Continuous top surface hard folding tonneau cover with flexible end caps

Abstract

A tonneau cover assembly (22) that includes two adjacent panel assemblies (24a, 24b), wherein each of the two adjacent panel assemblies comprise a frame assembly surrounding a panel (30); a hinge connecting the two adjacent panel assemblies and configured to enable one of the two adjacent panel assemblies to move relative to the other of the two adjacent panel assemblies; a skin or coating (28) disposed over at least a portion of the two adjacent panel assemblies and the hinge; and an end cap (42) configured to engage the frame assembly of each of the two adjacent panel assemblies.

Description

Docket No.: 2021A.041WO (9107537)CONTINUOUS TOP SURFACE HARD FOLDING TONNEAU COVER WITH FLEXIBLE END CAPSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] None.FIELD

[0002] These teachings relate to a tonneau cover and more specifically to a tonneau cover having a continuous top surface with flexible end caps.BACKGROUND

[0003] Some vehicles, like pick-up trucks, have an open-topped bed or cargo area that may be used for storing or transporting cargo. A cover, such as a tonneau cover or topper, may be placed over the cargo area. The cover may include one or more panels that can be opened to access cargo and / or the inside of the cargo area and then closed to conceal cargo from view and / or to prevent fluid and / or debris from entering the cargo area.

[0004] Many folding tonneau covers have a plurality of distinctly framed panels. Adjacent panels are typically connected with a hinge that may provide an entry point for fluid and / or debris to enter the cargo area. Moreover, the hinge may be visually unappealing as it may give the tonneau cover a non-uniform appearance. Accordingly, it may be desirable to improve the current state of the art.

[0005] For example, it may be desirable to have a folding tonneau cover with adjacent panels that appear to have a visually appealing continuous surface and that reduce or eliminate fluid and / or debris entry points.SUMMARY

[0006] These teachings relate to a tonneau cover assembly that includes two adjacent panel assemblies, wherein each of the two adjacent panel assemblies comprise a frame assembly surrounding a panel; a hinge connecting the two adjacent panel assemblies and configured to enable one of the two adjacent panel assemblies to move relative to the other of the two adjacent panel assemblies; a skin or coating disposed over at least a portion of the two adjacent panelDocket No.: 2021A.041WO (9107537)assemblies and the hinge; and an end cap configured to engage the frame assembly of each of the two adjacent panel assemblies.BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Fig. l is a perspective view of a vehicle and a tonneau cover.

[0008] Fig. 2A is a perspective view of a panel of the tonneau cover.

[0009] Fig. 2B is an exploded view of Fig. 2A.

[0010] Fig. 3 is a cross sectional view of a portion of the tonneau cover showing a portion of a panel, opposing leading and trailing frame parts, and the hinge.

[0011] Fig. 4 is a close up view of a portion of Fig. 3.

[0012] Fig. 5 is an exploded view of a portion of the tonneau cover.

[0013] FIG. 6 is a back view of an end cap.DETAILED DESCRIPTION

[0014] A vehicle 10 is illustrated in Fig. 1. The vehicle 10 comprises a bed or cargo area 12 and a passenger cab 14. The cargo area 12 is defined by a plurality of walls that include: opposing side walls 16a, 16b, a front wall 18 located adjacent the passenger cab 14, and a rear wall or tailgate 20 that opposes the front wall 18. The front wall 18 of the cargo area 12 may be a shared or common wall with a wall of the passenger cab 14. These vehicles may be one piece or uni-body vehicles. 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. The front wall 18 may also provide access to the passenger cab 14 via a pass through or fold down wall or door. The cargo area 12 has a bottom or floor 13 that is surrounded by the walls 16a, 16b, 18, 20. The bottom or floor 13 is opposite an open end of the cargo area 12.

