AU766381B2 - Tonneau cover - Google Patents

Description

Regulation 3.2

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT

(ORIGINAL)

Name of Applicant: Actual Inventor: Address for Service: Invention Title: TUFF TONNEAUS WHOLESALE PTY LTD of 16 Molan Street, Ringwood, Victoria 3141, Australia Nicholas John ARTHUR 1 Roseland Grove, Doncaster, Victoria 3108, Australia DAVIES COLLISON CAVE, Patent Attorneys, 1 Little Collins Street, Melbourne 3000, Victoria, Australia "TONNEAU COVER" Details of Associated Provisional Application No(s): PP9448 The following statement is a full description of this invention, including the best method of performing it known to me/us: P:\OPER\RJC\TONNEAU COVER.DOC 25/8/03 -2- TONNEAU COVER This invention relates to a tonneau cover for a vehicle.

Vehicles such as utilities, pick-up trucks and the like generally have a cabin behind which is an open storage compartment or space. The storage compartment or space enables transportation of articles exterior of the cabin, and such vehicles are typically used by tradesmen to carry tools and the like. The storage compartment can also be used for general transportation of goods if desired.

The open top of the storage compartment is generally covered by a tonneau cover which most typically comprises a flexible tonneau sheet formed from vinyl or like material. The sheet is secured to the periphery of the storage compartment by a rope or cord which is connected to the tonneau cover and which engages lugs on the side of the vehicle so as to tension the tonneau sheet over the storage compartment. This provides weatherproofing of articles within the storage compartment and also conceals the articles from view.

However, one problem with the above mentioned type of tonneau cover is that it does not provide any security for articles within the storage compartment and access can be gained to S: 20 the storage compartment by undoing the ropes or by simply slicing the tonneau sheet.

In order to provide a more secure tonneau cover, it is known to produce the cover from fibreglass, plastic, steel or aluminium. Such tonneau covers, for example, comprise a fibreglass moulded cover which is generally formed as a single integral unit and which is 25 coupled to the vehicle by struts or the like to enable the cover to be pivoted from a closed S position to an open position. A lock may be provided for locking the cover in the closed position. These covers provide the ability to lock the cover closed and also are difficult to break and thus provide good security for articles stored within the storage compartment.

However, one disadvantage of this type of cover is that it is relatively expensive being formed from fibreglass and furthermore, does not have the appearance of a conventional tonneau sheet. In order to provide the conventional appearance it is known to secure a P:\OPER\RJC\TONNEAU COVERDOC 25/8/03 -3tonneau sheet over the fibreglass cover but this further increases the cost of the total cover because of the need to provide the fibreglass cover as well as the flexible tonneau sheet.

These known covers are also relatively heavy.

The object of the present invention is to provide a tonneau cover which provides good security but which also is relatively inexpensive and lightweight.

The invention may be said to reside in a tonneau cover, including: a peripheral frame having a first connection portion and a second connection portion; a security panel coupled within the peripheral frame to the first connection portion of the frame; and a tonneau sheet having a coupling for engaging with the second connection portion to connect the tonneau sheet over the security panel and frame.

The formation of the cover from the security panel, peripheral frame and the tonneau sheet provides a relatively inexpensive structure which not only provides good security, but also has the appearance of a conventional flexible tonneau sheet. This structure also enables a S"relatively lightweight cover to be produced.

•oo• 20 The security panel can be formed from relatively inexpensive material and is thereby relatively less expensive than moulded fibreglass tonneau covers. In the preferred form of the invention, the security panel is formed from aluminium security mesh. In some embodiments, the security panel can be provided in two or more separate segments.

Preferably the first connection portion comprises flange portions extending inwardly from the peripheral frame, and the second connection portion comprises a first channel formed in an outer portion of the peripheral frame. Preferably the tonneau sheet has a clip coupled about the periphery thereof for location in the first channel to thereby couple the tonneau "sheet to the frame.

In one form of the invention the flange of the first connection portion is in the form of an inwardly facing channel. In that case, the security panel can be coupled to the frame by P:\OPER\RJC\TONNEAU COVERDOC 25/8/03 -4locating a peripheral portion of the security panel into the inwardly facing channel of the peripheral frame to thereby couple the panel to the frame.

Preferably the frame is formed from an extrusion and comprises first, second, third and fourth side frame sections which are coupled together to form said peripheral frame having a rectangular configuration.

