Tonneau cover and methods of manufacture thereof

Abstract

A hard, folding tonneau cover formed of sheet metal having certain exemplary properties is provided. The sheet metal has a yield strength is greater than a shear strength. The sheet metal may be aluminum alloyed with manganese. The tonneau cover further includes tonneau panels each having C-shaped longitudinal and transverse edges. The tonneau cover may further include a C-shaped profile that matches the C-shaped edges of the tonneau panels, such that the tonneau frame is configured to receive the tonneau panels. The tonneau cover may further include one or more cross-braces having a T-slot configured to receive latches.

Description

TONNEAU COVER AND METHODS OF MANUFACTURE THEREOFCross-Reference to Related Applications

[0001] This application claims priority to U.S. Provisional Patent Application Serial No. 63 / 517,790, filed on August 4, 2023, and titled “Tonneau Cover and Methods of Manufacture Thereof,” which application is herein incorporated by reference in its entirety.Field of the Disclosure

[0002] This disclosure relates, generally, to tonneau covers, and more specifically, to tonneau covers having hard or rigid panels.Background

[0003] One advantage of a pickup truck (hereafter the “truck”) is the ability to use the bed of the truck to transport cargo that might not otherwise be suitable for transporting in other vehicles. This cargo may include, for example, oversized items, like a large television, or items that might soil the interior of the vehicle, like garden supplies. The bed commonly includes a pair of opposed sidewalls joined at their forward and rearward ends by a front wall or bulkhead and rear wall or tailgate, respectively.

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

[0005] While various styles of tonneau covers exist, one popular style of tonneau cover is a hard, folding tonneau cover. A hard, folding tonneau cover typically includes a series of rigid panel sections that extend laterally across the width of the bed. Each panel section is connected to the adjacent panel section(s) by a hinge mechanism that also extends transversely across the width of the bed. When not required to cover the entire bed of the pickup truck, the panel sections may be successively folded one atop another, from the tailgate toward the bulkhead, into a nested stack leaving at least a portion of the bed open and uncovered.

[0006] Conventional hard, folding tonneau covers are typically formed from a hard foam or plastic having a honeycomb cross-section, where the foam or plastic is wrapped in an aluminum skin. These panels tend to be heavy and environmentally unfriendly, lack certain structural integrity in some weather conditions, and trap water in the honeycomb configuration.

[0007] Accordingly, what is needed is a hard, folding tonneau cover that has structural integrity, is water impervious, and is environmentally friendly. However, in view of the art considered as a whole at the time the subject of the present disclosure was made, it was not obvious to those of ordinary skill in the field of this disclosure how the shortcomings of the prior art could be overcome.

[0008] While certain aspects of conventional technologies have been discussed to facilitate disclosure of the invention, Applicants in no way disclaim these technical aspects, and it is contemplated that the claimed invention may encompass one or more of the conventional technical aspects discussed herein.

[0009] The present disclosure may address one or more of the problems and deficiencies of the prior art discussed above. However, it is contemplated that the subject matter of the disclosure may prove useful in addressing other problems and deficiencies in a number of technical areas. Therefore, the claimed invention should not necessarily be construed as limited to addressing any of the particular problems or deficiencies discussed herein.

[0010] In this specification, where a document, act or item of knowledge is referred to or discussed, this reference or discussion is not an admission that the document, act or item of knowledge or any combination thereof was at the priority date, publicly available, known to the public, part of common general knowledge, or otherwise constitutes prior art under the applicable statutory provisions; or is known to be relevant to an attempt to solve any problem with which this specification is concerned.Summary of the Disclosure

[0011] The present disclosure is generally directed to a foldable tonneau cover for use with a cargo box of a pickup truck. The tonneau cover includes a plurality of tonneau sections, each section having a hard or rigid tonneau panel. The tonneau panel may be manufactured from a single layer of an aluminum alloy sheet metal, such as aluminum alloyed with manganese. Additional structural integrity is provided by bending both the longitudinal and transverse edges of the panels into a C-shape. The foldable tonneau cover further includes a tonneau frame comprising one or more tonneau frame elements. The tonneau frame elements include C- shaped profiles corresponding to the C-shaped edges of the tonneau panels, such that the profiles of the tonneau frame elements can receive the edges of the tonneau panels. The frame elements may have an angled outer perimeter relative to the tonneau panel. Further, at least one elongated crossbeam may be secured to the bottom of each tonneau panel. The elongated crossbeam may include an integrated T-slot channel to receive one or more latches.

[0012] When the tonneau sections are in an unfolded position, the plurality of the tonneau sections substantially covers the cargo box. When the tonneau sections are in a folded position, two or more of the tonneau sections are arranged in a nested stack, and at least a portion of the cargo box is uncovered. The folding and unfolding of the tonneau sections is facilitated by hinge mechanisms arranged between adjacent sections. The hinge mechanisms may include a barrel hinge, an elastomeric hinge seal, and a second seal element.

[0013] The tonneau panel may be made of an aluminum alloy, such as a 3000 or 5000 series aluminum. As compared to conventional hard covers made from plastic or hard foam with an aluminum skin, the aluminum sheet metal provides a variety of advantageous characteristics, including improved yield strength, tensile strength, and shear strength. In some examples, the aluminum alloy may be about 98 to 99 percent aluminum and about 1 to 2 manganese.

[0014] The C-shaped edges of the longitudinal and transverse edges of the panels form gaps at each corner of the panels. These gaps are covered using corner constructions. The corner constructions effectively couple a pair of perpendicular tonneau frame elements. By covering the gaps formed by the longitudinal and transverse edges of the panels, the corner constructions shield the interior of the cargo box from the external environment. Further, the tonneau frame elements may also include elongated seals, such as fin seals or D-seals, to close off any gaps between the tonneau frame elements and the cargo box.

[0015] Generally, in one example, a foldable tonneau cover for use with a cargo box of a pickup truck is provided. The foldable tonneau cover includes a plurality of tonneau sections movable between an unfolded position and a folded position. The plurality of tonneau sections substantially covers the cargo box in the unfolded position. The plurality of tonneau sections is arranged in a nested stack in the folded position.

[0016] The foldable tonneau cover further includes a hinge mechanism. The hinge mechanism is positioned between at least two of the plurality of tonneau sections. The hinge mechanism facilitates transitioning of the plurality of tonneau sections between the folded position and the unfolded position.

[0017] Each of the plurality of tonneau sections includes a tonneau panel formed of a material consisting essentially of a sheet metal. The tonneau panel 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 substantially perpendicularly to the C-shaped edge of each of the transverse edges.

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

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

[0020] According to an example, the material is a 3000 series aluminum.

[0021] Generally, in another example, a foldable tonneau cover for use with a cargo box of a pickup truck is provided. The foldable tonneau cover includes a plurality of tonneau panels. Each of the plurality of tonneau panels is formed of a material consisting essentially of a sheet metal. The material has the following properties: (1) a yield strength of 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, wherein the yield strength is higher than the shear strength; (4) a first thickness at a center of each of the plurality of tonneau 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 tonneau panels between about 10.0 mm and about 15.0 mm.

