AU2019203615A1

AU2019203615A1 - Tonneau cover system

Info

Publication number: AU2019203615A1
Application number: AU2019203615A
Authority: AU
Inventors: David Jonathan Blundell; John Dudley Coulson; Gerald Christy Motley; Andrea Carmen Swart
Original assignee: Individual
Current assignee: Motley Gerald; Swart Andrea
Priority date: 2019-05-22
Filing date: 2019-05-22
Publication date: 2020-12-10

Abstract

A cover assembly 100 for covering a cargo bed 200, the cargo bed 200 comprising two pairs of opposing walls 210, 220, 230, 240 forming four walls of the cargo bed 200, the cover assembly 100 comprising a sheet of cover material 110, having two opposing ends and two opposing side edges, 5 which is secured to a roller 120 at one end and a drawbar 130 at or toward the other end, a guide track 140 extending along each of the side edges of the sheet of cover material 110 such that the side edges of the sheet of cover material 110 are retained by the guide tracks 140, wherein each guide track 140 extends along each of a pair of opposing walls 220, 230 of the cargo bed 200 at or near a top edge of each of the opposing walls 220, 230, an elongate spine 150 extending between the roller 120 and the 0 drawbar 130, positioned adjacent to the sheet of cover material 110, wherein the spine 150 acts upon the sheet of cover material 110 to form an elevated region 113 on the sheet of cover material 110 such that the sheet of cover material 110 slopes downward from the elevated region 113 toward at least one of the guide tracks 140. 1/7 160 15 113 100 110 130 240 140 220 115 Figure 1 160 210 140 151 150 - 230 130 200 140 220 240 Figure 2A

Description

1/7

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15 113 100

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Figure 1

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210 140 151

150 140 - 230

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Figure 2A

TONNEAU COVER SYSTEM INCORPORATION BY REFERENCE TECHNICAL FIELD

[0001] The present invention relates to a tonneau cover system. In a particular form the present invention relates to a tonneau cover system for weatherproofing and covering the cargo area of a vehicle.

BACKGROUND

[0002] Tonneau covers are used on cargo areas, such as cargo beds or trays, of pick-up trucks and utility vehicles to protect the bed and cargo from the external environment. It is desirable that the covers be weatherproof under normally encountered weather and driving conditions such that they are substantially watertight, able to shed water in a downpour and able to support the impact and weight of hailstones, while also being able to keep the cargo bed and cargo free of dust.

[0003] It is also desirable that the tonneau cover is compact and causes minimal loss of carrying capacity, while being quick and easy for a person to open, close and secure.

[0004] It is also desirable that the tonneau does not adversely affect the fuel efficiency of the vehicle through being excessively heavy or producing drag at highway speeds.

[0005] It is also desirable that the tonneau cover provides a secure closure for a cargo area and that access to opening the tonneau cover is only possible once the tailgate of the vehicle is opened.

[0006] It is against this background and the problems and difficulties associated therewith that the present invention has been developed.

SUMMARY

[0007] In one aspect, the invention is a cover assembly for covering a cargo bed, the cargo bed comprising two pairs of opposing walls forming four walls of the cargo bed, the cover assembly comprising: a sheet of cover material, having two opposing ends and two opposing side edges, which is secured to a roller at one end and a drawbar at or toward the other end; a guide track extending along each of the side edges of the sheet of cover material such that the side edges of the sheet of cover material are retained by the guide tracks, wherein each guide track extends each of a pair of opposing walls of the cargo bed at or near a top edge of each of the opposing walls; an elongate spine extending between the roller and the drawbar, positioned adjacent to the sheet of cover material; wherein the spine acts upon the sheet of cover material to form an elevated region on the sheet of cover material such that the sheet of cover material slopes downward from the elevated region toward at least one of the guide tracks. Each guide track may comprise a first channel in which an end of the drawbar slidably locates. The first channel of the guide track may further include a longitudinally extending slot opening into a longitudinally extending cavity, and wherein the sheet of cover material has a bead extending along the side edges thereof so that the sheet of cover material extends through the slot and each of these beads is retained in the longitudinal cavity of a respective guide track.

[0008] The first channel of the guide track may include features that reduce or limit the movement of water into the cargo bed vehicle and to provide drainage paths. For example, the guide track may include a longitudinally extending lip for retaining water. The lip may act as a gutter in order to assist with drainage of any leakage of moisture that may occur between the longitudinal bead, cavity and slot, such that the moisture is directed away from the cargo bed.