In the preferred form of the invention, the cover has a hinge member for pivotal coupling to a vehicle to enable the cover to be pivoted from a closed position to an open position. The cover may also have a lock for locking the cover in the closed position. At least one gas strut may be provided, coupled between the cover and the vehicle to hold the cover when in the open position.

In one embodiment the cover has at least one segment which is hinged to the remainder of the cover to enable the segment to be opened relative to the remainder of the cover.

A preferred embodiment of the invention is described in greater detail hereinafter, by way of S"example, with reference to the accompanying drawings, in which: Figure 1 is a schematic plan view of a vehicle including a tonneau cover according to the 20 preferred embodiment of the invention; S o: Figure 2 is a cross-sectional view along the line II-II of Figure 1; Figure 3 is a cross-sectional view of a frame member extrusion shown in isolation; Figure 4 is a schematic side view of a vehicle including a cover according to the preferred embodiment; 25 Figure 5 is a cut-away view of a front frame member hinged coupling; SFigure 6 is a plan view of an elbow member used in the preferred embodiment; Figure 7 is a side view showing an alternative embodiment of the invention; and Figure 8 is a cross-sectional view of a portion of a tonneau cover in accordance with another embodiment of the invention.

With reference to Figure 1, a vehicle 10, such as a utility, is shown in plan view, having a cabin 12 and a rear storage space 14 located behind the cabin. The storage space 14 is P:\OPER\RJC\TONNEAU COVERDOC 25/8/03 covered by a tonneau cover 5 constructed according to a preferred embodiment of the invention.

The tonneau cover 5 has a generally rectangular peripheral frame 16 comprising left and right side frame members 18, 20, a front frame member 22 and a rear frame member 24, the frame members are connected together at comers of the peripheral frame by elbows 30. The peripheral frame 16, when fitted to a vehicle 10O, is positioned at least substantially along the upper edge of tray walls of the vehicle which define the rear storage space 14.

The frame 16 supports a security panel 50 which extends across the entire internal area defined by the frame. Edges of the security panel 50 are attached along respective inner edges of the frame 16, as described in greater detail hereinbelow. The security panel 50 can be formed from a plurality of sections, if desired. Where a plurality of security panel sections are used, it is preferred that cross frame members be provided where the panel sections abut. Cross frame members 61 and 61 are shown in Figure 1, extending between the left and right frame members 18, 20, parallel to the front and rear frame members 22, 24.

Even if the security panel 50 is formed in a single section, one or more cross frame members may nevertheless be desirable to enhance the rigidity of the tonneau cover.

oooe 20 A tonneau sheet 40 extends over the security panel 50 and peripheral frame 16, and is secured to the peripheral frame 16 as described below in connection with Figure 2. The tonneau sheet 40 is shown partially cutaway in Figure 1 so as to illustrate the security panel therebeneath. The tonneau sheet is preferably formed from a vinyl material or the like, similar to a conventional tonneau sheet, thereby maintaining a conventional tonneau cover 25 appearance.

SFigure 2 is a cross-sectional view of the tonneau cover through II-I in Figure 1, and illustrates the structure of the frame member (20) and attachment between the frame, ooo• S 3 security panel and tonneau sheet. The frame members 18 to 24 are formed by extrusion and are all identical in cross-section. The extrusion cross-section is shown in isolation in Figure 3. The frame members 18-24 can be cut from a single extrusion or extruded to a specific length in order to form the peripheral frame 16.

P:\OPER\RJCTONNEAU COVERDOC- 25/8/03 -6- As seen best in Figure 3, the frame member 20 shown in cross-section comprises a base wall 32, an upstanding inner side wall 33, and a downwardly curving outer side wall 34. Toward the top of the inner side wall 33 there is formed a security panel attaching flange 35. An upwardly sloping outer wall 36 extends from the outer edge of the base wall, sloping toward the side wall 33, and is joined to the downwardly curving outer side wall 34 by an end wall 37. A portion 38 of the downwardly curving outer side wall 34 overhangs the upwardly sloping outer side wall from the join of the end wall 37, thus forming an upwardly angled channel 39 defined by the overhanging portion 38, the upwardly sloping outer side wall 36 and the end wall 37.