[0022] According to an example, each of the plurality of tonneau panels includes longitudinal edges and transverse edges. Each longitudinal edge and each transverse edge may be configured to be a C-shaped edge. The C-shaped edge of each of the longitudinal edges opens substantially perpendicularly to the C-shaped edge of each of the transverse edges.

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

[0024] Generally, in another example, a foldable tonneau cover for use with a cargo box of a pickup truck is provided. The foldable tonneau cover includes a plurality of tonneau sections. The plurality of tonneau sections is movable between an unfolded position and a folded position. The plurality of tonneau sections substantially covers the cargo box in the unfolded position. The plurality of tonneau sections is arranged in a nested stack in the folded position.

[0025] The foldable tonneau cover further includes a hinge mechanism. The hinge mechanism is positioned between at least two of the plurality of tonneau sections. The hinge mechanism facilitates transitioning of the plurality of tonneau sections between the foldedposition and the unfolded position.

[0026] Each of the plurality of tonneau sections includes a tonneau panel. The tonneau panel is formed of a material consisting essentially of a sheet metal. The tonneau panel 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 substantially perpendicularly to the C-shaped edge of each of the transverse edges.

[0027] Each tonneau panel has the following properties: (1) a yield strength of 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, wherein the yield strength is higher than the shear strength; (4) a first thickness at a center of the tonneau panel between about 1.0 mm and about 2.00 mm; (5) a second thickness at the C-shaped edge of the tonneau panel between about 10.0 mm and about 15.0 mm. The material is an aluminum alloy comprising (1) aluminum in an amount between about 98% and 99% chemical composition of the aluminum alloy and (2) manganese in an amount between about 1% and about 2% chemical composition of the aluminum alloy.

[0028] According to an example, the material of the sheet metal is a 3000 series aluminum alloy.

[0029] According to an example, the foldable tonneau cover further includes a gap between one of the longitudinal edges and an adjacent transverse edge at each corner of the tonneau panel.

[0030] According to an example, the foldable tonneau cover further includes a tonneau frame to which the C-shaped edge of each of the longitudinal edges and each of the transverse edges is secured, thereby forming an interface between the tonneau frame and each corresponding C-shaped edge.

[0031] According to an example, the foldable tonneau further includes a comer construction that covers the gap at one of the comers of the tonneau panel. The corner construction further includes a corner frame that interfaces with the tonneau frame at one of the longitudinal edges and one of the transverse edges.

[0032] According to an example, the foldable tonneau cover further includes one or more elongated seals disposed within a channel of the tonneau frame.

[0033] According to an example, the one or more elongated seals include a fin seal and / or a D seal.

[0034] According to an example, the tonneau frame has an angled outer perimeter. An angleof the angled outer perimeter is between about 20 degrees and about 60 degrees relative to a top surface of the tonneau panel.

[0035] According to an example, the tonneau frame includes a C-shaped profile that matches the C-shaped edge of the longitudinal edges and the transverse edges of the tonneau panel. Said C-shaped profile is configured to receive the C-shaped edge.

[0036] According to an example, the foldable tonneau cover further includes at least one elongated crossbeam secured to and extending along a bottom surface of each tonneau panel.

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

[0038] According to an example, the hinge mechanism includes a barrel hinge. The barrel hinge is disposed transversely across the foldable tonneau cover between the C-shaped edges of adjacent transverse edges. The hinge mechanism further includes an elastomeric hinge seal. The elastomeric hinge seal is disposed in underlying relation to the barrel hinge and transversely across the foldable tonneau cover between the C-shaped edges of adjacent transverse edges. The hinge mechanism further includes a second seal. The second seal is disposed in underlying relation to the elastomeric hinge seal and transversely across the foldable tonneau cover between the C-shaped edges of adjacent transverse edges.

[0039] Generally, in another example, the foldable tonneau cover further includes a stiffener element. The stiffener element is disposed in a transverse direction along a bottom surface of one or more tonneau panels. The stiffener element includes a plurality of flanges secured to the bottom surface of the one or more tonneau panels. The stiffener element further includes a connector section extending from each of the plurality of flanges. The connector section and the corresponding flange have an obtuse angle relative to each other. The stiffener element further includes an elongate section extending substantially parallel to a transverse axis of the tonneau panel. The elongate section extends between and connecting the connector sections together. The tonneau panel and the stiffener element define a spaced distance therebetween.

[0040] Generally, in another example, a method of manufacturing a foldable tonneau cover for use with a cargo box of a pickup truck is provided. The method includes (1) providing a first sheet metal having longitudinal edges and transverse edges, the first sheet metal having a cutout at each corner; (2) folding each longitudinal edge and each transverse edge of the first sheet metal into a C-shaped edge; (3) securing each C-shaped edge of the first sheet metal to a tonneau frame; (4) providing a second sheet metal having longitudinal edges and transverse edges, the second sheet metal having a cutout at each corner; (5) folding each longitudinal edge and each transverse edge of the second sheet metal into a C-shaped edge; (6) securing each C-shaped edge of the second sheet metal to the tonneau frame; and (7) connecting the first sheet metal and the second sheet metal together via a hinge mechanism disposed between C-shaped edges of adjacent transverse edges of the first and second sheet metals.

[0041] It should be appreciated that all combinations of the foregoing concepts and additional concepts discussed in greater detail below (provided such concepts are not mutually inconsistent) are contemplated as being part of the inventive subject matter disclosed herein. In particular, all combinations of claimed subject matter appearing at the end of this disclosure are contemplated as being part of the inventive subject matter disclosed herein. It should also be appreciated that terminology explicitly employed herein that also may appear in any disclosure incorporated by reference should be accorded a meaning most consistent with the particular concepts disclosed herein.

[0042] These and other aspects of the various embodiments will be apparent from and elucidated with reference to the embodiment(s) described hereinafter.Brief Description of the Drawings

[0043] In the drawings, like reference characters generally refer to the same parts throughout the different views. Also, the drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the various embodiments.

[0044] FIG. 1A is an upper perspective view of a tonneau cover having hard panels, according to an embodiment of the current disclosure, as installed on a cargo bed of a pickup truck, where the panels are in an unfolded position, according to aspects of the present disclosure.

[0045] FIG. IB is a side view of the tonneau cover of FIG. 1A, where the panels are in the process of transitioning to a folded position, according to aspects of the present disclosure.

[0046] FIG. 1C is a perspective view of the tonneau cover of FIG. 1 A extended along a side rail of the pickup truck, according to aspects of the present disclosure.

[0047] FIG. ID is a partial cross-sectional view of the tonneau cover of FIG. 1A along the side rail of FIG. 1C, showing the tonneau cover resting on the side rail with an indexing flange permitting center placement of the tonneau cover on the cargo box of the pickup truck, according to aspects of the present disclosure.