[0009] The cover assembly further comprises a head box for housing the roller. The guide tracks may be configured to drain forward into the head box, which is configured to drain into standard outlets provided in the cargo bed.

[0010] Preferably, the elongate spine is removably connected to the head box atone end and removably connected to the drawbar at another end.

[0011] Other aspects of the invention will be apparent from the description below of the preferred embodiment of the invention.

BRIEF DESCRIPTION OF DRAWINGS

[0012] Embodiments of the present invention will be discussed with reference to the accompanying drawings wherein:

[0013] Figure 1 is a schematic perspective view of a cover assembly, according to an embodiment, attached to a cargo area of a utility vehicle;

[0014] Figure 2A is a schematic view of the cover assembly of Figure 1 with the sheet of cover material removed to reveal a spine;

[0015] Figure 2B is a schematic view of the cover assembly of Figure 2A with detail of the base of the cargo area removed for clarity;

[0016] Figure 3 is a plan view of the cover assembly of Figure 2B;

[0017] Figure 4 is a side view of the cover assembly of Figure 1 with the sheet of cover material removed;

[0018] Figure 5 is a schematic view of the drawbar and guide track;

[0019] Figure 6 is a detailed cross-sectional view through the drawbar;

[0020] Figure 7 is a detailed cross-sectional view through the guide track;

[0021] Figure 8 is a detailed cross-sectional view through the guide track in isolation;

[0022] Figure 9 is a schematic perspective view of the head box, according to an embodiment;

[0023] Figure 10 is a partial cross-sectional view through the head box;

[0024] Figure 11 is a schematic perspective view of the spine in connection with the drawbar, according to an embodiment; and

[0025] Figure 12 is a side view of the spine in connection with the drawbar as shown in Figure 11.

DESCRIPTION OF EMBODIMENTS

[0026] Referring now to Figures 1, 2A, 2B and 3 there is shown a cover assembly 100 according to an embodiment, installed on the top of a cargo area 200 of a vehicle. The cargo area 200 comprises a front wall 210, left side wall 220 and right side wall 230 forming three walls of the cargo area 200 and a hinged tailgate 240 forming a fourth wall of the cargo area 200.

[0027] The cover assembly 100 comprises a sheet of cover material 110, one end of which is attached to a roller mechanism 120 (see figure 10) housed inside a head box 160, while the other end is attached to a drawbar 130. In this way, the sheet of cover material 110 may be rolled on to or off the roller mechanism 120 in a known fashion.

[0028] The head box 160 and roller mechanism 120 are affixed at or near the top edge of the front wall 210 of the cargo area 200. The roller mechanism 120 is spring loaded for manual operation, where the spring acts to bias the roller mechanism 120 to roll the cover material 110 onto the roller mechanism 120. In use, a user would pull the drawbar 130 away from the roller mechanism 120 with sufficient force to overcome the spring. The user would then secure the drawbar 130 at a deployed position, at or near the tailgate 240 of the cargo area 200, using an engaging arrangement (explained in further detail below) such that the roller mechanism 120 is prevented from retracting, and tension is maintained in the cover material 110 by the spring.

[0029] The cover material 110 is preferably manufactured from a resilient weatherproof material, such as a PVC coated polyester woven fabric.

[0030] The cover assembly 100 further comprises a pair of guide tracks 140 which extend along the left and right side walls 220, 230 at or near the top edge of each of the walls 220, 230. The cover material 110 is retained along its side edges 111 by the guide tracks 140 (explained in further detail below) such that when the cover material 110 is in a deployed position, the cover material 110 spans across the entire cargo area 200 and is retained at its two ends and side edges, by the roller mechanism 120, drawbar 130 and guide tracks 140 respectively.

[0031] Referring to Figures 7 and 8, each guide track 140 defines a first channel 141 in which an end of the drawbar 130 runs. The first channel 141 of the guide track 140 further includes a longitudinally extending slot 142 extending into a longitudinally extending cavity 143.

[0032] As seen in figures 5, 6 and 7, the sheet of cover material 10 has longitudinal beads 112 formed along its side edges 111, where these beads 112 run in the longitudinal cavities 143 and where they are formed so as to have a shape and dimension which is greater than the width of the slot 142 so as to prevent their escape from the aforementioned longitudinal cavities 143. The beads 112 are a loose fit within the cavity 143 to provide clearance that enables low friction movement of the beads 112 in the cavity 143.

