Tonneau cover panel assembly and methods of manufacture thereof

Abstract

A tonneau cover panel assembly is provided. The tonneau cover panel assembly includes a panel, a crossbeam, and a perimeter extrusion. The panel is formed of a material consisting essentially of a sheet metal. The panel includes a longitudinal edge. The crossbeam is arranged transversely across the bottom surface of the panel and is affixed to the panel via an adhesive material. The perimeter extrusion is mechanically coupled to the longitudinal edge of the panel. In one example, the longitudinal edge of the panel includes a deformable tab configured to mechanically retain the crossbeam to the panel. In another example, the tonneau cover panel assembly further includes a clip configured to mechanically engage with the crossbeam and the perimeter extrusion to mechanically retain the crossbeam to the panel.

Description

TONNEAU COVER PANEL ASSEMBLY AND METHODS OF MANUFACTURE THEREOFCross-Reference to Related Application

[0001] This application claims benefit of U.S. Provisional Patent Application No. 63 / 557,836, filed February 26, 2024, the contents of which are incorporated herein by reference.Field of the Disclosure

[0002] This disclosure relates, generally, to tonneau covers, and more specifically, to a panel assembly to secure a crossbeam to a tonneau cover panel.Background

[0003] One advantage of a pickup truck (hereafter the “truck”) is the ability to use a 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 tonneau cover. A hard tonneau cover typically includes a series of rigid panel sections that extend laterally across the width of the bed. Further, some panels include transverse support structures called crossbeams. These crossbeams may be used to provide additional rigidity to the panel, as well as to provide a means to attach additional components, such as clamps or retainers. These crossbeams are typically affixed to the panels through using liquid adhesive. However, these liquid adhesives can be challenging to apply during assembly and may be prone to failure during use. Accordingly, what is needed are improved assemblies and methods for securing a cross beam to a hard tonneau cover. 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 ofordinary skill in the field of this disclosure how the shortcomings of the prior art could be overcome.

[0006] 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.

[0007] 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.

[0008] 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

[0009] The present disclosure is generally directed to a tonneau cover panel assembly for mounting a crossbeam to a hard, rigid panel. The panel is defined by a pair of longitudinal edges and a pair of transverse edges. Both the longitudinal edges and the transverse edges are bended into a C-shape for improved structural integrity. The crossbeam is arranged transversely across the panel between the pair of longitudinal edges. The crossbeam is affixed to the panel via an adhesive material. The crossbeam is made of extruded aluminum and includes a T-slot for attaching additional components. Perimeter extrusions are coupled to the longitudinal edges of the panel via a barb configured to mechanically engage with the longitudinal edge. The crossbeam may be mechanically retained against the panel through either (1) deformable tabs arranged in the longitudinal edges or (2) removable clips configured to mechanically engage with both the crossbeam and the perimeter extrusion.

[0010] In one example, a liquid adhesive is used to affix the crossbeam to the panel. Each longitudinal edge includes a deformable tab to retain the crossbeam against the panel. The deformable tab is formed in a vertical window of each longitudinal edge. In some examples, the deformable tab may be folded into the T-slot of the crossbeam to align the crossbeam alongthe panel. The longitudinal edges may also include horizontal cut-out regions to provide additional alignment assistance.

[0011] In another example, a double-sided adhesive tape, such as VHB™ adhesive foam tape is used to affix the crossbeam to the panel. Clips are then used to mechanically retain the crossbeam against the panel by mechanically engaging with both the crossbeam and the perimeter extrusion. In some examples, the clips slidingly engage with the T-slots of the crossbeams. The clips may also be slidably inserted into the horizontal cut-out regions of the horizontal edges. The clips may also include deformable clip tabs configured to engage with the vertical window.

[0012] Generally, in one aspect, a tonneau cover panel assembly is provided. The tonneau cover panel assembly includes a panel. The panel is formed of a material consisting essentially of a sheet metal. The panel includes a longitudinal edge, a transverse edge, a top surface, and a bottom surface.

[0013] The tonneau cover panel assembly further includes a crossbeam. The crossbeam is arranged transversely across the panel. The crossbeam is affixed to the bottom surface of the panel via an adhesive material.