[0048] FIG. IE-1 is a partial cross-sectional view of the tonneau cover of FIG. 1 A showing the center panel, bulkhead panel, and double hinge mechanism therebetween, along with a T- slot or channel within a crossbeam, according to aspects of the present disclosure.

[0049] FIG. IE-2 is an enhanced cross-sectional view of the crossbeam shown in FIG. 1E- 1, according to aspects of the present disclosure.

[0050] FIG. 2A is a partial cross-sectional view of a generalized interface between a tonneau cover panel and a tonneau cover frame, according to aspects of the present disclosure.

[0051] FIG. 2B is a cross-sectional view of an interface between a tonneau cover panel and a tonneau cover frame along a tailgate of a cargo box of a pickup truck, according to aspects of the present disclosure.

[0052] FIG. 2C is a cross-sectional view of an interface between a tonneau cover panel and a tonneau cover frame along a bulkhead and siderail of a cargo box of a pickup truck, according to aspects of the present disclosure.

[0053] FIG. 2D is a cross-sectional view of an interface between a center panel and a hinge frame and an interface between a tailgate panel and another hinge frame with a hinge mechanism disposed between the hinge frames, according to aspects of the present disclosure.

[0054] FIG. 3 A is a partial cross-sectional view of a corner of a tonneau cover, according to aspects of the present disclosure.

[0055] FIG. 3B is a perspective view of the corner of FIG. 3 A with the corner construction removed, according to aspects of the present disclosure.

[0056] FIG. 3C is bottom perspective view of the corner of FIG. 3 A with the corner construction and frame elements removed, leaving only the hard panel, according to aspects of the present disclosure.

[0057] FIG. 4 is a flow chart of a method for manufacturing a foldable tonneau cover for use with a cargo box of a pickup truck, according to aspects of the present disclosure.

[0058] FIG. 5A is a bottom perspective view of a tonneau panel, according to an embodiment of the current invention, showing an optional stiffener element secured to the bottom surface thereof, according to aspects of the present disclosure.

[0059] FIG. 5B is an exploded view of the stiffener element and tonneau panel of FIG. 5 A, according to aspects of the present disclosure.

[0060] FIG. 5C is a side or end view of the stiffener element and tonneau panel of FIG. 5A, according to aspects of the present disclosure.

[0061] FIG. 6A is a perspective view of a hinge clip in a disengaged state for use with a tonneau cover, according to an embodiment of the current invention.

[0062] FIG. 6B is a perspective view of the hinge clip of FIG. 6A, wherein the hinge clip is in an engaged state, according to aspects of the present disclosure.

[0063] FIG. 6C is a side cross sectional view of adjacent tonneau sections in a folding / unfolding state with the hinge clip disengaged, according to aspects of the present disclosure.

[0064] FIG. 6D is a side cross sectional view of adjacent tonneau sections in an extended position with the hinge clip engaged, according to aspects of the present disclosure.

[0065] FIG. 7A is an elevated view of a bracket for installation along a sidewall of a pickup truck bed, where the bracket includes clamps and an optional anti-rotation brace to prevent rotation of the clamps when fastening to the truck bed sidewall, according to aspects of the present disclosure.

[0066] FIG. 7B is a side perspective view of the bracket, clamp, and anti-rotation brace of FIG. 7A, according to aspects of the present disclosure.Detailed Description of Embodiments

[0067] In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings, which form a part thereof, and within which are shown by way of illustration specific embodiments by which the subject matter of the disclosure may be practiced. It is to be understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the disclosure.

[0068] In certain exemplary embodiments, the present disclosure relates to a hard or rigid tonneau cover comprising a plurality of panels, each formed of one layer of sheet metal (e.g., aluminum alloyed with manganese) having edges bent into a substantial “C” shape along all edges in both the longitudinal direction and the transverse direction. The C-shaped edges provide structural integrity to the tonneau panels. In addition, the tonneau panel material has particular properties that allow it to be lightweight and flexible but still very strong. These benefits will be described as this specification continues.

[0069] Within the context of the present disclosure, the term “aluminum alloy” refers to a metal that is a combination of aluminum and another element, where aluminum is the predominant element in the combination. Examples of alloying elements are copper, magnesium, manganese, silicon, tin, nickel, and zinc, among others. Preferably, tonneau panels, according to certain embodiments of the current disclosure, comprise an aluminum alloy, where the alloying element is manganese. In a preferred embodiment, the amount of manganese in the aluminum alloy is between about 0.2% and about 2.2% by weight of the composition, more preferably between about 0.6% and about 2.0% by weight of the composition, and even more preferably between about 1.0% and about 2.0% by weight of thecomposition. In certain embodiments, each tonneau panel may be formed of 3003 -Hl 4 aluminum alloy, which has a manganese content of about 1.0% to about 2.0% by weight of the composition. In other embodiments, each tonneau panel may be formed of 3105-H24 aluminum alloy, which has a manganese content of about 0.2% to about 0.8% by weight of the composition.

[0070] Within the context of the present disclosure, the term “yield strength” refers to a measure of a maximum strength that can be applied to a material before that material changes shape permanently. Yield strength is typically recorded as units of megapascals (MPa) and may be determined by methods known in the art. Preferably, the tonneau panels taught by the present 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 contemplated that yield strength may be higher than those values listed above, based on the material of the sheet metal used for the tonneau panels.

[0071] Within the context of the present disclosure, the term “tensile strength” refers to a measure of a maximum strength that can be applied to a material before that material fractures. Tensile strength is typically recorded as units of megapascals (MPa) and may be determined by methods known in the art. Preferably, the tonneau panels taught by the present 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 contemplated that tensile strength may be higher than those values listed above, based on the material of the sheet metal used for the tonneau panels.

[0072] Within the context of the present disclosure, the term “shear strength” refers to a measure of a maximum shear force that can be applied to a material before that material fails in the shearing direction. Shear strength is typically recorded as units of megapascals (MPa) and may be determined by methods known in the art. Preferably, the tonneau panels taught by the present 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 contemplated that shear strength may be higher than those values listed above, based on the material of the sheet metal used for the tonneau panels, but should be lower than the yield and tensile strengths of the tonneau panel. This relationship allows the tonneau panel to be cut to size during manufacture but remain structurally strong against forces normal to the plane of the tonneau panel.

[0073] Within the context of the present disclosure, the term “thickness” refers to a measure of how thick a material is. Thickness is typically recorded as units of millimeters (mm) andmay be determined by methods known in the art. Preferably, the sheet metal of the tonneau panels taught by the present 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 tonneau panels have a thickness between about 10.0 mm and about 15.00 mm, more 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 contemplated that thicknesses may be higher than those values listed above, based on the material of the sheet metal used for the tonneau panels, but may cause the tonneau panels to be heavier than desired. In certain embodiments, each tonneau panel may be formed of 16-gauge or 14-gauge sheet metal, such as aluminum alloy (e.g., 3003- H14, 3105-H24, etc.).

