Corner construction for tonneau cover

Abstract

A corner assembly for a tonneau cover that includes a cap and a base that is matingly engaged with the cap. A patterned cut-corner of a flexible cover, the latter of which has a generally rectangular shape, is located and captively retained between the cap and the base. This corner assembly eliminates the time- and labor-intensive process of manufacturing tonneau cover corners via folding and manual stitching.

Description

CORNER CONSTRUCTION FOR TONNEAU COVER CROSS REFERENCE TO RELATED APPLICATION

[0001] This application is related to U.S. provisional application number 63 / 448,112, filed on February 24, 2023. BACKGROUND 1. Field of the Invention

[0002] The present invention generally relates to tonneau covers used in covering the cargo boxes of pickup trucks. More particularly, the present invention relates to foldable tonneau covers and the construction thereof. 2. Description of Related Technology

[0003] An advantage of a pickup truck is the ability to haul or store item in the cargo box or bed of the truck, located rearward of the passenger cabin (hereafter "cab") of the truck. The bed commonly includes a pair of opposed sidewalls joined at their forward and rearward ends by a front wall or bulkhead and rear wall or tailgate, respectively.

[0004] One accessory that exists to cover the bed of the truck is commonly referred to as a tonneau cover. Tonneau covers are used to cover the beds of pickup trucks for multiple reasons, including aesthetics, aerodynamics, and protection of any contents located in the bed, both from ejection and from environmental factors, such as rain, dirt, snow, and debris.

[0005] Various styles of tonneau covers exist and generally include soft tonneau covers and hard tonneau covers. Soft tonneau covers typically employ a frame defined by side frame members and transverse frame members, the latter of which extend between the side frame members. Additional transverse members, sometimes referred to as cross bows, may be provided between the transverse frame members. A cover of a flexible material is provided and retained over the entire foldable frame.

[0006] Soft tonneau covers can also come in a variety of styles and configurations, for example foldable tonneau covers, non-foldable tonneau covers, and roll-up tonneau covers. Foldable tonneau covers may be desirable because, when not required to cover the entire bed of the pickup truck, the tonneau cover may be folded toward the rear of the cab, leaving at least a portion of the bed open and uncovered. On the other hand, non-foldable tonneau covers may be desirable due to simplicity and a lack of moving parts. In addition, roll-up tonneau covers may be desirable due to its bed access, affordability, and ease of installation.

[0007] Regardless of the configuration or style of a soft tonneau cover, when constructing the cover and attaching it to the frame, one particularly complex and labor intensive aspect is the formation of the four corners of the cover. Conventional corners of a cover are of composed multiple parts (e.g., a tarp, attachment strips, edge banding, and plastic reinforcements), and require complex stitching on a three-dimensional plane to properly form the corner, thus preventing automation in manufacturing. Even with this complex and labor intensive process, these soft tarp corners are typically the first location where a soft cover can be damaged, for example by wear and tear, curling and rolling back, and they can cause problems over the life of the tonneau cover.

[0008] As seen from the above discussion, conventional corner construction is complex and not sufficiently robust. A construction that simplifies manufacturing of the corners and increases the robustness of the tonneau cover in its corners is desirable. SUMMARY

[0009] In satisfying the above need, as well as overcoming the enumerated drawbacks and other limitations of the related art, the present invention provides a corner assembly for a tonneau cover that eliminates the time- and labor-intensive process of manufacturing tonneau cover corners via folding and manual stitching.

[0010] Accordingly, in one aspect the invention is be embodied in a corner assembly for a tonneau cover that is provided with a cap, a base matingly engaged with the cap, and a flexible cover having a generally rectangular shape and including at least one patterned cut-corner, the patterned cut-corner located and captively retained between the cap and the base.

[0011] In another aspect, the invention is embodied in a method of assembling a corner assembly of a tonneau cover, the method including the steps of providing a cap and a base, providing a flexible cover having a generally rectangular shape and including at least one patterned cut-corner, locating the patterned cut-corner between the cap and the base; and matingly engaging the cap with the base so as to captively retain the patterned cut out corner between the cap and the base.

