1 Utility Vehicle Tub Canopy Attachment Assembly TECH NI CAL FI ELD The present invention relates to an assembly for attaching a rigid cover to a vehicle 'tub', being the open cargo bay common to pickup trucks and utility vehicles. BACKGROUND TO THE INVENTION Vehicles such as utility vehicles (commonly referred to as 'utes') or pickup trucks, which have an open topped cargo bay positioned behind a driving cab, often have a substantially rigid cover installed over the opening of the cargo bay to prevent moisture and dust ingress into the bay and also to provide a lockable volume in which goods may be securely stored. Such covers are commonly known as "utility tub canopies" or "truck bed caps". In the past, canopies have been secured over a vehicle tub by attaching a canopy to the side walls of the utility tub by various means, typically involving either mechanically fixing or clamping a rim of a canopy shell to a surface of a side-wall of the tub area. Most commonly a canopy is attached directly to a top surface of the vehicle tub by connecting a plurality of first extrusions bolted or screwed to the rim the canopy to a plurality of second extrusions bolted or screwed to the vehicle. Whilst this is a simple and secure arrangement to secure a canopy over a vehicle tub, the fixings that connect the first extrusions to the canopy rim protrude from the outer surfaces of the canopy and are generally considered unattractive. This is particularly the case when a canopy is affixed to a high-end, expensive vehicle, having a stylised, aerodynamic appearance. In order to address this issue, an additional trim is often affixed to the outer surface of the canopy to cover the visible fixings.
2 Furthermore, using the commonplace canopy attachment method described above, an attached canopy is arranged on top of the side walls of the vehicle tub inevitably creating a gap between the first extrusions and the exterior surfaces of the tub. This gap has been found to trap dirt and moisture, particularly when the vehicle is driven off-road, increasing the likelihood of corrosion of the extrusions and/or surfaces of the vehicle tub, and also allowing dirt and moisture to penetrate into the vehicle tub cargo area. It would therefore be useful to provide an assembly for fixing a canopy to the vehicle tub which provides a more seamless join between the canopy and the vehicle and improved appearance, when compared with prior art approached. Furthermore, it would be advantageous if such an assembly could be readily adjusted to allow the assembly to affix a range of canopies to a range fo different vehicle geometries. Also, it would prove useful to provide an assembly that is 'weather-proof' and reduces or eliminates regions which collect dirt and/or moisture. Accordingly, it would be useful to provide a solution that avoids or ameliorates any of the disadvantages present in the prior art or which provides an alternative to prior art approaches. SUMMARY OF THE INVENTION According to one aspect of the invention, there is provided an assembly for attaching a rim of a canopy shell adjacent to an exterior surface of a vehicle tub. The assembly comprises at least one rail adapted to be connected to a side-wall of the vehicle tub, and having a flange extending towards the exterior surface of the vehicle tub. The assembly includes at least one bracket having a receiving portion dimensioned to receive at least a portion of the flange and be affixed thereto. The assembly further includes a mount portion having one or more regions containing adhesive means configured to affix the bracket to the canopy shell.
3 In a preferred embodiment, the receiving portion includes a groove dimensioned to receive the flange. Most preferably, the mount portion defines two channels for containing the adhesive means. One of the two channels contains double-sided tape and the other channel contains glue. It is preferred that the at least one rail is formed from bent sheet metal and the at least one bracket is an extrusion. BRIEF DESCRIPTION OF THE DRAWINGS Preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which: Figure 1 is a cross-section view of an assembly connecting a rim of a canopy to a vehicle tub; Figures 2A & 2B are section detail views of the embodiment shown in Figure 1, viewed from inside and outside of the canopy; Figures 3A & 3B are cross-section views of an alternative assembly connecting a rim of a canopy to a vehicle tub; Figure 4 is a cross-section view of a further alternative assembly connecting a rim of a canopy to a vehicle tub; Figure 5 is a cross-section view of another assembly connecting a rim of a canopy to a vehicle tub; and Figures 6A & 6B are cross-section views of two variants of a further alternative assembly connecting a rim of a canopy to a vehicle tub.