[0074] Turning now to the figures, FIG. 1 is an upper perspective view of a foldable tonneau cover 100 as installed on a cargo box 3 of a pickup truck 1. The foldable tonneau cover 100 may be described in terms of a longitudinal axis LA travelling along the length of the cargo box 3 and a transverse axis TA travelling along the width of the cargo box 3. In the non-limiting example of FIG. 1, the tonneau cover 100 is divided into three tonneau sections 102a, 102b, 102c. The first tonneau section 102a is arranged as the rear section such that the first tonneau section 102a is proximate to the tailgate of the cargo box 3 of the pickup truck 1. Further to this example, the third tonneau section 102c is arranged as the bulkhead panel or front panel such that the third section 102c is arranged proximate to a passenger cab or cabin of the pickup truck 1. Accordingly, the second tonneau section 102b is arranged between the first tonneau section 102a and the third tonneau section 102c. While the example of FIG. 1 illustrates a three- section foldable tonneau cover 100, other foldable tonneau covers 100 may implement more or less than three sections. Similarly, while the tonneau cover 100 of FIG. 1 is substantially rectangular, other sizes, shapes, and proportions of the tonneau cover 100 may be implemented in further examples.

[0075] Further, each of the tonneau sections 102a, 102b, 102c comprises a tonneau panel 106a, 106b, 106c. Each tonneau panel 106a, 106b, 106c may be formed from a single layer of rigid sheet metal, such as 14- or 16-gauge aluminum, as compared to conventional tonneau covers, which typically comprise a multi-layer laminate including polymeric materials, such as expanded polystyrene and expanded polypropylene. Furthermore, any conventional singlelayer tonneau covers are thick and completely planar, i.e., without the bent edges as will become clearer as this specification continues.

[0076] In certain embodiments, each tonneau panel 106a, 106, 106c may be formed of3003- H14 aluminum alloy, which has a manganese content of about 1.0% to about 2.0% by weight of the composition. In other embodiments, each tonneau panel 106a, 106, 106c may be formed of 3105-H24 aluminum alloy, which has a manganese content of about 0.2% to about 0.8% by weight of the composition. Alternative aluminum alloy materials — whether known currently or in the future — are also contemplated herein having a manganese content in ranges as described above.

[0077] There are several benefits for using aluminum panels over conventional hard panels, typically made of hard plastic or foam wrapped in an aluminum skin. In particular, the aluminum panels are more eco-friendly than the conventional panels due to the lack of plastic or foam. Further, the aluminum panels provide greater structural integrity in all weather conditions, provide greater ultraviolet light resistance, and provide improved water resistance properties.

[0078] Further, using an aluminum alloy with about 1.2% manganese (characteristic of 3000 series aluminum alloys) provides a number of improvements over pure aluminum, such as greater strength while maintaining good formability and corrosion resistance, and high performance in a wide range of atmospheric conditions. In particular, these aluminum alloys are twenty percent stronger than 1100 series aluminum. It is further contemplated that a 5000 series aluminum alloy may be utilized, providing several benefits over conventionally used aluminum alloys in tonneau covers.

[0079] The tonneau panels 106a, 106b, 106c may be defined by a series of strength characteristics. In one example, each of the tonneau panels 106a, 106b, 106c may have a yield strength of between about 100 MPa and about 200 MPa, a tensile strength between about 130 MPa and about 230 MPa, and a shear strength between about 80 MPa and about 140 MPa. In this example, the yield strength is higher than the shear strength to allow each of the tonneau panels 106a, 106b, 106c to be cut to size during manufacturing but remain structurally strong against forces normal to the plane of the tonneau panel 106a, 106b, 106c. Further, the tonneau panels 106a, 106b, 106c may be defined by a center thickness of between 1.0 millimeters and 2.0 millimeters.

[0080] As shown in FIG. 1A, each tonneau panel 102a, 102b, 102c is defined by a pair of longitudinal edges 108al, 108a2, 108bl, 108b2, 108cl, 108c2 arranged perpendicularly to a pair of transverse edges HOal, 110a2, HObl, 110b2, HOcl, 110c2. The longitudinal edges 108al, 108a2, 108b 1, 108b2, 108cl, 108c2 are parallel to the longitudinal axis LA of the cargo box 3, while the transverse edges 1 lOal, 110a2, 110b 1 , 110b2, 1 lOcl, 110c2 are parallel to thetransverse axis TA of the cargo box 3. As will be demonstrated in subsequent 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 perpendicularly to the C-shaped edges 114 of the transverse edges 108, as shown, for example, in FIG. 3 A.

[0081] Examples of various properties of example aluminum alloys may be found in Table 1 below:Table 1

[0082] The tonneau cover 100 of FIG. 1A further includes four corner constructions 122a, 122b, 122c, 122b. The comer constructions 122a, 122b, 122c, 122d are described in more detail with reference to FIGS. 3A-3C.

[0083] The foldable nature of the tonneau cover 100 of FIG. 1A enables each pair of adjacent sections 102a, 102b, 102c to be arranged in either a folded position or an unfolded position. The panels 102a, 102b, 102c of the foldable tonneau cover 100 of FIG. 1A are all depicted as in unfolded positions UF relative to each other. In the unfolded position UF, each of the tonneau sections 102a, 102b, 102c sit substantially coplanar relative to each other. In the folded position F, as will be demonstrated in FIG. IB, at least two of the tonneau sections 102a, 102b, 102c are stacked on top of each other.

[0084] As further shown in FIG. 1 A, the first tonneau section 102a is rotatably coupled with the second tonneau section 102b via a first hinge mechanism 104a. Further, the second tonneausection 102b is also rotatably coupled with the third tonneau section 102c via a second hinge mechanism 104b. In the non-limiting example of FIG. 1 A, the first hinge mechanism 104a is a single hinge mechanism, while the second hinge mechanism 104b is a double hinge mechanism.

[0085] As shown in FIG. IB, the hinge mechanisms 104a, 104b enable the tonneau sections 102a, 102b, 102c to move from the unfolded position UF to the folded position F. As shown in FIG. IB, the first hinge mechanism 104a enables the first section 102a to rotate such that the first section 102a stacks on top of the second section 102a, such that the top surface of the first section 102a abuts the top surface of the second section 102b. Further, once the first section 102a has been folded onto the second section 102b, both the first and second sections 102a, 102b may be rotated together to stack onto the third section 102c.

[0086] To stack the first and second sections 102a, 102b on top of the third section 102c, the folded arrangement of the first and second sections 102a, 102b and the first hinge mechanism 104a rotate together via the second hinge mechanism 104b. Following the rotations, the first and second sections 102a, 102b are stacked on top of the third section 102c, with the second section 102b on top and the first section 102a in the middle. In other words, the bottom surface of the first section 102a abuts the top surface of the third section 102c, with the bottom surface of the second section 102b becoming the top exposed surface of the stacked sections 102a, 102b, 102c. The combined thickness of the first and second sections 102a, 102b may require the use of a spacer in the second hinge mechanism 104b to create enough clearance for both sections 102a, 102b in the folded position.