[0012] Further objects, features and advantages of this invention will become readily apparent to persons skilled in the art after review of the following description, including the claims, and with reference to the drawings that are appended to and form a part of this specification.

[0013] BRIEF DESCRIPTION OF THE DRAWINGS

[0014] For a fuller understanding of the invention, reference should be made to the following detailed description, taken in connection with the accompanying drawings, in which:

[0015] FIG. 1 is a perspective view of a pickup truck having a tonneau cover installed thereon, showing the tonneau cover in an extended position covering the bed and, in phantom, a folded position uncovering part of the bed.

[0016] FIG. 2 is a perspective view of the underlying frame of the tonneau cover seen in FIG. 1.

[0017] FIG. 3 is an enlarged view of a corner assembly of the tonneau cover of FIG. 1.

[0018] FIG. 4 is an exploded view of the construction of the corner assembly in FIG. 3.

[0019] FIG. 5 is a plan view of a cut sheet for the tarp used in the tonneau cover of FIG. 1.

[0020] FIG. 6 is an enlarged view of the cut-out for the corner of the tarp seen in FIG. 5.

[0021] FIG. 7 is a top perspective view of a cap used in the corner assembly of the tonneau cover.

[0022] FIG. 8 is a bottom perspective view of the cap seen in FIG. 7.

[0023] FIG. 9 is a top perspective view of a base used in the corner assembly of the tonneau cover.

[0024] FIG. 10 is a bottom perspective view of the base seen in FIG 9.

[0025] FIG. 11 is a bottom perspective view of the corner assembly seen in FIG. 3.

[0026] FIG. 12 is a cross-sectional view, generally taken along line 12-12 in FIG. 3, of the corner assembly.

[0027] Further objects, features and advantages of this invention will become readily apparent to persons skilled in the art after review of the following description, including the claims, and with reference to the drawings that are appended to and form a part of this specification. DETAILED DESCRIPTION

[0028] In the following detailed description of the embodiments, reference is made to the accompanying drawings, which form a part thereof, and within which are shown by way of illustration specific embodiments by which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the invention. It should be further noted that while the drawings illustrate a foldable tonneau cover, embodiments of the current invention can be utilized with any style of soft tonneau cover, as the current invention relates to the corner assembly of such a tonneau cover, securing the flexible cover (e.g., fabric) to the frame.

[0029] Referring now to the drawings, a pickup truck 10 is generally illustrated in FIG. 1 having a foldable tonneau cover 12 attached to the bed 14 of the truck 10. The tonneau cover 12 is shown as being mounted to the bed 14 of the truck 10 so as to cover or enclose the bed 14. The bed 14 is located rearward of the passenger cabin ("cab") 16 of the truck 10 and includes a bottom wall 17, a pair of opposed sidewalls 18 joined at their forward and rearward ends by a front wall or bulkhead 20 and rear wall or tailgate 22, respectively. The tops of the sidewalls are typically reinforced and define bed rails 24. The tonneau cover 12 may be mounted to or rest upon the bed rails 24.

[0030] The tonneau cover 12 is shown in FIG. 1 in an extended position where individual sections 28 of the tonneau cover 12 are adjacent one another and cover the bed 14. The tonneau cover 12 is foldable from the extended position to a folded position, shown in phantom, where the sections 28 are folded relative to one another toward the cab 16 or bulkhead 20 to uncover at least a portion of the bed 14.

[0031] As illustrated in FIG. 1, the tonneau cover 12 has four sections 28. However, the tonneau cover 12 may have more or less than four sections 28 and, representatively, the frame 30 shown in FIG. 2 provides for three sections, generally designated at 28'.