[0014] The longitudinal edge of the panel includes a deformable tab. The deformable tab is configured to mechanically retain the crossbeam to the bottom surface of the panel.

[0015] According to an example, the tonneau cover panel assembly further includes a perimeter extrusion. The perimeter extrusion is mechanically coupled to the longitudinal edge of the panel. The perimeter extrusion may include a barb. The barb is configured to mechanically engage with the longitudinal edge of the panel.

[0016] According to an example, the adhesive material is a liquid adhesive.

[0017] According to an example, the crossbeam is extruded aluminum.

[0018] According to an example, the crossbeam includes a T-slot. The deformable tab may be configured to fold into the T-slot of the crossbeam.

[0019] According to an example, the crossbeam is arranged perpendicularly to the longitudinal edge.

[0020] According to an example, the longitudinal edge comprises a horizontal cut-out region corresponding to the crossbeam.

[0021] According to an example, the deformable tab is arranged in a vertical window of the longitudinal edge.

[0022] Generally, in another aspect, a method for manufacturing a tonneau cover panel assembly is provided. The method includes providing a panel formed of a material consisting essentially of a sheet metal. The panel comprises a longitudinal edge.

[0023] The method further includes affixing a crossbeam to the panel via an adhesive material. The crossbeam is arranged transversely across the panel.

[0024] The method further includes folding a deformable tab of the longitudinal edge to mechanically couple the crossbeam to the panel.

[0025] Generally, in another aspect, a tonneau cover panel assembly is provided. The tonneau cover panel assembly includes a panel. The panel is formed of a material consisting essentially of a sheet metal. The panel includes a longitudinal edge, a transverse edge, a top surface, and a bottom surface.

[0026] The tonneau cover panel assembly further includes a crossbeam. The crossbeam is arranged transversely across the panel. The crossbeam is affixed to the bottom surface of the panel via an adhesive material.

[0027] The tonneau cover panel assembly further includes a perimeter extrusion. The perimeter extrusion is mechanically coupled to the longitudinal edge of the panel.

[0028] The tonneau cover panel assembly further includes a clip. The clip is configured to mechanically engage with the crossbeam and the perimeter extrusion to mechanically retain the crossbeam to the panel.

[0029] According to an example, the adhesive material is adhesive tape.

[0030] According to an example, the perimeter extrusion includes a barb. The barb is configured to mechanically engage with the longitudinal edge of the panel.

[0031] According to an example, the clip is configured to mechanically engage with a barb of the perimeter extrusion.

[0032] According to an example, the clip is configured to slidingly engage with a T-slot of the crossbeam.

[0033] According to an example, the clip is further configured to be inserted into a horizontal cut-out region of the longitudinal edge of the panel.

[0034] According to an example, the clip is further configured to engage with a vertical window of the longitudinal edge of the panel.

[0035] According to an example, the clip further includes one or more clip tabs configured to engage with the vertical window.

[0036] Generally, in another aspect, a method for manufacturing a tonneau cover panel assembly is provided. The method includes providing a panel formed of a material consisting essentially of a sheet metal. The panel includes a longitudinal edge.

[0037] The method further includes affixing a crossbeam to the panel via an adhesive material. The crossbeam is arranged transversely across the panel.

[0038] The method further includes mechanically coupling a perimeter extrusion to the longitudinal edge of the panel.

[0039] The method further includes mechanically engaging a clip with the crossbeam and the perimeter extrusion to mechanically retain the crossbeam to the panel.

[0040] Generally, in another aspect, a tonneau cover panel assembly is provided. The tonneau panel cover assembly includes a panel formed of a material consisting essentially of a sheet metal, the panel comprising a longitudinal edge, a transverse edge, a top surface, and a bottom surface.

[0041] The tonneau panel cover assembly further includes a crossbeam arranged transversely across the panel. The crossbeam is secured to the bottom surface of the panel both adhesively and mechanically.

[0042] 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.

[0043] 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

[0044] 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.

[0045] FIG. l is a bottom isometric view of a tonneau cover panel assembly, according to aspects of the present disclosure.

