Tonneau Cover Clamp Support With Shims for Flange Tolerance Gaps

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Solution Overview

Problem

The inconsistent spacing between the metal sheets and plastic cap flanges in pickup truck cargo boxes creates a challenge for securely clamping a tonneau cover rail, as the gaps between these flanges vary in size, making it difficult for the clamp to achieve a secure fit.

Innovation Solution

A clamp assembly that includes shims, which are placed between the flanges to fill the gaps, creating a solid structure that the clamp can securely attach to. The shims have openings and fastener slots to accommodate the clamp fastener, ensuring proper alignment and secure holding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple metal sheets and plastic cap are used to form the cargo box sidewall, then manufacturing flexibility and tolerance accommodation are improved, but consistent clamping surface is deteriorated

Engineering Contradiction:

Improvetolerance accommodationVSAvoidclamping surface consistency

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The shim acts as an intermediary component inserted between the clamp and the cargo box sidewall flanges. It compensates for gaps created by tolerance variations in the multi-sheet construction, providing a consistent clamping surface that allows the clamp to securely attach regardless of the underlying flange spacing variations.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If gap size between flanges varies due to sheet metal tolerance, then manufacturing ease is improved, but clamp security is deteriorated

Engineering Contradiction:

Improvesidewall assemblyVSAvoidclamp attachment security

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The shim allows the clamping system to adapt to varying gap parameters between flanges. By introducing this adjustable intermediate element, the system can accommodate different gap sizes resulting from sheet metal tolerance variations while maintaining reliable clamp attachment security.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If shims are added to fill gaps between flanges, then clamp attachment security is improved, but device complexity is worsened

Engineering Contradiction:

Improveclamp attachment securityVSAvoidclamp assembly structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The clamp assembly is segmented into distinct components: the clamp itself, the shim, and the fastener system. This segmentation allows the shim to be independently selected and installed to fill specific gap variations, providing a simple yet effective solution that enhances reliability without requiring complete redesign of the entire clamping mechanism.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS12220975B2Tonneau cover clamp shim and clamp support

Publication Date: 2025.02.11 TRUCK ACCESSORIES GROUP INC

AI summary

A clamp assembly for use with a tonneau cover assembly is provided. Illustratively, the clamp assembly may include a first clamp member, a second clamp member, a clamp fastener, and at least one shim. The second clamp member is located opposite the first clamp member to form a space located therebetween. The clamp fastener is extended through the space between the first clamp member and the second clamp member. The at least one shim is located in the space between the first clamp member and the second clamp member.