Cargo area cover and method for manufacturing the same

Abstract

A rigid, foldable sheet metal cargo bed cover with certain exemplary properties is provided. The sheet metal has a yield strength greater than its shear strength. The sheet metal may be a manganese-alloyed aluminum alloy. The cargo bed cover further comprises cover panels, each with C-shaped longitudinal and transverse edges. The cargo bed cover may also include a C-shaped profile that fits the C-shaped edges of the cover panels, so that the cover frame is configured to receive the cover panels. The cargo bed cover may further include one or more crossbeams with a T-slot profile configured to receive latches.

Description

Reference to related applications

[0001] This application claims priority over the preliminary US patent application with serial number 63 / 517,790, filed on August 4, 2023, entitled “Cargo area cover and method of making the same”, which is incorporated herein by reference in its entirety. Technical field of disclosure

[0002] This disclosure relates generally to cargo area covers and in particular to cargo area covers with hard or rigid panels. Technical background

[0003] One advantage of a pickup truck (hereinafter referred to as "truck") is the ability to use its cargo bed to transport goods that might not be suitable for transport in other vehicles. This cargo might include oversized items such as a large television or items that could soil the vehicle's interior, such as gardening equipment. The cargo bed typically comprises a pair of opposing side walls, joined at their front and rear ends by a front wall or partition and a rear wall or tailgate, respectively.

[0004] An accessory used to cover the cargo bed of a truck is commonly referred to as a tonneau cover. Tonneau covers are used to cover the cargo beds of pickup trucks for various reasons, including aesthetics, aerodynamics, and to protect items in the cargo bed from falling out and from environmental factors such as rain, dirt, snow, and grime.

[0005] Among the various types of tonneau covers, the hard, folding tonneau cover is a popular choice. A hard, folding tonneau cover typically consists of several rigid panel sections that extend laterally across the width of the truck bed. Each panel section is connected to the adjacent panel(s) by a hinge mechanism that also spans the width of the bed. If the entire bed of the pickup truck does not need to be covered, the panel sections can be folded sequentially from the tailgate toward the bulkhead into a layered stack, leaving at least one section of the bed open and uncovered.

[0006] Conventional hard, foldable cargo bed covers typically consist of a rigid foam or plastic with a honeycomb structure, encased in an aluminum skin. These panels are generally heavy and environmentally unfriendly, exhibit a lack of structural integrity under certain weather conditions, and tend to collect water within the honeycomb structure.

[0007] Accordingly, there is a need for a hard, foldable cargo cover that is structurally intact, waterproof, and environmentally friendly. However, given the prior art known at the time of disclosure of the present invention, it was not obvious to a person skilled in the art how the disadvantages of the prior art could be overcome.

[0008] Although certain aspects of conventional technologies for enabling the disclosure of the invention have been discussed, the applicants do not reject these technical aspects in any way, and it is assumed that the claimed invention may include one or more of the conventional technical aspects discussed herein.

[0009] The present disclosure may address one or more of the prior art problems and shortcomings discussed above. However, it is conceivable that the subject matter of the disclosure may prove useful in addressing other problems and shortcomings in a number of technical fields. Therefore, the claimed invention should not necessarily be interpreted as being limited to addressing only one of the specific problems or shortcomings discussed herein.

[0010] The reference to or discussion of any document, action, or body of knowledge in this description does not imply that the document, action, or body of knowledge, or any combination thereof, was publicly available, publicly known, part of common knowledge, or otherwise state of the art under applicable legal provisions as of the priority date, or that it is known to be relevant to the solution of any problem addressed in this description. Summary of Revelation

[0011] The present disclosure relates generally to a foldable cargo bed cover for use with a cargo box of a pickup truck. The cargo bed cover comprises a plurality of cover sections, each section having a hard or rigid cover plate. The cover plate may be made from a single layer of aluminum alloy sheet, for example, a manganese-alloyed aluminum alloy. Additional structural integrity is provided by bending both the longitudinal and transverse edges of the plates into a C-shape. The foldable cargo bed cover further comprises a cover frame, which includes one or more cover frame elements. The cover frame elements include C-shaped profiles that correspond to the C-shaped edges of the cover plates, such that the profiles of the cover frame elements can receive the edges of the cover plate.The frame elements may have an outer circumference angled relative to the cover plate. Furthermore, at least one elongated crossbeam may be attached to the underside of each cover plate. The elongated crossbeam may include an integrated T-slot channel for receiving one or more locking mechanisms.

[0012] When the cover sections are in an unfolded position, the majority of them essentially cover the cargo box. When the cover sections are in a folded position, two or more sections are arranged in a layered stack, and at least one section of the cargo box remains uncovered. Folding and unfolding the cover sections is enabled by hinge mechanisms located between adjacent sections. These hinge mechanisms may include a barrel hinge, an elastomeric hinge seal, and a secondary sealing element.

[0013] The cover plate can be made of an aluminum alloy, such as series 3000 or 5000 aluminum. Compared to conventional hard covers made of plastic or rigid foam with an aluminum skin, the aluminum sheet offers a variety of advantageous properties, including improved yield strength, tensile strength, and shear strength. In some examples, the aluminum alloy can contain approximately 98 to 99 percent aluminum and approximately 1 to 2 percent manganese.

[0014] The C-shaped edges of the panels' longitudinal and transverse edges create recesses at each corner. These recesses are covered by corner assemblies. The corner assemblies effectively connect a pair of vertical cover frames. By covering the recesses formed by the panel's longitudinal and transverse edges, the corner assemblies protect the interior of the cargo box from the external environment. Furthermore, the cover frames can also incorporate elongated gaskets, such as lamellar gaskets or D-seals, to seal any gaps between the cover frames and the cargo box.

[0015] In general, an example is provided of a foldable tonneau cover for use with a cargo box of a pickup truck. The foldable tonneau cover comprises multiple cover sections that are movable between an unfolded and a folded position. Most of the cover sections essentially cover the cargo box in the unfolded position. Most of the cover sections are arranged in a layered stack in the folded position.

[0016] The folding cargo cover also includes a hinge mechanism. The hinge mechanism is positioned between at least two of the cover sections. The hinge mechanism allows the cover sections to move between the folded and unfolded positions.

[0017] Each of the multiple cover sections comprises a cover plate formed from a material that is essentially a sheet of metal. The cover plate includes longitudinal edges and transverse edges. Each longitudinal edge and each transverse edge is configured to be a C-shaped edge. The C-shaped edge of each of the longitudinal edges opens essentially perpendicular to the C-shaped edge of each of the transverse edges.

[0018] According to an example, each cover plate has the following properties: (1) a yield strength between about 100 MPa and about 200 MPa; (2) a tensile strength between about 130 MPa and about 230 MPa; (3) a shear strength between about 80 MPa and about 140 MPa, the yield strength being higher than the shear strength; (4) a first thickness in the middle of the cover plate between about 1.00 mm and about 2.00 mm; and (5) a second thickness at the C-shaped edge of the cover plate between about 10.0 mm and about 15.0 mm.

[0019] For example, the material may be an aluminum alloy that contains (1) aluminum in an amount between about 98% and 99% of the chemical composition of the aluminum alloy and (2) manganese in an amount between about 1% and about 2% of the chemical composition of the aluminum alloy.

[0020] For example, the material is series 3000 aluminum.

