; and The flexible cover includes at least one patterned cut corner positioned and constrainedly retained between the cover and the base.

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