[0032] The frame 30 is formed by a plurality of interconnected longitudinal rails 32, cross rails or bows 34, and end rails 36. When mounted to a truck 10, the longitudinal rails 32 will generally define the opposing sides of the tonneau cover 12 and be located over the bed rails 24 of the bed 14. The end rails 36 will generally define the opposing ends of the tonneau cover 12 and be located over the bulkhead 18 and tailgate 22. As further discussed below, in the four corners of the tonneau cover 12, the longitudinal rails 32 and end rails 36 of the tailgate and bulkhead sections 28 are connected to one another by corner connectors, which may be in press fit engagement with the longitudinal sections or secured by mechanical fasteners, such as screws. The entire frame 30, and the tonneau cover 12 as a whole, is secured to the bed rails 24 or other parts of the bed 14 by clamps 38, which may be supported by the cross rails 34.

[0033] Each section 28 of the tonneau cover 12 is pivotally attached to an adjacent section(s) 28 of the tonneau cover 12. The section 28 of the tonneau cover located adjacent to the tailgate 22 (in the extended position), the "tailgate" section 28a, is pivotally attached to an intermediate section 28b by a hinge mechanism 40 (i.e., a hinge, flexible substrate, or similar connection). This is achieved by locating hinge mechanism 40 between the respective longitudinal rails 32 of the intermediate section 28b and tailgate section 28a. When the tailgate section 28a is moved toward the folded position, the tailgate section 28a is folded about the hinge mechanism 40, so that the top surface of the tailgate section 28a is adjacent the top surface of the intermediate section 28b.

[0034] The intermediate section 28b is also pivotally attached to either a second intermediate section 28b (FIG. 1) or to the section 28 located adjacent to the bulkhead 18 ("bulkhead" section 28c; see generally FIG. 2). A hinge mechanism 42 provides for this pivotal attachment and is located between the respective longitudinal rails 32 of the adjacent sections 28.

[0035] When the tonneau cover 12 is further moved to the folded position, the tailgate section 28a and intermediate section 28b are, together, folded about hinge mechanism 42 onto the bulkhead panel 28c. To accommodate the combined thickness of the tailgate and intermediate sections 28a, 28b, the hinge mechanism 42 may be provided as a double hinge mechanism having a spacer or an enlarged flexible member. Such hinge mechanisms 40, 42 are known in the industry and need not be further discussed herein.

[0036] Covering the frame 30 and secured to the longitudinal rails 32 and end rails 36 is a tarp or cover 44 formed of a flexible fabric material, such as vinyl. The cover 44 is preferably provided as a single sheet of material and extends over substantially all of the sections 28 of the tonneau cover 12. Accordingly, a section 28 is generally defined as being one of the portions of the tonneau cover 12 that extend between the end rails 36 and the hinge mechanisms 40, 42 or a portion extending between adjacent hinge mechanisms 40, 42. In one embodiment, the cover 44 is cut from a single base piece of material 46 in a generally rectangular in shape with lateral sides 48 and ends 50. As further discussed below, however, the corners of the cover 44 are not cut square.

[0037] Each of the lateral sides 48 and ends 50 of the cover 44 are joined, for example by stitching, to plastic edge strips (not shown). The edge strips, which may be formed by extrusion, preferably include an integral fastener (not shown) for securing the lateral sides 48 and ends 50 of the cover 44 to the longitudinal rails 32 and end rails 36 of the frame 30. While various configurations may be employed, in one embodiment the fastener may be provided as a projection with an enlarged terminal end or head, generally in the shape Christmas tree fastener. The longitudinal rails 32 and end rails 36 of the frame 30, which may be aluminum extrusions, may be formed with a slot having a reduced width entrance opening that faces generally outwardly when positioned on the bed rails 24. To secure the cover 44 to the frame 30, the fasteners are inserted into the slot. As the fasteners are inserted into the slot, the enlarged head is elastically deformed by the reduced width entrance opening, which has a width smaller than the head. Once passing through the entrance opening, the resiliency of the head returns the deformed head to its original shape, capturing the head of the projection in the slot and securing the lateral sides 48 and ends 50 of the cover 44 to the frame 30.

[0038] Generally, in the traditional construction of soft tonneau covers, the corners of the cover are one of the most labor intensive features to construct. The traditional corner construction typically entails a shaped plastic reinforcement beneath the lower surface of the cover, precise folding of the cover over the reinforcement, and multiple lines of stitching along a three dimensional profile followed by stitching of edge banding around the corner, all being manually performed. This complex process and construction is eliminated by the corner assembly 62 disclosed herein.

