Tonneau cover with coating

Abstract

A tonneau cover for a vehicle that includes a cargo area, the cargo area having a tailgate, two spaced-apart side walls, a front wall that opposes the tailgate, and a floor, the tonneau cover has: at least two panels, each of the two panels comprising a top side and an opposing bottom side, the opposing bottom side is configured to face the floor when the tonneau cover is in a closed position; and a carrier applied onto the top side of the at least two panels, wherein the carrier is configured to connect the at least two panels together and to provide a hinge between the at least two panels.

Description

PCT / US24 / 47367 19 September 2024 (19.09.2024)Filed via USPTO. Gov. on September 19, 2024Docket No.: 2021A.030WO (8877357)TONNEAU COVER WITH COATINGCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and the benefit of US 63 / 605,779 filed on December 04, 2023, the entirety of which is hereby incorporated by reference herein for all purposes.FIELD

[0001] These teachings relate to a cover for a vehicle cargo area.BACKGROUND

[0002] Some vehicles, like pick-up trucks, have a bed or cargo area that may be used for storing or transporting cargo. A cover, such as a tonneau cover, may be placed over the cargo area. The tonneau cover may be opened to provide access to the cargo and / or the inside of the cargo area and closed to conceal the cargo from view and / or to prevent fluid and / or debris from entering the cargo area. While many tonneau covers are suitable for their intended purpose, continued improvement in the art is desirable.SUMMARY

[0003] These teachings provide a tonneau cover for a vehicle. The tonneau cover according to these teachings may be a folding tonneau cover or a rolling tonneau cover.

[0004] A folding tonneau cover may include two or more panels. At least one of the two or more panels of the folding cover are configured to be folded to at least partially open or expose the cargo area. At least one of the two or more panels of the folding cover are configured to be folded to at least partially close or conceal the cargo area.

[0005] A rolling tonneau cover may include a plurality of panels. The plurality of panels are configured to roll or pivot to at least partially open or expose the cargo area. The plurality of panels are configured to roll or pivot to at least partially close or conceal the cargo area. The panels of a rolling tonneau cover may be referred to as slats.

[0006] The tonneau cover may include a carrier. The carrier may function to connect together two or more of the panels of the tonneau cover. The carrier may function to provide aPCT / US24 / 47367 19 September 2024 (19.09.2024)Filed via USPTO. Gov. on September 19, 2024Docket No.: 2021A.030WO (8877357) hinge, pivot, or folding region so that at least one of the panels may be folded, pivoted, rolled, or otherwise rearranged or moved relative to one or more other panels of the tonneau cover. Besides the carrier, the tonneau cover may be free of other hinge or pivot elements between the two or more panels. However, in some configurations, the tonneau cover may include one or more hinge or pivot elements between the two or more panels.

[0007] The carrier may be one or more layers that function to restrict or prevent fluid and / or debris from entering the cargo box and / or penetrating the one or more panels. The carrier may be or may have one or more layers that function to restrict or prevent fluid from entering the cargo box between two or more adjacent panels. The carrier may be sprayed onto the one or more panels. The carrier may be a bed liner material. The carrier may function to provide a substantially smooth appearance of the tonneau cover. The carrier may include a grain or other surface features. The carrier may be a coating that is provided over the one or more panels or slats. The carrier may be one or more layers. The one or more layers may be sprayed, dripped, applied onto, rolled, or applied in any suitable method. The carrier may be a vinyl or scrim material. The carrier may be a scrim material that may be found adhered to the bottom or back side of a vinyl material. The carrier may be a mesh or screen material. The carrier may be substantially resistant to compression. The carrier may be or contain a polypropylene, polyester, or nylon material. The carrier may be a woven or non-woven material. The carrier may be a fabric. The carrier may be a plastic or resin. The carrier may be a tape or laminate. The carrier may be thermoformed. The carrier may be a material that is applied onto the one or more panels, cores, or slats and then subsequently cured to harden or provide additional strength characteristics. The carrier may be insert molded onto or over the one or more panels, cores, or slats. The carrier may be painted. The carrier may be sufficiently adhered to the one or more panels, slats, or cores to prevent separation after applying the carrier. A binder, primer, promoter, or other surface treatment may be applied to the carrier and / or the one or more panels, cores, or slats to facilitate and promote adhesion between the carrier and the one or more panels, cores, or slats.

