Cargo bed cover panel assembly and method of manufacturing the same

Abstract

A cargo bed cover panel assembly is provided. The cargo bed cover panel assembly includes a panel, a cross beam, and a perimeter extrusion. The panel is formed of a material consisting essentially of sheet metal. The panel includes longitudinal edges. The cross beam is disposed transversely on a bottom surface of the panel and is attached to the panel by an adhesive material. The perimeter extrusion is mechanically coupled to the longitudinal edges of the panel. In one example, the longitudinal edges of the panel include deformable tabs configured to mechanically retain the cross beam to the panel. In another example, the cargo bed cover panel assembly further includes a clip configured to mechanically engage with the cross beam and the perimeter extrusion to mechanically retain the cross beam to the panel.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 557,836, filed February 26, 2024, the contents of which are incorporated herein by reference. Technical Field

[0003] This disclosure generally relates to cargo box covers, and more specifically, to a panel assembly for securing a crossbeam to a cargo box cover panel. Background Technology

[0004] One advantage of pickup trucks (hereinafter referred to as "trucks") is their ability to use the truck bed to transport goods that may not be suitable for transport in other vehicles. These goods may include, for example, oversized items (such as large television sets) or items that may soil the interior of the vehicle (such as gardening supplies). The truck bed typically consists of a pair of opposing side walls, which are connected at their front and rear ends by a front wall or partition and a rear wall or tailgate, respectively.

[0005] An accessory used to cover the cargo bed is commonly known as a cargo bed cover. Cargo bed covers are used to cover pickup truck cargo beds for reasons including aesthetics, aerodynamics, and protection of any items inside the cargo bed—preventing items from falling out and protecting them from environmental factors such as rain, dust, snow, and debris.

[0006] While various styles of cargo box covers exist, a popular style is the rigid cargo box cover. Rigid cargo box covers typically comprise a series of rigid panel segments that extend laterally across the width of the cargo box. Additionally, some panels include lateral support structures known as crossbeams. These crossbeams can be used to provide additional rigidity to the panels and can also serve as a means of attaching additional components, such as clamps or retainers. These crossbeams are typically attached to the panels using liquid adhesives. However, these liquid adhesives can be difficult to apply during assembly and can be prone to failure during use. Therefore, improved components and methods are needed to secure the crossbeams to the rigid cargo box cover. However, given the full extent of the prior art as considered by those skilled in the art at the time of this disclosure, it is not obvious to those of ordinary skill in the art how to overcome the aforementioned deficiencies of the prior art.

[0007] Although certain conventional technical aspects are discussed herein to facilitate the disclosure of this invention, the applicant does not waive these technical aspects in any way, and it is anticipated that the claimed invention may cover one or more of the conventional technical aspects discussed herein.

[0008] This disclosure addresses one or more problems and deficiencies in the prior art discussed above. However, it is anticipated that the subject matter of this disclosure may prove useful in addressing other problems and deficiencies in various technical fields. Therefore, the claimed invention should not necessarily be construed as limited to addressing any particular problem or deficiency discussed herein.

[0009] In this specification, when a document, act, or knowledge item is mentioned or discussed, such mention or discussion does not constitute an admission that the document, act, or knowledge item or any combination thereof was publicly available, known to the public, common general knowledge, or otherwise constitutes prior art under applicable law as of the priority date; nor does it constitute an admission that its knowledge is related to any attempt to solve any problem of concern in this specification. Summary of the Invention

[0010] This disclosure generally relates to a cargo box cover panel assembly for mounting a crossbeam to a rigid panel. The panel is defined by a pair of longitudinal edges and a pair of transverse edges. Both the longitudinal and transverse edges are curved into a C-shape to improve structural integrity. The crossbeam is arranged transversely between the pair of longitudinal edges of the panel. The crossbeam is attached to the panel by an adhesive material. The crossbeam is made of extruded aluminum and includes T-slots for attaching additional components. A peripheral extrusion is coupled to the longitudinal edge of the panel by barbs configured to mechanically engage with the longitudinal edge. The crossbeam can be mechanically held against the panel by one of two methods: (1) deformable tabs arranged in the longitudinal edge, or (2) removable clips configured to mechanically engage both the crossbeam and the peripheral extrusion.

[0011] In one example, a liquid adhesive is used to attach the crossbeam to the panel. Each longitudinal edge includes a deformable tab for holding the crossbeam against the panel. The deformable tab is formed in a vertical window at each longitudinal edge. In some examples, the deformable tab can be folded into a T-slot in the crossbeam to align the crossbeam along the panel. The longitudinal edges may also include horizontal cutout areas to provide additional alignment assistance.

[0012] In another example, double-sided tape (such as VHB™ adhesive foam tape) is used to attach the crossbeam to the panel. The crossbeam is then mechanically held against the panel by engaging with both the crossbeam and the peripheral extrusion. In some examples, the clip slidably engages a T-slot of the crossbeam. The clip can also slidably insert into a horizontal cutout area of ​​the transverse edge. The clip may also include a deformable clip configured to engage with the vertical window.

[0013] In one aspect, a cargo box cover panel assembly is provided. The cargo box cover panel assembly includes a panel. The panel is formed of a material substantially composed of a sheet metal. The panel includes longitudinal edges, transverse edges, a top surface, and a bottom surface.