[0039] As seen in FIGS. 3-4, the corner assembly 62 includes three primary components: a cap 64, a base 66, and a patterned cut-corner 68 of the cover 44. The cap and base 64, 66 are configured for mating engagement and clamp, sandwich and / or captively retain the cut-corner 68 therebetween.

[0040] As seen in FIGS. 3, 4, 7, and 8, the cap 64 includes a substantially flat top 70 from which extends, outwardly and downwardly, a conical skirt portion 72. The skirt portion 72 is delimited in the circumferential direction to approximately ninety degrees. The flat top 70 and the skirt portion 72 generally form a partial frustoconical shape. Optionally extending from a lateral side of the skirt portion 72 and overlying the cover 44 (specifically a lateral side 48 or end 50) in the assembled corner construction is a tang 74, which may be used for branding purposes.

[0041] The lower or underside of the cap 64 includes a plurality of features that aid in engaging the cap 64 with the base 66 and securely retaining the cut-corner 68 therebetween. These features include a first pair of indexing pins 76 extending downward from the skirt portion 72, a second pair of indexing pins 78 extending downward 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.

[0042] As seen in FIGS. 4, 9, and 10, the base 66 has a shape corresponding to the cap 64 and includes features corresponding to those of the cap 64. Generally, the base 66 is defined by a wedge or pie-shaped body 84 having a substantially flat top 86 with a ribbed or grooved surface 87 and a conical outboard surface 88 extending downwardly and outwardly from the top 86. Similar to the cap 64, the flat top 86 and outboard surface 88 generally form a partial frustoconical shape that corresponds to and fits within the frustoconical shape of the flat top 70 and the skirt portion 72 of the cap 64. Struts 90 extend from sides 91 of the body 84, generally opposite from the outboard surface 88. The struts 90 are configured for mating engagement with and inserted into the ends of the longitudinal rails 32 and end rails 36 of the tailgate and bulkhead sections 28a, 28c of the frame 30. As previously mentioned and without limiting the means of attachment, this engagement may be a press fit engagement and may be further frictionally, adhesively, and / or mechanically secured.

[0043] The corresponding features of the base 66 include a first pair of indexing holes 92 defined in the conical outboard surface 88 of the body 84, a second pair of indexing holes 94 defined in the flat top 86, a first mounting bore 96 defined in the conical outboard surface 88, and a second mounting bore 98 defined in the flat top 86. In the corner assembly 62, the first and second pairs of indexing holes 92, 94 respectively receive the first and second pairs of indexing pins 76, 78, and the first and second mounting bores 96, 98 respectively receive the first and second mounting bosses 80, 82.

[0044] The mounting bosses 80, 82 include threaded portions 100 therein, which may be provided by insert molding an internally threaded barrel 102 with the cap 64, and more specifically with each of the mounting bosses 80, 82. To retain and secure the cap 64 with the base 66, threaded fasteners 103 may be inserted through openings in the mounting bores 96, 98 and into engagement with the threaded portions 100 of mounting bosses 80, 82.

[0045] As noted above, the cut-corner 68 of the cover 44 is clamped between cap 64 and the base 66 when those pieces are secured together. To facilitate engagement of the cut-corner 68 with the cap and base 64, 66, the cut-corners 68 are not provided as a ninety degree intersection of the lateral sides 48 and ends 50 of the cover 44. Rather, as seen in FIGS. 4-6, each cut-corner 68 is defined along its edges by a convex portion 104 that is recessed by a step 105 relative to the lateral sides 48 and ends 50 of the cover 44. The step 105 can fold over the plastic and be stitched to the edge strip (not shown) during the sewing process. Preferably, the convex portion 104 is formed as an approximately ninety degree section of a circle. Alternatively, the convex portion 104 is not recessed relative to the lateral sides 48 and ends 50 and is instead formed as a smooth transition from those sides 48 and ends 50 (i.e., the step 105 is not present).