4 DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS The assembly of the invention is intended to operate with a variety of makes, models, sizes and geometries of vehicles and canopies. The attachment assembly is adapted for use with vehicles which have a 'tub', which is normally a cargo tray having side-walls and a tailgate, which define an open top. These vehicles are commonly known as pickup trucks, utility vehicles, small trucks and the like. Any vehicle with an open area that can be covered or partially covered by a canopy or awning may be considered as suitable for the present invention. As well as cars and trucks, the invention may be used with towable trailers or caravans, boats or yachts, bicycle or motorbike trailers, or sidecars. The invention is essentially applicable to means of transportation that have a tray section open to the air which a user wishes to cover with a canopy. Ideally the open section is in the form of a tray or tub with existing sides, although not all side-walls are necessary. Generally, one or more of the sides may open to allow easy access to the tray section, for example, a pivotable tailgate. This kind of tray area surrounded by one or more sides is referred to in the specification as a tub, which also is sometimes known as a box. One of the tub's sides may be the driving cabin. The sides may all be the same or different general height and sizes. Commonly the vehicle may have a high cab side towards the front of the vehicle, two sides on the left and right of the vehicle and a tailgate, the sides and tailgate being less tall than the cabin. However the reference to a canopy in this specification is intended to be interpreted in its broadest sense, to cover attaching any kind of canopy to a suitable vehicle. Generally, the canopy will be a substantially rigid canopy, of a suitable size and shape that it will cover the tub area of the vehicle that it is to be used with. Canopies are also known as 'caps'. They preferably are formed from a rigid material however may also be of fabric or soft materials, or a 5 combination of different such materials. Commonly the canopy is made from fibre-glass, plastic, metal sheeting, or the like. Often windows, openings, or panels of a different material are incorporated in the canopy. It is envisioned that specific canopies will be produced for different vehicle models. However, bespoke canopies may be made on an individual basis. The invention may also be used with flat or tonneau canopies or lids. Generally the canopy will be a semi-permanent fixture, able to be attached and removed at will, although users will frequently install the canopy and leave it in place for extended periods of time. In Figure 1 a preferred embodiment is shown for an attachment assembly or mounting system for attaching a canopy to the tub of a pickup truck or utility vehicle. In the Figure, a cross-sectional view is provided showing a canopy shell (10), of which only the rim is shown, attached adjacent to a sidewall (11) of the vehicle tub, by means of an example of the attachment assembly (12). The tub sidewall (11) has an inner, interior surface (13) that faces towards the interior of the tub, a top surface (14), and an outer or exterior surface (15) that faces away from the tub and is the outer skin of the vehicle. The canopy shell (10) has an end (16), and the shell is affixed to the vehicle to extend below the top surface of the sidewall, overlapping the upper portion of the sidewall. The tub (not shown) has a floor or bed and generally four sidewalls. One sidewall will generally be at the cab end of the vehicle and an opposing sidewall as a tailgate. The attachment assembly will generally be used on the left and right sidewalls that connect the tailgate to the cab. The height of the canopy will normally match the height of the cab, and so the canopy will provide a streamlined appearance to the vehicle, such that the canopy can blend in to the surfaces of the cab and the sidewalls of the tub and appear to be part of the vehicle. The attachment assembly may be applied to the cab end sidewall, or may not.
