Modular truck bed floor

Abstract

A modular bed floor is disclosed. A pickup truck bed includes a plurality of panels that are longer in a longitudinal direction than in a lateral direction, the plurality of panels assembled together along longitudinally extending edges and to laterally adjacent ones of the plurality of panels. Each of the plurality of panels includes a plurality of support structures that longitudinally extend along a length of the plurality of panels, the plurality of support structures supporting the plurality of panels on laterally extending cross members. A left side panel defines a left wheel well cutout, a longitudinally extending center panel includes first and second complementary interlocking features on opposite longitudinally extending sides, and a longitudinally extending right side panel defines a right wheel well cutout. The left side panel includes the first interlocking feature and the right side panel includes the second interlocking feature, the first and second interlocking features each receiving one of the complementary interlocking features of the center panel.

Description

Technical Field

[0001] This disclosure relates to a pickup truck bed floor that includes multiple extruded sections assembled together at longitudinally extending edges. Background Technology

[0002] Pickup trucks include cargo boxes that can be used to transport a wide variety of goods, from building materials to recreational equipment. Existing pickup truck cargo boxes are formed as sheet metal stampings, which are then assembled onto crossbars and beams, which are in turn assembled to the pickup truck's frame and chassis. Sheet metal parts are typically limited by the thickness of the sheet metal blank and become locally thinner when stretched into the desired shape.

[0003] Sheet metal is supplied in specified metric thicknesses, which affect the formability limits of the part. Thicker blanks are stronger and more resistant to penetration and dents, but increase the overall weight of the vehicle. Formability limits restrict the shape and depth of floor stiffeners, as exceeding these limits can lead to cracking. Aluminum bodies can be significantly lighter than steel bodies, but are subject to more formability limits.

[0004] If additional support structures are needed for the carriage, the advantage of using an aluminum carriage to significantly reduce weight will be reduced. The weight of the supporting crossbars and beams is also part of the total weight of the carriage. Generally, thinner carriage floors require more support structures and more assembly work.

[0005] This disclosure aims to address the issues mentioned above and other issues summarized below. Summary of the Invention

[0006] This disclosure relates to a pickup truck body comprising a plurality of longitudinally extending extruded aluminum sheets, the aluminum sheets including extruded integral inverted T-shaped protrusions extending beneath the lower surface of the sheets, the sheets being received on the upper surface of transverse members. The top wall of the truck body may be extruded to a thickness greater than that of other portions to minimize weight and increase the robustness and penetration resistance of the top wall.

[0007] A flat top wall can be configured to be supported by longitudinally extending stiffeners, which are in turn supported by transverse crossbars. Different stiffener configurations and orientations can be provided depending on the reinforcement and assembly design requirements.

[0008] Each plate includes at least one longitudinal edge suitable for interlocking or assembly to the longitudinal edges of adjacent plates. The longitudinal edges of adjacent plates are complementary in cross-section to facilitate interlocking the plates together.

[0009] According to one aspect of this disclosure, a pickup truck body is disclosed, comprising: a plurality of panels, longer in a longitudinal direction than in a transverse direction, the plurality of panels being assembled together along longitudinally extending edges and assembled to a transversely adjacent panel among the plurality of panels. Each of the plurality of panels includes a plurality of support structures extending longitudinally along the length of the plurality of panels, the plurality of support structures supporting the plurality of panels on transversely extending transverse members.

[0010] According to one embodiment of the invention, the support structure is an inverted T-shaped protrusion extending below the lower surface of the plate.

[0011] According to one embodiment of the invention, the support structure is a longitudinally extending rib that defines an isosceles trapezoidal space extending through the length of the rib.

[0012] According to one embodiment of the present invention, the longitudinally extending edge of the first plate of the plate includes an upper flange that includes a portion of the top surface of the first plate, and the longitudinally extending edge of the second plate of the plate includes a lower flange that is disposed below the upper flange when the plates are assembled together.

[0013] According to one embodiment of the invention, the longitudinally extending edge of the first plate in the plate includes a T-shaped protrusion, and the longitudinally extending edge of the second plate in the plate defines a T-shaped groove that receives the T-shaped protrusion when the plates are assembled together.

[0014] According to one embodiment of the invention, the T-shaped protrusion extends downward from the longitudinally extending rib, and the T-shaped groove is defined in an elongated edge block portion on the longitudinally extending edge of the second plate formed in the plate.