[0021] In another example, a folding tonneau cover is provided for use with a cargo box of a pickup truck. The folding tonneau cover comprises a plurality of cover panels. Each of the plurality of cover panels is formed from a material that is essentially a sheet. The material has the following properties: (1) a yield strength between about 100 MPa and about 200 MPa; (2) a tensile strength between about 130 MPa and about 230 MPa; (3) a shear strength between about 80 MPa and about 140 MPa, the yield strength being higher than the shear strength; (4) a first thickness in the center of each of the plurality of cover panels between about 1.0 mm and about 2.00 mm; and (5) a second thickness at an edge of each of the plurality of cover panels between about 10.0 mm and about 15.0 mm.

[0022] For example, each of the majority of cover plates comprises longitudinal edges and transverse edges. Each longitudinal edge and each transverse edge can be configured to be a C-shaped edge. The C-shaped edge of each of the longitudinal edges opens essentially perpendicular to the C-shaped edge of each of the transverse edges.

[0023] According to one example, the material is an aluminum alloy comprising: (1) aluminum in an amount between about 98% and 99% of the chemical composition of the aluminum alloy and (2) manganese in an amount between about 1% and about 2% of the chemical composition of the aluminum alloy.

[0024] In another example, a folding tonneau cover is provided for use with a cargo box of a pickup truck. The folding tonneau cover comprises multiple cover sections. These multiple cover sections are movable between an unfolded position and a folded position. In the unfolded position, the multiple cover sections essentially cover the cargo box. In the folded position, the multiple cover sections are arranged in a layered stack.

[0025] The folding cargo cover also includes a hinge mechanism. The hinge mechanism is positioned between at least two of the majority of the cover sections. The hinge mechanism allows the majority of the cover sections to move between the folded and unfolded positions.

[0026] Each of the multiple cover sections includes a cover plate. The cover plate is formed from a material that is essentially a sheet of metal. The cover plate includes longitudinal edges and transverse edges. Each of the longitudinal edges and each of the transverse edges is configured to be a C-shaped edge. The C-shaped edge of each of the longitudinal edges opens essentially perpendicular to the C-shaped edge of each of the transverse edges.

[0027] Each cover plate has the following properties: (1) a yield strength between approximately 100 MPa and approximately 200 MPa; (2) a tensile strength between approximately 130 MPa and approximately 230 MPa; (3) a shear strength between approximately 80 MPa and approximately 140 MPa, the yield strength being higher than the shear strength; (4) a first thickness in the center of the cover plate between approximately 1.0 mm and approximately 2.00 mm; (5) a second thickness at the C-shaped edge of the cover plate between approximately 10.0 mm and approximately 15.0 mm. The material is an aluminum alloy comprising (1) aluminum in an amount between approximately 98% and 99% of the chemical composition of the aluminum alloy and (2) manganese in an amount between approximately 1% and approximately 2% of the chemical composition of the aluminum alloy.

[0028] For example, the sheet metal material is a 3000 series aluminum alloy.

[0029] According to one example, the foldable cargo cover also has a recess at each corner of the cover plate between one of the longitudinal edges and an adjacent transverse edge.

[0030] According to one example, the foldable cargo cover further comprises a cover frame to which the C-shaped edge of each of the longitudinal edges and each of the transverse edges is attached, thereby forming an interface between the cover frame and each associated C-shaped edge.

[0031] According to one example, the folding cargo cover further comprises a corner structure that covers the recess at one of the corners of the cover panel. The corner structure further comprises a corner frame that is connected to the cover frame at one of the longitudinal edges and one of the transverse edges.

[0032] According to one example, the foldable cargo cover further comprises one or more elongated seals arranged within a channel of the cover frame.

[0033] For example, the one or more elongated seals include a lamellar seal and / or a D-seal.

[0034] For example, the cover frame has an angled outer circumference. The angle of the angled outer circumference is between approximately 20 degrees and approximately 60 degrees relative to the upper surface of the cover plate.

[0035] For example, the cover frame includes a C-shaped profile that fits the C-shaped edge of the longitudinal and transverse edges of the cover plate. The C-shaped profile is configured to accommodate the C-shaped edge.

[0036] According to one example, the foldable cargo cover further comprises at least one elongated crossbeam that is attached to the underside of each cover panel and extends along it.

[0037] According to one example, the at least one elongated crossbeam includes an integrated T-slot channel configured to accommodate one or more interlocks.

[0038] According to one example, the joint mechanism comprises a barrel joint. The barrel joint is arranged transversely across the folding cargo cover between the C-shaped edges of adjacent transverse edges. The joint mechanism further comprises an elastomeric joint seal. The elastomeric joint seal is arranged below the barrel joint and transversely across the folding cargo cover between the C-shaped edges of adjacent transverse edges. The joint mechanism further comprises a second seal. The second seal is arranged below the elastomeric joint seal and transversely across the folding cargo cover between the C-shaped edges of adjacent transverse edges.

[0039] In another example, the folding cargo cover generally includes a stiffening element. The stiffening element is arranged transversely along the underside of one or more cover panels. The stiffening element comprises a plurality of flanges attached to the underside of the one or more cover panels. The stiffening element also includes a connecting section extending from each of the plurality of flanges. The connecting section and the corresponding flange form an obtuse angle with each other. The stiffening element further includes an elongated section extending substantially parallel to a transverse axis of the cover panel. The elongated section extends between the connecting sections and links them together. The cover panel and the stiffening element define a space between them.

[0040] In general, another example provides a method for manufacturing a foldable cargo bed cover for use with a cargo box of a pickup truck.The method comprises (1) providing a first sheet with longitudinal and transverse edges, the first sheet having a cutout at each corner; (2) folding each longitudinal and transverse edge of the first sheet into a C-shaped edge; (3) attaching each C-shaped edge of the first sheet to a cover frame; (4) providing a second sheet with longitudinal and transverse edges, the second sheet having a cutout at each corner; (5) folding each longitudinal and transverse edge of the second sheet into a C-shaped edge; (6) attaching each C-shaped edge of the second sheet to the cover frame; and (7) joining the first sheet and the second sheet via a hinge mechanism arranged between the C-shaped edges of adjacent transverse edges of the first and second sheets.

[0041] It is understood that all combinations of the foregoing concepts and additional concepts further explained below (provided these concepts are not incompatible with one another) are made available as part of the subject matter disclosed herein. In particular, all combinations of the claimed subject matter listed at the end of this disclosure are considered to be part of the subject matter disclosed herein. It should also be noted that terms expressly used herein, which may also appear in a disclosure incorporated by reference, should be given a meaning that most closely corresponds to the specific concepts disclosed herein.