6 The attachment assembly (12) comprises a mount rail (17) that is adapted to be connected to the vehicle. In the example shown in Figure 1, the rail is arranged along at least some sections of the top surface (14) of the sidewall (11). Optionally, a flat seal (18) may be placed between the rail (17) and the top surface of the sidewall, such as a strip or extrusion of rubber, or section of foam tape, to provide a water and dust seal, and to reduce noise and vibration. The rail (17) is a continuous metal strip, such as steel or aluminium, preferably formed from bent sheet metal therefore being readily adaptable to side-wall geometry variations of different vehicle models. However other materials with an appropriate structural integrity may be used, such as plastics, or a metallic die-casting or extrusion. The rail (17) has a first portion (19) that lies along the top surface (14) of the sidewall (11) and a second portion (20) that is bent at an angle aligned with the inner surface (13) of the sidewall. Usually, the rail will be "L" shaped having a right angled bend. The rail may be formed as a continuous extrusion and cut to length according to the dimensions of the vehicle tub it is fitted to. This may involve trimming width from the rail, according to the width of the tub side-wall and/or cutting the rail to an appropriate length. However for common models of vehicles, preselected standard widths and lengths of rail are provided. The rail (17) is removably attached to the side wall (11) by any suitable means. As a preferred arrangement, there are a plurality of mechanical fasteners (21), such as screws, bolts or rivets, that pass through corresponding holes in the rail and affixed through the sidewall. Preferably these fasteners (21) will be positioned along the second (i.e. side) portion (20) of the mounting rail. However they may be attached via the top portion (19) and into the upper surface (14) of the sidewall. Adhesive may also be used to attach the rail, but ideally the rail is attached in a manner that permits its occasional removal, for example, for cleaning. Alternatively, other attachment methods may be utilised to secure the rail to both upper and interior surfaces of the sidewall. As another alternative, a clamping 7 system can be used to grip the top side (18) of the rail and the upper surface (14) of the side wall. The rail (17) is preferably provided as a single, continuous strip that is adapted to fit along the entire length of the left and right sidewalls. Otherwise it may be discontinuous, and provided in several individual lengths. In this case, the discontinuous lengths preferably abut each other, without gaps, to assist in weather-proofing the system. Alternatively, the rail may be provided in discontinuous sections that are evenly spaced along the sidewall, with gaps between them. Some tub sidewalls are provided with nubs or other obstructing features on the sidewall surfaces, and in this case the rail may be attached in sections to avoid the obstructions. The attachment assembly (12) has at least one bracket (22) that at least partially receives and is affixed to a flange portion of the rail (17), being a tab that is arranged extending from one side of the rail towards the exterior surface of the sidewall (15). The bracket typically has a groove (23) dimensioned to receive the rail flange and abut top and bottom surfaces of the flange. The groove is formed between two protrusions that grip the top and bottom surfaces of the flange at an end portion thereof to hold the rail firmly in place. The groove may be retained in connection with the rail by friction alone however an adhesive or a plurality of rivets or other mechanical fasteners are preferred. A combination of such means may also be employed. The bracket (22) has a first portion (23) that abuts or lies against the surface of the rail (17), and a second portion (24) that is arranged at an angle to the first portion. An outer face of the second portion of the bracket is arranged to abut an inner surface of the canopy shell (10). The second portion of the bracket (24) is attached proximal to the rim (16) of the canopy and preferably spaced apart from the rim, such that the rim is suspended below the top surface (14) of the sidewall. This creates a visually seamless join between the canopy and the vehicle that can improve the aerodynamics of the vehicle.
8 The bracket (22) has means for it to be affixed to the canopy shell. Any suitable means may be utilised for this purpose, such as rivets, screws or adhesives. However, it is most preferred to use adhesives and/or double sided adhesive tapes, to avoid fixings protruding through the canopy shell and interrupting the outer surfaces of the canopy. In this case, adhesive or double sided tape is applied between the canopy's inner face, and the second portion of the bracket (24). As a further preferred arrangement, the outer face of the bracket (24) has one or more channels (25, 26) that run along its length, adapted to retain the adhesive means. Most preferred is an arrangement where there are two channels, an upper channel (25) that accommodates double sided adhesive tape, and a lower channel (26), positioned nearer the edge of the canopy that accommodates glue. The bracket (22) may be made of any suitable material such as steel, plastics or aluminium, and is preferably formed from an extrusion in order to