[0087] FIG. 1C is a perspective view of the tonneau cover 100 of FIG. 1A extended along a first side rail of the pickup truck 1. FIG. 1C depicts a plurality of tonneau frame elements 118a-e forming a tonneau frame 118 around the tonneau panels 106a, 106b, 106c. First tonneau frame element 118a is positioned transversely along the rear wall or tailgate of the cargo box 3. Second, third, and fourth tonneau frame elements 118b, 118c, 118d are positioned longitudinally along the side rail. Fifth tonneau frame element 118e is positioned along the bulkhead of the cargo box 3. The remaining tonneau frame elements 118f, 118g, 118h (not shown) are arranged opposite of the fourth, third, and second tonneau frame elements 118d, 118c, 118b, respectively. As shown in FIG. 2A, the tonneau frame elements 118 each include a C-shaped profile 136 configured to receive the C-shaped edges 112, 114 of the longitudinal edges 108 and the transverse edges 110 of the tonneau panels 106. In some examples, the tonneau frame elements 118a-e are metal components formed by extrusion.

[0088] FIG. ID is a partial cross-sectional view of the tonneau cover 100 of FIG. 1 A along the side rail of FIG. 1C. FIG. ID shows the tonneau cover 100 resting on the side rail with an indexing flange 5. The indexing flange 5 allows the tonneau cover 100 to sit semi -flush with the top plane of the cargo box 3 and allows the tonneau cover 100 to be precisely centered along the transverse axis TA. In one example, the indexing flange 5 allows the tonneau cover 100 to extend 7.5 millimeters into the cargo box 3 and 18 millimeters above the cargo box 3. In further examples, the indexing flange 5 may be arranged on the opposite side (or both sides) of the tonneau cover 100.

[0089] Further, FIG. ID also depicts a cross-section of the second tonneau frame element 118b positioned along the side rail. As will be shown in more detail in subsequent figures, the tonneau frame element 118b is defined by an angled outer perimeter 132b. The angled outer perimeter 132b may be slanted at an angle 148b of between about twenty degrees and about sixty degrees relative to a top surface 134 of tonneau panel 106 as shown in more detail in FIG. 2A.

[0090] FIG. IE-1 is a partial cross-sectional view of the tonneau cover 100 of FIG. 1A showing the second (center) tonneau panel 106b, the third (bulkhead) tonneau panel 106c, and the second (double) hinge mechanism 104b therebetween. Further, FIG. IE-1 depicts an elongated crossbeam 138b arranged on the bottom surface of the second tonneau panel 106b. Further, FIG. IE-1 also depicts another elongated crossbeam 138c arranged on the bottom surface of the third tonneau panel 106c. The elongated crossbeams 138 are secured to and extend along the tonneau panels 106 to provide additional structural support to the panels 106. When paired with the rigid frame elements 118, the elongated crossbeams 138 and the frame elements 118 make the tonneau panels 106 rigid against uniform loads while simultaneously being flexible against heavy point loads.

[0091] Further, at least one of the elongated crossbeams may include an integrated t-slot channel 140 running longitudinally through the crossbeam 138. The enlarged portion of FIG. IE-1, depicted in FIG. IE-2, shows a t-slot channel 140b running through the crossbeam 138b arranged below the second tonneau panel 106b. The t-slot channel 140b may be configured to receive one or more latches or other components. It is contemplated herein that the channel 140 can take alternative configurations as well, particularly if receiving components therein.

[0092] FIG. 2A is a partial cross-sectional view of a generalized interface 120 between a tonneau panel 106 and a tonneau frame element 118. The tonneau panel 106 includes a longitudinal edge 108 and a transverse edge 110 arranged perpendicularly to each other. The longitudinal edge 108 and the transverse edge 110 each include C-shaped edges 112, 114 toprovide additional structural support to the tonneau panel 106. In one example, the C-shaped edges 112, 114 may have a thickness of about ten millimeters to about fifteen millimeters. As can be seen in FIG. 2 A, because the longitudinal edge 108 and the transverse edge 110 are arranged perpendicularly to each other, the C-shaped edges 112 of the longitudinal edges 108 open substantially perpendicularly to the C-shaped edges 114 of the transverse edges 110.

[0093] FIG. 2A also shows the interface 120 between the C-shaped edges 112, 114 of the tonneau panel 106 and the C-shaped profile 136 of the tonneau frame element 118. As shown in FIG. 2A, the C-shaped profile 136 is slightly taller than the C-shaped edges 112, 114, enabling the C-shaped edges 112, 114 to be secured within the C-shaped profile 136. This arrangement can also be seen in FIG. 3 A.

[0094] The tonneau frame element 118 also includes an angled outer perimeter 132. The angled outer perimeter 132 is angled relative to the top surface 134 of the tonneau panel 106. In some examples, the angle 148 between the angled outer perimeter 132 and the top surface 134 may range from about twenty degrees to about sixty degrees. In the non-limiting example of FIG. 2A, the angle 148 is shown as approximately twenty-eight degrees. The angled outer perimeter 132 may aid in preventing water or other environmental elements from collecting on the tonneau frame element 118 and may strengthen the respective tonneau frame element 118.

[0095] FIG. 2B is a cross-sectional view of an interface between a tonneau panel 106 and a tonneau frame element 118 along a tailgate of a cargo box 3 of a pickup truck 1. As shown in FIG. 2B, an elongated seal 126 is engaged with a channel 152 of the tonneau frame element 118. In the non-limiting example of FIG. 2B, the elongated seal 126 is embodied as a fin seal 128. Alternative options include a D-seal, for example to accommodate a different height between the bulkhead and the tailgate. Other suitable seals are contemplated herein as well.

[0096] FIG. 2C is a cross-sectional view of an interface between a tonneau panel 106 and a tonneau frame element 118 along a bulkhead or siderail of a cargo box 3 of a pickup truck 1. As shown in FIG. 2C, an elongated seal 126 is engaged with a channel 152 of the tonneau frame element 118. In the non-limiting example of FIG. 2B, the elongated seal 126 is embodied as a fin seal 128. However, the fins of the fin seal 128 of FIG. 2C extend outwards and away from the tonneau panel 106, whereas the fins of the fin seal 128 of FIG. 2B extend inwards and towards the tonneau panel 106. In both cases, the fin seals 128 engage with the cargo box 3 to protect the inside of the cargo box 3 from the external environment.

[0097] FIG. 2D is a cross-sectional view of an interface between a second (center) tonneau panel 106b and a second hinge frame 154b and an interface between a first (tailgate) tonneau panel 106a and a first hinge frame 154a. A hinge mechanism 104a is disposed between the firstand second tonneau panels 106a, 106b to enable the first tonneau panel 106a to rotate relative to the second tonneau panel 106b. As shown in FIG. 2D, the first and second hinge frames 154a, 154b have C-shaped profiles to receive the C-shaped edges 114a2, 114bl of the transverse edges 110a2, 1 lObl of the adjacent tonneau panels 106a, 106b.