[0042] These and other aspects of the various embodiments will be made clear and explained with reference to the embodiment(s) described below. Brief description of the drawings

[0043] In the drawings, identical reference numerals generally refer to identical parts in the different views. Furthermore, the drawings are not necessarily to scale, but primarily serve to illustrate the principles of the various embodiments. Fig. Figure 1A is an upper perspective view of a cargo cover with fixed panels according to an embodiment of the present disclosure, as installed on a loading platform of a pickup truck, wherein the panels are in an unfolded position according to aspects of the present disclosure. Fig. 1B is a side view of the cargo cover made of Fig. 1A, wherein, according to aspects of the present disclosure, the plates are in the process of transitioning into a folded position. Fig. 1C is a perspective view of the cargo cover from Fig. 1A, which, according to aspects of the present disclosure, extends along a side rail of the pickup truck. Fig. 1D is a partial cross-sectional view of the cargo area cover made of Fig. 1A along the side rail Fig. 1C, showing the cargo cover resting on the side rail, wherein an indexing flange enables the central placement of the cargo cover on the cargo box of the pickup truck according to aspects of the present disclosure. Fig. 1E-1 is a partial cross-sectional view of the cargo area cover made of Fig. 1A, showing the middle plate, the partition plate and the intervening double-joint mechanism together with a T-slot or channel within a crossbeam according to aspects of the present disclosure. Fig. 1E-2 is an enlarged cross-sectional view of the in Fig. 1E-1 shown crossbar according to aspects of the present revelation. Fig. 2A is a partial cross-sectional view of a generalized interface between a cover frame and a cover plate according to aspects of the present disclosure. Fig. 2B is a cross-sectional view of an interface between a cover plate and a cover frame along a tailgate of a cargo box of a pickup truck according to aspects of the present disclosure. Fig. 2C is a cross-sectional view of an interface between a cover plate and a cover frame along a partition and a side rail of a cargo box of a pickup truck according to aspects of the present disclosure. Fig. 2D is a cross-sectional view of an interface between a middle plate and a hinged frame and an interface between a tailgate plate and another hinged frame with a hinge mechanism arranged between the hinged frames according to aspects of the present disclosure. Fig. Figure 3A is a partial cross-sectional view of a corner of a cargo cover according to aspects of the present disclosure. Fig. 3B is a perspective view of the corner from Fig. 3A, wherein the corner construction has been removed, according to aspects of the present disclosure. Fig. 3C is a perspective view of the underside of the corner from Fig. 3A, wherein the corner construction and the frame elements have been removed, leaving only the solid plate according to aspects of the present disclosure. Fig. Figure 4 is a flowchart of a process for manufacturing a foldable cargo cover for use with a cargo box of a pickup truck according to aspects of the present disclosure. Fig. Figure 5A is a perspective underside view of a cover plate according to an embodiment of the present invention, showing an optional stiffening element attached to its underside according to aspects of the present disclosure. Fig. 5B is an exploded view of the stiffening element and the cover plate made of Fig. 5A according to aspects of the present revelation. Fig. 5C is a side or end view of the stiffening element and the cover plate made of Fig. 5A according to aspects of the present revelation. Fig. Figure 6A is a perspective view of a hinge clamp in a released state for use with a cargo cover according to an embodiment of the present invention. Fig. 6B is a perspective view of the joint clamp from Fig. 6A, wherein the joint clamp is in an engaged state according to aspects of the present disclosure. Fig. Figure 6C is a lateral cross-sectional view of adjacent cover sections in a folded / unfolded state with the hinge clamp released according to aspects of the present disclosure. Fig. Figure 6D is a lateral cross-sectional view of adjacent cover sections in an extended position with the hinge clamp engaged, according to aspects of the present disclosure. Fig. Figure 7A is a top view of a bracket for installation along a side wall of a pickup truck bed, wherein the bracket includes clamps and an optional anti-rotation device to prevent the clamps from rotating when attached to the side wall of the truck bed, according to aspects of the present disclosure. Fig. 7B is a side perspective view of the bracket, the clamp and the anti-rotation device. Fig. 7A according to aspects of the present revelation. Detailed description of the embodiments

[0044] The following detailed description of the preferred embodiments refers to the accompanying drawings, which form part thereof and in which specific embodiments are shown for illustration purposes, with which the subject matter of the disclosure can be carried out. It is understood that other embodiments may be used and structural modifications made without deviating from the scope of the disclosure.

[0045] In certain exemplary embodiments, the present disclosure relates to a fixed or rigid cargo cover comprising a plurality of plates, each formed from a layer of sheet metal (e.g., a manganese-alloyed aluminum alloy), with edges bent into a substantially "C" shape along all edges in both the longitudinal and transverse directions. The C-shaped edges provide the structural integrity of the cover plate. Furthermore, the cover plate material exhibits special properties that make it lightweight and flexible, yet very strong. These advantages are explained later in this description.

[0046] In the context of this disclosure, the term "aluminium alloy" refers to a metal that is a combination of aluminum and another element, wherein aluminum is the predominant element in the combination. Examples of alloying elements include copper, magnesium, manganese, silicon, tin, nickel, and zinc. Preferably, cover plates 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 between about 0.2 wt.% and about 2.2 wt.% of the composition, more preferably between about 0.6 wt.% and about 2.0 wt.% of the composition, and more preferably between about 1.0 wt.% and about 2.0 wt.% of the composition. In certain embodiments, each cover plate can be formed from a 3003-H14 aluminum alloy having a manganese content of about 1.0 wt.%.In other embodiments, each cover plate may be formed from a 3105-H24 aluminum alloy having a manganese content of approximately 0.2 to approximately 0.8 wt.% of the composition.

[0047] In the context of this disclosure, the term "yield strength" refers to a measure of the maximum force that can be exerted on a material before that material permanently deforms. The yield strength is typically expressed in megapascals (MPa) and can be determined by methods known in the art. Preferably, the cover plates described in this disclosure have a yield strength between about 100 MPa and about 200 MPa, more preferably between about 120 MPa and about 200 MPa, or even more preferably between about 140 MPa and about 200 MPa. It is conceivable that the yield strength may be higher than the values ​​given above, depending on the sheet metal material used for the cover plates.

[0048] In the context of this disclosure, the term "tensile strength" refers to a measure of the maximum force that can be exerted on a material before it breaks. Tensile strength is typically expressed in megapascals (MPa) and can be determined by methods known in the art. Preferably, the cover plates described in this disclosure have a tensile strength between about 130 MPa and about 230 MPa, more preferably between about 150 MPa and about 210 MPa, or even more preferably between about 170 MPa and about 200 MPa. It is conceivable that the tensile strength may be higher than the values ​​listed above, depending on the sheet metal material used for the cover plates.

[0049] 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 that material fails in the shear direction. Shear strength is typically expressed in megapascals (MPa) and can be determined by methods known in the art. Preferably, the cover plates described in this disclosure have a shear strength between about 80 MPa and about 140 MPa, more preferably between about 90 MPa and about 130 MPa, or even more preferably between about 100 MPa and about 120 MPa. It is conceivable that the shear strength may be higher than the values ​​listed above, depending on the sheet material used for the cover plate; however, it should be lower than the yield strength and the tensile strength of the cover plate.This relationship makes it possible to cut the cover plate to size during manufacturing, while still remaining structurally stable against forces acting perpendicular to the plane of the cover plate.

[0050] In the context of this disclosure, the term "thickness" refers to a measure of how thick a material is. Thickness is typically specified in millimeters (mm) and can be determined by methods known in the art. Preferably, the sheet metal of the cover plates described in this disclosure has a thickness between about 1.0 mm and about 2.0 mm, more preferably between about 1.15 mm and about 1.85 mm, or even more preferably between about 1.25 mm and about 1.65 mm. In certain embodiments, the C-shaped edges of the cover plates have a thickness between about 10.0 mm and about 15.00 mm, preferably between about 11.0 mm and about 14.0 mm, or even more preferably between about 12.0 mm and about 14.0 mm. It is conceivable that the thicknesses could be greater than the values ​​listed above due to the sheet metal material used for the cover plates; however, this could result in the cover plates being heavier than desired.In certain embodiments, each cover plate can be formed from 16-gauge or 14-gauge sheet metal, such as an aluminum alloy (e.g. 3003-H14, 3105-H24, etc.).