[0014] The cargo box cover panel assembly also includes a crossbeam. The crossbeam is arranged laterally across the panel. The crossbeam is attached to the bottom surface of the panel by an adhesive material.

[0015] The longitudinal edge of the panel includes deformable tabs. The deformable tabs are configured to mechanically hold the crossbeam to the bottom surface of the panel.

[0016] According to one example, the cargo box cover panel assembly also includes a peripheral extrusion member. The peripheral extrusion member is mechanically coupled to a longitudinal edge of the panel. The peripheral extrusion member may include barbs. The barbs are configured to mechanically engage with the longitudinal edge of the panel.

[0017] According to one example, the adhesive material is a liquid adhesive.

[0018] According to one example, the crossbeam is made of extruded aluminum.

[0019] According to one example, the crossbeam includes a T-slot. The deformable tab can be configured to fold into the T-slot of the crossbeam.

[0020] According to one example, the crossbeam is arranged perpendicular to the longitudinal edge.

[0021] According to one example, the longitudinal edge includes a horizontal cutout area corresponding to the crossbeam.

[0022] According to one example, the deformable tab is arranged in a vertical window at the longitudinal edge.

[0023] In general, on another aspect, a method for manufacturing a cargo box cover panel assembly is provided. The method includes providing a panel formed of a material substantially composed of a sheet of metal. The panel includes longitudinal edges.

[0024] The method further includes attaching a crossbeam to the panel using an adhesive material. The crossbeam is arranged laterally across the panel.

[0025] The method further includes folding the deformable tabs of the longitudinal edge to mechanically attach the beam to the panel.

[0026] In another aspect, a cargo box cover panel assembly is provided. The cargo box cover panel assembly includes a panel. The panel is formed of a material substantially composed of a sheet metal. The panel includes longitudinal edges, transverse edges, a top surface, and a bottom surface.

[0027] The cargo box cover panel assembly also includes a crossbeam. The crossbeam is arranged laterally across the panel. The crossbeam is attached to the bottom surface of the panel by an adhesive material.

[0028] The cargo box cover panel assembly also includes a peripheral extrusion member. The peripheral extrusion member is mechanically attached to the longitudinal edge of the panel.

[0029] The cargo box cover panel assembly also includes clips. The clips are configured to mechanically engage with the crossbeam and the peripheral extruder to mechanically hold the crossbeam to the panel.

[0030] According to one example, the adhesive material is tape.

[0031] According to one example, the peripheral extrusion includes barbs. The barbs are configured to mechanically engage with the longitudinal edge of the panel.

[0032] According to one example, the clamp is configured to mechanically engage with the barbs of the peripheral extruder.

[0033] According to one example, the clip is configured to slidably engage the T-slot of the crossbeam.

[0034] According to one example, the clip is also configured to be inserted into a horizontal cutout area at the longitudinal edge of the panel.

[0035] According to one example, the clip is also configured to engage with the vertical window at the longitudinal edge.

[0036] According to one example, the clip also includes one or more clips configured to engage with the vertical window.

[0037] In general, on another aspect, a method for manufacturing a cargo box cover panel assembly is provided. The method includes providing a panel formed of a material substantially composed of a sheet of metal. The panel includes longitudinal edges.

[0038] The method further includes attaching a crossbeam to the panel using an adhesive material. The crossbeam is arranged laterally across the panel.

[0039] The method also includes mechanically attaching peripheral extrusions to the longitudinal edge of the panel.

[0040] The method further includes mechanically engaging the clamp with the crossbeam and the peripheral extruder to mechanically hold the crossbeam to the panel.

[0041] In general, on another aspect, a cargo box cover panel assembly is provided. The cargo box cover panel assembly includes a panel formed of a material substantially composed of a sheet metal, the panel including longitudinal edges, transverse edges, a top surface, and a bottom surface.

[0042] The cargo box cover panel assembly also includes a crossbeam arranged transversely across the panel. The crossbeam is directly fixed to the bottom surface of the panel by adhesive and mechanical means.

[0043] It should be understood that all combinations of the foregoing concepts and the additional concepts discussed in more detail below (assuming these concepts do not contradict each other) are considered part of the inventive subject matter disclosed herein. In particular, all combinations of the claimed subject matter appearing at the end of this disclosure are considered part of the inventive subject matter disclosed herein. It should also be recognized that terms expressly adopted herein, which may also appear in any disclosure incorporated by reference, should be given the meaning most consistent with the specific concepts disclosed herein.

[0044] These and other aspects of the various embodiments will be apparent from the embodiments described below and will be explained with reference to the embodiments described below. Attached Figure Description

[0045] In the accompanying drawings, the same reference numerals generally refer to the same parts in different views. Furthermore, the drawings are not necessarily drawn to scale, but generally focus on illustrating the principles of various embodiments.

[0046] Figure 1 This is a bottom isometric view of the cargo box cover panel assembly according to aspects of this disclosure.

[0047] Figure 2 Based on the aspects of this disclosure Figure 1 Another isometric view of the cargo box cover panel assembly, where the peripheral extrusions are hidden to show the deformable tabs.

[0048] Figure 3 It is an isometric view of the longitudinal edges of the crossbeam and the panel with deformable tabs according to aspects of this disclosure.

[0049] Figure 4 Based on the aspects of this disclosure Figure 3 Another isometric view of the beam and longitudinal edges.

[0050] Figure 5 This is an isometric view of another longitudinal edge of a panel having a deformable tab that has been folded against a crossbeam, according to an aspect of this disclosure.