[0098] The non-limiting example of the hinge mechanism 104a includes a barrel hinge 142a, an elastomeric hinge seal 144, and a second seal 146. The barrel hinge 142a enables the first tonneau panel 106a to rotate about the barrel hinge 142a to stack on top of the second tonneau panel 106b to start the folding process illustrated in FIG. IB. The barrel hinge 142a is disposed transversely across the tonneau cover 100 such that the barrel hinge 142a is oriented in parallel with the transverse axis TA shown in FIG. 1 A. As can be seen in FIG. 2D, the barrel hinge 142a is positioned between the first and second hinge frames 154a, 154b. Therefore, the barrel hinge 142a is also positioned between the transverse edges 110a2, 1 lObl of the adjacent tonneau panels 106a, 106b.

[0099] The hinge mechanism 104a further includes an elastomeric hinge seal 144a. The elastomeric hinge seal 144a is configured to maintain protection of the interior of the cargo box 3 during folding and unfolding. As shown in FIG. 2D, the elastomeric hinge seal 144a is disposed in underlying relation to the barrel hinge 142a, though it is contemplated herein that the hinge seal 144a may be aligned with and / or disposed between the barrel hinge 142a. One or more barrel hinges 142a may be positioned between the adjacent tonneau panels 106a, 106b. The elastomeric hinge seal 144a is arranged transversely across the width of the tonneau cover 100 between the first tonneau panel 106a and the second tonneau panel 106b. As can be seen in FIG. 2D, the elastomeric hinge seal 144a engages with the first hinge frame 154a and the second hinge frame 154b such that the elastomeric hinge seal 144a will bend and compress during folding, and regain its original shape following unfolding.

[0100] The hinge mechanism 104a further includes a second seal 146a. The second seal 146a may be defined by a vertical portion 162a and a series of horizontal bumps 164a, where the terms “vertical” and “horizontal” are used herein relative to the tonneau 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 further protection to the interior of the cargo box 3 during folding and unfolding. Specifically, the horizontal bumps 164a extend parallel to the longitudinal axis LA and compress when the tonneau panels 106a, 106b are unfolded relative to each other, thus eliminating any gap and / or closing the seam between tonneau panels 106a, 106b. The second seal 146a is arranged in underlying relation to the elastomeric hinge seal 144a. The second seal 146a is also arranged transversely across the tonneau cover 100 in between the first and secondtonneau panels 106a, 106a such that the second seal 146a compresses when the tonneau cover 100 is in the unfolded position, and expands when the tonneau cover 100 is in the folded position. Thus, the second seal 146a may be considered to be arranged perpendicularly to the elastomeric hinge seal 144a.

[0101] FIG. 3 A is a partial cross-sectional view of a comer of a tonneau cover 100. In particular, the FIG. 3 A illustrates a corner of the third tonneau panel 106c proximate to the driver side of the bulkhead of the pickup truck 1, though the corner construction 122b is illustrative only and not limited to that position on the tonneau cover 100. A C-shaped edge 112cl of a longitudinal edge 108cl of the third tonneau panel 106c is shown, along with a C- shaped edge 114c2 of a transverse edge 110c2.

[0102] FIG. 3 A also shows a fourth tonneau frame element 118d with a C-shaped profile 136d to receive the longitudinal edge 108cl of the tonneau panel 106c. An elongated seal 126a, embodied as a fin seal 128 is coupled to the fourth tonneau frame element 118d.

[0103] A fifth tonneau frame element 118e, arranged perpendicularly to the fourth tonneau frame element 118d, also includes a C-shaped profile 136e to receive the transverse edge 110c2 of the tonneau panel 106c. An elongated seal 126b, embodied as a D-seal 130 is coupled to the fifth tonneau frame element 118e. The D-seal 130 may be arranged along the bulkhead of cargo box 3. D-seals 130 typically have higher ranges of compression than fin seals 128. As different types of pickup trucks 1 have different bulkhead heights, a D-seal 130 may be able to accommodate a wider range of bulkhead heights than other types of seals.

[0104] Further, FIG. 3A shows a corner construction 122b. The comer construction 122b includes a corner frame 124. The corner frame 124 interfaces with the fourth and fifth tonneau frame elements 118d, 118e to cover a gap 116b between the longitudinal edge 108cl and the transverse edge 110c2. This gap 116b is shown in FIGS. 3B and 3C. Covering the gap 116b provides further protection for the interior of the cargo box 3 and the internal components of the tonneau cover 100 against external elements.

[0105] Further, FIG. 3C illustrates a pair of chamfers in the edges of the third tonneau panel 106c. In particular, a first chamfer 156cl is formed in the C-shaped edge 112cl of the longitudinal edge 108cl, and a second chamfer 158c2 is formed in the C-shaped edge 114c2 of the transverse edge 110c2. The chamfers 156cl, 158c2 allow the longitudinal and transverse edges 108cl, 110c2 to be formed as close as possible to each other, thereby reducing the size of the gap 116b.

[0106] FIG. 4 is a flowchart of a method 900 of manufacturing a foldable tonneau cover for use with a cargo box of a pickup truck. The method 900 includes, in step 902, providing a firstsheet metal having longitudinal edges and transverse edges, the first sheet metal having a cutout at each comer. The method 900 further includes, in step 904, folding each longitudinal edge and each transverse edge of the first sheet metal into a C-shaped edge. The method 900 further includes, in step 906, securing each C-shaped edge of the first sheet metal to a tonneau frame. The method 900 further includes, in step 908, providing a second sheet metal having longitudinal edges and transverse edges, the second sheet metal having a cutout at each corner. The method 900 further includes, in step 910, folding each longitudinal edge and each transverse edge of the second sheet metal into a C-shaped edge. The method further includes, in step 912, securing each C-shaped edge of the second sheet metal to the tonneau frame. The method further includes, in step 914, connecting the first sheet metal and the second sheet metal together via a hinge mechanism disposed between C-shaped edges of adjacent transverse edges of the first and second sheet metals.

[0107] In some embodiments, the tonneau cover 100 may further include a stiffener element, as illustrated in FIGS. 5A-5C, on a bottom surface of one or more tonneau panels 106a, 106b, 106c (collectively 106). If present, the stiffener element 170 includes a plurality of flanges 172a, 172b (collectively 172) spaced apart, a connector section 174a, 174b (collectively 174) extending from each flange 172, and an elongate section 176 that traverses the connector sections 174. The stiffener element 170 is configured such that a spaced distance exists between the bottom surface of the respective tonneau panel 106 and the elongate section 176. The spaced distance results in greater stiffening of the tonneau panel 106; indeed, as the value of the spaced distance increases, the stiffening may increase as well, and vice versa. Here, for example, the distance between the top surface of a tonneau panel 106 and the bottom surface of the corresponding elongate section 176 can be the same as or similar to the thickness of a corresponding C-shaped edge 112, 114. As indicated, these thicknesses can be about 10.0 mm to about 15.0 mm, resulting in the spaced distance between about 6.0 mm and about 13.0 mm. The similar thicknesses, which can also be seen in FIG. 5C, facilitate stacking of multiple tonneau covers 100.