[0008] The carrier may be applied onto all or a portion of the one or more panels, cores, or slats. For example, the carrier may be applied onto an entire top or A-surface of the one or more panels, slats, or cores; onto an entire bottom or B-surface of the one or more panels, slats, or cores; onto one or more sides or edges of the one or more panels, slats, or cores; or anyPCT / US24 / 47367 19 September 2024 (19.09.2024)Filed via USPTO. Gov. on September 19, 2024Docket No.: 2021A.030WO (8877357) combination thereof One or more regions of the one or more slats, panels, or cores may be free of any carrier. For example, regions where the panels, cores, or slats are configured to move or flex may include no carrier or a reduced amount of carrier material. The carrier material may be removed or thinned after application to remove or thin the carrier material. The one or more cores, panels or slats may be masked or protected to prevent applied of the carrier material to one or more regions thereof. The carrier material may be applied onto one or more hinges, frames, handles, latches, or other components that are attached to the one or more panels of the tonneau cover. The carrier material may be applied in a liquid form or a solid form. The carrier material may be applied as a sheet material. The carrier material may be applied via a printing or by applying droplets onto the one or more cores. The carrier material may be sprayed onto the one or more cores. The carrier may be applied in aerosol form.

[0009] The carrier may have a texture finish, a wood-look finish, a glossy finish, a matte finish, a color matched finish (to the vehicle), a grain finish, or any combination thereof. The carrier may be waterproof or water resistant. The carrier may be scratch resistant. The carrier may be sufficiently strong to support a sufficient weight on the tonneau cover. The carrier may have a transparent finish. The carrier may have a translucent finish. The carrier may be or have a clear finish. The carrier may be a fabric or carpet material.

[0010] The carrier may be applied onto or over one or more panels. Panel, slat, or core may be used interchangeably herein unless otherwise noted. The core may be a foam or Styrofoam material. The core may be a plastic, paper-based, biodegradable, metal material, or any combination thereof. The core may be made of a material that is recyclable. The core may be or include a fabric or carpet material. The core may be made of a recycled material. The core may be made of or contain metal, aluminum, steel, carbon fiber, plastic, or any combination thereof. The core may be a woven or non-woven material. The core may be a polystyrene material. The core may be wood. The core may be a hollow material. The core may have a substantially solid center. The core may have a honeycomb shape or configuration. The core may have one or more layers. The core may be a laminate or may be laminated. The core may be or may include cardboard. The core may be transparent.

[0011] The carrier may also be applied to other members of the tonneau cover, including one or more support rails, canisters, or both. The support rails may be the extruded, molded, or machined members that are attached to the side walls of the cargo area of the vehicle andPCT / US24 / 47367 19 September 2024 (19.09.2024)Filed via USPTO. Gov. on September 19, 2024Docket No.: 2021A.030WO (8877357) configured to support the one or more panels of the tonneau cover. A canister may be arranged in the cargo area and configured to house or store the tonneau cover panels or slate when the tonneau cover is moved into an open or retracted position.

[0012] The core may be a machined material. The core may have a substantially uniform thickness. The core may have a varying thickness. The core may be made from a substantially uniform thickness and subsequently thinned or machined in local areas. The thinned or machined local areas may enable the core to bend or flex, to enable the tonneau cover to move, rotate, bend, flex, or fold when being moved between an open and closed position. The thinning or machining may take place via a heating or melting process. The thinning or machining may take place via a milling or cutting process. The thinning or machining may take place before, during, or after the carrier is applied onto the one or more cores.BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Fig. 1 A is a rear perspective view of a vehicle and a folding tonneau cover.

[0014] Fig. IB is a rear perspective view of a vehicle and a folding tonneau cover.

[0015] Fig. 2A is a rear perspective view of a vehicle and a rolling tonneau cover.

[0016] Fig. 2B is a rear perspective view of a vehicle and a rolling tonneau cover.

[0017] Fig. 3A is a cross-sectional or schematic view of a tonneau cover.

[0018] Fig. 3B is a cross-sectional or schematic view of a tonneau cover.

[0019] Fig. 3C is a cross-sectional or schematic view of a tonneau cover.

[0020] Fig. 4A is a cross-sectional or schematic view of a tonneau cover.

[0021] Fig. 4B is a cross-sectional or schematic view of a tonneau cover.

[0022] Fig. 5A illustrates a method step of making a tonneau cover.

[0023] Fig. 5B illustrates a method step of making a tonneau cover.

[0024] Fig. 5C illustrates a method step of making a tonneau cover.

[0025] Fig. 5D illustrates a method step of making a tonneau cover.

[0026] Fig. 6 illustrates a side view of a vehicle and a rolling tonneau cover.

[0027] Fig. 7 is a cross-sectional or schematic view of a tonneau cover.

[0028] Fig. 8 is a cross-sectional or schematic view of a tonneau cover.

[0029] Fig. 9 is a cross-sectional or schematic view of a tonneau cover.

[0030] Fig. 10 is a cross-sectional or schematic view of a panel of a tonneau cover.PCT / US24 / 47367 19 September 2024 (19.09.2024)Filed via USPTO. Gov. on September 19, 2024Docket No.: 2021A.030WO (8877357)

[0031] Fig. 11 is a perspective view of a panel of a tonneau cover.DETAILED DESCRIPTION

[0032] A vehicle 10 is illustrated in Figs. 1A, IB, 2A, and 2B.