[0046] FIG. 2 is a further isometric view of the tonneau cover panel assembly of FIG. 1, wherein a perimeter extrusion is hidden to show a deformable tab, according to aspects of the present disclosure.

[0047] FIG. 3 is an isometric view of a crossbeam and a longitudinal edge of a panel having a deformable tab, according to aspects of the present disclosure.

[0048] FIG. 4 is another isometric view of the crossbeam and the longitudinal edge of FIG. 3, according to aspects of the present disclosure.

[0049] FIG. 5 is an isometric view of another longitudinal edge of the panel having a deformable tab which has been folded against the crossbeam, according to aspects of the present disclosure.

[0050] FIG. 6 is another isometric view of the longitudinal edge and the crossbeam of FIG. 5, according to aspects of the present disclosure.

[0051] FIG. 7 is a cross-sectional view of aspects of a tonneau cover panel assembly, according to aspects of the present disclosure.

[0052] FIG. 8 is a further cross-sectional view of the aspects of the tonneau cover panel assembly of FIG. 7, according to aspects of the present disclosure.

[0053] FIG. 9 is a cross-sectional view of further aspects of a tonneau cover panel assembly, according to aspects of the present disclosure.

[0054] FIG. 10 is an isometric view of a longitudinal edge of a panel with a vertical window, according to aspects of the present disclosure.

[0055] FIG. 11 is an isometric view of a clip, according to aspects of the present disclosure.

[0056] FIG. 12 is a further isometric view of a clip, according to aspects of the present disclosure.

[0057] FIG. 13 is an isometric view of the clip of FIGS. 11 and 12 coupled with the longitudinal panel and crossbeam of FIG. 10, according to aspects of the present disclosure.

[0058] FIG. 14 is a further isometric view of the clip of FIGS. 11 and 12 coupled with the longitudinal panel and crossbeam of FIG. 10, according to aspects of the present disclosure.

[0059] FIG. 15 is an isometric view of a perimeter extrusion coupled to longitudinal panels of FIGS. 13 and 14, according to aspects of the present disclosure.

[0060] FIG. 16 is a cross-sectional view of aspects of a tonneau cover panel assembly including a clip, according to aspects of the present disclosure.

[0061] FIG. 17 is a method for manufacturing a tonneau cover panel assembly, according to aspects of the present disclosure.

[0062] FIG. 18 is a further method for manufacturing a tonneau cover panel assembly, according to aspects of the present disclosure.Detailed Description of Embodiments

[0063] 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.

[0064] In certain exemplary embodiments, the present disclosure relates to hard or rigid tonneau cover 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.

[0065] 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 the composition. In certain embodiments, each tonneau panel may be formed of 3003-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 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.

[0066] 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 thepresent 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.

[0067] 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.

[0068] 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.

[0069] 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) and may 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 tonneaupanel may be formed of 16-gauge or 14-gauge sheet metal, such as aluminum alloy (e.g., 3003- H14, 3105-H24, etc.).

[0070] Turning now to the figures, FIG. 1 is a bottom isometric view of a tonneau cover panel assembly 10. The tonneau cover panel assembly 10 may be combined with additional tonneau cover panel assemblies to form a tonneau cover configured to be installed on a cargo box of a pickup truck. The tonneau cover may be foldable or rigid. As shown in FIG. 1, the tonneau cover panel assembly 10 includes a panel 100 and a crossbeam 106. The panel 100 may be defined by a bottom surface 101, a pair of longitudinal edges 102a, 102b, a top surface 103, and a pair of transverse edges 104a, 104b. In some examples, the longitudinal edges 102a, 102b travel along the length of the cargo box, while the transverse edges 104a, 104b travel along the width of the cargo box. Accordingly, the tonneau cover may include several panels 100 to cover the cargo box. In some examples, the tonneau cover may include any number of panels 100, though three or four panels 100 is typical. Further, while the panel 100 of FIG. 1 is substantially rectangular, other sizes, shapes, and proportions of the tonneau cover may be implemented in further examples.

[0071] The panel 100 may be formed from a single layer of rigid sheet metal, such as 14- or 16-gauge aluminum. In certain embodiments, the panel 100 may be formed of 3003-H14 aluminum alloy, which has a manganese content of about 1.0% to about 2.0% by weight of the composition. In other embodiments, the panel 100 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.