[0051] Referring to the characters, it shows Fig. Figure 1 shows a top perspective view of a folding cargo bed cover 100 as it is attached to a cargo box 3 of a pickup truck 1. The folding cargo bed cover 100 can be described by a longitudinal axis LA running along the length of the cargo box 3 and a transverse axis TA running along the width of the cargo box 3. In the non-restrictive example of Fig. In Figure 1, the cargo cover 100 is divided into three cover sections 102a, 102b, and 102c. The first cover section 102a is arranged as the rear section, so that it is located near the tailgate of the cargo box 3 of the pickup truck 1. Furthermore, in this example, the third cover section 102c is arranged as a partition panel or front panel, so that it is located near a driver's cab or passenger compartment of the pickup truck 1. Accordingly, the second cover section 102b is located between the first cover section 102a and the third cover section 102c. While the example in Figure 1... Fig. While Figure 1 shows a three-part folding cargo cover 100, other folding cargo covers 100 may have more or fewer than three sections. Similarly, the cargo cover 100 is in Fig. 1 essentially rectangular, while in other examples other sizes, shapes and proportions of the cargo cover 100 may be used.

[0052] Furthermore, each of the cover sections 102a, 102b, 102c comprises a cover plate 106a, 106b, 106c. Each cover plate 106a, 106b, 106c can be formed from a single layer of rigid sheet metal, for example, 14- or 16-gauge aluminum, unlike conventional cargo bed covers, which are typically made of a multi-layered laminate containing polymeric materials such as expanded polystyrene and expanded polypropylene. Moreover, all conventional single-layer cargo bed covers are thick and completely planar, i.e., without curved edges, as will become clearer later in this description.

[0053] In certain embodiments, each cover plate 106a, 106, 106c can be formed from a 3003-H14 aluminum alloy having a manganese content of about 1.0 to about 2.0 wt% of the composition. In other embodiments, each cover plate 106a, 106, 106c can be formed from a 3105-H24 aluminum alloy having a manganese content of about 0.2 to about 0.8 wt% of the composition. Alternative aluminum alloy materials—whether currently known or known in the future—with a manganese content in the ranges described above are also considered here.

[0054] The use of aluminum sheets over conventional hardboards, which are typically made of rigid plastic or foam and encased in an aluminum skin, offers several advantages. In particular, aluminum sheets are more environmentally friendly than conventional sheets due to the elimination of plastic or foam. Furthermore, aluminum sheets provide greater structural integrity under all weather conditions, higher UV resistance, and improved water resistance.

[0055] Furthermore, the use of an aluminum alloy with approximately 1.2% manganese (characteristic of 3000 series aluminum alloys) provides a number of improvements over pure aluminum, such as higher 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 20 percent stronger than 1100 series aluminum. Consideration is also being given to using a 5000 series aluminum alloy, which offers several advantages over aluminum alloys conventionally used for cargo bed covers.

[0056] The cover plates 106a, 106b, 106c can be defined by a series of strength properties. For example, each of the cover plates 106a, 106b, 106c can have a yield strength between approximately 100 MPa and approximately 200 MPa, a tensile strength between approximately 130 MPa and approximately 230 MPa, and a shear strength between approximately 80 MPa and approximately 140 MPa. In this example, the yield strength is higher than the shear strength so that each of the cover plates 106a, 106b, 106c can be cut during manufacturing but still remain structurally stable against forces acting perpendicular to the plane of the cover plate 106a, 106b, 106c. Furthermore, the cover plates 106a, 106b, 106c can be defined by a center thickness between 1.0 millimeters and 2.0 millimeters.

[0057] As in Fig. As shown in Figure 1A, each cover plate 102a, 102b, 102c is defined by a pair of longitudinal edges 108a1, 108a2, 108b1, 108b2, 108c1, 108c2, which are arranged perpendicular to a pair of transverse edges 110a1, 110a2, 110b1, 110b2, 110c1, 110c2. The longitudinal edges 108a1, 108a2, 108b1, 108b2, 108c1, 108c2 are parallel to the longitudinal axis LA of the cargo box 3, while the transverse edges 110a1, 110a2, 110b1, 110b2, 110c1, 110c2 are parallel to the transverse axis TA of the cargo box 3. As demonstrated in the following figures, each longitudinal edge 108 and transverse edge 110 is configured to be a C-shaped edge 112, 114. Accordingly, the longitudinal edges 108 and the transverse edges 110 are perpendicular to each other, and the C-shaped edges 112 of the longitudinal edges 108 open substantially perpendicular to the C-shaped edges 114 of the transverse edges 108, as shown, for example, in Fig. 3A shown.

[0058] Examples of various properties of example aluminium alloys are listed in Table 1 below: Table 1 3003-H14 Aluminium 3105-H24 Aluminium Bereich Mangan % 1,0-2,0 0,20-0,80 0,2-2,2 Streckgrenze 186 MPa 130-140 MPa 100-200 MPa Zugfestigkeit 200 MPa 172 MPa 130-230 MPa Scherfestigkeit 110 MPa 110 MPa 80-140 MPa Dicke (16 Gauge) 1,29 mm 1,29 mm 1,0-2,0 mm Dicke (14 Gauge) 1,63 mm 1,63 mm Dicke an der C-förmigenKante ~13,5 mm ~12,8 mm 10,0-15,0 mm

[0059] The cargo area cover 100 made of Fig. 1A further comprises four corner constructions 122a, 122b, 122c, 122d. The corner constructions 122a, 122b, 122c, 122d are described with reference to the Fig. 3A-3C described in more detail.

[0060] The foldability of the cargo area cover 100 from Fig. 1A allows each pair of adjacent sections 102a, 102b, 102c to be arranged either in a folded or an unfolded position. The panels 102a, 102b, 102c of the folding cargo cover 100 are made of Fig. 1A shows all sections in an unfolded position UF relative to each other. In the unfolded position UF, the cover sections 102a, 102b, 102c are essentially coplanar to each other. In the folded position F, as in Fig. As shown in Figure 1B, at least two of the cover sections 102a, 102b, 102c are stacked on top of each other.

[0061] As in Fig. As further shown in Figure 1A, the first cover section 102a is rotatably connected to the second cover section 102b via a first hinge mechanism 104a. Furthermore, the second cover section 102b is rotatably connected to the third cover section 102c via a second hinge mechanism 104b. In the non-restrictive example of Fig. 1A the first joint mechanism 104a is a single joint mechanism, while the second joint mechanism 104b is a double joint mechanism.

[0062] As in Fig. As shown in Figure 1B, the hinge mechanisms 104a, 104b allow the cover sections 102a, 102b, 102c to move from the unfolded position UF to the folded position F. As shown in Fig. As shown in Figure 1B, the first hinge mechanism 104a allows the first section 102a to rotate so that the first section 102a is stacked onto the second section 102b, with the upper surface of the first section 102a abutting the upper surface of the second section 102b. Once the first section 102a has been folded onto the second section 102b, both the first and second sections 102a, 102b can be rotated together to form a stack on top of the third section 102c.