[0033] The vehicle 10 comprises a bed or cargo area 12 and a passenger area or cab 14. The illustrated vehicle 10 is a pickup truck. However, the vehicle may be any other suitable vehicle that may find use having such a cover, such as a utility vehicle, boat, trailer, ATV, UTV, semitruck, dump truck, camper, etc.

[0034] The cargo area 12 may be defined by one or a plurality of walls. The cargo area 12 may include: two opposing and spaced-apart side walls 16a, 16b, a front wall 18 that is located adjacent to the passenger cab 14, a rear wall or tailgate 20 that opposes the front wall 18, and a floor 22 that is surrounded by the aforementioned walls 16, 18, 20. Two or more of the walls may be a single, combined, or integral wall. One or more of these walls may be split into two or more walls. For example, the tailgate, side wall, or front wall may be split into two or more walls to provide versatile access to the cargo area or passenger area of the vehicle.

[0035] The front wall 18 of the cargo area 12 may be a shared or common wall with a back wall of the passenger cab 14. Such vehicles may be a one piece or uni-body construction. In other vehicles, the front wall 18 may be a separate wall, segment, or portion of the vehicle from a rear wall of the passenger cab 14. In some configurations, the front wall 18 may provide access to the passenger cab 14 via a pass through or fold down wall or door.

[0036] In Figs. 1A and IB, a tonneau cover 100 is placed over the cargo area 12. The tonneau cover 100 is a folding tonneau cover. The folding tonneau cover 100 comprises at least two panels. In the illustrated example, the folding tonneau cover 100 comprises a plurality of panels 102, 104, 106. The panels 102, 104, 106 of the tonneau cover 100 are configured to be folded and unfolded to move the tonneau cover 100 between a closed configuration (Fig. 1A) and an open configuration (Fig. IB). During the folding and unfolding, the panels 102, 104, 106 are configured to be folded or pivoted relative to one another and / or the cargo area 12. In Fig. 2B, the panel 102 is folded on top of the panel 104. The folded panels 102, 104 may also be configured to be folded or pivoted onto the panel 106 to further open the tonneau cove The tonneau cover 100 may include only two panels (e.g., 102, 104). r. The tonneau cover 100 mayPCT / US24 / 47367 19 September 2024 (19.09.2024)Filed via USPTO. Gov. on September 19, 2024Docket No.: 2021A.030WO (8877357) include more than two panels (e.g., 102, 104, 106), or even more than three panels (e.g., three panels, four panels, five panels, etc.)

[0037] In Figs. 2A and 2B, a tonneau cover 100 is placed over the cargo area 12. The tonneau cover 100 is a rolling tonneau cover. The rolling tonneau cover 100 comprises at least two panels. In the illustrated configuration, the rolling tonneau cover 100 comprises a plurality of panels 102, 104, 106, etc. In some instances, one or more of the panels 102, 104, 106 may be referred to as a slat.

[0038] The panels 102, 104, 106 of the tonneau cover 100 are configured to be rolled and unrolled to move the tonneau cover 100 between a closed configuration (Fig. 2A) and an open configuration (Fig. 2B). During the rolling and unrolling, the panels 102, 104, 106 are configured to move, rotate, articulate, and / or pivot relative to one another. The panels 102, 104, 106, etc. may be rolled into a roll as illustrated in Fig. 2B. In some configurations, the panels 102, 104, 106, etc. may be rolled and stored in a canister. The canister may be located anywhere in the vehicle 10 or the cargo area 12, for example, near the front wall 18 of the cargo area adjacent to the passenger area 12.

[0039] Fig. 3 A illustrates a tonneau cover 100. The tonneau cover 100 comprises at least two panels. In this example, the tonneau cover 100 comprises panels 102, 104, and 106. Each of the panels 102, 104, 106 comprise a top side 108 and an opposing bottom side 110. In vehicle position, the top side 108 is configured to face outwardly when the tonneau cover is in a closed configuration. In vehicle position, the opposing bottom side 110 is configured to face the floor 22 of the cargo area 12 (Figs. 1 A, 2A) at least when the tonneau cover is in a closed position.

[0040] The tonneau cover 100 comprises a carrier 112. The carrier 112 is applied onto the top side 108 of the at least two panels 102, 104, 106. The carrier 112 is configured to connect the at least two panels 102, 104, 106 together. The carrier 112 is configured to provide a hinge 114 between two adjacent panels 102 and 104, 104 and 106, etc.

[0041] The panels 102, 104, 106 are arranged so that a gap 116 is defined between opposing or adjacent edges 118 of the panels 102, 104, 106. In other words, two or more adjacent panels 102, 104 and 104, 106 are spaced spart from one another and are not connected to one another, except via the carrier 112. The carrier 112 is configured to restrict or prevent fluid and / or debris from passing through the gap 116 between two or more adjacent panels.PCT / US24 / 47367 19 September 2024 (19.09.2024)Filed via USPTO. Gov. on September 19, 2024Docket No.: 2021A.030WO (8877357)

[0042] Figs. 3B and 3C illustrate one of the panels 106 being folded or rotated about the hinge 114 of the carrier 112.