[0051] Figure 6 Based on the aspects of this disclosure Figure 5 Another isometric view of the longitudinal edge and the beam.

[0052] Figure 7 These are cross-sectional views of various aspects of the cargo box cover panel assembly according to various aspects of this disclosure.

[0053] Figure 8 Based on all aspects of this disclosure Figure 7 Another cross-sectional view of various aspects of the cargo box cover panel assembly.

[0054] Figure 9 This is a cross-sectional view of another aspect of the cargo box cover panel assembly according to this disclosure.

[0055] Figure 10 It is an isometric view of the longitudinal edge of a panel having a vertical window according to an aspect of this disclosure.

[0056] Figure 11 It is an isometric view of the clips according to various aspects of this disclosure.

[0057] Figure 12 This is another isometric view of the clip according to various aspects of this disclosure.

[0058] Figure 13 Based on the aspects of this disclosure and Figure 10 The longitudinal panels and crossbeams are connected Figure 11 and Figure 12 An isometric view of the clip.

[0059] Figure 14 Based on the aspects of this disclosure and Figure 10 The longitudinal panels and crossbeams are connected Figure 11 and Figure 12 Another isometric view of the clamp.

[0060] Figure 15 It is linked to aspects of this disclosure. Figure 13 and Figure 14 Isometric view of the perimeter extrusion of the longitudinal panel.

[0061] Figure 16 It is a cross-sectional view of various aspects of the cargo box cover panel assembly, including the clamping elements, according to various aspects of this disclosure.

[0062] Figure 17 This is a method for manufacturing a cargo box cover panel assembly according to aspects of this disclosure.

[0063] Figure 18 This is another method for manufacturing cargo box cover panel assemblies according to aspects of this disclosure. Detailed Implementation

[0064] In the following detailed description of preferred embodiments, reference is made to the accompanying drawings, which form part of the preferred embodiments and illustrate, by way of illustration, specific embodiments in which the subject matter of this disclosure 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 this disclosure.

[0065] In some exemplary embodiments, this disclosure relates to rigid or hard cargo box cover panels, each panel being formed from a single sheet of metal (e.g., a manganese-aluminum alloy) with its edges bent into a generally "C" shape in both longitudinal and transverse directions. The C-shaped edges provide structural integrity to the cargo box panel. Furthermore, the cargo box panel material possesses specific properties that make it lightweight and flexible yet still very strong. These advantages will be described later in this specification.

[0066] In the context of this disclosure, the term "aluminum alloy" refers to a metal in which aluminum is combined with another element, wherein aluminum is the principal element in the combination. Examples of alloying elements include copper, magnesium, manganese, silicon, tin, nickel, and zinc. Preferably, the cargo compartment panels according to certain embodiments of this disclosure comprise an aluminum alloy, wherein the alloying element is manganese. In a preferred embodiment, the manganese content in the aluminum alloy is from about 0.2% to about 2.2% by weight of the composition, more preferably from about 0.6% to about 2.0% by weight of the composition, and even more preferably from about 1.0% to about 2.0% by weight of the composition. In some embodiments, each cargo compartment panel may be formed of a 3003-H14 aluminum alloy having a manganese content of from about 1.0% to about 2.0% by weight of the composition. In other embodiments, each cargo compartment panel may be formed of a 3105-H24 aluminum alloy having a manganese content of from about 0.2% to about 0.8% by weight of the composition.

[0067] In the context of this disclosure, the term "yield strength" refers to a measure of the maximum strength that can be applied to a material before it undergoes permanent deformation. Yield strength is typically expressed in megapascals (MPa) and can be determined by methods known in the art. Preferably, the cargo box panels taught in this disclosure have a yield strength of about 100 MPa to about 200 MPa, more preferably about 120 MPa to about 200 MPa, or even more preferably about 140 MPa to about 200 MPa. Based on the sheet metal material used for the cargo box panels, yield strengths higher than those listed above are anticipated.

[0068] In the context of this disclosure, the term "tensile strength" refers to a measure of the maximum strength that can be applied to a material before it fractures. Tensile strength is typically recorded in megapascals (MPa) and can be determined by methods known in the art. Preferably, the cargo box panel taught in this disclosure has a tensile strength of about 130 MPa to about 230 MPa, more preferably about 150 MPa to about 210 MPa, or even more preferably about 170 MPa to about 200 MPa. Based on the sheet metal material used for the cargo box panel, it is contemplated that the tensile strength may be higher than the values ​​listed above.

[0069] In the context of this disclosure, the term "shear strength" refers to a measure of the maximum shear force that can be applied to a material before it fails in the shear direction. Shear strength is typically recorded in megapascals (MPa) and can be determined by methods known in the art. Preferably, the cargo box panels taught in this disclosure have a shear strength of about 80 MPa to about 140 MPa, more preferably about 90 MPa to about 130 MPa, or even more preferably about 100 MPa to about 120 MPa. Based on the sheet metal material used for the cargo box panels, the shear strength is expected to be higher than the values ​​listed above, but should be lower than the yield strength and tensile strength of the cargo box panels. This relationship allows the cargo box panels to be cut to size during manufacturing while still maintaining structural strength against forces perpendicular to the plane of the cargo box cover.