[0033] The beads 112 have a generally circular cross-section but may also be rectangular in shape, where a pair of longer sides of this rectangular shape extend in a direction across the sheet of cover material 110. The beads 112 according to this embodiment are comprised of a continuous extruded strip that is welded onto each edge of the cover material 110.

[0034] In addition to a continuous extruded form, the bead 112 may also comprise discrete elements spaced apart and positioned along the edge of the cover material 110 such as , for example, spherical elements that are spaced along the edge of the cover material 110. In addition, one half of a zipper may also be used. The zipper teeth are attached to a strip of material that can be welded or attached to the edge of the cover material 110. The use of plastic or metal zipper teeth have the added advantage of improved wear resistance and lower friction within the cavity 143.

[0035] Further, the use of discrete and spaced elements, including the example of one half of a zipper, is that the discrete elements will interlock or engage when rolled onto the roller 120. This assists in minimising the resultant diameter of the bead 112 on the roller 120 and assists in resisting unwinding of the bead 112 on the roller 120.

[0036] Referring now to Figure 6, where it can be seen that a similar retention method is employed where the sheet of cover material 110 meets the drawbar 130. A bead 114 or the like locates in a longitudinal cavity 131 of the drawbar 130, where the bead 114 is formed so as to have a shape and dimension which is greater than the width of a slot 132; this then prevents the escape of the bead 114 from the aforementioned cavity 131.

[0037] Referring to Figures 5, 6 and 7, a latch pin 137 is installed in each side of the drawbar 130 to lock it in place at the end of the guide track 140 adjacent the tailgate 240. Each latch pin 137 is stainless steel and is spring loaded outwardly into the locked position. A handle 138 is attached to each latch pin 137 with each handle 138 threadably attaching to the latch pin 137 through a cut-out or channel 139 in the drawbar 130. The latch pin 137 can be retracted against the spring force and its movement is limited by the handle 138 abutting against the end of the channel 139. The handle 138 and channel 139 are located on the underside of the drawbar 130 so that there is no access to the handle 138 for release of the latch pin 137 once the tailgate 240 is closed. As the tailgate 240 is lockable, this means that the cover assembly 100 provides a secure tamper resistant closure of the cargo area 200.

[0038] As can be seen from Figures 6 and 7, the extrusion that comprises the drawbar 130 has a cavity that is suited to locating the latch pin 137. A bung 185 can be pushed into position within this cavity and held in place via a tight fit. A spring can be placed between the end of the latch pin 137 and the bung 185 and the latch pin 137 is then held in place once the handle 138 is engaged with the pin 137. The channel 139 within which the handle 138 locates may have an extension 186 that allows the latch to be locked in an open position by rotating the latch pin 137 and handle 138 so that the handle locates in the extension 186. This then locks the handle 138 and latch pin 137 in this position.

[0039] In order to easily pull the drawbar 130 and attached cover material 110 from a fully open position to the closed and locked position, while standing behind the tailgate 240, a cord (not shown)is attached to the drawbar 130 and is long enough to extend to the tailgate area. This enables the cover assembly 100 to be moved into the closed position without having to reach the drawbar 130 from the side of the vehicle.

[0040] The latches, which are spring loaded, self-latch once pulled to the end of a mounting rail 180. The latch pins 137 slide against the flange 146 of the guide track 140, and move into the aperture 145 under the spring force once the latch pin 137 and aperture 145 align.

[0041] The cord maybe provided with Velcro-type securement points on the drawbar 130 and/or side walls 220 and 230 to enable the cord to be stowed in an elevated position away from the base 250 of the cargo area 200. The Velcro securement points can also be used to keep the cord to one side of the cargo area 200 while allowing it to be easily accessible when it is needed to close the cover assembly 100. The cord may be fed through a tie down fitting attached to the inside wall of one of the left or right side walls 220 or 230. The tie down fitting (not shown) is typically provided to secure cargo using ropes or cords and comprise a ring or eyelet through which the cord can be fed with the end of the cord being returned to a point where it can attach to a Velcro type retainer to hold it in place adjacent the mid-point of the drawbar 130.

[0042] The mounting rails 180 have a flange 181 that locates against the inside edge of the left and right side walls 220 and 230. Threaded fasteners are used to locate through the flange and into the left and right side walls 220 and 230 to secure the rails 180 in place. The guide tracks 140 locate within the mounting rails 180 and are secured via threaded fasteners or rivets that locate through the top surface of the rail 180 and through the guide track 140 on the side of the flange 146 opposite to the drawbar 130. Three for four screws or fasteners are used and spaced along each rail 180. The heads of the screws or rivets may be tapered so that their upper surface locates flush with the top surface of the rail 180.