In use, the frame member extrusion is arranged so that the security panel attaching flange extends inwardly of the peripheral frame when constructed. As seen in Figure 2, the edge of the security panel 50 overlies the flange 35, and is attached thereto by welding or some other suitable form of bonding so that the security panel 50 is securely connected to the peripheral frame 16. In an alternative construction, the extrusion can be formed with two inner flange portions spaced apart to form a channel marginally larger than the thickness of the security panel 50. Then, the edges of the security panel can be held within that channel around the eeoo 0 inner portion of the peripheral frame 16, thus securing the panel 50 and frame 16 together S: 20 without requiring welding or the like.

The flexible tonneau sheet 40 is formed from vinyl material in the preferred embodiment, as is conventional, and has secured about its periphery a sealing clip 51 which generally comprises a strip of plastic material which is sewn, adhered or otherwise fixed to the 25 periphery of the tonneau sheet 40. As best shown in Figure 2, the periphery 43 of the .00 tonneau sheet wraps around the strip 51. In order to secure the tonneau sheet 40 to the frame o 16, the clip 51 is inserted into the channel 39 and the tonneau sheet stretched over the top of o othe security panel 50 and downwardly curving outer side walls 34 of the frame members.

The clip 51 connected about the periphery of the tonneau cover is secured within the channels 39 of the frame sections and may be held in place there by a friction fit in the channels or with the use of an adhesive. Thus, the tonneau cover 40 is stretched across P:\OPERRCTONNEAU COVERDOC 25/8/03 -7security panel 50 and the frame members 18- 24 and securely coupled to the frame members 18-24.

It should be noted that the clip 51 which is formed from the strip of plastic material extends the length of the peripheral side portions of the cover 40 but is generally not provided in the elbow sections 30 of the cover.

The base wall 21 of the frame members may have a rubber pad 42 connected to its underside where it will engage the upper edge of side wall 11 of the storage space 14 of the vehicle (Figure 2).

The elbows 30 may comprise metal brackets or the like which merely insert into the hollow interior 43 of the frame members and which are bolted, riveted or otherwise secured to the frame members in order to secure the frame members together. In other embodiments, the elbows 30 may take the configuration shown in Figure 6 which have a body portion 97 which has short arms 99 extending from each end which are received in the hollow opening 43 of the frame members (Figure 2) so as to secure the frame members together. The arms 99 may be a solid friction fit or alternatively could be glued, bolted or otherwise attached to the frame sections in order to couple the frame sections 18 to 24 together.

Alternatively, the frame members can be attached to one another to form the peripheral frame 16 without the use of elbows 30, simply by cutting the frame member extrusion ends at appropriate angles and welding the angled ends together.

25 Where cross frame members 60, 61 are included in the tonneau cover construction, the ends S" thereof are attached to the side walls 33 of the side frame members 18, 20. The cross frame members 60, 61 can be of a box cross-section, for example, with a flat upper surface to which the underside of the security panel can be attached in the same manner as the security 3 panel is attached to the flanges 35 of the frame members.

On the other hand, the cross frame members can be of an I-shaped cross-section with channels adapted to receive edges of the security panel 50, particularly where the panel 50 is P:\OPER\RWJC\TONNEAU COVER.DOC- 25/8/03 -8formed in several sections, and channel flanges 35 are used to secure the panel to the peripheral frame. In that case, the cover shown in Figure 1 can be assembled by joining the side frame members 18 and 20 to the front frame member 22 by elbows 30 and then sliding a first section of the security panel 50 into place along the opposed flange channels of the frame sections 18 and 20 and into engagement with the frame member 22. The first cross-member 60 can then be located in place so as to engage the remainder of the periphery of the first panel section. The next panel section can then be slid into the opposed channels of the frame members 18 and 22 and cross frame member 60. The second cross frame member 61 is then located in place, and the final panel section can then be slid into place and the entire assembly secured by the rear frame member 24, coupled to the side frame members 18, 20 by elbows It should be understood that the above assembly merely represents one way in which the cover can be assembled from the components previously described. Other methods of assembly are also possible.

Figure 8 shows another possible construction of the frame in accordance with an embodiment of the present invention, shown from the same view as Figure 2 and employing 2 the same reference numerals where appropriate. As can be seen from Figure 8, in this embodiment the plastic strip 41 extends from the channel 39 of the frame member marginally below the base wall 32 of the frame member. The edge of the tonneau sheet is sewn or stapled, for example, to the plastic strip 41 along the protruding portion of the strip. In this embodiment, a strip of rubber material 62 is provided around the protruding edge of the plastic strip 41, which takes the place of the rubber pad 42 shown in Figure 2.