[0070] In the context of this disclosure, the term "thickness" refers to a measure of the thickness of a material. Thickness is typically recorded in millimeters (mm) and can be measured by methods known in the art. Preferably, the metal sheet of the cargo compartment panel taught in this disclosure has a thickness of about 1.0 mm to about 2.0 mm, more preferably about 1.15 mm to about 1.85 mm, or even more preferably about 1.25 mm to about 1.65 mm. In some embodiments, the C-shaped edge of the cargo compartment panel has a thickness of about 10.0 mm to about 15.00 mm, more preferably about 11.0 mm to about 14.0 mm, or even more preferably about 12.0 mm to about 14.0 mm. Based on the metal sheet material used for the cargo compartment panel, a thickness higher than the values ​​listed above is contemplated, but this may result in the cargo compartment panel being heavier than desired. In some embodiments, each cargo compartment panel may be formed from a 16-gauge or 14-gauge metal sheet (such as an aluminum alloy (e.g., 3003-H14, 3105-H24, etc.)).

[0071] Now turn to the attached diagram. Figure 1 This is a bottom isometric view of the cargo bed cover panel assembly 10. The cargo bed cover panel assembly 10 can be combined with additional cargo bed cover panel assemblies to form a cargo bed cover configured for mounting on a pickup truck bed. The cargo bed cover can be foldable or rigid. Figure 1 As shown, the cargo box cover panel assembly 10 includes a panel 100 and a crossbeam 106. The panel 100 may be defined by a bottom surface 101, a pair of longitudinal edges 102a, 102b, a top surface 103, and a pair of transverse edges 104a, 104b. In some examples, the longitudinal edges 102a, 102b extend along the length direction of the cargo box, while the transverse edges 104a, 104b extend along the width direction of the cargo box. Therefore, the cargo box cover may include a plurality of panels 100 to cover the cargo box. In some examples, the cargo box cover may include any number of panels 100, but typically three or four panels 100. Furthermore, although... Figure 1The panel 100 is roughly rectangular, but other sizes, shapes and proportions of cargo box covers may be implemented in other examples.

[0072] Panel 100 may be formed from a single layer of rigid metal sheet (such as 14 or 16 aluminum). In some embodiments, panel 100 may be formed from 3003-H14 aluminum alloy with a manganese content of about 1.0% to about 2.0% by weight of the composition. In other embodiments, panel 100 may be formed from 3105-H24 aluminum alloy with a manganese content of about 0.2% to about 0.8% by weight of the composition. Alternative aluminum alloy materials having manganese contents within the above ranges—whether currently known or emerging in the future—are also considered herein.

[0073] Using aluminum panels offers several advantages over conventional rigid panels, which are typically made of hard plastic or foam wrapped in aluminum. In particular, aluminum panels are more environmentally friendly than conventional panels due to the absence of plastic or foam. Furthermore, aluminum panels provide greater structural integrity in all weather conditions, offer greater UV resistance, and provide improved water resistance.

[0074] Furthermore, using aluminum alloys containing approximately 1.2% manganese (a characteristic of 3000 series aluminum alloys) offers many improvements over pure aluminum, such as greater strength while maintaining good formability and corrosion resistance, as well as high performance under a wide range of atmospheric conditions. In particular, these aluminum alloys are approximately 20 percent stronger than 1100 series aluminum.

[0075] Panel 100 may be defined by a range of strength properties. In one example, the cargo box panel 100 may have a yield strength of about 100 MPa to about 200 MPa, a tensile strength of about 130 MPa to about 230 MPa, and a shear strength of about 80 MPa to about 140 MPa. In this example, the yield strength is higher than the shear strength, allowing the cargo box panel 100 to be cut to size during manufacturing while still maintaining structural strength against forces perpendicular to the plane of the cargo box panel 100. Furthermore, panel 100 may be defined by a center thickness of about 1.0 mm to 2.0 mm.

[0076] like Figure 1 As shown, panel 10 is defined by a pair of longitudinal edges 102a, 102b arranged perpendicular to a pair of lateral edges 104a, 104b. Each longitudinal edge 102 and lateral edge 104 is configured as a C-shaped edge. Therefore, the longitudinal edge 102 and lateral edge 104 are perpendicular to each other, and the C-shaped edge of the longitudinal edge 102 is substantially perpendicular to the C-shaped edge opening of the lateral edge 104. Examples of various properties of exemplary aluminum alloys can be found in Table 1 below:

[0077] Table 1

[0078] like Figure 1 As further shown, the crossbeam 106 is arranged transversely across the bottom surface 101 of the panel 100. Figure 1 In a non-limiting example, the crossbeam 106 is arranged generally vertically on the panel 100 and extends from the first longitudinal edge 102a to the second longitudinal edge 102b. The crossbeam 106 may be made of an adhesive material 108 (such as...). Figure 2 (As shown) Attached to the bottom surface of panel 100. In Figure 1 In some examples, the adhesive material 108 may be a liquid adhesive, such as glue. In some examples, the crossbeam 106 is formed from extruded aluminum. The crossbeam 106 may serve two main purposes. First, the crossbeam 106 provides additional rigidity to the panel 100. Second, the crossbeam 106 may include a T-slot 116 configured to attach various components, such as clamps or retainers, to the panel 100. The portion of the crossbeam 106 outside the T-slot may be referred to as the outer surface 134.