[0015] According to one embodiment of the invention, a T-shaped protrusion extends upward from the longitudinal edge of a first plate in the plate, and a T-shaped groove is defined in an elongated upright rib formed on the longitudinally extending edge of a second plate in the plate.

[0016] According to one embodiment of the present invention, the elongated upright rib may be one of a plurality of solid straight ribs disposed on the top surface of the plate.

[0017] According to one embodiment of the invention, the longitudinally extending edge of the first plate in the plate includes an upper flange that includes a portion of the top surface of the first plate in the plate, and the longitudinally extending edge of the second plate in the plate may include a lower flange that is disposed below the upper flange when the plates are assembled together. The lower flange includes a flange end oriented to adjoin one side of a longitudinally extending rib that defines an isosceles trapezoidal space through the length of the rib.

[0018] According to one embodiment of the invention, at least one fastener is inserted through the end of the flange and one side of the longitudinally extending rib.

[0019] According to another aspect of this disclosure, a vehicle body is disclosed, comprising: a longitudinally extending left side panel defining a left wheel housing cutout; a longitudinally extending central panel including a first complementary interlocking feature and a second complementary interlocking feature located on opposite longitudinally extending sides; and a longitudinally extending right side panel defining a right wheel housing cutout. The left side panel includes the first interlocking feature, and the right side panel includes the second interlocking feature, the first interlocking feature and the second interlocking feature each receiving one of the complementary interlocking features of the central panel.

[0020] The support structure may be an inverted T-shaped protrusion extending below the lower surface of the plate. Alternatively, the support structure may be a longitudinally extending rib defining an isosceles trapezoidal space extending through the length of the rib.

[0021] The longitudinally extending edge of the first plate in the panel may include an upper flange that includes a portion of the top surface of the first plate. The longitudinally extending edge of the second plate in the panel may include a lower flange that is positioned below the upper flange when the panels are assembled together.

[0022] The longitudinally extending edge of the first plate in the panel may include a T-shaped protrusion, and the longitudinally extending edge of the second plate in the panel may define a T-shaped groove that receives the T-shaped protrusion when the panels are assembled together. The T-shaped protrusion may extend downward from a longitudinally extending rib, and the T-shaped groove may be defined in an elongated edge block portion formed on the longitudinally extending edge of the second plate in the panel. The T-shaped protrusion extends upward from the longitudinal edge of the first plate in the panel, and the T-shaped groove is defined in an elongated upright rib formed on the longitudinally extending edge of the second plate in the panel. The elongated upright rib may be one of a plurality of solid straight ribs disposed on the top surface of the panel.

[0023] The longitudinally extending edge of the first plate in the panel may include an upper flange that includes a portion of the top surface of the first plate, and the longitudinally extending edge of the second plate in the panel may include a lower flange disposed below the upper flange when the panels are assembled together. The lower flange may include a flange end oriented to abut one side of a longitudinally extending rib that defines an isosceles trapezoidal space extending through the length of the rib. At least one fastener may be inserted through the flange end and one side of the longitudinally extending rib.

[0024] The above and other aspects of this disclosure will now be described with reference to the accompanying drawings. Attached Figure Description

[0025] Figure 1It is a right rear-side perspective view of a pickup truck with the rear tailgate closed, including the cargo box manufactured according to one embodiment of the present disclosure.

[0026] Figure 2 This is a right rear-side perspective view of a pickup truck with the tailgate open, including according to... Figure 1 The carriage manufactured according to the embodiment shown.

[0027] Figure 3 This is a partial cross-sectional perspective view of a carriage manufactured according to a second embodiment of the present disclosure.

[0028] Figure 4 yes Figure 3 The image shows a partial sectional view of the carriage.

[0029] Figure 5 This is a partial cross-sectional perspective view of a carriage manufactured according to a third embodiment of the present disclosure.

[0030] Figure 6 yes Figure 5 The image shows a partial sectional view of the carriage.

[0031] Figure 7 This is a partial cross-sectional view manufactured according to the fourth embodiment, showing the fastener being oriented as if to be inserted into the carriage.

[0032] Figure 8 yes Figure 7 The image shows a partial sectional view of the carriage, where fasteners secure two panels of the carriage together. Detailed Implementation

[0033] The embodiments shown in the accompanying drawings are illustrated. However, it should be understood that the disclosed embodiments are intended to be illustrative only and may be implemented in various forms and alternative forms. The drawings are not necessarily drawn to scale; some features may be exaggerated or minimized to show details of specific components. The specific structural and functional details disclosed should not be construed as limiting, but only as a representative basis for teaching those skilled in the art how to practice the disclosed concepts.