[0043] Figs. 4A and 4B illustrate a tonneau cover 100. The tonneau cover 100 may be substantially the same as the one illustrated and described above at Fig. 3A; therefore, like elements will not be described again. The tonneau cover 100 comprises a second carrier 120 that is provided in between the carrier 112 and the top surface 108 of the at least two panels 102, 104, 106. The second carrier 120 may function to provide a connection between the panels 102, 104, 106 before the carrier 112 is applied. The second carrier 120 may function to prevent the carrier 112 from dripping or falling into the gap 116 before the carrier 112 is applied. The second carrier 120 may have the same material and / or functional characteristics as the first carrier 112. The second carrier 120 may have different material and / or functional characteristics as the first carrier 112.

[0044] In Fig. 4A, the second carrier 120 extend along an entirety of the top surfaces 108 of the panels 102, 104, 106.

[0045] In Fig. 4B, the second carrier 120 extends along the top surfaces 108 only in a region of the 116 defined between the adjacent panels 102, 104 and 104, 106.

[0046] Figs. 5A-5D illustrate an exemplary fixture 200 for making or assembling the tonneau cover 100. The fixture 200 comprises a plurality of bays 202, 204, 206. The bays 202, 204, 206 are defined between a pair of walls or separators 208. Each of the bays 202, 204, 206 are sized and configured to receive a respective panel 102, 104, 106. The number of bays of the fixture 200 will correspond at least to the number of panels of the tonneau cover.

[0047] A method 300 of making the tonneau cover 100 according to these teachings may include one or more of the following steps.

[0048] The method 300 may include a step of inserting 302 a panel into a respective one of the bays of the fixture. For example, panel 102 may be inserted, placed, or received into bay 202, panel 104 may be inserted, placed, or received into bay 204, panel 106 may be inserted, placed, or received into bay 206, etc.

[0049] The method 300 may include a step of applying 304 the carrier 112 onto the top surfaces of the panels. For example, the carrier 112 may be applied, sprayed, provided, adhered, onto the top surfaces 108 of the panels 102, 104, 106. The separators 208 may be configured to maintain the carrier 112 within the footprint of the top surface of the panels. The separators 208PCT / US24 / 47367 19 September 2024 (19.09.2024)Filed via USPTO. Gov. on September 19, 2024Docket No.: 2021A.030WO (8877357) may be configured to restrict or prevent the carrier 112 from falling or dripping into the gap 116 defined between adjacent panels.

[0050] In the event that the tonneau cover is to have a second carrier between the top surfaces of the panel and the carrier, the method may include a step of applying a second carrier onto the desired region of the top surfaces of the panels (See e.g., Fig. 4A and 4B, carrier 120).

[0051] In some configurations, a gap may be defined between an edge of some panels and a separator. This may allow for the carrier 112 to also cover a side edge of one or more panels. For example, referring to Fig. 5C, a gap 112 may be defined between an edge of the panels 102, 106, which may be the outer panels, so that the carrier 112 also coves the side edges of the panels. This may provide for a more finished look.

[0052] The method may include a step of removing 306 the tonneau cover 100 from the fixture 200.

[0053] Fig. 6 illustrates a tonneau cover 100. The tonneau cover 100 is a rolling tonneau cover. The rolling tonneau cover 100 comprises a plurality of panels 102, 104, 122, etc. A hinge 114 is included between adjacent panel 102, 104, 122. The panels 122, 102, 104, 106, etc. and the corresponding hinges 114 may be formed according to the method disclosed herein.

[0054] Fig. 7 illustrates a tonneau cover 100. The tonneau cover 100 is a folding tonneau cover but may also or instead be a rolling tonneau cover. The tonneau cover 100 comprises a plurality of panels 102, 104 etc. The panels 102, 104 are covered in a carrier 124. The carrier 124 may cover all surfaces of the panels 102, 104 (e.g., top, bottom, sides). The panels 102, 104, etc. may be formed according to the method disclosed herein. A hinge 114 is included or defined between the adjacent panels 102, 104 and may be made of the carrier material 112 as a living hinge.