[0072] 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 can provide greater structural integrity in all weather conditions, provide greater ultraviolet light resistance, and provide improved water resistance properties.

[0073] Further, using an aluminum alloy with about 1.2% manganese (characteristic of 3000 series aluminum alloys) can provide a number of improvements over pure aluminum, such as greater strength while maintaining good formability and corrosion resistance, along with high performance in a wide range of atmospheric conditions. In particular, these aluminum alloys are approximately twenty percent stronger than 1100 series aluminum.

[0074] The panel 100 may be defined by a series of strength characteristics. In one example, the tonneau panel 100 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 the tonneau panel 100 to be cut to size during manufacturing but remain structurally strong against forces normal to the plane of the tonneau panel 100. Further, the panel 100 may be defined by a center thickness of between 1.0 millimeters and 2.0 millimeters.

[0075] As shown in FIG. 1, the panel 10 is defined by a pair of longitudinal edges 102a, 102b arranged perpendicularly to a pair of transverse edges 104a, 104b. Each longitudinal edge 102 and transverse edge 104 is configured to be a C-shaped edge. Accordingly, the longitudinal edges 102 and the transverse edges 104 are perpendicular to each other, and the C-shaped edges of the longitudinal edges 102 open substantially perpendicularly to the C-shaped edges of the transverse edges 104.

[0076] Examples of various properties of example aluminum alloys may be found in Table 1 below:Table 1

[0077] As further shown in FIG. 1, a crossbeam 106 is transversely arranged along the bottom surface 101 the panel 100. In the non-limiting example of FIG. 1, the crossbeam 106 is arranged substantially perpendicularly along the panel 100 and extends from the first longitudinal edge 102a to the second longitudinal edge 102b. The crossbeam 106 can be affixedto a bottom surface of the panel 100 using an adhesive material 108 (as shown in FIG. 2). In the example of FIG. 1, the adhesive material 108 may be a liquid adhesive, such as glue. In some examples, the crossbeam 106 is formed of extruded aluminum. The crossbeam 106 can serve two primary purposes. First, the crossbeam 106 provides additional rigidity to the panel 100. Second, the crossbeam 106 may include a T-slot 116 configured to attach various components to the panel 100, such as clamps or retainers. The portions of the crossbeam 106 outside of the T-slot may be referred to as outer surfaces 134.

[0078] The tonneau cover panel assembly 10 further includes perimeter extrusions 112a, 112b. Each of the perimeter extrusions 112a, 112b is coupled to one of the longitudinal edges 102a, 102b of the panel 100. The perimeter extrusions 112a, 112b allow the tonneau cover panel assembly 10 to be arranged on the cargo box of the pickup truck. The perimeter extrusions 112a, 112b may be made of any appropriate material, such as extruded aluminum.

[0079] FIG. 2 illustrates the tonneau cover panel assembly 10 of FIG. 1 with the crossbeam 106 and a first perimeter extrusion 112a hidden to show additional aspects of the assembly 10. FIG. 2 illustrates an adhesive material 108 arranged transversely along the panel 100 between the longitudinal edges 102a, 102b. The adhesive material 108 may be a liquid adhesive, such as glue. In other embodiments, the adhesive material may be an adhesive tape. The adhesive material 108 is used to affix the crossbeam 106 to the panel 100.

[0080] Further, FIG. 2 illustrates a deformable tab 110a in the first longitudinal edge 102a of the panel 100. The deformable tab 110a may be used to mechanically retain the crossbeam 106 to the panel 100. In some examples, the deformable tab 110a is folded onto the crossbeam 106 to retain the crossbeam 106 while a liquid adhesive cures. The deformable tab 110a may also be used to align the crossbeam 106 in a perpendicular arrangement across the panel. As will be shown in subsequent figures, another deformable tab may be arranged in the second longitudinal edge 102b of the panel 100. In some examples, the deformable tab 110a is made of the same material as the panel 100, such as sheet metal.