[0034] Reference Figure 1 The pickup truck 10 is shown from a right rear view and includes a cargo box 12 manufactured according to the present disclosure. The cargo box 12 includes an extrusion platform with increased thickness to prevent penetration of the cargo box 12 or the platform.

[0035] Reference Figure 2 The pickup truck 10 shown has a cargo box 12 formed by three extruded panels. A left side panel 16, a right side panel 18, and a central panel 20 interlock to form a smooth platform 22 of the cargo box 12. As shown, the left side panel 16 includes a wheel housing cutout 24. The right side panel 18 also includes a wheel housing cutout, which is a mirror image of the left side wheel housing cutout 24, but from... Figure 2 The angle shown is not visible. Plates 16, 18 and 20 each include at least one longitudinal edge 28 extending in the longitudinal direction.

[0036] As used herein, the term "longitudinal" refers to the length of the vehicle and extends in the longitudinal direction. The term "lateral" as used herein refers to the direction across the vehicle or the lateral direction of the vehicle.

[0037] Multiple laterally extending transverse members 30 support the carriage 12. Figure 2 Only the rearmost laterally extending transverse member 30 is marked; however, it should be understood that the other laterally extending transverse members 30 are arranged below the carriage 12 in a longitudinally spaced manner.

[0038] Multiple ribs 32 are disposed below each of the plates 16, 18, and 20. Ribs 32 are formed on the lower surface 34 of the platform 22. Ribs 32 define isosceles trapezoidal openings 36.

[0039] An upper flange 38 is located at the longitudinal edge 28 of the left side plate 16. The upper flange 38 includes a portion of the top surface 40 of the platform 22. A lower flange 42 is located on the central plate 20 and supports the upper flange 38 of the left side plate 16. An upper flange 38 supported by the lower flange 42 of the right side plate 18 is located on the right side of the central plate 20. The upper flange 38 and the lower flange 42 are complementary interlocking features formed during the extrusion process, and they are assembled together to form an interlocking extruded car body.

[0040] Reference Figure 3 and Figure 4 The diagram illustrates a carriage 50 of an alternative embodiment, supported by a plurality of inverted T-shaped protrusions extending from the lower surface 54 of the carriage 50 or platform. A plurality of transverse members are provided beneath the carriage 50. The inverted T-shaped protrusions 52 support the carriage 50 on the transverse members 56.

[0041] A plurality of ribs 58 are provided on the top of the carriage 50. The ribs 58 define an isosceles trapezoidal opening 60. The rib 58 at the longitudinal edge 28 of one of the plates (left side plate 16) includes a portion of the top wall 62 of the rib 58.

[0042] An inverted T-shaped interlocking member 64 extends below the top wall 62 and is received in a complementary inverted T-shaped interlocking groove 66 in the central plate 20. The complementary inverted T-shaped interlocking groove 66 is defined by a block portion 68 provided on the longitudinal edge 28 of the central plate 20. The inverted T-shaped interlocking member 64 and the complementary inverted T-shaped interlocking groove 66 are formed during extrusion to provide a continuous interlocking engagement between the left side plate 16 and the central plate 20. A similar complementary interlocking structure is also provided between the right side plate 18 and the central plate 20.

[0043] Reference Figure 5 and Figure 6 The diagram illustrates a carriage 70 of an alternative embodiment, which includes a plurality of ribs 72. The ribs 72 define isosceles trapezoidal openings 74 extending longitudinally along the carriage 70. The lower surfaces 76 of the ribs 72 are supported on transverse members 78. The plurality of transverse members 78 support the carriage 70 and are longitudinally spaced below the carriage 70.

[0044] Multiple solid rectangular ribs 80 are provided on the top surface 82 of the carriage 70. The solid rectangular ribs 80 and the top surface 82 have thick cross sections to resist any potential penetration of the carriage 70. The solid rectangular ribs 80 and the top surface 82 form the platform of the carriage 70.

[0045] T-shaped protrusions 84 are positioned adjacent to the longitudinally extending edge 86 of the right side plate 18. Complementary longitudinally extending T-shaped grooves 88 are provided near or adjacent to the longitudinally extending edge 90 of the central plate 20. The T-shaped protrusions 84 are received complementaryly in the longitudinally extending T-shaped grooves 88 to provide a continuous compression interlocking engagement between the right side plate 18 and the central plate 20.