[0015] A tonneau cover assembly 22 may be disposed on top of or over the open or top end of the cargo area 12. The tonneau cover assembly 22 may include one or more panel assemblies. In Fig. 1, the cover 12 includes four panel assemblies 24a, 24b, 24c, and 24d. However, the tonneau cover assembly 12 may include any number of panel assemblies, including as little as only two adjacent panel assemblies. Adjacent panel assemblies may be connected to one another by one or more hinges 26a, 26b, and 26c. The one or more hinges may be configured to enable one of the two adjacent panel assemblies to move relative to the other of the two adjacent panelDocket No.: 2021A.041WO (9107537)assemblies. A skin or coating 28 may be disposed over or applied onto at least a portion of the two adjacent panel assemblies and the hinge. The skin or coating 28 may provide a uniform or monolithic look. The skin or coating 28 may seal any gaps or spaces at the hinges and or between adjacent panel assemblies.

[0016] For purposes of orientation, panel assembly 24a may be referred to as the first or rear panel assembly; panel assembly 24b may be referred to as the second panel assembly; panel assembly 24c may be referred to as the third panel assembly; panel assembly 24d may be referred to as the fourth or front panel assembly. The panel assembly closest to the passenger cab 14 (24d in this example) may be referred to as a cab panel assembly. The panel assembly closest to the tailgate 20 (24a in this example) may be referred to as a tail panel, assembly It is understood that reference to the panel assemblies as “first”, second”, “third” etc. herein does not limit the scope of these teachings to a particular orientation or position of the panel assemblies. Instead, unless otherwise noted, reference to a first panel assembly having certain features does not mean that it must be only the panel assembly 24a that has the feature. Instead, reference to a first panel assembly having certain features may mean that panel assembly 24b, 24c, 24d, 24x, 24x’ etc. can also or can instead have that feature unless otherwise expressly noted. This is especially true when reviewing and interpreting the rest of the disclosure and claims.

[0017] Fig. 2A illustrates a panel assembly 24x of the tonneau cover assembly, and Fig. 2B is an exploded view of Fig. 2A. The panel assembly 24x in Fig. 2A may be any one of the panel assemblies 24a, 24b, 24c, 24d, etc. illustrated in Fig. 1.

[0018] The panel assembly 24x comprises a panel 30 surrounded by a frame assembly. The frame assembly comprises a pair of opposing side or lateral frame parts 32 a front frame part 34’ and a rear frame part 34. Each of the opposing side or lateral frame parts 32 comprises a channel, opening , or panel receiving region 36 for receiving the panel 30. The panel 30 may be press fit into the channel or opening 36 and / or secured thereto via one or more fasteners. Each of the front and rear frame parts 34’, 34 also comprises a channel, opening, or panel receiving region 36 for receiving the panel 30.

[0019] Adjacently located frame parts 32, 34 or 34’ may be connected or secured together with a comer frame brace 38. A comer frame brace 38 may connect or secure together perpendicularly arranged or oriented frame parts of the frame assembly. That is, a corner frame brace 38 may connect the front frame part 34’ or the rear frame part 34 to one of the pair ofDocket No.: 2021A.041WO (9107537)opposing side or lateral frame parts 32. Opposing ends of the corner frame brace 38 are configured to slide into receiving channels defined in the corresponding frame parts 32, 34 and may be secured thereto via one or more fasteners.

[0020] Each of the opposing leading 34’ and trailing frame parts 34 comprises a hinge connector 40. The hinge connector 40 may be located at an opposite end of the frame part 34 from the channel or opening 36 into which the panel is received. The hinge connector 40 may be configured to connect a hinge 26 to the panel assembly 24x.

[0021] The frame assembly comprises one or more end caps 42. An end cap may be configured to engage the frame assembly of each adjacently located panel assembly. Each end cap 42 may cover a comer frame brace 38. A fastener such as a screw or bolt may be driven into one or more clearance holes in the end cap 42 and corner frame brace 38 to connect those parts to the respective frame part 34, 34’ and 32.

[0022] Fig. 3 is a cross sectional view of a portion of the tonneau cover showing a portion of a panel 30, opposing leading 34’ and trailing 34 frame parts, and the hinge 26. The end cap is not shown in this view.