[0063] To stack the first and second sections 102a, 102b onto the third section 102c, the folded arrangement of the first and second sections 102a, 102b and the first hinge mechanism 104a rotate together over the second hinge mechanism 104b. After the rotations, the first and second sections 102a, 102b are stacked onto the third section 102c, with the second section 102b on top and the first section 102a in the middle. In other words, the underside of the first section 102a rests against the upper surface of the third section 102c, with the underside of the second section 102b becoming the upper exposed surface of the stacked sections 102a, 102b, 102c. The combined thickness of the first and second sections 102a, 102b may necessitate the use of a spacer in the second hinge mechanism 104b to provide sufficient clearance for both sections 102a, 102b in the folded position.

[0064] Fig. 1C is a perspective view of the cargo cover 100 made of Fig. 1A, which extends along a first side rail of the pickup truck 1. Fig. Figure 1C shows a plurality of cover frame elements 118a-e forming a cover frame 118 around the cover plates 106a, 106b, 106c. The first cover frame element 118a is positioned transversely along the rear wall or tailgate of the cargo box.

[0065] 3. The second, third, and fourth cover frame elements 118b, 118c, 118d are positioned longitudinally along the side rail. The fifth cover frame element 118e is positioned along the partition wall of the cargo box 3. The remaining cover frame elements 118f, 118g, 118h (not shown) are arranged opposite the fourth, third, and second cover frame elements 118d, 118c, 118b, respectively. As shown in Fig. As shown in Figure 2A, the cover frames 118 each have a C-shaped profile 136 configured to accommodate the C-shaped edges 112, 114 of the longitudinal edges 108 and the transverse edges 110 of the cover plates 106. In some examples, the cover frames 118a-e are metal components formed by extrusion.

[0066] Fig. 1D is a partial cross-sectional view of the cargo area cover 100 made of Fig. 1A along the side rail Fig. 1C. Fig. Figure 1D shows the cargo cover 100, which rests on the side rail with an indexing flange 5. The indexing flange 5 allows the cargo cover 100 to sit semi-flush with the upper surface of the cargo box 3 and enables precise centering of the cargo cover 100 along the transverse axis TA. In one example, the indexing flange 5 allows the cargo cover 100 to extend 7.5 millimeters into the cargo box 3 and 18 millimeters beyond it. In other examples, the indexing flange 5 can be located on the opposite side (or on both sides) of the cargo cover 100.

[0067] Furthermore, it shows Fig. Figure 1D also shows a cross-section of the second cover frame 118b, which is positioned along the side rail. As shown in more detail in the following figures, the cover frame element 118b is defined by an angled outer circumference 132b. The angled outer circumference 132b can be inclined at an angle 148b of between about twenty degrees and about sixty degrees relative to an upper surface 134 of the cover plate 106, as shown in Fig. 2A shown in more detail.

[0068] Fig. 1E-1 is a partial cross-sectional view of the cargo area cover 100 made of Fig. 1A, which shows the second (middle) cover plate 106b, the third (partition) cover plate 106c and the second (double) hinge mechanism 104b between them. It also shows Fig. 1E-1 shows an elongated crossbeam 138b, which is arranged on the underside of the second cover plate 106b. It also shows Fig. 1E-1 provides another elongated crossbeam 138c, which is arranged on the underside of the third cover plate 106c. The elongated crossbeams 138 are attached to the cover plates 106 and extend along them to provide the plates 106 with additional structural support. In combination with the rigid frame elements 118, the elongated crossbeams 138 and the frame elements 118 make the cover plates 106 rigid under uniform loads and at the same time flexible under heavy point loads.

[0069] Furthermore, at least one of the elongated crossbeams can have an integrated T-slot channel 140 that runs longitudinally through the crossbeam 138. The in Fig. 1E-2 shown enlarged section from Fig. Figure 1E-1 shows a T-slot channel 140b that passes through the crossbeam 138b located below the second cover plate 106b. The T-slot channel 140b can be configured to accommodate one or more latches or other components. It is considered herein that the channel 140b can also assume alternative configurations, particularly when accommodating components.

[0070] Fig. Figure 2A is a partial cross-sectional view of a generalized interface 120 between a cover plate 106 and a cover frame 118. The cover plate 106 comprises a longitudinal edge 108 and a transverse edge 110, which are arranged perpendicular to each other. The longitudinal edge 108 and the transverse edge 110 each have C-shaped edges 112, 114 to provide additional structural support for the cover plate 106. In one example, the C-shaped edges 112, 114 can have a thickness of about ten millimeters to about fifteen millimeters. As shown in Figure 2A, the cover plate 106 has a longitudinal edge 108 and a transverse edge 110, which are arranged perpendicular to each other. Fig. As can be seen in 2A, the C-shaped edges 112 of the longitudinal edges 108 open essentially perpendicular to the C-shaped edges 114 of the transverse edges 110, since the longitudinal edges 108 and the transverse edges 110 are arranged perpendicular to each other.

[0071] Fig. Figure 2A also shows the interface 120 between the C-shaped edges 112, 114 of the cover plate 106 and the C-shaped profile 136 of the cover frame 118. As shown in Fig. As shown in Figure 2A, the C-shaped profile 136 is slightly larger than the C-shaped edges 112, 114, allowing the C-shaped edges 112, 114 to be fastened within the C-shaped profile 136. This arrangement is also shown in Fig. 3A can be seen.

[0072] The cover frame 118 also includes an angled outer circumference 132. The angled outer circumference 132 is angled relative to the upper surface 134 of the cover plate 106. In some examples, the angle 148 between the angled outer circumference 132 and the upper surface 134 can be between about twenty degrees and about sixty degrees. In the non-restrictive example of Fig. 2A shows the angle 148 at approximately twenty-eight degrees. The angled outer circumference 132 can help prevent water or other environmental influences from accumulating on the cover frame 118 and can reinforce the respective cover frame 118.

[0073] Fig. 2B is a cross-sectional view of an interface between a cover plate 106 and a cover frame 118 along a tailgate of a cargo box 3 of a pickup truck 1. As shown in Fig. As shown in Figure 2B, an elongated seal 126 engages with a channel 152 of the cover frame. 118. In the non-restrictive example of Fig. 2B, the elongated seal 126 is designed as a lamellar seal. 128. Alternative options include, for example, a D-seal to compensate for a difference in height between the partition and the tailgate. Other suitable seals are also considered here.

[0074] Fig. 2C is a cross-sectional view of an interface between a cover plate 106 and a cover frame element 118 along a partition or side rail of a cargo box 3 of a pickup truck 1. As shown in Fig. As shown in Figure 2C, an elongated seal 126 engages with a channel 152 of the cover frame element 118. In the non-restrictive example of Fig. 2B, the elongated seal 126 is designed as a lamellar seal 128. The lamellae of the lamellar seal 128 in Fig. However, 2C extend outwards and away from the cover plate 106, while the lamellae of the lamellar seal 128 in Fig. 2B extend inwards and towards the cover plate 106. In both cases, the lamellar seals 128 engage in the cargo box 3 to protect the interior of the cargo box 3 from the external environment.

[0075] Fig. Figure 2D is a cross-sectional view of an interface between a second (middle) cover plate 106b and a second hinge frame 154b, and of an interface between a first (tailgate) cover plate 106a and a first hinge frame 154a. A hinge mechanism 104a is arranged between the first and second cover plates 106a and 106b so that the first cover plate 106a can rotate relative to the second cover plate 106b. As shown in Fig. As shown in 2D, the first and second hinge frames 154a, 154b have C-shaped profiles to accommodate the C-shaped edges 114a2, 114b1 of the transverse edges 110a2, 110b1 of the adjacent cover plates 106a, 106b.