[0079] The cargo box cover panel assembly 10 also includes peripheral extrusions 112a, 112b. Each peripheral extrusion 112a, 112b is coupled to one of the longitudinal edges 102a, 102b of the panel 100. The peripheral extrusions 112a, 112b enable the cargo box cover panel assembly 10 to be mounted on the cargo box of a pickup truck. The peripheral extrusions 112a, 112b can be made of any suitable material, such as extruded aluminum.

[0080] Figure 2 It shows Figure 1 The cargo box cover panel assembly 10, wherein the crossbeam 106 and the first peripheral extrusion 112a are concealed to reveal additional aspects of the assembly 10. Figure 2 An arrangement of adhesive material 108 is shown between the longitudinal edges 102a, 102b of the transverse span of panel 100. Adhesive material 108 may be a liquid adhesive, such as glue. In other embodiments, adhesive material may be tape. Adhesive material 108 is used to attach the crossbeam 106 to panel 100.

[0081] also, Figure 2 A deformable tab 110a is shown in the first longitudinal edge 102a of panel 100. The deformable tab 110a can be used to mechanically hold a crossbeam 106 to panel 100. In some examples, the deformable tab 110a folds onto the crossbeam 106 to hold the crossbeam 106 during the curing of the liquid adhesive. The deformable tab 110a can also be used to arrange the crossbeam 106 vertically across panel 100. As shown in subsequent figures, another deformable tab can be arranged in the second longitudinal edge 102b of panel 100. In some examples, the deformable tab 110a is made of the same material as panel 100, such as a metal sheet.

[0082] Figure 3The various aspects of the cargo box cover panel assembly 10 are shown in more detail. In particular, Figure 3 Various aspects of the first longitudinal edge 102a and the crossbeam 106 are shown. The first longitudinal edge 102a includes a vertical side 126a and a flange 128b to form a C-shaped edge. Furthermore, a vertical window 120a is formed in the vertical side 126a of the first longitudinal edge 102a. A deformable tab 110a is disposed within the vertical window 120a. Additionally, the flange 128a includes a horizontal cutout region 118a. As shown in subsequent figures, the second longitudinal edge 102a may also include a vertical side 126b having a deformable tab 110b and a vertical window 102b, and a flange 128b having the cutout region 118b.

[0083] In some embodiments, the crossbeam 106 includes a T-slot 116. During assembly, a horizontal cutout region 118a guides the placement of the crossbeam 106 on a panel 100 to which adhesive material 108 has been applied. Deformable tabs 110a are then folded into the T-slots 116 of the crossbeam 106 to mechanically hold the crossbeam 106 against the panel 100. Holding the crossbeam 106 against the panel 100 may be particularly important during the curing of the liquid adhesive. Folding the deformable tabs 110a into the T-slots 116 also ensures that the crossbeam 106 is arranged perpendicular to the first longitudinal edge 102a. It is understood that if the T-slots 116 are not present on the crossbeam 106, the deformable tabs 110a may be folded onto the bottom surface 101 of the crossbeam 106 or other suitable crossbeam surface. Ultimately, the purpose of the deformable tabs 110a, 110b is to fold over a portion of the crossbeam 106 (e.g., Figure 5 As shown), this mechanically fixes the crossbeam 106 to the cargo box cover panel 100.

[0084] Figure 4 It shows Figure 3 Another perspective on characteristics. For example... Figure 4 As shown, the first longitudinal edge 102a of the panel 100 includes a vertical side 126a and a flange 128a. A deformable tab 110a is disposed within a vertical window 120a of the first longitudinal edge 102a. The deformable tab 110a is configured to fold into a T-slot 116 of the crossbeam 106.

[0085] Figure 5 Various aspects of the second longitudinal edge 102b and the crossbeam 106 are shown. The second longitudinal edge 102b includes a vertical side portion 126b and a flange 128b to form a C-shaped edge of the panel 100. Furthermore, a vertical window 120b is formed in the vertical side portion 126b of the second longitudinal edge 102b. A deformable tab 110b is arranged within the vertical window 120b. Additionally, the flange 128b includes a horizontal cutout region 118b. Figure 5As shown, deformable tab 110b folds into the T-slot 116 of crossbeam 106 to hold crossbeam 106 against panel 100. It can be understood that deformable tab 110a can similarly fold into the T-slot 116 of crossbeam 106 at opposite ends to mechanically secure both sides of crossbeam 106 to the bottom surface 101 of cargo box cover panel assembly 10.

[0086] Figure 6 It shows Figure 5 Another perspective on characteristics. For example... Figure 6 As shown, the second longitudinal edge 102b of panel 100 includes a vertical side 126b and a flange 128b. A deformable tab 110b is disposed within a vertical window 120b of the second longitudinal edge 102b. The deformable tab 110b is configured to fold into a T-slot 116 of crossbeam 106. As noted, it can be understood that deformable tabs 120a can similarly fold into T-slots 116 of crossbeam 106 at opposite ends of crossbeam 106.

[0087] Figure 7 and Figure 8 Cross-sectional views of various aspects of the cargo box cover panel assembly 10 are shown. In particular, Figure 7 and Figure 8 A panel 100 is shown, having a first longitudinal edge 102a, a crossbeam 106, and a first peripheral extrusion 112a. The peripheral extrusion 112a includes a C-shaped portion arranged around the first longitudinal edge 102a. The peripheral extrusion 112a is mechanically connected to the first longitudinal edge 102a of the panel 100 by barbs 114a. Figure 7 and Figure 8 As shown, the barb 114a engages with the flange 128a of the first longitudinal edge 102a to secure the first peripheral extrusion 112a to the first longitudinal edge 102a of the panel 100. The crossbeam 106 is attached to the panel 100 by adhesive material 108. Figure 7 and Figure 8 The deformable tab 110a remains folded and upright. Therefore, Figure 7 and Figure 8 The deformable tab 110a does not assist in keeping the crossbeam 106 against the panel 100.