[0108] In certain embodiments, each connector section 174 extends from its respective flange 172 at an obtuse angle. Preferably, the obtuse angle between the connector section 174 and the flange 172, as taught by 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 benefits, such as greater stiffening during use and nesting / stacking ability during manufacture.

[0109] The stiffener element 170 may be formed of any suitable material and may be the same as or different material from tonneau panels 106. For example, the stiffener element 170 may be formed from a 20-gauge aluminum alloy.

[0110] In certain embodiments, shown in FIGS. 6A-6D, a hinge clip, generally denoted by the reference numeral 200, may be included on the bottom of the first hinge mechanism 104a and / or on the bottom of the second hinge mechanism 104b. Sometimes, when a latch is not located at or near a hinge mechanism, the hinge mechanism may be susceptible to lifting off of the truck bed or siderail, as the case may be, if sufficient force is applied, resulting in a small gap between the truck bed and the tonneau cover when the tonneau cover is in an extended position. In such a case, hinge clip 200 may be utilized to connect adjacent tonneau sections to each other in the extended or unfolded position.[OHl] The hinge clip 200 is formed of a first component 202 connected to one tonneau section and a second component 204 connected to an adjacent tonneau section, where first and second components 202, 204 are configured to have a snug fit engagement, using a tongue and groove mechanism for example (i.e., tongue 206 of the first component 202 and groove 208 of the second component 204) when engaged with one other. This engagement permits the first and second components 202, 204 to become automatically disengaged upon sufficient force being placed on them, for example when a user is folding tonneau sections 102 relative to one another. As depicted in FIGS. 6C-6D, the hinge clip 200 is positioned under the second hinge mechanism 104b, which is a double hinge mechanism, to couple together second tonneau section 102b and third tonneau section 102c. FIG. 6C shows the hinge clip 200 disengaged during the folding or unfolding process, and FIG. 6D shows the hinge clip 200 engaged when the second tonneau section 102b and the third tonneau section 102c are in an extended position relative to each other. Preferably, one hinge clip 200 would be positioned close to a longitudinal edge of one tonneau section 102b, 102c and another hinge clip 200 would be positioned close to an opposite longitudinal edge of the same tonneau section 102b, 102c. As can be readily understood, the hinge clip 200 may also be positioned under any hinge mechanisms 104 of the tonneau cover 100, where it is desired to couple adjacent tonneau sections 102 to one another in the extended position.

[0112] In certain embodiments, where brackets must be installed on a sidewall of the pickup truck, for example to receive a plunger of a quick latching mechanism, an issue sometimes arises when the clamp portion of the bracket can rotate when a user is attempting to tighten the bracket onto the truck bed sidewall. See FIG. 7 A, which shows a hypothetical situation of the clamp 302 rotating. To alleviate this issue, an anti-rotation brace 300 can be installed betweenthe clamps 302 and the bracket 304, where the anti-rotation brace 300 conforms to the edge of the clamps 302. The anti-rotation brace 300 also includes apertures 306 configured to align with apertures in the bracket 304 and apertures in the clamps 302, such that a bolt 308 or other fastener can be inserted through the bracket 304, anti-rotation brace 300, and clamp 302. Additionally, the anti-rotation brace 300 has a length that is longer than a total distance of the clamps 302, such that if a clamp 302 tries to rotate, an edge of the clamp 302 will contact the anti-rotation brace 300, which is fixed in place, thus preventing rotation of the clamp. This can be seen in FIG. 7B.

[0113] All definitions, as defined and used herein, should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and / or ordinary meanings of the defined terms.

[0114] As used herein in the specification and in the 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” shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one, of a number or list of elements, and, optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as “only one of’ or “exactly one of,” or, when used in the claims, “consisting of,” will refer to the inclusion of exactly one element of a number or list of elements. In general, the term “or” as used herein shall only be interpreted as indicating exclusive alternatives (i.e. “one or the other but not both”) when preceded by terms of exclusivity, such as “either,” “one of,” “only one of,” or “exactly one of.”

[0115] As used herein in the specification and in the claims, the phrase “at least one” or “one or more” in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements. This definition also allows that elements can optionally be present other than the elements specifically identified within the list of elements to which the phrase “at least one” refers, whether related or unrelated to those elements specifically identified.

[0116] It should also be understood that, unless clearly indicated to the contrary, in any methods claimed herein that include more than one step or act, the order of the steps or acts of the method is not necessarily limited to the order in which the steps or acts of the method are recited.

[0117] In the claims, as well as in the specification above, all transitional phrases such as “comprising,” “including,” “carrying,” “having,” “containing,” “involving,” “holding,”“composed of,” and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases “consisting of’ and “consisting essentially of’ shall be closed or semi-closed transitional phrases, respectively.

[0118] As used herein, “about” means approximately or nearly, and in the context of a numerical value or range set forth means ±15% of the numerical. In exemplary embodiments, the term “about” can include traditional rounding according to significant figures of the numerical value. In addition, the phrase “about ‘x’ to ‘y’” includes “about ‘x’ to about ‘y’”.

[0119] Further, any range of numbers recited in the specification or claims, such as that representing a particular set of properties, units of measure, conditions, physical states or percentages, is intended to literally incorporate expressly herein by reference or otherwise, any number falling within such range, including any subset of numbers within any range so recited. For example, whenever a numerical range with a lower limit, RL, and an upper limit RU, is disclosed, any number R falling within the range is specifically disclosed. In particular, the following numbers R within the range are specifically disclosed: R=RL±k(RU-RL), where k is a variable ranging from 1% to 100% with a 1% increment, e.g., k is 1%, 2%, 3%, 4%, 5%. . . . 50%, 51%, 52% ...95%, 96%, 97%, 98%, 99%, or 100%. Moreover, any numerical range represented by any two values of R, as calculated above, is also specifically disclosed.

[0120] Other implementations are within the scope of the following claims and other claims to which the applicant can be entitled.

[0121] While various examples have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other means and / or structures for performing the function and / or obtaining the results and / or one or more of the advantages described herein, and each of such variations and / or modifications is deemed to be within the scope of the examples described herein. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and / or configurations will depend upon the specific application or applications for which the teachings is / are used. Those skilled in the art will recognize or be able to ascertain using no more than routine experimentation, many equivalents to the specific examples described herein. It is, therefore, to be understood that the foregoing examples are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, examples can be practiced otherwise than as specifically described and claimed. Examples of the present disclosure are directed to each individual feature, system, article, material, and / or method described herein. In addition, any combination of two or more such features, systems, articles, materials, and / ormethods, if such features, systems, articles, materials, and / or methods are not mutually inconsistent, is included within the scope of the present disclosure.