[0076] The non-restrictive example of the joint mechanism 104a comprises a barrel joint 142a, an elastomeric joint seal 144, and a second seal 146. The barrel joint 142a allows the first cover plate 106a to rotate around the barrel joint 142a in order to stack onto the second cover plate 106b and the in Fig. to start the folding process shown in 1B. The barrel joint 142a is arranged transversely across the cargo area cover 100, so that the barrel joint 142a is parallel to the one shown in Fig. The transverse axis TA shown in 1A is aligned. As in Fig. As can be seen in 2D, the barrel joint 142a is located between the first and the second joint frames 154a, 154b. Therefore, the barrel joint 142a is also positioned between the transverse edges 110a2, 110b1 of the adjacent cover plates 106a, 106b.

[0077] The joint mechanism 104a further comprises an elastomeric joint seal 144a. The elastomeric joint seal 144a is configured to maintain the protection of the interior of the cargo box 3 during folding and unfolding. As shown in Fig. As shown in Figure 2D, the elastomeric joint seal 144a is arranged below the barrel joint 142a, although it is considered here that the joint seal 144a may be aligned with and / or arranged between the barrel joint 142a. One or more barrel joints 142a may be positioned between the adjacent cover plates 106a, 106b. The elastomeric joint seal 144a is arranged transversely across the width of the cargo cover 100 between the first cover plate 106a and the second cover plate 106b. As shown in Fig. As can be seen in 2D, the elastomeric joint seal 144a engages in the first joint frame 154a and the second joint frame 154b, so that the elastomeric joint seal 144a bends and compresses when folded and returns to its original shape after unfolding.

[0078] The hinge mechanism 104a further comprises a second seal 146a. The second seal 146a can be defined by a vertical section 162a and a series of horizontal protrusions 164a, the terms "vertical" and "horizontal" here referring to the cargo cover 100 in an unfolded position UF and installed on the cargo box 3 of the pickup truck 1. The second seal 146a is configured to provide additional protection for the interior of the cargo box 3 during folding and unfolding. In particular, the horizontal protrusions 164a extend parallel to the longitudinal axis LA and are compressed when the cover plates 106a, 106b are unfolded relative to each other, thereby eliminating any gap and / or closing the seam between the cover plates 106a, 106b. The second seal 146a is located below the elastomeric hinge seal 144a.The second seal 146a is also arranged transversely across the cargo cover 100 between the first and second cover plates 106a, 106a, such that the second seal 146a is compressed when the cargo cover 100 is in the unfolded position and expands when the cargo cover 100 is in the folded position. Therefore, it can be assumed that the second seal 146a is arranged perpendicular to the elastomeric hinge seal 144a.

[0079] Fig. 3A is a partial cross-sectional view of a corner of a cargo cover 100. In particular, it shows Fig. 3A shows a corner of the third cover plate 106c near the driver's side of the partition of the pickup truck 1, the corner construction 122b being for illustrative purposes only and not limited to this position on the cargo cover 100. A C-shaped edge 112c1 of a longitudinal edge 108c1 of the third cover plate 106c is shown together with a C-shaped edge 114c2 of a transverse edge 110c2.

[0080] Fig. Figure 3A also shows a fourth cover frame element 118d with a C-shaped profile 136d for receiving the longitudinal edge 108c1 of the cover plate 106c. An elongated seal 126a, designed as a lamellar seal 128, is connected to the fourth cover frame element 118d.

[0081] A fifth cover frame element 118e, arranged perpendicular to the fourth cover frame element 118d, also includes a C-shaped profile 136e for receiving the transverse edge 110c2 of the cover plate 106c. An elongated seal 126b, configured as a D-seal 130, is connected to the fifth cover frame 118e. The D-seal 130 can be arranged along the partition wall of the cargo box 3. D-seals 130 typically have a higher compression range than lamellar seals 128. Since different types of pickup trucks 1 have different partition wall heights, a D-seal 130 may be able to cover a wider range of partition wall heights than other types of seals.

[0082] Furthermore, it shows Fig. 3A a corner construction 122b. The corner construction 122b comprises a corner frame 124. The corner frame 124 is connected to the fourth and fifth cover frames 118d, 118e to cover a recess 116b between the longitudinal edge 108c1 and the transverse edge 110c2. This recess 116b is in the Fig. 3B and Fig. 3C is shown. Covering the recess 116b provides additional protection for the interior of cargo box 3 and the internal components of the cargo cover 100.

[0083] Furthermore, it shows Fig. 3C has a pair of chamfers on the edges of the third cover plate 106c. In particular, a first chamfer 156c1 is formed in the C-shaped edge 112c1 of the longitudinal edge 108c1, and a second chamfer 158c2 is formed in the C-shaped edge 114c2 of the transverse edge 110c2. The chamfers 156c1, 158c2 make it possible to form the longitudinal and transverse edges 108c1, 110c2 as close together as possible, thereby reducing the size of the recess 116b.

[0084] Fig. Figure 4 is a flowchart of a process 900 for manufacturing a foldable cargo bed cover for use with a cargo box of a pickup truck. The process 900 comprises, in step 902, providing a first sheet of metal with longitudinal and transverse edges, wherein the first sheet has a cutout at each corner. The process 900 further comprises, in step 904, folding over each longitudinal and transverse edge of the first sheet to form a C-shaped edge. The process 900 further comprises, in step 906, attaching each C-shaped edge of the first sheet to a cover frame. The process 900 further comprises, in step 908, providing a second sheet of metal with longitudinal and transverse edges, wherein the second sheet has a cutout at each corner. The process 900 further comprises, in step 910, folding over each longitudinal and transverse edge of the second sheet to form a C-shaped edge.The method further comprises, in step 912, attaching each C-shaped edge of the second sheet to the cover frame. The method further comprises, in step 914, connecting the first sheet and the second sheet to each other via a hinge mechanism arranged between C-shaped edges of adjacent transverse edges of the first and second sheets.

[0085] In some embodiments, the cargo cover 100 may further comprise a stiffening element, as shown in the Fig. Figures 5A-5C show a stiffening element 170 on the underside of one or more cover plates 106a, 106b, 106c (collectively 106). If present, the stiffening element 170 comprises a plurality of spaced-apart flanges 172a, 172b (collectively 172), a connecting section 174a, 174b (collectively 174) extending from each flange 172, and an elongated section 176 spanning the connecting sections 174. The stiffening element 170 is configured such that there is a gap between the underside of the respective cover plate 106 and the elongated section 176. This gap results in greater stiffening of the cover plate 106; in fact, the stiffening can also increase with increasing distance and vice versa. For example, the distance between the upper surface of a cover plate 106 and the underside of the corresponding elongated section 176 can be equal to or similar to the thickness of a corresponding C-shaped edge 112, 114.As indicated, these thicknesses can range from approximately 10.0 mm to approximately 15.0 mm, resulting in a spacing of approximately 6.0 mm to approximately 13.0 mm. The similar thicknesses also found in... Fig. 5C can be seen, enabling the stacking of multiple cargo covers 100.

[0086] In certain embodiments, each connecting section 174 extends from its respective flange 172 at an obtuse angle. Preferably, the obtuse angle between the connecting section 174 and the flange 172, as taught in the present disclosure, is between about 95 degrees and about 140 degrees, more preferably between about 100 degrees and about 130 degrees, or even more preferably between about 105 degrees and about 120 degrees. The obtuse angle provides certain advantages, such as greater stiffness during use and improved nesting / stacking capabilities during manufacturing.