[0088] Figure 9 Cross-sectional views of further aspects of the cargo box cover panel assembly 10 are shown. In particular, Figure 9 A panel 100 is shown, having a second longitudinal edge 102b, a crossbeam 106, and a second peripheral extrusion 112b. The peripheral extrusion 112b is mechanically connected to the second longitudinal edge 102b of the panel 100 by barbs 114b. Figure 9As shown, the barb 114a engages with the flange 128b of the second longitudinal edge 102b to secure the second peripheral extrusion 112b to the second longitudinal edge 102b of the panel 100. The crossbeam 106 is attached to the panel 100 by an adhesive material 108. Furthermore, a deformable tab 110b folds down onto the crossbeam 106, thereby holding the crossbeam 106 against the panel 100. In a preferred example, both deformable tabs 110a and 110b fold down onto the crossbeam 106 to hold the crossbeam against the panel 100.

[0089] Figure 10 An isometric view of a variant of the longitudinal edge 102 of panel 100 is shown. A crossbeam 106 with a T-slot 116 is disposed on the bottom surface 101 of panel 100 by an adhesive material 108. In this example, the adhesive material 108 may be double-sided tape, such as VHB™ adhesive foam tape. While tape is generally easier to use and install than liquid adhesive, it is generally less strong. Therefore, additional features may be required to hold the crossbeam 106 to panel 116.

[0090] The longitudinal edge 102 may be defined by a vertical edge 126 and a flange 128. The vertical side 126 and the flange 128b together form a C-shaped edge with other aspects of the panel 100. The flange 128 includes a cutout region 118 to assist in the placement and alignment of the beam 106 on the panel 100. The vertical edge 126 includes a vertical window 120. Notably, unlike previous embodiments, the vertical window 120 does not include a deformable tab 110 or other features for holding the beam 106 against the panel 100.

[0091] Figure 11 and Figure 12A non-limiting isometric view is shown of a clip 122 for holding a crossbeam 106 against a panel 100. Clip 122 includes a pair of clips 124a, 124b, a central portion 130, and a wing 132. Wing 132 includes a pair of protrusions 136a, 136b and a crossbar 138. As shown in subsequent figures, clips 124a, 124b and the central portion 130 are configured to slide into a vertical window 120 of the longitudinal edge 102, such that clips 124a, 124b engage with the vertical window 120, thereby securing clip 122 to the longitudinal edge 102. The central portion 130 engages within a T-slot 116 of the crossbeam 106, while the protrusions 136a, 136b and the crossbar 138 of the wing 132 engage above the outer surface 134 of the crossbeam 106. The crossbar 138 of the wing 132 is also configured to engage with and fit within the cutout area 118 of the flange 128, further ensuring proper alignment of the clip 112 with the longitudinal edge 102 and the crossbeam 106. This engagement or fitting of the crossbar 138 with the cutout area 118 also ensures proper positioning of the crossbeam 106 along the bottom surface of the panel 100. The clip 122 may be a one-piece body made of plastic or other suitable material. In particular, the material of the clip 122 should be selected to allow the clips 124a, 124b to deform and engage with the vertical window 120 of the longitudinal edge 102.

[0092] Figure 13 and Figure 14 An isometric view is shown showing the connection between clip 122 and the longitudinal edge 102 and crossbeam 106 of panel 100. Clips 124a, 124b and intermediate portion 130 of clip 122 slide into vertical windows 120 of longitudinal edge 102. Clips 124a, 124b engage with vertical windows 120 to secure clip 122 to longitudinal edge 102. Intermediate portion 130 slides into T-slot 116 of crossbeam 106. Protrusions 136a, 136b and crossbar 138 of wing 132 are arranged above outer surface 134 of crossbeam 106. When clips 124a, 124b engage with vertical windows 120, crossbar 138 of wing 132 slides into and substantially fills cutout area 118 of flange 128.

[0093] Figure 15 An isometric view showing the connection between the peripheral extruder 112 and the longitudinal edge 102 is shown. As will be shown, the peripheral extruder 112 can also be connected to the clamp 122, thereby locking the panel 100, the crossbeam 106, the peripheral extruder 112 and the clamp 122 together, while holding the crossbeam 106 against the bottom surface 101 of the panel 100.

[0094] Figure 16 It shows Figure 15 The cross-section of the component includes panel 100, crossbeam 106, peripheral extrusion 112, and clamp 122. For example... Figure 13-15As shown, a portion of clip 122 is inserted into the vertical window 120 of the longitudinal edge 102 of panel 100. (Reference) Figure 16 The C-shaped portion of the peripheral extrusion 112 surrounds the panel 100, the crossbeam 106, and the clamp 122. The peripheral extrusion 112 includes barbs 114 configured to engage with (1) the crossbar 138 of the wing 132 of the clamp 122 and (2) the flange 128 of the first longitudinal edge 102 of the panel 100. Therefore, Figure 7-9 The space between the crossbeam 106 and the peripheral extruder 112 shown is filled by the clip 122. Therefore, the clip 122 and the peripheral extruder 112 prevent the crossbeam 106 from being lifted off the panel 100. Furthermore, in some examples, a second clip (generally similar to clip 122) may similarly engage with another longitudinal edge of the panel 100, located on the opposite side of the crossbeam 106, to secure the other end of the crossbeam 106 to the panel 100.