[0055] In some configurations, the tonneau cover 100 may comprise a single panel. The single panel may cover all or substantially all of the cargo area when the tonneau cover is in a closed position. One or more (e.g., or all) sides of the single panel may be coated or covered with the carrier material. The panel may be made of a foam or other lightweight material. The tonneau cover 100 may improve upon traditional twin sheet thermoformed ABS or fiberglass or aluminum one piece covers by simplifying manufacturing, product weight, and / or manufacturing costs.PCT / US24 / 47367 19 September 2024 (19.09.2024)Filed via USPTO. Gov. on September 19, 2024Docket No.: 2021A.030WO (8877357)

[0056] Fig. 8 illustrates a tonneau cover 100. The tonneau cover 100 is a folding tonneau cover but may also or instead be a rolling tonneau cover. The tonneau cover 100 comprises a plurality of panels 102, 104 etc. The panels 102, 104 are covered by a carrier 112 on one or more sides of the panels 102, 104. A flexible strip of material or flexing element 126 may be provided over the carrier material 112 and over the gap 116 region. In some configurations, the flexing element 126 may be provided under the carrier 112 or encapsulated within a thickness of the carrier 112.

[0057] The flexing element 112 may be an elastic or bias able material and may function to reinforce the hinge 114 defined between the two panels 102, 104 in the carrier material 112. In some configurations, the flexing element 112 may be a hinge. A second carrier 120 may then be applied over the carrier 112 and the flexing element 126. The flexing element 126 may be encapsulated or sandwiched between the carriers 120, 112. The two carriers 120, 112 may be made of the same or different materials.

[0058] Fig. 9 illustrates a tonneau cover 100. The tonneau cover 100 is a folding cover but may also or may instead be a rolling tonneau cover. The tonneau cover 100 comprises a plurality of panels 102, 104. A flexible strip of material or flexing element 126 may be provided over the gap 116 region defined between the adjacent panels 102, 104. The panels 102, 104 and the flexing element 126 are covered by a carrier 112. The carrier 112 may be provided over the panels 102,104 and the flexing element 126 such that the outer or A-surface of the tonneau cover 100 is substantially smooth. The flexing element 126 may be made of the same material as the carrier 112 or a different material. The flexing element 126 may be made of any of the carrier materials disclosed herein.

[0059] Fig. 10 illustrates a panel 102 of the tonneau cover. The panel 102 may be a panel of a folding cover or a panel or slat of a rolling cover. The panel 102 may include one or a plurality of recessed regions 128. The recessed regions 128 may be locally thinned or machined regions of the core or panel 102. The recessed regions 128 may allow for the panel or core to bend, pivot, or flex, so the panel can be used in a folding or rolling tonneau cover application. The recessed regions 128 may have any suitable shapes or profiles, such as triangular, oval, rounded, tear dropped, square, linear, or a combination thereof. A carrier 112 may be provided over one or more surfaces of the panel 102. The carrier 112 may be provided on only the top or A-side ofPCT / US24 / 47367 19 September 2024 (19.09.2024)Filed via USPTO. Gov. on September 19, 2024Docket No.: 2021A.030WO (8877357) the panel and / or on the bottom or B-side of the panel that includes the one or more recessed regions. The recessed regions 128 may function as hinge or a living hinge.

[0060] Fig. 11 illustrates the panel 102 of Fig. 10 bending about the recessed regions 128 or living hinges.

[0061] The carrier may be one or more hardened materials or layers that may be substantially impermeable to damage when items are placed on the one or more panels or when the one or more panels are folded, rolled, or pivoted.

[0062] The carrier may be rigid. The carrier may have some elastomeric characteristics and may have some give when contacted by other items so that the carrier is not damaged.

[0063] The carrier may include a polyethylene; fiber reinforced plastic; acrylonitrile butadiene styrene (ABS); thermoplastic olefin (TPO); reinforced polymers; or a combination thereof.

[0064] The carrier may be a foam, an open sell foam, a closed cell foam, a natural rubber, a synthetic rubber, a single part reactive chemical applied in liquid form, a multi part reactive chemical applied in liquid form, polyurethane, polyethylene, cross-linked polyurethane, reticulated polyurethane foam, polyvinyl chloride (PVC), rubber, glue, or a combination thereof

[0065] The carrier may be in roll form, sheets, or both and then added to the one or more panels. The carrier may be applied to one or more of the panels by gluing, spraying, dipping, rolling, or a combination thereof.

[0066] The carrier may be applied on a first side of one or more panels (e.g., top or exterior surface relative to the cargo area when the tonneau system is in the closed position), a second or bottom side (e.g., interior surface relative to the cargo area when the tonneau cover is in the closed position), a height or thickness of the one or more panels (e.g., one or more sides or walls of the panels, or a combination thereof.