The cover material 110 is located in the cavity 143 of each guide track 140 prior to the fixing of the guide track 140 to the mounting rail 180. With the cover material 110 fully extended, and with the drawbar 130 in its latched position, the position of the guide tracks 140 in the mounting rails 180 can be adjusted to find the position where the desired tightness is achieved in the cover material 110, where upon they can then be secured in place. The desired tension in the cover material 110 is such that the spine 150 can be inserted to lift the cover material 110 and have the required tightness. The adjustability of the guide track 140 with respect to the mounting rail 180 provides a significant advantage in achieving the required tension in the cover material 110 along the length of the cargo area 200.

[0043] Referring to Figures I to 4, where there is shown the cover assembly 100 with the sheet of cover material removed to reveal a rigid spine 150 having a square cross section, which extends longitudinally across the cargo area 200 between the headbox 160 and the drawbar 130. The spine 150 removably engages with headbox 160 and the drawbar 130 (explained in further detail below) and is positioned adjacent to the sheet of cover material 110. The spine 150 comprises a raised section 151 at a point intermediate its two ends such that it acts upon the cover material 110 to form an elevated region

113 in the cover material 110 such that the cover material 110 slopes downward from the elevated region 113 toward the guide tracks 140, drawbar 130 and head box 160 (as best shown in Figure 1).

[0044] It will be appreciated that the spine 150 is not limited to having a square cross section, and may take the form of a plurality of geometric shapes, such as circular, triangular, quadrilateral, or other polygonal shapes.

[0045] It will be appreciated that the combination of the tension in the cover material110, the elevated region 113, and the sloped arrangement of the cover material 110, assists in preventing rainwater (or other liquids or materials) from pooling on top of the cover material 110.

[0046] In use, rainwater would flow off the cover material 110, following the slope toward the guide tracks 140, drawbar 130 and head box 160. The guide tracks 140, drawbar 130 and head box 160 are configured such that water is directed so as not to flow in to the cargo area 200.

[0047] Referring to Figure 1 it can be seen that the cover assembly 100 may also incorporate transverse stiffening members 115 into the cover material 110 (2 or 3 each side of the spine 150), in order to prevent sagging, ponding, or a belly of water forming on top of the cover material110. The stiffening members 115 do not detract from the ability of the cover material 110 to be rolled on to the roller 120, or the ability to fit in to a small head box 160. The stiffening members 115 may be manufactured from fibreglass strips, or similar resilient material, and may be located in pockets (not shown) formed in the cover material 110 or attached directly to the cover material 110 by welding or adhesive.

[0048] As can be seen in Figure 8, the first channel 141 of the guide track 140 features a longitudinally extending lip 144 which acts as a gutter in order to assist with drainage of any leakage of moisture that may occur between the longitudinal bead 114, cavity 143 and slot 142, such that the moisture is directed away from the cargo area 100. The guide tracks 140 are configured to drain forward into the head box 160, which is configured to drain into standard outlets provided in the cargo area 200 (explained in further detail below).

[0049] In alternative embodiments, the lip may be replaced by a semi-circular, or other shaped runnel or gutter for the purpose of draining any leakage of moisture that may occur.

[0050] Referring now to Figures 9 and 10, where it can be seen that the head box 160 houses the roller 120, and comprises a top hood 161, a bottom section 162, and two end plates 164. As can be seen in Figure 10, where there is shown a partial cross sectional view of the head box 160, a bracket 165 is provided at each end of the head box 160, where the brackets (not shown) attach to each of the end plates 164 and acts as mounting points for end components of the roller mechanism 120.

[0051] The head box 160 features an opening 166 through which the cover material 110 extends and connects to the drawbar 130. The head box 160 may optionally feature a brush or wiper 167 which extends along the length of the opening 166 and acts to clean the cover material 110 before it enters the head box 160 and winds on to the roller mechanism 120.

[0052] As can be seen in Figure 10, the bottom section 162 of the head box 160 comprises a sloped floor 163 which drains toward at least one drainage point consisting of a hole in the floor 163 through which a grommet 168 is inserted and to which is attached an elbow fitting 169 and a drainage hose 170 which is plumbed in to standard outlets provided in the cargo area (not shown).

[0053] As previously discussed, the spine 150 removably engages with head box 160 and the drawbar 130 and is positioned adjacent to the sheet of cover material 110. Figures 9 and 10 show a spine receiving means 171 positioned approximately at a mid-point along the length of the head box 160 and underneath the opening 166 of the head box 160. The spine receiving means 171 comprises a square opening 172 for receiving the spine 150 with flared edges 173 shaped to assist a user locating the end of the spine 150 within the opening 172.