Claims

ClaimsWhat is claimed is:

1. A foldable tonneau cover for use with a cargo box of a pickup truck, the foldable tonneau cover comprising: a plurality of tonneau sections movable between an unfolded position and a folded position, wherein the plurality of tonneau sections substantially covers the cargo box in the unfolded position, wherein the plurality of tonneau sections is arranged in a nested stack in the folded position; and a hinge mechanism positioned between at least two of the plurality of tonneau sections to facilitate transitioning of the plurality of tonneau sections between the folded position and the unfolded position; wherein each of the plurality of tonneau sections comprises a tonneau panel formed of a material consisting essentially of a sheet metal, the tonneau panel comprising 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 perpendicularly to the C-shaped edge of each of the transverse edges.

2. The foldable tonneau cover of claim 1, wherein each tonneau panel has the following properties: a yield strength of 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 at a center of the tonneau panel between about 1.00 mm and about 2.00 mm, and a second thickness at the C-shaped edge of the tonneau panel between about 10.0 mm and about 15.0 mm.

3. The foldable tonneau cover of claim 1, wherein the material is an aluminum alloy comprising: aluminum in an amount between about 98% and 99% chemical composition of the aluminum alloy, and manganese in an amount between about 1% and about 2% chemical composition of the aluminum alloy.

4. The foldable tonneau cover of claim 1, wherein the material is a 3000 series aluminum.

5. A foldable tonneau cover for use with a cargo box of a pickup truck, the foldable tonneau cover comprising a plurality of tonneau panels, wherein each of the plurality of tonneau panels is formed of a material consisting essentially of a sheet metal and has the following properties: a yield strength of 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 at a center of each of the plurality of tonneau panels between about 1.0 mm and about 2.00 mm, and a second thickness at an edge of each of the plurality of tonneau panels between about 10.0 mm and about 15.0 mm.

6. The foldable tonneau cover of claim 5, wherein each of the plurality of tonneau panels 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 perpendicularly to the C-shaped edge of each of the transverse edges.

7. The foldable tonneau cover of claim 5, wherein the material is an aluminum alloy comprising: aluminum in an amount between about 98% and 99% chemical composition of the aluminum alloy, and manganese in an amount between about 1% and about 2% chemical composition of the aluminum alloy.

8. A foldable tonneau cover for use with a cargo box of a pickup truck, the tonneau cover comprising: a plurality of tonneau sections movable between an unfolded position and a folded position, wherein the plurality of tonneau sections substantially covers the cargo box in the unfolded position, wherein the plurality of tonneau sections is arranged in a nested stack in the folded position; and a hinge mechanism positioned between at least two of the plurality of tonneau sections to facilitate transitioning of the plurality of tonneau sections between the folded position and the unfolded position; wherein each of the plurality of tonneau sections comprises a tonneau panel formed of a material consisting essentially of a sheet metal, the tonneau panel comprising longitudinal edges and transverse edges, wherein each of the longitudinal edges and each of the transverse edges is configured to be a C-shaped edge, such that the C-shaped edge of each of the longitudinal edges opens substantially perpendicularly to the C-shaped edge of each of the transverse edges; wherein each tonneau panel has the following properties: a yield strength of 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 at a center of the tonneau panel between about 1.0 mm and about 2.00 mm, a second thickness at the C-shaped edge of the tonneau panel 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% chemical composition of the aluminum alloy, and manganese in an amount between about 1% and about 2% chemical composition of the aluminum alloy.

9. The foldable tonneau cover of claim 8, wherein the material of the sheet metal is a 3000 series aluminum alloy.

10. The foldable tonneau cover of any one of the preceding claims, further comprising a gap between one of the longitudinal edges and an adjacent transverse edge at each comer of the tonneau panel.

11. The foldable tonneau cover of any one of the preceding claims, further comprising a tonneau frame to which the C-shaped edge of each of the longitudinal edges and each of the transverse edges is secured, thereby forming an interface between the tonneau frame and each corresponding C-shaped edge.

12. The foldable tonneau cover of claims 10 and 11, further comprising a corner construction that covers the gap at one of the comers of the tonneau panel, wherein the corner construction further comprises a corner frame that interfaces with the tonneau frame at one of the longitudinal edges and one of the transverse edges.

13. The foldable tonneau cover of claim 10, further comprising one or more elongated seals disposed within a channel of the tonneau frame.

14. The foldable tonneau cover of claim 13, wherein the one or more elongated seals comprise a fin seal and / or a D seal.

15. The foldable tonneau cover of claim 11 , wherein the tonneau frame has an angled outer perimeter, an angle of the angled outer perimeter being between about 20 degrees and about 60 degrees relative to a top surface of the tonneau panel.

16. The foldable tonneau cover of claim 11, wherein the tonneau frame comprises a C- shaped profile that matches the C-shaped edge of the longitudinal edges and the transverse edges of the tonneau panel, said C-shaped profile configured to receive the C-shaped edge.

17. The foldable tonneau cover of any one of the preceding claims, further comprising at least one elongated crossbeam secured to and extending along a bottom surface of each tonneau panel.

18. The foldable tonneau cover of claim 17, wherein the at least one elongated crossbeam comprises an integrated T-slot channel configured to receive one or more latches therein.

19. The foldable tonneau cover of any one of the preceding claims, wherein the hinge mechanism comprises: a barrel hinge disposed transversely across the foldable tonneau cover between the C- shaped edges of adjacent transverse edges, an elastomeric hinge seal disposed in underlying relation to the barrel hinge and transversely across the foldable tonneau cover between the C-shaped edges of adjacent transverse edges, and a second seal disposed in underlying relation to the elastomeric hinge seal and transversely across the foldable tonneau cover between the C-shaped edges of adjacent transverse edges.

20. The foldable tonneau cover of any one of the preceding claims, further comprising a stiffener element disposed in a transverse direction along a bottom surface of one or more tonneau panels, the stiffener element comprising: a plurality of flanges secured to the bottom surface of the one or more tonneau panels, a connector section extending from each of the plurality of flanges, wherein the connector section and the corresponding flange have an obtuse angle relative to each other, and an elongate section extending substantially parallel to a transverse axis of the tonneau panel, the elongate section extending between and connecting the connector sections together, wherein the tonneau panel and the stiffener element define a spaced distance therebetween.

21. A method of manufacturing a foldable tonneau cover for use with a cargo box of a pickup truck, the method comprising: providing a first sheet metal having longitudinal edges and transverse edges, the first sheet metal having a cutout at each corner; folding each longitudinal edge and each transverse edge of the first sheet metal into a C-shaped edge; securing each C-shaped edge of the first sheet metal to a tonneau frame; providing a second sheet metal having longitudinal edges and transverse edges, the second sheet metal having a cutout at each corner; folding each longitudinal edge and each transverse edge of the second sheet metal into a C-shaped edge; securing each C-shaped edge of the second sheet metal to the tonneau frame; andconnecting the first sheet metal and the second sheet metal together via a hinge mechanism disposed between C-shaped edges of adjacent transverse edges of the first and second sheet metals.

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