[0046] Around the center or mid-point of the convex portion 104, a notch 106 is formed in the edge of the cut-corner 68. The notch 106 may be V-shaped and can extend to a depth that is greater than one-half of the radius of curvature of the convex portion 104. It should be noted that the notch can take any shape, so long as the cut-corner 68 can be secured between the cap 64 and the base 66 without any gaps or openings being present through the corner construction as a whole.

[0047] Also formed in the cut-corner 68 are a series of holes. Two ovalized holes 108 are formed substantially adjacent to the lateral extents of the convex portion 104 and three round holes 110 are formed in a general semi-circle about the apex of the notch 106. It should be noted that the holes can take any shape to accommodate the cap 64 and the base 66 in a secure manner, while preventing rips due to stretching when the corner is fully assembled.

[0048] In assembling the components of the corner assembly 62, the base 66 is mounted to the longitudinal rails 32 and the end rails 36 of the frame 30. A cut-corner 68 of the cover 44 is then positioned over the base 66 such that the ovalized holes 108 are positioned over the indexing holes 92, with the convex portion 104 overlying the conical outboard surface 88 of the base 66. In doing so, the holes 110 surrounding the apex of the notch 106 are positioned over indexing holes 94 and the mounting bore 98. The provision of the notch 106 in the cut-corner 68 allows the cover 44 to be positioned over the base 66 without requiring folding or additional positioning on the base 66.

[0049] With the cut-corner 68 positioned over the base 66 (with corresponding holes and bores aligned), the cap 64 is mounted to the base 66 by causing insertion of the indexing pins 76, 78 and mounting boss 82 through the respective ovalized holes 108 and holes 110 of the cover 44 and through the indexing holes 92, 94 and the mounting bore 98 of the base 66. The cap 64 and the base 66 can then be secured together with the fasteners 103 through the corresponding mounting bosses and bores 80, 82, 96, 98. It is noted that mounting boss 80 of the cap 64 and mounting bore 96 of the base 66 are positioned within notch 106 of the cover 44. As such, there is typically no hole in the cover 44 associated with the mounting boss / bore 80, 96. When the cap 64 and the base 66 are secured together, the cover 44 is clamped between the cap 64 and base 66, and particularly between lower surface of the flat top 70 of the cap 64 and the upper surface of the flat top 86 of the base 66. The ribbed bottom surface 83 of the cap 64 and the ribbed top surface 87 of the base 66 cooperate in gripping the cover 44 in the corner assembly 62, increasing friction, and keeping the cover 44 taut over the frame 30. The ribbed surfaces 83, 87 also aid in channeling water in the corner assembly 62 outward and away from under the tonneau cover 12.

[0050] It should be further noted that in certain embodiments, the attachment features of the cap 64 and the base 66 may be reversed, such that the indexing pins and mounting bosses are located on the base 66, while the indexing holes and mounting bores are located on the cap 64. Such a scenario may be desirable, so that the cover 44 can be stretched and secured on the base 66 (without needing to physically hold it aligned) until the cap 64 is positioned on top of the base 66. In yet alternative embodiments, the cap 64 and the base 64 may have a mixture of these features, for example the cap 64 having indexing pins and mounting bores and the base 66 having indexing holes and mounting bosses. In alternative embodiments of the patterned cut-corner 68, the various features thereof (the convex portion 104, the recessed step 105, the notch 106 and the holes 108), may be used alone or in combination with one or more of the other features. Any combination of these features is envisioned herein.

[0051] As seen from the above description, the corner assembly 62 of the tonneau cover 12 allows for the corner to be constructed with a minimum of complexity and manual labor as compared to the traditional manner of forming a tonneau cover corner. As a result time and cost savings can be realized in the production of tonneau covers.

[0052] Although the invention has been described with reference to certain specific embodiments incorporating the principles of the invention, one skilled in the art will readily appreciate that the invention is susceptible to modification, variation and change without departing from the true spirit and fair scope of the invention, as defined in the claims that follow. The scope of the claims should therefore not be limited by the preferred embodiments, but should be given the broadest interpretation consistent with the description as a whole. The terminology used herein is therefore intended to be understood in the nature of words of description and not words of limitation.

