Stacking Rigid Tonneau Cover With Interlocking Slats
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Solution Overview
Problem
Existing tonneau covers for pickup truck beds lack security, are bulky, and do not provide adequate weather resistance, with soft covers being easily accessible and hard covers being heavy and cumbersome.
Innovation Solution
A retractable cover system featuring laterally spaced guide rails, multiple interlocking slats, a spring-biased pulley system, and a motorized drive assembly that allows the slats to slide between deployed and stowed configurations, providing security, compactness, and weather resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If soft tonneau covers are used, then the cover can be stowed in a small space, but the cover lacks security and can be easily cut
Solution Approach 1:
The cover is divided into multiple rigid slats that can be individually stacked and stored in a compact magazine when not in use. Each slat maintains structural integrity and security properties while the segmented design allows compact stowage in the truck bed corner.
Solution Approach 2:
The slats are constructed from rigid materials such as aluminum or composite materials that provide both security (resistance to cutting and forced entry) and weather resistance. This composite construction maintains security while enabling compact folding storage.
2Reliability
If hard covers are used, then security is improved, but the cover becomes heavy and bulky
Solution Approach 1:
The heavy hard cover is segmented into multiple lighter slats that can be individually handled and stacked. This reduces the weight of any single component and allows the cover to be folded into a compact configuration, improving maneuverability while maintaining overall security when deployed.
Solution Approach 2:
The cover transitions from a static heavy structure to a dynamic system where rigid slats can be moved between deployed and stowed positions. The motorized drive assembly enables easy movement of the segmented slats, making the system adaptable and reducing the practical weight burden during operation.
3Reliability
If hard covers are used, then security is improved, but the cover occupies significant truck bed space
Solution Approach 1:
The cover is segmented into multiple slats that fold together like an accordion, allowing the rigid structure to be compacted into a small magazine mounted in the truck bed corner. This maintains security when deployed while minimizing space consumption when stowed.
Solution Approach 2:
The slats are nested within each other when stowed, with each slat fitting into the space created by the previous slat. This nested configuration dramatically reduces the volume occupied in the truck bed while maintaining the full security functionality when deployed.
4Device complexity
If manual operation is used, then device complexity is reduced, but ease of operation deteriorates for many customers
Solution Approach 1:
The system incorporates a motorized drive assembly that automatically moves the slats between deployed and stowed positions, eliminating the need for manual effort. The motor responds to simple user input (button press or remote control), making operation convenient while the overall system remains relatively simple in design.
Solution Approach 2:
Manual mechanical operation is replaced with an electric motorized system. The motorized drive assembly uses electrical power to move the slats, replacing the need for manual cranking or lifting, thereby improving ease of operation while adding only moderate complexity to the system.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system offers a secure, compact, and weather-resistant tonneau cover that can be easily operated manually or automatically, ensuring robustness and efficient use of truck bed space while maintaining accessibility.
Implementation Method 1
a spring-biased pulley system that is configured to cooperate with the follower and biases the slats toward the tracks
Implementation Method 2
a spring-biased pulley system that is configured to cooperate with the follower
Implementation Method 3
a motor that is operatively coupled to the shaft. The motor is configured to rotationally drive the shaft about the rotational axis to move the slats between the deployed and stowed configurations
Implementation Method 4
The shaft includes a gear that is arranged at its opposing ends. Each slat includes an end with teeth that cooperate with the gear
Data Source
AI summary
A retractable cover system includes laterally spaced apart guide rails that define an opening and each provide a track. The system further includes a cover that has multiple slats that are configured to interlock with one another in a deployed configuration. The slats cooperate with the drive assembly and are slidable in the tracks between first and second positions within the opening in response to actuation of the drive assembly. The slats are stacked onto one another in a stowed configuration. The system further includes a follower that supports the slats. The system further includes a spring-biased pulley system that is configured to cooperate with the follower and biases the slats toward the tracks.