[0054] Referring now to Figures 11 and 12, where there is shown the spine 150 in connection with the drawbar 130. Positioned approximately at a mid-point along the length of the drawbar 130 and underneath the slot 132 is a spine receiving means 133. The spine receiving means 133 is affixed to the drawbar 130 via a pair of fasteners, however it is appreciated that the spine receiving means 133 could be affixed to the drawbar 130 in any manner. The spine receiving means 133 comprises a tongue 135 with raised sides 136 which locate the spine 150.

[0055] In use, the spine 150 would be secured in place underneath the deployed sheet of cover material by first orienting it correctly (with its raised section 151 on top) and then locating and inserting a first end of the spine 150 within the opening 172 of the spine receiving means 171 on the head box 160, the flared edges 173 of the spine receiving means 171 assisting a user in locating the spine 150 within the opening 172. The second end of the spine 150 may then be located on top of the tongue 135 and between the raised sides 136 of the spine receiving means 133. In order to locate the spine 150 on top of the tongue 135, the spine 150 will be lifted upwardly, against the sheet of cover material 110, and over one of the raised sides 136. Once in position at both ends, the spine 150 will be held in place by the two receiving means 171, 133 and downward pressure applied by the sheet of cover material 110.

[0056] In alternative embodiments, the spine 150 may be flexible or rigid, and may be inserted into alternative receiving means located on the head box 160 and draw bar 130 and rotated such that its raised section 151 is on top, and the receiving means lock the spine 150 in position. In addition to the use of a square cross-section metal spine 150, carbon or glass fibre reinforced plastic may also be used.

[0057] Throughout the specification and the claims that follow, unless the context requires otherwise, the words "comprise" and "include" and variations such as "comprising" and "including" will be understood to imply the inclusion of a stated integer or group of integers, but not the exclusion of any other integer or group of integers.

[0058] The reference to any prior art in this specification is not, and should not be taken as, an acknowledgement of any form of suggestion that such prior art forms part of the common general knowledge.

[0059] It will be appreciated by those skilled in the art that the invention is not restricted in its use to the particular application described. Neither is the present invention restricted in its preferred embodiment with regard to the particular elements and/or features described or depicted herein. It will be appreciated that the invention is not limited to the embodiment or embodiments disclosed, but is capable of numerous rearrangements, modifications and substitutions without departing from the scope of the invention as set forth and defined by the following claims.

Claims

1. A cover assembly for covering a cargo bed, the cargo bed comprising two pairs of opposing walls forming four walls of the cargo bed, the cover assembly comprising: a sheet of cover material, having two opposing ends and two opposing side edges, which is secured to a roller at one end and a drawbar at or toward the other end; a guide track extending along each of the side edges of the sheet of cover material such that the side edges of the sheet of cover material are retained by the guide tracks, wherein each guide track extends each of a pair of opposing walls of the cargo bed at or near a top edge of each of the opposing walls; an elongate spine extending between the roller and the drawbar, positioned adjacent to the sheet of cover material; wherein the spine acts upon the sheet of cover material to form an elevated region on the sheet of cover material such that the sheet of cover material slopes downward from the elevated region toward at least one of the guide tracks.

2. The cover assembly of claim 1, wherein each guide track comprises a first channel in which an end of the drawbar slidably locates.

3. The cover assembly of claim 2, wherein the first channel of the guide track further includes a longitudinally extending slot opening into a longitudinally extending cavity, and wherein the sheet of cover material has a bead extending along the side edges thereof so that the sheet of cover material extends through the slot and each of these beads is retained in the longitudinal cavity of a respective guide track.

4. The cover assembly of claim 2 or 3, wherein the first channel of the guide track further includes a longitudinally extending lip suitable for retaining water.

5. The cover assembly of claim 4, wherein the lip acts as a gutter in order to assist with drainage of any leakage of moisture that occurs between the longitudinal bead, cavity and slot, such that the moisture is directed away from the cargo bed.

6. The cover assembly of any of the preceding claims, further comprising a head box for housing the roller.

7. The cover assembly of claim 6, wherein the guide tracks are configured to drain forward into the head box, which is configured to drain into standard outlets provided in the cargo bed.

8. The cover assembly of claim 6 or 7, wherein the elongate spine is removably connected to the head box at one end and removably connected to the drawbar at another end