[0053] It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention that, as a matter of language, might be said to fall therebetween.

Claims

1. A corner assembly for a tonneau cover having a frame configured to be disposed at least partially on or along sidewalls, a bulkhead, and / or a tailgate of a cargo box of a pickup truck, the corner assembly comprising: a cap; a base matingly engaged with the cap and configured to be disposed at a corner of a cargo box of a pickup truck, wherein at least one of the cap and base is configured to engage with the frame of the tonneau cover; and a flexible cover having a generally rectangular shape and including at least one patterned cut-corner, the patterned cut-corner located and captively retained between the cap 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 cap defines a first shape and the base defines a second shape, the second shape corresponding to and fitting within the first shape.

3. The corner assembly according to claim 1, wherein the cap 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 interfitting parts of the cap and base.

4. The corner assembly according to claim 1, wherein the one or more first and second attachment features comprise at least one of indexing pins and indexing holes that correspond to each other, and / or mounting bosses and mounting bores that correspond to each other.

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

6. The corner assembly according to claim 5, wherein the one or more second attachment features comprise at least one indexing hole and / or mounting bore provided in a surface of the base opposed to the cap and corresponding to the at least one indexing 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 comprise a first grooved surface provided in the cap and the one or more second attachment features comprise a second grooved surface provided in the base, wherein the first and second grooved surfaces 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 includes one or more holes formed in the cover, wherein the one or more holes correspond with the one or more first and second attachment features of the cap and the base.

9. The corner assembly according to claim 8, wherein the patterned cut-corner further includes a V-shaped notch.

10. The corner assembly according to claim 1, wherein the patterned cut-corner includes a V-shaped notch.

11. The corner assembly according to claim 1, wherein the patterned cut-corner of the flexible cover includes a convex portion extending between a lateral side and an end of the cover.

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

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-corner includes one or more holes formed in the cover, wherein the one or more holes correspond with the one or more first and second attachment features of the cap and the base.

15. The corner assembly according to claim 1, wherein: the cap includes a substantially flat top and a conical skirt portion that define a partial frustoconical shape, the base includes a substantially flat top and a conical skirt portion that define a partial frustoconical shape, and the partial frustoconical shape of the base corresponding to and fitting with the partial frustoconical shape of the cap.

16. A method of assembling a corner assembly of a tonneau cover, the method comprising the steps of: providing a cap; providing a base providing a flexible cover having a generally rectangular shape and including at least one patterned cut-corner; locating the patterned cut-corner between the cap and the base; and matingly engaging the cap with the base so as to captively retain the patterned cut out corner between the cap and the base.

17. The method according to claim 16, wherein the cap and the base include one or more retaining features and the patterned cut-out corner includes one or more holes provided in the cover, the method further comprising the step of correspondingly positioning the one or more holes with the one or more retaining features prior to matingly engaging the cap with the base.

18. The method according to claim 17, wherein the step of correspondingly positioning the one or more holes with the one or more retaining features includes extending one or more of the retaining features through the one or more holes.

19. The method according to claim 16, wherein the cap and the base each include a substantially flat top and a conical skirt portion that define partial frustoconical shapes, the patterned cut-corner includes a convex portion and a notch centrally provided in the convex portion, and the method further comprising the step of closing the notch so that the patterned cut- corner is without any gaps or openings and thereafter matingly engaging the cap with the base.

20. A tonneau cover assembly, comprising: a frame configured to be disposed at least partially on or along sidewalls, a bulkhead, and / or a tailgate of a cargo box of a pickup truck; a flexible cover having a generally rectangular shape and configured to be directly or indirectly attached to the frame; a corner assembly, comprising: a cap; a base matingly engaged with the cap; at least one of the cap and base being engaged with the frame; and the flexible cover including at least one patterned cut-corner, the patterned cut- corner located and captively retained between the cap and the base.