[0023] The front and rear frame parts 34’, 34 may include one or more locking tabs or fingers 44. The one or more locking tabs or fingers 44 may extend into the channel or opening 36 and may function to maintain a maximum depth of insertion of the panel 30 into the one or more channels or openings 36 and / or may function to provide an interface fit against the panel 30 to lock or maintain the panel 30 within the channel 36. The one or more locking tabs or fingers 44 may be at least partially deflectable and / or deformable to contact or engage an edge of the panel 30. In other configurations, the locking tab or fingers 44 may be sufficiently rigid to prevent over insertion of the panel 30 into the channel 36.

[0024] The hinge connector 40 may include a hinge receiving opening or channel 46. The hinge receiving opening or channel 46 may function to receive or engage a part of the hinge 26 to maintain a connection between the hinge 26 and the frame part 34’, 34. More specifically, the hinge receiving opening or channel 46 may be sized and to engage a wing, finger, or extension 48 of the hinge 26. The wing, finger, or extension 48 of the hinge 26 may be secured or retained in the hinge receiving opening or channel 46 by the interference fit or by a fasteners such as an adhesive.Docket No.: 2021A.041WO (9107537)

[0025] A skin or coating may be applied over the hinge 26 and the leading and trailing frame parts 34’, 34 and optionally over the side frame parts 32. The skin or coating may cover any gaps G defined between the material of the seal 26 and the frame parts 34’, 34. Advantageously, this may give the cover a monolithic or one-piece look and / or prevent or restrict fluid and / or debris from entering the cargo area through the gaps G. The skin or coating may be a flexible coating such as polyurea.

[0026] Referring now to Fig. 4, the front and rear frame parts 34’, 34 comprise a recess or thinned region 50 above the hinge receiving opening or channel 46. A finger 52 of the hinge 26 may extend over or may be received into the recessed or thinned region 50 of the frame part 34’, 34 so that a top surface of the hinge 26 is substantially planar with a top surface of the frame part 34’, 34. Of course in other configurations, the top surface of the hinge 26 may be slightly higher or lower than a top surface of the frame part 34’, 34. The finger 52 may be secured or attached to the frame part 34’, 34 and / or in the thinned region 50 via a fastener such as an adhesive. A skin or coating may be applied over the hinge 26 and the leading and trailing frame parts 34’, 34. The skin or coating may cover any gaps G defined between the material of the seal 26 and the frame parts 34’, 34.

[0027] Referring now to Fig. 5 and 6, the end cap 42 comprises two parts, namely a first part 60 and a second part 62. The two parts 60, 62 are connected together with a top connector 64. The top connector 64 may pliable or resilient material that can bend or flex when the cover panels are moved or pivoted between the open and closed configurations of the cover.

[0028] The end cap 42 comprises a pair of hinge receiving openings 54. The hinge wings, fingers, or extensions 48 are configured to extend into the hinge receiving openings 54 of the end cap. The hinge wings, fingers, or extensions 48 may be generally parallel to each other and extend laterally outward from the hinge.

[0029] The end cap 42 comprises a pair of end cap fingers 58 extending from a back side of the end cap 42. The frame parts 34’, 34 comprise an end cap receiving opening 56 that are configured to engage or receive the end cap fingers 58.

[0030] These teachings provide a tonneau cover assembly. The cover may be an apparatus or assembly for at least partially covering or concealing at least a portion of a vehicle, such as a cargo area. The cover may be a tonneau cover, topper, cap, tent, or a combination thereof.Docket No.: 2021A.041WO (9107537)

[0031] The cover may be attached, placed, supported, connected or made to rest on one or more top surfaces of the one or more walls defining a cargo area. The cover may be attached, placed, supported, connected, or made to rest on one or more rails or supports that are attached or connected to one or more surfaces of one or more walls defining the cargo area. The cover or one or more components thereof may be an aftermarket product that is / are attached to a vehicle by a vehicle owner. The cover or one or more components thereof (e.g., the one or more panels, torsion elements, frames, frame members, hinges, etc.) may be assembled, installed, and / or integrated into the vehicle or cargo area by an OEM (Original Equipment Manufacturer).