[0081] FIG. 3 shows aspects of the tonneau cover panel assembly 10 in more detail. In particular, FIG. 3 illustrates aspects of the first longitudinal edge 102a and the crossbeam 106. The first longitudinal edge 102a includes a vertical side 126a and a flange 128b to form the C- shaped edge. Further, a vertical window 120a is formed in the vertical side 126a of the first longitudinal edge 102a. The deformable tab 110a is arranged within the vertical window 120a. Further, the flange 128a includes a horizontal cut-out region 118a. As will be shown in subsequent figures, the second longitudinal edge 102a may also include a vertical side 126bhaving a deformable tab 110b and a vertical window 102b, as well as a flange 128b having a cut-away region 118b.

[0082] In some embodiments, the crossbeam 106 includes T-slot 116. During assembly, the horizontal cut-out region 118a guides the placement of the crossbeam 106 on the panel 100 where an adhesive material 108 has been applied. The deformable tab 110a is then folded into the T-slot 116 of the crossbeam 106 to mechanically retain the crossbeam 106 against the panel 100. Retaining the crossbeam 106 against the panel 100 may be particularly important as the liquid adhesive cures. Folding the deformable tab 110a into the T-slot 116 also ensures that the crossbeam 106 is perpendicularly arranged relative to the first longitudinal edge 102a. It can be appreciated that, if the T-slot 116 is not present on the crossbeam 106, the deformable tab 110a can be folded onto a bottom surface 101 of the crossbeam 106 or other suitable surface of the crossbeam 106. Ultimately, the objective of deformable tabs 110a, 110b is to fold over a portion of the crossbeam 106 (as seen in FIG. 5) and thus mechanically secure the crossbeam 106 to the tonneau cover panel 100.

[0083] FIG. 4 illustrates another perspective of the features of FIG. 3. As shown in FIG. 4, the first longitudinal edge 102a of the panel 100 includes a vertical side 126a and flange 128a. A deformable tab 110a is arranged within a vertical window 120a of the first longitudinal edge 102a. The deformable tab 110a is configured to fold into the T-slot 116 of the crossbeam 106.

[0084] FIG. 5 illustrates aspects of the second longitudinal edge 102b and the crossbeam 106. The second longitudinal edge 102b includes a vertical side 126b and a flange 128b to form a C-shaped edge of the panel 100. Further, a vertical window 120b is formed in the vertical side 126b of the second longitudinal edge 102b. The deformable tab 110b is arranged within the vertical window 120b. Further, the flange 128b includes a horizontal cut-out region 118b. As shown in FIG. 5, the deformable tab 110b is folded into the T-slot 116 of the crossbeam 106 to retain the crossbeam 106 against the panel 100. It can be appreciated that the deformable tab 110a can similarly fold into the T-slot 116 of the crossbeam 106 on the opposite end of the crossbeam 106 to mechanically secure both sides of the crossbeam 106 to the bottom surface 101 of the tonneau cover panel assembly 10.

[0085] FIG. 6 illustrates another perspective of the features of FIG. 5. As shown in FIG. 6, the second longitudinal edge 102b of the panel 100 includes a vertical side 126b and flange 128b. A deformable tab 110b is arranged within a vertical window 120b of the second longitudinal edge 102b. The deformable tab 110b is configured to fold into the T-slot 116 of the crossbeam 106. As noted, it can be appreciated that the deformable tab 120a can similarly fold into the T-slot 116 of the crossbeam 106 on the opposite end of the crossbeam 106.

[0086] FIGS. 7 and 8 illustrate cross-sectional views of aspects of the tonneau cover panel assembly 10. In particular, FIGS. 7 and 8 illustrate a panel 100 with a first longitudinal edge 102a, a crossbeam 106, and a first perimeter extrusion 112a. The perimeter extrusion 112a includes a C-shaped portion arranged around the first longitudinal edge 102a. The perimeter extrusion 112a mechanically couples to the first longitudinal edge 102a of the panel 100 via barb 114a. As can be seen in FIGS. 7 and 8, the barb 114a engages with the flange 128a of the first longitudinal edge 102a to secure the first perimeter extrusion 112a to the first longitudinal edge 102a of the panel 100. The crossbeam 106 is affixed to the panel 100 via the adhesive material 108. The deformable tab 110a of FIGS. 7 and 8 remains unfolded and upright. Accordingly, the deformable tab 110a of FIGS. 7 and 8 does not aid in the retention of the crossbeam 106 against the panel 100.