The rubber strip 62 has a channel within which the protruding edge of plastic strip 41 is seated in use. The rubber strip 62 may be similar to the material commonly used for sealing around vehicle doors for example. The rubber strip 62 protrudes beneath the base wall 32 of the frame member to thus cushion the tonneau cover on the vehicle storage compartment """wall 11, as shown in Figure 8. Additionally, in this embodiment as illustrated, an S 30 underneath cover material 64 is provided which extends across the underside of the security panel 50 and cross frame members 60, 61 as well as the underside surfaces of the peripheral frame 16. The edge of the underside cover material lies between the frame member and the P:\OPERUC\TONNEAU COVERDOC- 25/8/03 -9rubber strip 62. The underside cover material may comprise a fibrous matting or carpet-like material, for example, and is preferably affixed to the underside of the tonneau cover with adhesive.

Figure 4 shows a schematic side view of a vehicle 10 with a tonneau cover 5 fitted. The cover has at least one gas strut 70 pivotally connected to it on a ball joint 72 which is fixed to a bracket (not shown) coupled to the side frame member(s) 18 and/or 20. The other end of the strut 70 is pivotally coupled to inner of the side wall 11 of the storage compartment 14 of the vehicle. The gas struts so coupled between the vehicle side walls and tonneau cover can assist in pivotally lifting the tonneau cover about the forward edge thereof for ease of access to the interior of the storage compartment 14. The tonneau cover 5 as seen in Figure 4 is in a partially lifted position.

In order to attach the tonneau cover to the vehicle, a pivotal connection is provided between the front frame member 22 and the front edge of the storage compartment wall. In the preferred embodiment, such pivotal connection is provided a plurality of curved tongues attached to the front frame member 22 which interfit with brackets on the vehicle storage compartment wall. One such tongue and bracket coupling is shown in side cut-away view in Figure 5. As illustrated, a tongue 84 is attached to the base wall 32 of the frame member 22, 20 and extends forwardly curving upward. The extending portion of the tongue 84 passes *o through a slot 83 in a female bracket 82. The female bracket is L-shaped with a base portion attached to the vehicle and an upstanding portion formed with the slot 83. The bracket 82 is secured by the base portion to the front storage compartment wall 80 adjacent rear cabin wall 92 of the vehicle cabin 12. The tongues 84 and brackets 82 form a hinge so that the 25 cover 5 can be lifted into an open position by pivotal movement as indicated by arrow A in Figure 5. In use, the tonneau cover is held in the open position by the air strut 70 (Figure 4) until downward pressure is applied to cause the air strut 70 to collapse and pivot into a fully closed position with the cover 5 resting on side walls 11 of the vehicle. The tongue and 3 bracket coupling also allows for the tonneau cover to be easily remove from the vehicle.

This is achieved by detaching the air struts from the tonneau cover and then pivoting the rear of the cover 5 up beyond its normal angle, whereby the tongues 84 disengage from the bracket slots 83. However, it will be appreciated that whilst the cover is in its horizontal P:\OPER\RJC\TONNEAU COVERDOC 25/8/03 position (such as when the vehicle is driven), the tonneau cover cannot slide back because the upwardly curved tongues catch on the upstanding bracket portions to prevent such undesired movement.

At the rear of the tonneau cover 5, a locking mechanism is provided so that, when locked, the tonneau cover cannot be lifted, tilted or otherwise removed from over the vehicle storage compartment. A locking mechanism for that purpose is illustrated in Figure 1, having a rotatable keyed lock 52 accessible from the top of the tonneau cover at the rear thereof. The keyed lock operatively rotates an arm member supported beneath the security panel of the tonneau cover to push and pull on locking rods 53 which extend along the underside of the cover to the side walls of the storage compartment. In the locked orientation of the lock 52 the distal ends of the rods 53 engage in holes in the storage compartment side walls, or brackets fitted thereto, which holds the tonneau cover in place. In the unlocked configuration the locking rods 53 are disengaged from the respective side walls to allow the tonneau cover to move for access to the storage compartment.

Figure 7 shows another embodiment of the invention which is identical to that previously described except that the cover 5 has a rear segment 5a which is pivotal relative to the .g• Sremainder of the cover as indicated by arrow B in Figure 7. The segment 5a enables the S. 20 back portion of the storage compartment 10 to be open so that articles which are higher than the tray depth of the storage compartments can be loaded into the vehicle without the need to completely remove or open the cover 5. All that is necessary is for the segment 5a to be open so that the articles can be loaded in and project above the height of the cover 5 and thereby be transported.

se* The segment 5a can be coupled to the remainder of the cover 5 by a hinge 101 which may extend along one of the cross- frame members 60 or 61. Alternatively, two cross-frame members 61 may be arranged in side by side relationship with the hinge being therebetween.

