Truck Bed Cover Assembly With Tool-Free Mode Conversion
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Solution Overview
Problem
Existing roll-up truck bed covers are limited in their adaptability, requiring specific tools or knowledge to convert between manual, spring-assisted, and electric motor operation, and cannot be easily switched or operated manually in case of failure.
Innovation Solution
A cover assembly with a rotatable shaft and collapsible curtain engaging means that allows easy conversion between manual, semi-automated, and automated operation by slidably receiving a torsion spring or electric motor assembly, with a housing box featuring helical trackways for reduced friction and a clamping system for tool-free conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a spring-loaded shaft or electric motor is permanently integrated into the roll-up cover, then the cover can be automatically or semi-automatically operated, but the device cannot be converted to manual operation and requires replacement of the spring or motor in case of failure
Solution Approach 1:
The housing box is divided into a fixed portion and a removable portion that can be detached from each other. The spring-loaded shaft or electric motor is mounted on the removable portion, allowing it to be easily removed and replaced. This segmentation enables the cover to be converted between manual and motor-assisted operation modes without permanent integration, resolving the contradiction between ease of operation and adaptability.
Solution Approach 2:
The system is designed to be dynamically reconfigurable, allowing the user to switch between manual and motor-assisted operation modes as needed. The removable portion with the spring or motor can be attached or detached based on operational requirements, providing dynamic adaptability that resolves the contradiction between having automatic operation capability and maintaining convertibility.
2Ease of manufacture
If conventional helical trackways are used to guide the cover, then the cover can be stored in a rolled-up configuration, but the cover does not roll up straight when force is not applied evenly and excessive friction occurs
Solution Approach 1:
The patent replaces conventional helical trackways with a cylindrical drum surface. The curtain is wrapped around the drum in a spiral pattern, and the drum rotates to wind or unwind the curtain evenly. This curved cylindrical surface ensures that the curtain rolls up straight and evenly regardless of where force is applied, eliminating the friction and misalignment problems associated with helical trackways while maintaining rolled-up storage capability.
3Extent of automation
If an electric motor is mounted on an auxiliary shaft inside or outside the housing box, then the cover can be automatically operated, but the motor cannot be easily replaced and tools or specific knowledge are required for conversion
Solution Approach 1:
The housing box is segmented into fixed and removable portions. The electric motor or spring-loaded shaft is mounted on the removable portion, which can be easily detached from the fixed portion. This segmentation allows the motor to be quickly replaced without tools or specialized knowledge, resolving the contradiction between automation and ease of repair.
Solution Approach 2:
The removable portion is designed to accommodate either an electric motor or a spring-loaded shaft, making it multi-functional. This universal design allows the same structural component to support different actuation mechanisms, enabling easy conversion between automatic and manual operation modes while simplifying repair and replacement operations.
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
Enables seamless conversion between manual and motor-assisted operation without tools or knowledge, ensuring continuous functionality even in case of motor or spring failure, with reduced friction and enhanced operational ease.
Implementation Method 1
The hinged connection of individual slats enables the slat array to form a continuous cover that, once mounted in a pair of side rails, can be either completely or partially extended or retracted and stored in a rolled-up configuration inside a housing
Implementation Method 2
The housing box for storing the rollable curtain has side walls comprising helical trackways to help guide the rollable curtain free of excessive frictional resistance upon extending or retracting the same
Data Source
Figure 1~2
Figure 3~5
Figure 6a~7b
AI summary
A cover assembly for the truck bed of a pick-up type vehicle, said cover assembly comprising a rollable curtain (1) having a plurality of transverse adjacent panels (2) hingedly linked to one another; a pair of side rails (3, 4) adapted to be mounted on upper portions of the side walls of the truck bed for guiding the end portions of the transverse adjacent panels (2) and a housing box (5) adapted for receiving and storing the rollable curtain (1), wherein the housing box (5) comprises a transverse rotatable shaft (6) mounted therein, one or more sleeve elements (7, 8) mounted on said transverse rotatable shaft (6), one or more collapsible curtain engaging means (9, 10) each mounted to said one or more sleeve elements (7, 8), respectively, and designed to engage an inner end of the rollable curtain (1), and side walls (11, 12), each having inwardly extending continuous helical trackways defining a rolling path.