[0087] FIG. 9 illustrates a cross-sectional view of further aspects of the tonneau cover panel assembly 10. In particular, FIG. 9 illustrates a panel 100 with a second longitudinal edge 102b, a crossbeam 106, and a second perimeter extrusion 112b. The perimeter extrusion 112b mechanically couples to the second longitudinal edge 102b of the panel 100 via barb 114b. As can be seen in FIG. 9, the barb 114a engages with the flange 128b of the second longitudinal edge 102b to secure the second perimeter extrusion 112b to the second longitudinal edge 102b of the panel 100. The crossbeam 106 is affixed to the panel 100 via the adhesive material 108. Further, the deformable tab 110b is folded down onto the crossbeam 106, thereby retaining the crossbeam 106 against the panel 100. In a preferred example, both of the deformable tabs 110a, 110b would be folded down onto the crossbeam 106 to retain the crossbeam against the panel 100.

[0088] FIG. 10 illustrates an isometric view of a variation of a longitudinal edge 102 of a panel 100. A crossbeam 106 having a T-slot 116 is arranged on the bottom surface 101 of the panel 100 via an adhesive material 108. In this example, the adhesive material 108 may be a double-sided adhesive tape, such as VHB™ adhesive foam tape. While adhesive tape is generally easier to use and to install than a liquid adhesive, the adhesive tape is typically not as strong as a liquid adhesive. Accordingly, additional features may be required to retain the crossbeam 106 to the panel 116.

[0089] The longitudinal edge 102 may be defined by a vertical edge 126 and a flange 128. The vertical side 126 and the flange 128b form the C-shaped edge with the other aspects of the panel 100. The flange 128 includes a cut-out region 118 to aid in placement and alignment of the crossbeam 106 across the panel 100. The vertical edge 126 includes a vertical window 120.Notably, unlike the previous embodiments, vertical window 120 does not include a deformable tab 110 or other features to retain the crossbeam 106 against the panel 100.

[0090] FIGS. 11 and 12 illustrate isometric views of a non-limiting example of a clip 122 used to retain the crossbeam 106 against the panel 100. The clip 122 includes a pair of clip tabs 124a, 124b, a middle portion 130, and a winged portion 132. The winged portion 132 includes a pair of protrusions 136a, 136b and a crossbar 138. As will be demonstrated in subsequent figures, the clip tabs 124a, 124b and the middle portion 130 are configured to slide into the vertical window 120 of the longitudinal edge 102 such that the clip tabs 124a, 124b engage with the vertical window 120, thereby securing the clip 122 to the longitudinal edge 102. The middle portion 130 fits within the T-slot 116 of the crossbeam 106, while the protrusions 136a, 136b and the crossbar 138 of the winged portion 132 fit over the outer surfaces 134 of the crossbeam 106. The crossbar 138 of the winged portion 132 is further configured to fit within and engage with the cut-out region 118 of the flange 128, further ensuring that the clip 112 is properly aligned with the longitudinal edge 102 and the crossbeam 106. This fitting or engagement of the crossbar 138 with the cut-out region 118 also ensures that the crossbeam 106 is properly positioned along the bottom surface of the panel 100. The clip 122 may be a unitary body made of plastic or other appropriate materials. In particular, the material of clip 122 should be chosen to allow the clip tabs 124a, 124b to deform and engage with the vertical window 120 of the longitudinal edge 102.

[0091] FIGS. 13 and 14 illustrate isometric views of the clip 122 coupled to the longitudinal edge 102 of the panel 100 and the crossbeam 106. The clip tabs 124a, 124b and the middle portion 130 of the clip 122 are slid into the vertical window 120 of the longitudinal edge 102. The clip tabs 124a, 124b engage with the vertical window 120 to secure the clip 122 to the longitudinal edge 102. The middle portion 130 slides into the T-slot 116 of the crossbeam 106. The protrusions 136a, 136b and the crossbar 138 of the winged portion 132 are arranged over the outer surfaces 134 of the crossbeam 106. When the clip tabs 124a, 124b engage with the vertical window 120, the crossbar 138 of the winged portion 132 slides into and substantially fills the cut-out region 118 of the flange 128.