[0046] Reference Figure 7 and Figure 8 The diagram illustrates a carriage 100 or platform of another alternative embodiment, supported by a plurality of ribs 102. The ribs 102 define isosceles trapezoidal openings 104. The ribs 102 extend below the lower surface 106 of the carriage 100. The ribs 102 include a bottom wall 108 and converging sidewalls 110 extending from the bottom wall 108 into the carriage 100.

[0047] The left side plate 16 includes a top edge flange 112. The central plate 20 has a top surface 114 that engages and supports the top edge flange 112. The top surface 114 extends below the top edge flange 112. The lower edge flange 116 includes a support portion 118 extending into a tilting orientation portion 120. The tilting orientation portion 120 is configured parallel to one of the converging sidewalls 110. Fasteners 122 (e.g., flow drill screws) are driven through the tilting orientation portion 120 and into the converging sidewall 110 to secure the left side plate 16 to the central plate 20.

[0048] for Figures 2 to 8For each embodiment shown, the method of assembling the cargo box 12 to the pickup truck 10 is similar in that the left side panel 16 and the right side panel 18 are assembled to the central panel 20 along their longitudinal edges 28. Complementary interlocking features are provided along the longitudinal edges 28. The panels 16, 18, and 20 are extruded and thus have a continuous cross-section in the transverse section. The panels 16, 18, and 20 may be formed in the same extrusion die or in the same extrusion die. The left side panel 16 and the right side panel 18 are trimmed after extrusion to define wheel housing cutouts 24 on their outer longitudinal edges 28. The interlocking features on the outer longitudinal edges 28 may be trimmed from the outer longitudinal edges 28 of the left side panel 16 and the right side panel 18, or may be left intact and used to facilitate the attachment of the cargo box 12 to the sidewall of the pickup truck 10. The panels 16, 18, and 20 are assembled together as an integral cargo box 12 to define a platform 22. The platform 22 is preferably thicker than the support structure of the cargo box, so that the platform has increased penetration resistance. The openings are defined by the ribs of the supporting structure to reduce the total weight of the carriage 12.

[0049] The above embodiments are specific examples and do not describe all possible forms of this disclosure. Features of the illustrated embodiments can be combined to form further embodiments of the disclosed concept. The terms used in this specification are descriptive and not restrictive. The scope of the claims is broader than the specifically disclosed embodiments and also includes modifications to the illustrated embodiments.

Claims

1. A pickup truck body, comprising: Multiple plates, longer in the longitudinal direction than in the transverse direction, are assembled together along their longitudinally extending edges and to a transversely adjacent plate. Each of the multiple plates includes multiple support structures extending longitudinally along its length, supporting the plates on transversely extending transverse members. The multiple support structures are longitudinally extending ribs, each rib defining an isosceles trapezoidal space through its length, the cross-section of which is closed perpendicular to the longitudinal direction. The longitudinally extending edge of the first plate of the plurality of plates includes an upper flange, the upper flange including a portion of the top surface of the first plate, and the longitudinally extending edge of the second plate of the plurality of plates includes a lower flange. When the first plate and the second plate are assembled together, the lower flange is disposed below the upper flange, and the lower flange includes an end, the end of which is oriented to adjoin one side of a longitudinally extending rib.

2. The carriage according to claim 1, wherein, At least one fastener is inserted through the end of the lower flange and one side of the longitudinally extending rib.

3. A carriage, comprising: The longitudinally extending left side plate defines the cutout in the left wheel housing; The longitudinally extending central plate includes a first complementary interlocking feature and a second complementary interlocking feature located on opposite longitudinally extending sides. The longitudinally extending right side plate defines the cutout in the right wheel housing; and Multiple support structures are installed on the lower surfaces of the left, central, and right side panels. The left side plate includes a first interlocking feature, and the right side plate includes a second interlocking feature. The first and second interlocking features receive one of the complementary interlocking features of the central plate. The plurality of support structures are longitudinally extending ribs that define an isosceles trapezoidal space through the length of the ribs. The cross-section of the isosceles trapezoidal space perpendicular to the longitudinal direction is closed. The first complementary interlocking feature and the second interlocking feature include an upper flange that includes a portion of the top surface of the left side plate and the central plate. The second complementary interlocking feature and the second interlocking feature include a lower flange that is disposed below the upper flange when the plates are assembled together.

4. The carriage according to claim 3, wherein, The lower flange includes an end portion that is oriented to adjoin one side of a longitudinally extending rib.

5. The carriage according to claim 4, wherein, At least one fastener is inserted through the end of the lower flange and one side of the longitudinally extending rib.

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