[0067] The carrier should be sufficiently flexible so that it can cover (without adhesion) or coat (with adhesion) and allow the panels to repeatedly flex, pivot, or roll from an open to closed position and closed to open position. For example, the carrier should not tear or otherwise fail after repeated opening and closing and opening for about 100 cycles, for about 500 cycles, for about 1000, cycles, for about 2000 cycles, for about 3000 cycles, for about 4,000 cycles, for about 5,000 cycles ,or more than 5,000 cycles. If the carrier is too stiff, it may have a brittle failure or may plastically deform during the opening and closing of the tonneau cover.PCT / US24 / 47367 19 September 2024 (19.09.2024)Filed via USPTO. Gov. on September 19, 2024Docket No.: 2021A.030WO (8877357)

[0068] The carrier may be selected so that it has a durometer of about 55 Shore D or less, about 50 Shore D or less, about 45 Shore A or less, about 80 Shore A or less, or about 75 Shore A or less, as measured according to ISO 868, at 23° C., at 15 seconds of contact. If the carrier is too flexible it may fail by tearing. Preferably the carrier is selected so that it has a durometer of about 40 Shore A or more, about 50 Shore A or more, or about 60 Shore A or more. The carrier should be selected to have a generally high elongation at failure so that it able to withstand the required stretching during movement or articulation of the one or more panels. The carrier may have an elongation at failure of about 80% or more, about 100% or more, about 120% or more, and more preferably about 150% or more, as measured according to ASTM D412 at 23° C. The carrier may have an elongation at failure of about 500% or less, however higher elongation at failure is also possible. The carrier may be sufficiently flexible so that when the carrier is applied to a panel, the carrier may be folded by about 90 degrees or more, about 135 degrees or more, or even about 180 degrees or more without cracking.

[0069] The carrier may be one or more layers that function to create a dent resistant layer, create a scratch resistant layer, or a combination thereof. The carrier may be sufficiently stiff so that it provides good protection against impact and abrasion. For example, the carrier may be characterized by a tensile stress at 100% elongation of about 0.5 MPa or more, about 2 MPa or more, about 4 MPa or more, or about 6 MPa or more, as measured according to ASTM D412 at 23° C. The carrier may have a stiffness that is sufficiently low so that the resistance to the opening and closing of the hinge does not cause difficulty in operating the hinge. For example, the carrier may be characterized by a tensile stress at 100% elongation of about 30 MPa or less, about 18 MPa or less, about 12 MPa or less, or about 10 MPa or less. The carrier may be substantially or entirely free of high melt temperature polymers having a generally high melting temperature (e.g., greater than about 90° C., greater than about 110° C., greater than about 130° C., or greater than about 150° C.). If present, the amount of the high melt temperature polymer preferably is about 35 weight percent or less, about 25 weight percent or less, about 15 weight percent or less, about 5 weight percent or less, or about 0 weight percent, based on the total weight of the one or more polymers in the carrier. The melting temperature may be measured by differential scanning calorimetry at a heating rate of about 10° C. / min.

[0070] The carrier preferably is substantially or entirely free of high glass temperature polymers having a generally high glass transition temperature (e.g., greater than about 50° C.,PCT / US24 / 47367 19 September 2024 (19.09.2024)Filed via USPTO. Gov. on September 19, 2024Docket No.: 2021A.030WO (8877357) greater than about 70° C., greater than about 110° C., or greater than about 130° C.). If present, the amount of the high glass transition temperature polymer preferably is about 35 weight percent or less, about 25 weight percent or less, about 15 weight percent or less, about 5 weight percent or less, or about 0 weight percent, based on the total weight of the one or more polymers in the carrier. The glass transition temperature may be measured using dynamic mechanical testing at a heating rate of about 10° C. / min and an amplitude of about 5%.

[0071] The polymer of the carrier may include a thermoplastic polymer or a cross-linked polymer. As used herein, a cross-linked polymer is a polymer having a sufficient amount of cross-links so that it does not flow, even when heated to at least 50° C. above its glass transition temperature and melting temperature. The cross-linked polymer may be present in the carrier in an amount of about 30% or more, about 50 weight percent or more, about 70 weight percent or more, about 90 weight percent or more, or about 100 weight percent, based on the total weight of the one or more polymers.

[0072] The carrier may include additional components in addition to the one or more polymers. The carrier may include one or more catalysts or cross-linking agents. The carrier may include one or more fillers. The one or more fillers may include reinforcing filler(s) and / or nonreinforcing filler(s). The carrier may include one or more stabilizers, such as a light stabilizer, a heat stabilizer, a stabilizer to reduce damage from exposure to salt, ozone, or exhaust gases, or a process stabilizer. The carrier may include one or more colorants (e.g., black or other color). The carrier may be colored to color match the vehicle on which the tonneau cover is intended to be used with. The carrier may include one or more inhibitors that inhibits the cross-linking of the carrier until after it is applied to a surface. The carrier may include one or more flow modifiers to adjust the viscosity of the carrier before cross-linking. For example, the flow modifier may be an organic or inorganic material that increases or decreases the viscosity of the carrier (or a portion of the carrier) before cross-linking. The amount of the one or more polymers in the carrier preferably is about 25 weight percent or more, more preferably about 40 weight percent or more, and most preferably about 60 weight percent or more, based on the total weight of the carrier. The amount of the one or more polymers may be about 100 weight percent or less, or about 95 weight percent or less, based on the total weight of the carrier.