simplify the manufacture and assembly of the invention. For example, where the assembly (12) comprises a bent sheet metal rail (17) and an extruded bracket (22), this advantageously allows the geometry of the assembly (12) to be readily configured to attach a model-specific canopy shell (10) to a relevant vehicle model tub. As the rail (17) is bent to form the required geometry for each model-specific assembly (12), adapting the geometry of the rail (17) to conform to the geometry of the vehicle model tub is simple and cost effective. This means that a common extruded bracket (22) can be used for the assembly (12), regardless of which vehicle model the assembly (12) is configured for, thereby reducing the number of different components required for forming various model-specific assemblies (12), consequently reducing the complexity and cost of each assembly (12). Furthermore, the extruded bracket (22) may be configured having complex geometry, in order to satisfy particular design requirements, without substantially affecting the overall complexity and cost of the assembly (12). The bracket (22) is preferably provided as a continuous strip, but may be provided as separate strips that preferably abut together. Alternatively, the 9 bracket may be discontinuous and arranged evenly along the edges of the canopy. Gaps may be provided where the sidewall has obstructions, for instance. The assembly (12) also preferably includes a seal (27) located between the exterior surface of the sidewall (15) and an inner face of the canopy or the bracket (22), such that it firmly presses against the exterior surface of the side wall (15) and the canopy, above the rim of the canopy (16). Preferably such a seal is resilient and configured to exert force on both the sidewall and the canopy to provide a robust seal that prevent moisture and dust ingress. The seal may also include an adhesive portion to adhere the seal to the canopy shell or bracket. The cross-sectional shape of the seal may match the shape of the space it occupies, or may be a simple round cross section, which is compressed to fit the area it occupies, for example. The assembly (12) also includes a fixing cover (28) positioned between the outer portion of the bracket (24) and the grooved portion (23) to cover the portion of the bracket through which fasteners are secured to attach the bracket (22) to the rail (17). The cover is preferably adapted to be slidably engaged with the bracket, covering the fasteners to prevent accidental impacts with the fasteners and provide an improved visual appeal. Figure 2A shows a detailed section view of the attachment assembly (12) shown in Figure 1 secured to a vehicle and a canopy. Viewed from inside the tub of the vehicle, the interior surface of the sidewall (13) can be seen to be attached to the rail (17) by a plurality of fasteners, in this case bolts (21). The rail is also attached to the bracket (22), the bracket configured to affix to the inside surface of the canopy (10) by an adhesive or adhesive layer secured within one or more channels (25, 26). The assembly also comprises an asymmetric seal (27) arranged between the bracket and the exterior surface of the sidewall (15). In Figure 2B, the assembly (12) described in the previous figure is shown from outside of the vehicle. This illustrates that when a canopy (10) is attached to a vehicle using the assembly, the exterior surface of the canopy 10 is not interrupted or otherwise pierced or damaged by any fastening means, providing a continuous, smooth appearance. Furthermore, using the bracket (22) in such an arrangement, allows the lower edge or rim (16) of the canopy to be suspended below the upper surface (14) of the sidewall, disguising the join between the canopy and the vehicle and further enhancing the smooth visual transition between the body of the vehicle and the exterior surface of the canopy. Figures 3A-3B show an alternative attachment assembly (30) connecting the canopy (10) to the vehicle side-wall (11). The assembly includes a rail (31) affixed to the inner surface (13) of the side-wall using a plurality of bolts, the rail supported by the top surface (14) of the side-wall and extending towards the exterior surface (15) to form a tab or flange (32). A bracket (33) has a first portion (34), adapted to receive and grip the flange, and a second portion (35) adapted to conform to the inner surface of the canopy shell and house one or more adhesive regions. The second portion is shown having two channels (36, 37), each of which containing one or more adhesive regions. Each channel may house the same or different adhesive means, depending on design requirements. For instance, in some applications, it is preferable that a first channel (36) contains a relatively weak adhesive, such as double-sided tape, to allow the canopy to be temporarily fixed in a position (and potentially removed and repositioned) during installation of the canopy to the vehicle. The second channel (37) is then filled with a strong adhesive, such as a glue or epoxy resin being injected into the channel, to permanently secure the canopy to the bracket. In this embodiment, the second portion of the bracket is also secured to the flange by an adhesive being injected into the groove, once the bracket is correctly positioned in relation to the rail. In Figure 4, a further alternative assembly (40) is shown, connecting the