S 30 The security panel 50 may be formed from any solid material, but most preferably comprises aluminium security mesh. This is a mesh of rigid aluminium members with holes of several square inches between the joined members. Such aluminium security mesh is typically used P:\OPER\RJC\TONNEAU COVERDOC 25/8/03 -11in the construction of security doors for houses, often covered with fly-screen material. The aluminium security mesh has been found to be particularly useful applied to the present invention, because it is lightweight yet rigid and not easily breached. Even though the security mesh has holes of several square inches, these holes are typically not large enough for an adult to reach a hand through and also too small for most tools and the like to be removed therethrough from the storage compartment.

The preferred embodiment of the invention thus provides a cover which provides security for articles in a storage compartment of a vehicle and also one which has the appearance of a conventional tonneau cover formed only from a flexible vinyl tonneau sheet. The cover can be easily removed from the vehicle by disengaging the tongues 84 from the female brackets 82 secured to the vehicle cabin 10 and by releasing the air struts 70 from the storage compartment walls 11.

The security panels 50 prevent access being gained to the interior of the storage compartment by cutting the tonneau sheet 40 or removing the tonneau sheet 40 from the peripheral frame 16.

The foregoing detailed description of the present invention has been present by way of 20 example only, and since modifications within the spirit and scope of the invention may S•readily be effected by persons skilled within the art, it is to be understood that this invention is not limited to the particular embodiments described hereinabove.

Throughout this specification and claims which follow, unless the context requires 25 otherwise, the word "comprise", and variations such as "comprises" and "comprising", will °be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

3 The reference to any prior art in this specification is not, and should not be taken as, an acknowledgment or any form of suggestion that that prior art forms part of the common general knowledge in Australia.

Claims (2)

12- THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS: 1. A tonneau cover, including: a peripheral frame having a first connection portion and a second connection portion; a security panel coupled within the peripheral frame to the first connection portion of the frame; and a tonneau sheet having a coupling for engaging with the second connection portion to connect the tonneau sheet over the security panel and frame. 2. A tonneau cover as claimed in claim 1, wherein the security panel comprises a rigid metal mesh panel. 3. A tonneau cover as claimed in claim 2, wherein the first connection portion comprises flange portions extending inwardly from the peripheral frame. 4. A tonneau cover as claimed in claim 3, wherein the second connection portion comprises a first channel formed in an outer portion of the peripheral frame. .ooo A tonneau cover as claimed in claim 4, wherein the flange of the first connection S0 20 portion is in the form of an inwardly facing channel. 6. A tonneau cover as claimed in claim 5, wherein the security panel is coupled to the frame by locating a peripheral portion of the security panel into the inwardly facing channel of the peripheral frame to thereby couple the panel to the frame. 7. A tonneau cover as claimed in claim 6, wherein the frame is formed from an 000. extrusion and comprises first, second, third and fourth side frame sections which are coupled together to form said peripheral frame having a substantially rectangular configuration. 8. A tonneau cover as claimed in claim 4, wherein the tonneau sheet has a clip coupled about the periphery of thereof for location in the first channel to thereby couple the tonneau sheet to the frame. P:\OPER\RJC\TONNEAU COVER.DOC- 25/8/03 -13- 9. A tonneau cover as claimed in claim 8, wherein the cover has a hinge member for pivotal coupling to a vehicle to enable the cover to be pivoted from a closed position to an open position. A tonneau cover as claimed in claim 9, wherein the cover has a lock for locking the cover in the closed position. 11. A tonneau cover as claimed in claim 8, wherein the cover has at least one segment which is hinged to the remainder of the cover to enable the segment to be opened relative to the remainder of the cover. 12. A tonneau cover as claimed in claim 9, wherein the cover has at least one strut for coupling with the vehicle to hold the cover when in the open position.

13. A tonneau cover substantially as hereinbefore described with reference to the accompanying drawings. 9* 20 DATED this 25th day of August 2003 TUFF TONNEAUS WHOLESALE PTY LTD By DAVIES COLLISON CAVE Patent Attorneys for the Applicant 0 00