[0073] The carrier preferably is formed by a carrier composition that cross-links at a sufficient speed so that it has a gel time of about 30 minutes or less at about 23° C. Preferably thePCT / US24 / 47367 19 September 2024 (19.09.2024)Filed via USPTO. Gov. on September 19, 2024 Docket No.: 2021A.030WO (8877357) gel time is about 20 minutes or less, more preferably about 10 minutes or less, even more preferably about 5 minutes or less and most preferably about 3 minutes or less. The gel time may be about 10 seconds or more, about 20 seconds or more, about 30 seconds or more, or about 45 seconds or more.

[0074] The carrier composition may be provided as a single part that forms the cross-linked carrier or as two or more parts that when combined forms the cross-linked carrier. For example, the carrier composition may include or consist of an A part and a B part which react to form the cross-linked carrier. The A part and the B part preferably have similar viscosities so that they can be easily mixed. For example, the ratio of the higher viscosity part to the lower viscosity part may be about 50 or less, about 10 or less, about 5 or less, about 4 or less, about 3 or less, about 2 or less, or about 1. The A part and / or the B part may include one or more flow modifiers (such as discussed herein) and / or include polymers, monomers or prepolymers selected to achieve the desired viscosity ratio. For example, the viscosity of a component may be adjusted by adjusting the molecular weight of a polymer or prepolymer in the part. The A part may include a first compound and the B part may include a second compound that react to form the cross-links. The first compound and / or the second compound is a polymer, a prepolymer, or a monomer. Preferably, the first compound and the second compound are each a polymer, a prepolymer, or a monomer. The multi-part composition preferably is shelf sable (e.g., at a temperature of about 30° C.) for about 1 month or more, about 3 months or more, about 6 months or more, or about 12 months or more. One or a multi-functional compound having a functionality greater than 2, for forming the cross-links. The first compound and / or the second compound may be the multifunctional compound, or the multi-functional compound may be present as an additional compound in the A part, the B part, or an additional part.

[0075] A particularly preferred carrier composition includes one or more monomers, prepolymers, or polymers having at least two isocyanate groups, at least two amine groups, at least two imide groups, at least alcohol containing groups, or at least two alkoxy groups available for reacting. The carrier composition preferably includes different monomers, prepolymers, or polymers having functional groups that react to form the cross-linked carrier. For example, the first compound or the second compound may be a compound containing at least two isocyanate groups and the other compound may be a compound having at least two functional groups capable of reacting with the isocyanate groups. The carrier may include a polymer having ureaPCT / US24 / 47367 19 September 2024 (19.09.2024)Filed via USPTO. Gov. on September 19, 2024Docket No.: 2021A.030WO (8877357) linkages (e.g., a polyurea). The polyurea may be formed from the cross-linking reaction of an isocyanate (e.g., polyisocyanate compound) and an amine (e.g., a polyamine compound). The carrier may include a polymer having carbamate linkages (e.g., a polyurethane). The polyurethane may be formed from the cross-linking reaction of an isocyanate (e.g., a polyisocyanate compound) and an alcohol (e.g., a polyol). The coating may be a single layer (e.g., a monolithic coating) that is applied over the entire exterior surface of the foldable tonneau system. The coating may be a plurality of discrete layers that are applied over predetermined regions so that there are ends where the coating stops and then begins again with gaps there between.

[0076] The carrier may be applied to the panel by one or more method discussed herein. The carrier may be applied by spraying the coating over one or more of the panels. The carrier may be sprayed on like a spray on bed liner or may be a spray on bed liner material. The bed liner material may be polyurea. The carrier may be sprayed on over the panels individually. The carrier may be sprayed on the panels when the panels are spaced apart from one another, abut one another, are in a jig or other fixture, or a combination thereof. The carrier may have a viscosity so that some of the coating may enter a gap between adjacent panels. Once applied, the carrier may permanently bond to the panels. The method may include a step of curing the carrier with moisture, heat, ultraviolet, time, or a combination thereof. The method may include a step of moving the panel, to introduce the carrier into the gap regions or to introduce a living hinge into the hinge regions. An air knife, roller, blade, or a combination thereof may meter the amount of carrier applied, smooth the carrier, or both.

[0077] The tonneau cover may include one or a plurality of panels (i.e., at least two panels). The one or more panels may be made of a sheet. The one or more panels may be made of a polymer, foam, metal, aluminum, titanium, polystyrene, expanded polystyrene, acrylonitrile butadiene styrene (ABS), Styrofoam, or a combination thereof. The one or more panels may be made of an open cell foam, a closed cell foam, or a combination of both. The one or more panels may be made of aluminum skins with an expanded polystyrene material core.