[0032] The vehicle may be any vehicle. The vehicle preferably has a cargo area or bed. The cargo area or bed may be any area or portion of a vehicle that may be used for storing and / or transporting goods or cargo. The cargo area may be a cargo box, bed, trunk, storage compartment, or a combination thereof. The cargo area may be located in a front portion of a vehicle, a middle portion of a vehicle, and / or a rear portion of a vehicle. The cargo area may be located behind or adjacent a passenger area of a vehicle, where one or more passengers, occupants, and / or drivers may sit. A cargo area may be a trailer that is configured to be pulled, towed, or pushed by a vehicle. The cargo area may be any part of the vehicle that has an open top. The cargo area or open top can be at least partially closed or covered by a cover. The cargo area may be part of a pickup truck. The cargo area may be part of a utility task vehicle or utility terrain vehicle (UTV). In some configurations, the cargo area may have another cover or top on it, and the cover according to these teachings may be provided between the floor of the cargo area and the cover or top. For example, the cover according to these teachings may be provided inside a vehicle or sport utility vehicle (SUV) to close or cover or conceal contends in the hatch, trunk, or other region of the vehicle.

[0033] The cover may be an assembly comprising one or more panels. A panel as used herein may be any of the one or more parts, portions, components, or sections of the cover that are moveable or can be moved relative to another part, portion, component or section of the cover, a vehicle, a cargo area, or a combination thereof. The one or more panels may be separate or discrete pieces that are joined together with one or more hinges, spacers, torsion elements, frames, frame members, or other panels.

[0034] The one or more panels may be made of a suitable material, such as plastic, metal, foam, composite, wood, fiberglass, or a combination thereof. The one or more panels may beDocket No.: 2021A.041WO (9107537)substantially rigid, soft or flexible, bendable, resilient, or a combination thereof The one or more panels may comprise a core that is covered in a skin. The core may be a plastic material such as extruded polypropylene or foam. The skin may be a sheet or spray that covers the core. The skin may be TPU, TPV, TPE, and / or TPR, polyrea, bed liner material, etc. The one or more panels may be made of the same or similar material as the cargo area or fenders so that the cover and the cargo area and vehicle have a uniform appearance. The one or more panels may be made of a single material or may be formed of multiple materials or components that are assembled together. The one or more panels may include one or more frames or frame members that provide strength and rigidity to the panels.

[0035] The cover may include one or more hinges. A panel may include one or more hinges. A hinge may be a joint, turning point, juncture, axis journal or other feature about which one or more panels or spacers can be move, pivot, swing, bend, fold, roll, flex, displace, or otherwise change position relative to one or more other panels, the cargo box, the vehicle, or a combination thereof. A hinge may allow or provide for the one or more panels to be moved between the open and closed configuration, or into a position in between the open and closed configuration. A hinge may be provided between two panels. A hinge may define or separate two adjacent panels. A hinge may also be attached to both a fixed or nonmoving portion of the vehicle or cargo bed and to a panel of the cover. A hinge may be comprised of one or more hinges or hinge portions. A hinge may comprise a plurality of hinges provided adjacent one another, which may increase or provide additional movement, pivoting, or folding of the one or more panels relative to each other and / or the vehicle. A hinge may comprise one or more spacer bars. A spacer bar may be provided between adjacent hinges. A spacer bar may increase spacing between adjacent panels connected to the panels; reinforce or provide rigidity to the hinge assembly or cover or both. One or more torsion elements may be attached to or provided adjacent a spacer bar. One or more of the torsion elements may be attached or connected to a spacer bar. A spacer bar may have the same material or construction as one or more of the panels. The spacer bar may be plastic, metal, injection molded, extruded, or stamped. A hinge may comprise one or more brackets attached to or made part of the one or more panels or hinges that turn on one or more pins. A hinge may be a living hinge formed or defined in one panel. This means that two or more panels may be part of one unitary panel but divided or defined into separate panels by way of a livingDocket No.: 2021A.041WO (9107537)hinge. The one or more hinges may be made of an elastomeric and / or resilient material that is added between two adjacent panels.

[0036] 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.

[0037] 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.

[0038] 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.