[0095] refer to Figure 10-16 The described configuration offers numerous advantages. By inserting the clip 122 into the vertical window 120 of the longitudinal edge 102 and the T-slot 116 of the crossbeam 106, and then attaching the peripheral extruder to the clip 122 and the flange 128 of the panel 100, any force that would pull the crossbeam 106 off the panel 100 is subsequently distributed throughout the clip 122, the vertical side 126 of the longitudinal edge 102 of the panel 100, and the peripheral extruder 112 to provide additional support. Furthermore, Figure 11 and Figure 12 The retaining force applied to the crossbeam 106 by the clamp 122 is distributed across both the T-slot 116 and the outer surface 134, and not just within the T-slot 116, to achieve improved support. This additional support allows for the use of an adhesive material 108, embodied in tape, instead of a liquid adhesive, to achieve easier and faster assembly, as the tape is easier to apply to the panel 100 and requires no curing time.

[0096] Figure 17 This is a flowchart of a method 800 for manufacturing a cargo box cover panel assembly 10. Method 800 includes, in step 802, providing a panel 100 formed of a material substantially composed of a metal sheet. The panel 100 includes a longitudinal edge 102.

[0097] Method 800 further includes, in step 804, attaching the crossbeam 106 to the panel 100 by means of an adhesive material 108. The crossbeam 106 is arranged laterally across the panel 100. The adhesive material 108 may be a liquid adhesive, such as glue.

[0098] Method 800 also includes a deformable tab 110 folded over the longitudinal edge 102 to mechanically attach the beam 106 to the panel 100. Using the deformable tab 110 to hold the beam 106 against the panel 100 allows the liquid adhesive to cure.

[0099] Figure 18 This is a flowchart of another method 900 for manufacturing a cargo box cover panel assembly 10. Method 900 includes, in step 902, providing a panel 100 formed of a material substantially composed of a sheet metal. The panel 100 includes longitudinal edges.

[0100] Method 900 further includes, in step 904, attaching the crossbeam 106 to the panel 100 by means of an adhesive material 108. The crossbeam 106 is arranged laterally across the panel 100. The adhesive material 108 may be tape.

[0101] Method 900 further includes, in step 906, mechanically attaching the peripheral extruder 112 to the longitudinal edge 102 of the panel 100.

[0102] Method 900 further includes, in step 908, mechanically engaging the clip 122 with the crossbeam 106 and the peripheral clamp 112 to mechanically retain the crossbeam 106 to the panel 100. In some examples, this step may include sliding the clip 122 along a T-slot of the crossbeam to insert a portion of the clip 122 into a vertical window 120 of the longitudinal edge 102. The clip 122 may also include one or more clips 124 to secure the clip 122 to the vertical window 120. The barbs 114 of the peripheral clamp 112 may then engage the clip 122 and the longitudinal edge 102 to further secure the clip 122. In some further examples, the peripheral clamp 112 may be engaged with the longitudinal edge 102 of the panel 100 after the clip 122 has been engaged with the crossbeam 106 and the longitudinal edge 102 of the panel 100.

[0103] All definitions defined and used herein should be understood as control dictionary definitions, definitions in referenced incorporated literature, and / or the general meaning of the defined terms.

[0104] As used herein in the specification and claims, “or” should be understood to have the same meaning as “and / or” as defined above. For example, when separating items in a list, “or” or “and / or” should be interpreted as inclusive, i.e., including multiple elements or at least one of the elements in the list, but also including more than one, and optionally, additional unlisted items. Only when the opposite terms are explicitly indicated, such as “only one” or “exactly one”, or when used in the claims, “consisting of…” will refer to including multiple elements or exactly one of the elements in the list. In general, when preceded by an exclusive term (e.g., “any,” “one of,” “only one of,” or “exactly one of”), the term “or” as used herein should be interpreted only to indicate an exclusive alternative (i.e., “one or the other but not both”).

[0105] As used herein in the specification and claims, the phrase "at least one" or "one or more" relating to a list of one or more elements should be understood to mean at least one element selected from any one or more elements in the list, but not necessarily including at least one of each element specifically listed in the list, and does not exclude any combination of elements in the list. This definition also allows for the optional presence of elements other than those specifically identified within the list of elements referred to by the phrase "at least one," whether related to or unrelated to those specifically identified elements.

[0106] It should also be understood that, unless expressly stated to the contrary, in any method claimed herein that includes more than one step or action, the order of the steps or actions of the method is not necessarily limited to the order in which the steps or actions of the method are described.

[0107] In the claims and the foregoing description, all transitional phrases, such as “comprising,” “including,” “carrying,” “having,” “containing,” “involving,” “holding,” “containing,” etc., shall be understood as open-ended, meaning including but not limited to. Only the transitional phrases “consisting of…” and “consisting substantially of…” shall be closed or semi-closed transitional phrases, respectively.