[0087] The stiffening element 170 can be made of any suitable material and can be made of the same or a different material than the cover plates 106. For example, the stiffening element 170 can be made of a 20-gauge aluminum alloy.

[0088] In certain embodiments, which are described in the Fig. As shown in Figures 6A-6D, a hinge clamp, generally designated by reference numeral 200, may be provided on the underside of the first hinge mechanism 104a and / or on the underside of the second hinge mechanism 104b. If a locking device is not located on or near a hinge mechanism, the hinge mechanism may, under certain circumstances, be lifted if sufficient force is applied, resulting in a small gap between the loading platform and the cargo cover when the cargo cover is in an extended position. In such a case, the hinge clamp 200 may be used to join adjacent cover sections together in the extended or unfolded position.

[0089] The hinge clamp 200 consists of a first component 202 connected to a cover section and a second component 204 connected to an adjacent cover section. The first and second components 202, 204 are configured to interlock tightly when connected, for example, by means of a tongue-and-groove mechanism (i.e., the tongue 206 of the first component 202 and the groove 208 of the second component 204). This engagement allows the first and second components 202, 204 to disengage automatically when sufficient force is applied to them, for example, when a user folds the cover sections 102 relative to each other. As shown in the Fig. As shown in Figures 6C-6D, the hinge clamp 200 is positioned under the second hinge mechanism 104b, which is a double hinge mechanism to connect the second cover section 102b and the third cover section 102c. Fig. Figure 6C shows the hinge clamp 200, which is released during the folding or unfolding process, and Fig. Figure 6D shows the hinge clamp 200, which is engaged when the two cover sections 102b and 102c are in an extended position relative to each other. Preferably, one hinge clamp 200 would be positioned near a longitudinal edge of one cover section 102b, 102c, and another hinge clamp 200 would be positioned near an opposite longitudinal edge of the same cover section 102b, 102c. As is readily apparent, the hinge clamp 200 can also be positioned under any hinge mechanism 104 of the cargo cover 100, where it is desirable to couple adjacent cover sections 102 in the extended position.

[0090] In certain embodiments where brackets must be attached to a side wall of the pickup truck, for example to accommodate a locking piston, a problem sometimes arises if the bracket section can rotate when a user attempts to tighten the bracket to the side wall of the truck bed. See Fig. Figure 7A shows a hypothetical situation in which the terminal 302 rotates. To remedy this problem, an anti-rotation device 300 can be installed between the terminals 302 and the bracket 304, with the anti-rotation device 300 being adapted to the edge of the terminals 302. The anti-rotation device 300 also includes openings 306 configured to align with openings in the bracket 304 and openings in the terminals 302, so that a bolt 308 or other fastener can be inserted through the bracket 304, the anti-rotation device 300, and the terminal 302. Additionally, the anti-rotation device 300 has a length greater than the total distance between the terminals 302, so that if a terminal 302 attempts to rotate, an edge of the terminal 302 contacts the anti-rotation device 300, which is fixed in place, thus preventing the terminal from rotating. This is in Fig. 7B can be seen.

[0091] All definitions defined and used herein shall be understood to take precedence over dictionary definitions, definitions in documents referenced herein and / or the ordinary meanings of the defined terms.

[0092] As used here in the description and in the claims, "or" should be understood as synonymous with "and / or" in the sense defined above. When separating elements in a list, for example, "or" or "and / or" is to be interpreted inclusively, i.e., as including at least one, but also more than one, element of a number or list of elements, and optionally additional, unlisted elements. Only terms that clearly indicate the opposite, such as "only one of" or "exactly one of," or, when used in the claims, "consisting of," refer to the inclusion of exactly one element of a number or list of elements. In general, the term "or," as used here, is to be interpreted as indicating exclusive alternatives (i.e., "either one or the other, but not both") only when it is preceded by terms of exclusivity, such as..."either", "one of", "only one of" or "exactly one of".

[0093] As used herein in the description and claims, the expression “at least one” or “one or more” in relation to a list of one or more elements should be understood to mean at least one element selected from one or more elements in the list of elements, but does not necessarily include at least one of each individual element expressly mentioned in the list of elements, and does not exclude combinations of elements in the list of elements. This definition also allows for the optional presence of elements other than those expressly mentioned in the list of elements to which the expression “at least one” refers, regardless of whether they are related to the expressly mentioned elements or not.

[0094] It is also understood that, unless explicitly stated otherwise, in all processes claimed herein which comprise more than one step or action, the sequence of the steps or actions of the process is not necessarily limited to the order in which the steps or actions of the process are listed.

[0095] In the claims and the description above, all transitional phrases such as "comprising," "including," "bearing," "having," "containing," "comprising," "maintaining," "composed of," and the like are to be understood as open, i.e., they mean "including but not limited to." Only the transitional phrases "consisting of" and "essentially consisting of" are closed and semi-closed transitional phrases, respectively.

[0096] As used here, "about" means approximately or nearly, and in the context of a specified numerical value or range, it means ±15% of the numerical value. In exemplary embodiments, the term "about" may include conventional rounding according to the significant digits of the numerical value. Furthermore, the expression "about 'x' to 'y'" includes "about 'x' to about 'y'".

[0097] Furthermore, any range of numbers specified in the description or the claims, which, for example, represents a particular set of properties, units of measurement, conditions, physical states, or percentages, shall be expressly incorporated into this description by reference or otherwise, including all subsets of numbers within such specified range. For example, if a range of numbers with a lower bound RL and an upper bound RU is specified, every number R falling within this range shall be expressly disclosed. In particular, the following numbers R within the range are expressly disclosed: R = RL + k(RU - RL), where k is a variable in the range from 1% to 100% with a step size of 1%, e.g., k is 1%, 2%, 3%, 4%, 5%, ... 50%, 51%, 52%, ... 95%, 96%, 97%, 98%, 99%, or 100%.Furthermore, any range of numbers represented by any two values ​​of R, as calculated above, is also explicitly disclosed.

[0098] Other embodiments fall within the scope of the following claims and other claims to which the applicant may be entitled.

[0099] Although various examples have been described and illustrated here, those skilled in the art will readily recognize a multitude of other means and / or structures for performing the function and / or achieving the results and / or one or more of the advantages described herein, and each of these variations and / or modifications will be considered to fall within the scope of the examples described here. More generally, those skilled in the art will readily recognize that all parameters, dimensions, materials, and configurations described herein are to be understood as examples and that the actual parameters, dimensions, materials, and / or configurations will depend on the specific application(s) for which the teaching(s) is / are used. Those skilled in the art will recognize many equivalents to the specific examples described herein or will be able to determine them through routine experimentation.It is therefore understood that the foregoing examples serve only as examples and that, within the scope of the attached claims and their equivalents, examples may also be implemented differently than specifically described and claimed. The examples of this disclosure relate to each individual feature, system, article, material, and / or process described herein. Furthermore, any combination of two or more such features, systems, articles, materials, and / or processes, provided that such features, systems, articles, materials, and / or processes are not incompatible with one another, falls within the scope of this disclosure. QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] US 63 / 517,790

[0001]