[0092] FIG. 15 illustrates an isometric view of a perimeter extrusion 112 coupled to the longitudinal edge 102. As will be demonstrated, the perimeter extrusion 112 may also couple to the clip 122, thereby locking together the panel 100, the crossbeam 106, the perimeter extrusion 112, and the clip 122, along with retaining the crossbeam 106 against the bottom surface 101 of the panel 100.

[0093] FIG. 16 illustrates a cross-section of the components of FIG. 15, including the panel 100, the crossbeam 106, the perimeter extrusion 112, and the clip 122. As indicated in FIGS. 13-15, portions of the clip 122 are inserted into the vertical window 120 of the longitudinal edge 102 of the panel 100. Referring to FIG. 16, the C-shaped portion of the perimeter extrusion 112 surrounds the panel 100, the crossbeam 106, and the clip 122. The perimeter extrusion 112 includes a barb 114 configured to engage with (1) the crossbar 138 of the winged portion 132 of the clip 122 and (2) the flange 128 of the first longitudinal edge 102 of the panel 100. Accordingly, the space in between the crossbeam 106 and the perimeter extrusion 112 shown in FIGS. 7-9 is filled in by the clip 122. Accordingly, the clip 122 and the perimeter extrusion 112 prevent the crossbeam 106 from lifting off of the panel 100. Further, in some examples, a second clip, which is substantially similar to the clip 122, may be similarly engaged with the other longitudinal edge of the panel 100 on the opposite side of the crossbeam 106 to secure the other end of the crossbeam 106 to the panel 100.

[0094] The configuration described with reference to FIGS. 10-16 provides a number of benefits. By inserting the clip 122 into the vertical window 120 of the longitudinal edge 102 and the T-slot 116 of the crossbeam 106, and then coupling the perimeter extrusion to the clip 122 and the flange 128 of the panel 100, any force that would pull the crossbeam 106 off of the panel 100 is then distributed throughout the clip 122, the vertical side 126 of the longitudinal edge 102 of the panel 100, and the perimeter extrusion 112 for additional support. Further, the retaining force applied by the clip 122 of FIGS. 11 and 12 to the crossbeam 106 is distributed against both the T-slot 116 and the outer surface 134, rather than just within the T-slot 116, for improved support. This additional support allows for the use of an adhesive material 108 embodied as adhesive tape, rather than liquid adhesive, for easier and quicker assembly, as the adhesive tape is easier to apply to the panel 100 and does not require time to cure.

[0095] FIG. 17 is a flowchart of a method 800 for manufacturing a tonneau cover panel assembly 10. The method 800, includes, in step 802, providing a panel 100 formed of a material consisting essentially of a sheet metal. The panel 100 comprises a longitudinal edge 102.

[0096] The method 800 further includes, in step 804, affixing a crossbeam 106 to the panel 100 via an adhesive material 108. The crossbeam 106 is arranged transversely across the panel 100. The adhesive material 108 may be a liquid adhesive, such as glue.

[0097] The method 800 further includes folding a deformable tab 110 of the longitudinal edge 102 to mechanically couple the crossbeam 106 to the panel 100. Using the deformable tab 110 to retain the crossbeam 106 against the panel 100 may allow for the liquid adhesive to cure.

[0098] FIG. 18 is a flowchart of another method 900 for manufacturing a tonneau cover panel assembly 10. The method 900 includes, in step 902, providing a panel 100 formed of a material consisting essentially of a sheet metal. The panel 100 includes a longitudinal edge.

[0099] The method 900 further includes, in step 904, affixing a crossbeam 106 to the panel 100 via an adhesive material 108. The crossbeam 106 is arranged transversely across the panel 100. The adhesive material 108 may be an adhesive tape.

[0100] The method 900 further includes, in step 906, mechanically coupling a perimeter extrusion 112 to the longitudinal edge 102 of the panel 100.