[0078] One or more of the panels of the tonneau cover may be free of a frame surrounding the panel. One or more of the panels of the tonneau cover may include a frame surrounding the panel.PCT / US24 / 47367 19 September 2024 (19.09.2024)Filed via USPTO. Gov. on September 19, 2024Docket No.: 2021A.030WO (8877357)

[0079] The explanations and illustrations presented herein are intended to acquaint others skilled in the art with the invention, its principles, and its practical application. The above description is intended to be illustrative and not restrictive. Those skilled in the art may adapt and apply the invention in its numerous forms, as may be best suited to the requirements of a particular use.

[0080] Accordingly, the specific embodiments of the present invention as set forth are not intended as being exhaustive or limiting of the teachings. The scope of the teachings should, therefore, be determined not with reference to this description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The omission in the following claims of any aspect of subject matter that is disclosed herein is not a disclaimer of such subject matter, nor should it be regarded that the inventors did not consider such subject matter to be part of the disclosed inventive subject matter.

[0081] Plural elements or steps can be provided by a single integrated element or step. Alternatively, a single element or step might be divided into separate plural elements or steps.

[0082] The disclosure of "a" or "one" to describe an element or step is not intended to foreclose additional elements or steps. For example, disclosure of “a motor” does not limit the teachings to a single motor. Instead, for example, disclosure of “a motor” may include “one or more motors.”

[0083] While the terms first, second, third, etc., may be used herein to describe various elements, components, regions, layers and / or sections, these elements, components, regions, layers and / or sections should not be limited by these terms. These terms may be used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings.

[0084] Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in usePCT / US24 / 47367 19 September 2024 (19.09.2024)Filed via USPTO. Gov. on September 19, 2024Docket No.: 2021A.030WO (8877357) or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0085] The invention illustratively disclosed herein suitably may be practiced in the absence of any element which is not specifically disclosed herein.

[0086] Any of the elements, components, regions, layers and / or sections disclosed herein are not necessarily limited to a single embodiment. Instead, any of the elements, components, regions, layers and / or sections disclosed herein may be substituted, combined, and / or modified with any of the elements, components, regions, layers and / or sections disclosed herein to form one or more embodiments that may be or not be specifically illustrated or described herein.

[0087] The disclosures of all articles and references, including patent applications and publications, testing specifications, are incorporated by reference for all purposes. Other combinations are also possible as will be gleaned from the following claims, which are also hereby incorporated by reference into this written description.

Claims

PCT / US24 / 47367 19 September 2024 (19.09.2024)Filed via USPTO. Gov. on September 19, 2024Docket No.: 2021A.030WO (8877357)CLAIMS1) A tonneau cover for a vehicle comprising a cargo area, the cargo area having a tailgate, two spaced-apart side walls, a front wall that opposes the tailgate, and a floor, the tonneau cover comprising: at least two panels, each of the two panels comprising a top side and an opposing bottom side, the opposing bottom side is configured to face the floor when the tonneau cover is in a closed position; and a carrier applied onto the top side of the at least two panels, wherein the carrier is configured to connect the at least two panels together and to provide a hinge between the at least two panels.2) The tonneau cover according to claim 1, wherein the tonneau cover is a folding tonneau cover.3) The tonneau cover according to claim 1, wherein the tonneau cover is a rolling tonneau cover.4) The tonneau cover according to claim 1, or any one of the previous claims, wherein the carrier is configured to prevent fluid and / or debris from entering a gap defined between two of the at least two panels.5) The tonneau cover according to claim 1, or any one of the previous claims, wherein at least one of the at least two panels comprises a Styrofoam.6) The tonneau cover according to claim 5 or any one of the previous claims, wherein the Styrofoam is coated with a second carrier before the carrier is applied onto the top surface of the at least two panel.7) The tonneau cover according to claim 6 or any one of the previous claims, wherein the carrier and the second carrier are the same material.PCT / US24 / 47367 19 September 2024 (19.09.2024)Filed via USPTO. Gov. on September 19, 2024Docket No.: 2021A.030WO (8877357)8) The tonneau cover according to claim 6 or any one of the previous claims, wherein the carrier and the second carrier are different materials.9) The tonneau cover according to claim 1 or any one of the previous claims, wherein a gap is defined between opposing edges of the at least two panels.10) The tonneau cover according to claim 9 or any one of the previous claims, wherein the tonneau cover comprises a second carrier that is provided in between the carrier and the top surface of the at least two panels and that spans the gap.11) The tonneau cover according to claim 1 or any one of the previous claims, wherein at least one of the at least two panels comprises aluminum.12) The tonneau cover according to claim 1 or any one of the previous claims, wherein the carrier is sprayed onto at least one of the panels.13) The tonneau cover according to claim 12 or any one of the previous claims, wherein the carrier is a bed liner material.14) The tonneau cover according to claim 1 or any one of the previous claims, wherein the tonneau cover is free of another hinge between the at least two panels.15) The tonneau cover according to claim 1 or any one of the previous claims, wherein the tonneau cover is free of a frame surrounding one or all of the at least two panels.

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