Claims

A foldable cargo bed cover for use with a cargo box of a pickup truck, the foldable cargo bed cover comprising: a plurality of cover sections movable between an unfolded position and a folded position, the plurality of cover sections in the unfolded position substantially covering the cargo box, the plurality of cover sections in the folded position being arranged in a layered stack; and a hinge mechanism positioned between at least two of the plurality of cover sections to allow the plurality of cover sections to transition between the folded position and the unfolded position;wherein each of the plurality of cover sections comprises a cover plate formed from a material consisting substantially of a sheet, the cover plate having longitudinal edges and transverse edges, each longitudinal edge and each transverse edge being configured to be a C-shaped edge such that the C-shaped edge of each of the longitudinal edges opens substantially perpendicular to the C-shaped edge of each of the transverse edges. The foldable cargo cover according to claim 1, wherein each cover plate has the following properties: a yield strength between about 100 MPa and about 200 MPa, a tensile strength between about 130 MPa and about 230 MPa, a shear strength between about 80 MPa and about 140 MPa, wherein the yield strength is higher than the shear strength, a first thickness in the middle of the cover plate between about 1.00 mm and about 2.00 mm and a second thickness at the C-shaped edge of the cover plate between about 10.0 mm and about 15.0 mm. The foldable cargo cover according to claim 1, wherein the material is an aluminum alloy comprising: aluminum in an amount between about 98% and 99% of the chemical composition of the aluminum alloy and manganese in an amount between about 1% and about 2% of the chemical composition of the aluminum alloy. The foldable cargo cover according to claim 1, wherein the material is a 3000 series aluminum. Folding cargo bed cover for use with a cargo box of a pickup truck, wherein the folding cargo bed cover comprises a plurality of cover plates, each of the plurality of cover plates being formed from a material consisting essentially of a sheet and having the following properties: a yield strength between about 100 MPa and about 200 MPa, a tensile strength between about 130 MPa and about 230 MPa, a shear strength between about 80 MPa and about 140 MPa, wherein the yield strength is higher than the shear strength, a first thickness in the middle of each of the plurality of cover plates between about 1.0 mm and about 2.00 mm, and a second thickness at an edge of each of the plurality of cover plates between about 10.0 mm and about 15.0 mm. The foldable cargo cover according to claim 5, wherein each of the plurality of cover plates comprises longitudinal edges and transverse edges, wherein each longitudinal edge and each transverse edge is configured to be a C-shaped edge such that the C-shaped edge of each of the longitudinal edges opens substantially perpendicular to the C-shaped edge of each of the transverse edges. The foldable cargo cover according to claim 5, wherein the material is an aluminum alloy comprising: aluminum in an amount between about 98% and 99% of the chemical composition of the aluminum alloy and manganese in an amount between about 1% and about 2% of the chemical composition of the aluminum alloy. A foldable cargo bed cover for use with a cargo box of a pickup truck, the cargo bed cover comprising: a plurality of cover sections movable between an unfolded position and a folded position, the plurality of cover sections in the unfolded position substantially covering the cargo box, the plurality of cover sections in the folded position being arranged in a layered stack; and a hinge mechanism arranged between at least two of the plurality of cover sections to allow the plurality of cover sections to move between the folded position and the unfolded position;wherein each of the plurality of cover sections comprises a cover plate formed from a material consisting substantially of a sheet, the cover plate comprising longitudinal edges and transverse edges, each of the longitudinal edges and each of the transverse edges being configured to be a C-shaped edge such that the C-shaped edge of each of the longitudinal edges opens substantially perpendicular to the C-shaped edge of each of the transverse edges; wherein each cover plate has the following properties: a yield strength between about 100 MPa and about 200 MPa, a tensile strength between about 130 MPa and about 230 MPa, a shear strength between about 80 MPa and about 140 MPa, the yield strength being higher than the shear strength, a first thickness in the middle of the cover plate between about 1.0 mm and about 2.00 mm, a second thickness at the C-shaped edge of the cover plate between about 10.0 mm and about 15.0 mm;wherein the material is an aluminum alloy, comprising: aluminum in an amount between about 98% and 99% of the chemical composition of the aluminum alloy and manganese in an amount between about 1% and about 2% of the chemical composition of the aluminum alloy. The foldable cargo cover according to claim 8, wherein the sheet material is a 3000 series aluminum alloy. The foldable cargo cover according to one of the preceding claims, which further comprises a recess between one of the longitudinal edges and an adjacent transverse edge at each corner of the cover plate. The foldable cargo cover according to one of the preceding claims, further comprising a cover frame to which the C-shaped edge of each of the longitudinal edges and each of the transverse edges is attached, thereby forming an interface between the cover frame and each associated C-shaped edge. The foldable cargo cover according to claims 10 and 11, which further comprises a corner construction that covers the recess at one of the corners of the cover plate, wherein the corner construction further comprises a corner frame that is connected to the cover frame at one of the longitudinal edges and one of the transverse edges. The foldable cargo cover according to claim 10, which further comprises one or more elongated seals arranged within a channel of the cover frame. The foldable cargo cover according to claim 13, wherein the one or more elongated seals comprise a lamellar seal and / or a D-seal. The foldable cargo cover according to claim 11, wherein the cover frame has an angled outer circumference, wherein an angle of the angled outer circumference is between about 20 degrees and about 60 degrees relative to an upper surface of the cover plate. The foldable cargo cover according to claim 11, wherein the cover frame comprises a C-shaped profile that is compatible with the C-shaped edge of the longitudinal edges and transverse edges of the cover plate, wherein the C-shaped profile is configured to accommodate the C-shaped edge. The foldable cargo cover according to one of the preceding claims, which further comprises at least one elongated crossbeam which is attached to an underside of each cover plate and extends along it. The foldable cargo cover according to claim 17, wherein the at least one elongated crossbeam comprises an integrated T-slot channel configured to accommodate one or more locking devices. The foldable cargo cover according to one of the preceding claims, wherein the joint mechanism comprises: a barrel joint arranged transversely across the foldable cargo cover between the C-shaped edges of adjacent transverse edges, an elastomeric joint seal arranged below the barrel joint and transversely across the foldable cargo cover between the C-shaped edges of adjacent transverse edges, and a second seal arranged below the elastomeric joint seal and transversely across the foldable cargo cover between the C-shaped edges of adjacent transverse edges. The foldable cargo cover according to one of the preceding claims, further comprising a stiffening element arranged in a transverse direction along a bottom surface of one or more cover plates, the stiffening element comprising: a plurality of flanges attached to the underside of the one or more cover plates, a connecting section extending from each of the plurality of flanges, the connecting section and the associated flange forming an obtuse angle to each other, and an elongated section extending substantially parallel to a transverse axis of the cover plate, the elongated section extending between and connecting the connecting sections, the cover plate and the stiffening element defining a distance between them. A method for manufacturing a foldable cargo bed cover for use with a cargo box of a pickup truck, comprising: providing a first sheet of metal having longitudinal edges and transverse edges, the first sheet having a cutout at each corner; folding each longitudinal edge and each transverse edge of the first sheet to form a C-shaped edge; attaching each C-shaped edge of the first sheet to a cover frame; providing a second sheet of metal having longitudinal edges and transverse edges, the second sheet having a cutout at each corner; folding each longitudinal edge and each transverse edge of the second sheet to form a C-shaped edge; attaching each C-shaped edge of the second sheet to the cover frame; and connecting the first sheet and the second sheet to each other via a hinge mechanism arranged between C-shaped edges of adjacent transverse edges of the first and second sheets.

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