[0108] As used herein, “about” means approximately or close to, and in the context of the numerical value or range described, it means ±15% of that value. In exemplary embodiments, the term “about” may include conventional rounding based on the significant figures of the numerical value. Furthermore, the phrase “about “x” to “y” includes “about “x” to about “y”.

[0109] Furthermore, any range of numbers listed in the specification or claims, such as ranges representing a particular set of properties, units of measurement, conditions, physical states, or percentages, is intended to be expressly incorporated herein by reference or otherwise. Any number falling within such range includes any subset of numbers within any listed range. For example, whenever a range of values ​​having a lower limit RL and an upper limit RU is disclosed, any number R falling within that range is specifically disclosed. In particular, the following number R within that range is specifically disclosed: R = RL + k(RU - RL), where k is a variable ranging from 1% to 100% in increments of 1%, for example, k is 1%, 2%, 3%, 4%, 5%... 50%, 51%, 52%... 95%, 96%, 97%, 98%, 99%, or 100%. Furthermore, any range of values ​​represented by any two R values ​​calculated as above is also specifically disclosed.

[0110] Other embodiments are within the scope of the following claims and other claims that the applicant may be authorized to.

[0111] While various examples have been described and illustrated herein, those skilled in the art will readily conceive of various other means and / or structures for performing the functions described herein and / or obtaining the results and / or one or more advantages described herein, and each of these variations and / or modifications is considered to be within the scope of the examples described herein. More generally, those skilled in the art will readily understand that all parameters, dimensions, materials, and configurations described herein are intended to be exemplary, and actual parameters, dimensions, materials, and / or configurations will depend on one or more specific applications using the teachings. Those skilled in the art will recognize or be able to determine many equivalents of the specific examples described herein using experiments not exceeding those of ordinary practice. Therefore, it should be understood that the foregoing examples are presented by way of example only, and that the examples may be implemented in ways different from the specific descriptions and claims within the scope of the appended claims and their equivalents. The examples of this disclosure relate to each individual feature, system, article, material, and / or method described herein. Furthermore, any combination of two or more such features, systems, articles, materials, and / or methods is included within the scope of this disclosure if such features, systems, articles, materials, and / or methods do not contradict each other.

Claims

1. A cargo box cover panel assembly, comprising: A panel, the panel being formed of a material substantially composed of a metal sheet, the panel including longitudinal edges, transverse edges, a top surface and a bottom surface; A crossbeam, the crossbeam being arranged laterally across the panel, wherein the crossbeam is attached to the bottom surface of the panel via an adhesive material; A peripheral extrusion member, the peripheral extrusion member being mechanically connected to the longitudinal edge of the panel; and A clip, configured to mechanically engage with the crossbeam and the peripheral extruder, to mechanically hold the crossbeam to the panel.

2. The cargo box cover panel assembly according to claim 1, wherein, The adhesive material is tape or liquid adhesive.

3. The cargo box cover panel assembly of claim 1, wherein the peripheral extrusion includes barbs configured to mechanically engage with the longitudinal edge of the panel.

4. The cargo box cover panel assembly according to claim 1, wherein, The clamp is configured to mechanically engage with the barbs of the peripheral extruder.

5. The cargo box cover panel assembly according to claim 1, wherein, The crossbeam is formed from extruded aluminum.

6. The cargo box cover panel assembly according to claim 1, wherein, The crossbeam includes a T-shaped groove.

7. The cargo box cover panel assembly according to claim 6, wherein, The clamp is configured to slidably engage with the T-slot of the crossbeam.

8. The cargo box cover panel assembly according to claim 1, wherein, The longitudinal edge includes a horizontal cutout area corresponding to the crossbeam.

9. The cargo box cover panel assembly of claim 8, wherein the clip is further configured to be inserted into the horizontal cutout region of the longitudinal edge of the panel.

10. The cargo box cover panel assembly according to claim 1, wherein, The longitudinal edge includes a vertical window corresponding to the crossbeam.

11. The cargo box cover panel assembly of claim 10, wherein the clip is further configured to engage with the vertical window of the longitudinal edge of the panel.

12. The cargo box cover panel assembly according to claim 11, wherein, The clip also includes one or more clips configured to engage with the vertical window.

13. A method for manufacturing a cargo box cover panel assembly, comprising: A panel is provided, formed of a material substantially composed of a metal sheet, the panel including longitudinal edges; The crossbeams are attached to the panel via an adhesive material, wherein the crossbeams are arranged laterally across the panel; The peripheral extrusion is mechanically attached to the longitudinal edge of the panel; and The clamp is mechanically engaged with the crossbeam and the peripheral extrusion to mechanically hold the crossbeam to the panel.

14. A cargo box cover panel assembly, comprising: A panel, the panel being formed of a material substantially composed of a metal sheet, the panel including longitudinal edges, transverse edges, a top surface and a bottom surface; A crossbeam, the crossbeam being arranged laterally across the panel, wherein the crossbeam is directly fixed to the bottom surface of the panel by adhesive and mechanical means; and A peripheral extrusion member, which is mechanically attached to the longitudinal edge of the panel.

15. The cargo box cover panel assembly of claim 14, further comprising a clip configured to mechanically engage with the crossbeam and the peripheral extruder to mechanically retain the crossbeam to the panel.

16. The cargo box cover panel assembly according to claim 14, wherein, The longitudinal edge of the panel includes deformable tabs configured to mechanically hold the crossbeam to the bottom surface of the panel.

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