[0039] 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.”

[0040] 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.

[0041] 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 oneDocket No.: 2021A.041WO (9107537)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 use 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.

[0042] The invention illustratively disclosed herein may be practiced in the absence of any element which is not specifically disclosed herein.

[0043] 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 not be specifically illustrated or described herein.

[0044] 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

Docket No.: 2021A.041WO (9107537)CLAIMS1) A tonneau cover assembly comprising:two adjacent panel assemblies, wherein each of the two adjacent panel assemblies comprise a frame assembly surrounding a panel;a hinge connecting the two adjacent panel assemblies and configured to enable one of the two adjacent panel assemblies to move relative to the other of the two adjacent panel assemblies;a skin or coating disposed over at least a portion of the two adjacent panel assemblies and the hinge; andan end cap configured to engage the frame assembly of each of the two adjacent panel assemblies.2) The tonneau cover assembly according to claim 1, wherein the frame assembly comprises a pair of opposing side or lateral frame parts, a front frame part, and a rear frame part, wherein each of the front frame part and the rear frame part comprise an end cap receiving opening each one of which are configured to a finger of the end cap.3) The tonneau cover assembly according to claim 2, wherein the end cap comprises a first part and a second part, the first part is connected to the second part by a top connector, wherein the top connector is made of a flexible material that is configured to bend or flex when one or both of the two adjacent panels are moved or folded.4) The tonneau cover assembly according to claim 2, wherein the end cap comprises a pair of hinge receiving openings and the hinge comprises a pair of extensions or fingers that are configured to extend into the hinge receiving openings.5) The tonneau cover assembly according to claim 2, wherein the end cap comprises two fingers that are configured to engage an end cap receiving opening defined in the front frame part of one of the panels and the rear frame part of the other panel.6) The tonneau cover assembly according to claim 2 or any one of the previous claims, wherein the front frame part and / or the rear frame part comprises a hinge connector, the hingeDocket No.: 2021A.041WO (9107537)connector comprises a hinge receiving opening or channel that is configured to receive or engage a wing, finger, or extension of the hinge.7) The tonneau cover assembly according to claim 1 or any one of the previous claims, wherein the hinge comprises two wings, fingers, or extensions that are generally parallel to each other and are configured to engage two openings defined in the end cap.8) The tonneau cover assembly according to claim 7, wherein the two wings, fingers, or extensions are projections that extend laterally outward from the hinge.9) The tonneau cover assembly according to claim 1 or any one of the previous claims, wherein the front frame part and the rear frame part comprise a recessed or thinned region and the hinge comprises a finger that extends into the recessed or thinned region.10) The tonneau cover assembly according to claim 9 or any one of the previous claims, wherein a top surface of the hinge and the top surface of the front frame and / or a top surface of the rear frame part are substantially planar.11) The tonneau cover assembly according to claim 1 or any one of the previous claims, wherein the front frame part or the rear frame part comprises a channel or opening for receiving a panel.12) The tonneau cover assembly according to claim 11 or any one of the previous claims, wherein the channel or opening comprises one or more locking tabs or fingers.13) The tonneau cover assembly according to claim 12 or any one of the previous claims, wherein the one or more locking tabs or fingers configured to restrict an insertion depth of the panel into the channel or opening and / or to engage the panel to secure the panel therein.14) The tonneau cover assembly according to claim 1 or any one of the previous claims, wherein the tonneau cover assembly comprises four panels and three hinges.Docket No.: 2021A.041WO (9107537)15) The tonneau cover assembly according to claim 1 or any one of the previous claims, wherein the tonneau cover assembly comprises an end cap on each side of the two adjacent panels.16) The tonneau cover assembly according to claim 1 or any one of the previous claims, wherein the skin or coating is polyrea.17) The tonneau cover assembly according to claim 1 or any one of the previous claims, wherein the tonneau cover assembly comprises a comer frame brace connecting the front frame part or the rear frame part to one of the pair of opposing side or lateral frame parts.18) A vehicle comprising the tonneau cover assembly according to claim 1 or any one of the previous claims.

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