[0101] The method 900 further includes, in step 908, mechanically engaging a clip 122 with the crossbeam 106 and the perimeter extrusion 112 to mechanically retain the crossbeam 106 to the panel 100. In some examples, this step may include sliding the clip 122 along a T-slot of the crossbeam to insert a portion of the clip 122 into a vertical window 120 of the longitudinal edge 102. The clip 122 may also include one or more clip tabs 124 to secure the clip 122 to the vertical window 120. A barb 114 of the perimeter extrusion 112 may then engage the clip 122 and the longitudinal edge 102 to further secure the clip 122. In some further examples, the perimeter extrusion 112 may be coupled to the longitudinal edge 102 of the panel 100 after the clip 122 has engaged with the crossbeam 106 and the longitudinal edge 102 of the panel 100.

[0102] 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.

[0103] 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.”

[0104] 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. Thisdefinition 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.

[0105] 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.

[0106] 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.

[0107] 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’”.

[0108] 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.

[0109] Other implementations are within the scope of the following claims and other claims to which the applicant can be entitled.

[0110] 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 beexemplary 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 / or methods, 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 tonneau cover panel assembly, comprising: a panel formed of a material consisting essentially of a sheet metal, the panel comprising a longitudinal edge, a transverse edge, a top surface, and a bottom surface; a crossbeam arranged transversely across the panel, wherein the crossbeam is affixed to the bottom surface of the panel via an adhesive material; a perimeter extrusion mechanically coupled to the longitudinal edge of the panel; and a clip configured to mechanically engage with the crossbeam and the perimeter extrusion to mechanically retain the crossbeam to the panel.

2. The tonneau cover panel assembly of claim 1, wherein the adhesive material is adhesive tape or a liquid adhesive.

3. The tonneau cover panel assembly of claim 1, wherein the perimeter extrusion comprises a barb configured to mechanically engage with the longitudinal edge of the panel.

4. The tonneau cover panel assembly of claim 1, wherein the clip is configured to mechanically engaged with a barb of the perimeter extrusion.

5. The tonneau cover panel assembly of claim 1, wherein the crossbeam is formed of extruded aluminum.

6. The tonneau cover panel assembly of claim 1, wherein the crossbeam comprises a T- slot.

7. The tonneau cover panel assembly of claim 6, wherein the clip is configured to slidingly engage with the T-slot of the crossbeam.

8. The tonneau cover panel assembly of claim 1, wherein the longitudinal edge comprises a horizontal cut-out region corresponding to the crossbeam.

9. The tonneau cover panel assembly of claim 8, wherein the clip is further configured to be inserted into the horizontal cut-out region of the longitudinal edge of the panel.

10. The tonneau cover panel assembly of claim 1, wherein the longitudinal edge comprises a vertical window corresponding to the crossbeam.

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

12. The tonneau cover panel assembly of claim 11, wherein the clip further comprises one or more clip tabs configured to engage with the vertical window.

13. A method for manufacturing a tonneau cover panel assembly, comprising: providing a panel formed of a material consisting essentially of a sheet metal, the panel comprising a longitudinal edge; affixing a crossbeam to the panel via an adhesive material, wherein the crossbeam is arranged transversely across the panel; mechanically coupling a perimeter extrusion to the longitudinal edge of the panel; and mechanically engaging a clip with the crossbeam and the perimeter extrusion to mechanically retain the crossbeam to the panel.

14. A tonneau cover panel assembly, comprising: a panel formed of a material consisting essentially of a sheet metal, the panel comprising a longitudinal edge, a transverse edge, a top surface, and a bottom surface; a crossbeam arranged transversely across the panel, wherein the crossbeam is secured directly to the bottom surface of the panel both adhesively and mechanically; and a perimeter extrusion mechanically coupled to the longitudinal edge of the panel.

15. The tonneau cover panel assembly of claim 14, further comprising a clip configured to mechanically engage with the crossbeam and the perimeter extrusion to mechanically retain the crossbeam to the panel.

16. The tonneau cover panel assembly of claim 14, wherein the longitudinal edge of the panel comprises a deformable tab configured to mechanically retain the crossbeam to the bottom surface of the panel.

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