canopy (10) to the vehicle side-wall (11). The assembly comprises two different rails (41, 42), a first rail (41) connected to the inner surface (13) of the side-wall and a second rail (42) connected to the first rail and extending towards the exterior surface (15) to provide a flange (43), 11 adapted to connect to a bracket (44). The dual rail approach allows for the first rail to be a standard component, applicable to any vehicle, and the second rail having adjustment means, such as plurality of fixing apertures to secure a fastener between the first and second rail, to allow the assembly to be adjusted in width, according to the side-wall geometry of the vehicle model. The second rail is also supported above the top surface (14) of the side-wall by a seal (45) to support the weight of the canopy and assembly, and provide further protection against moisture ingress into the tub. The bracket (44) includes a flange groove (46), adapted to receive the rail flange (43) and allow fasteners to be secured through, fixing the flange to the bracket. The bracket also includes a canopy fixing portion having three channels (47-49) which are utilised differently for different design requirements. For instance, top channel (47) may be adapted to house adhesive tape, forming a weak adhesion between the bracket and canopy shell to allow for position adjustment between these components during installation, bottom channel (49) adapted to receive glue to permanently affix the bracket to the canopy shell and middle channel (48) to provide a barrier between the top and bottom channels to prevent the glue from coming into contact with the adhesive tape. The barrier may simply be an air filled void or include foam tape to provide a physical barrier. Alternatively, top channel (47) and bottom channel (49) may be filled with different glue compositions, with middle channel (48) acting as a dam to prevent the different glues from mixing with each other. In a further alternative arrangement, top channel (47) and bottom channel (49) may both house the same or different adhesive tapes and middle channel (48) is filled with a glue. An additional seal (50) is provided between the inner surface of the canopy shell (10) and the exterior surface (15) of the side-wall to further prevent dust and moisture ingress into the tub. This may be a length of foam tape or an extruded block of resilient material. The bracket also includes a wiring loom channel (51) separated from the flange groove (43) and canopy attachment region by walls, forming an enclosed volume adapted to receive 12 electrical cables and the like. The wiring channel (51) is adapted to receive a cover (52), able to be slidably engaged with the bracket. In Figure 5 a further alternative assembly (60) is shown, connecting the canopy shell (10) to the side-wall (11) of the vehicle tub. The assembly includes the same components as the assembly (40) shown in the previous figure, with an alternative rail (61) arrangement. The rail (61) is mounted directly to the inner-surface (13) of the side-wall and connects to the bracket (44) as previously discussed in relation to Figure 4. In Figures 6A-6B two variations of a further alternative assembly (70, 80) are shown, connecting the canopy shell (10) to the side-wall (11) of the vehicle tub, both including a clamp mechanism (71) adapted to connect a rail (72, 81) to the side-wall. In Figure 6A, the assembly includes a rail (72) having a substantially right angled cross-section, having a first portion positioned against the inner surface (13) of the side-wall and a second portion extending towards the exterior surface (15) of the side-wall forming a flange (73) that is connected to the same bracket (44) shown in the previous two figures. The rail is secured to the side-wall by one or more clamp mechanisms (71), adapted to urge the second portion of the rail against the top surface (14) of the side-wall. In the example shown, a seal (74) is positioned between the rail and the top-surface however in other embodiments this may not be present. The clamp mechanism may comprise any conventional clamping means. In the example shown, the mechanism includes a top portion (75), slidably engaged with a bottom portion (76) and actuated by a clamping bolt (77), whereby as the bolt is rotated, the top portion is drawn towards the bottom portion and increases the compressive force between the side wall and the rail. In Figure 6B, the assembly has an alternative rail (81) having a first portion which defines one or more apertures (82) adapted to receive one or more respective clamping mechanisms (71), and a second portion which forms a flange (83) which is connected to the same bracket arrangement (44) 13 previously discussed. Each clamping mechanism secured through an aperture (82) also urges the rail against the top surface (14) of the side wall, securing the rail (and associated bracket) to the side-wall of the vehicle. It will be apparent that obvious variations or modifications may be made that are in accordance with the spirit of the invention and so are intended to be part of the invention, and any such obvious variations or modifications are therefore within the scope of the invention. INDUSTRIAL APPLICABILITY The invention can be utilised in the automotive, marine and other relevant transport industries which require a rigid cover to be secured over a cargo bay of a vehicle.