U.S. patent application number 10/422311 was filed with the patent office on 2003-10-23 for method of making cover system for truck box with fastening means.
Invention is credited to Dimmer, Jerry R..
Application Number | 20030197394 10/422311 |
Document ID | / |
Family ID | 21695770 |
Filed Date | 2003-10-23 |
United States Patent
Application |
20030197394 |
Kind Code |
A1 |
Dimmer, Jerry R. |
October 23, 2003 |
Method of making cover system for truck box with fastening
means
Abstract
A fastening system for a flexible cover system for a truck box
includes a first fastening material on the side edges of the
flexible cover and a second fastening material that releasably
engages with the first fastening material. The second fastening
material comprises a fastening surface bonded to a substantially
rigid elongated slat, and is slidingly received in channel portions
of side rails mounted on the side of the truck box. The first
fastening material can be one member of a hook and loop type
fastener and the second fastening material can be the mating member
of the hook and loop type fastener.
Inventors: |
Dimmer, Jerry R.; (Yankton,
SD) |
Correspondence
Address: |
JONES DAY
77 WEST WACKER
CHICAGO
IL
60601-1692
US
|
Family ID: |
21695770 |
Appl. No.: |
10/422311 |
Filed: |
April 24, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10422311 |
Apr 24, 2003 |
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10001384 |
Oct 31, 2001 |
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6568740 |
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Current U.S.
Class: |
296/100.16 |
Current CPC
Class: |
B60J 7/085 20130101 |
Class at
Publication: |
296/100.16 |
International
Class: |
B60P 007/04 |
Claims
I claim:
1. An improved cover system for an open top container or truck box,
the open top container or truck box having a front wall, a rear
wall, and two side walls, wherein at least one of the walls has a
top edge, the system having a flexible cover material with
dimensions approximately the same as the dimensions of the open top
and an upwardly facing and a downwardly facing surface, a first
fastening means disposed along at least a portion of at least one
side edge of the downwardly facing surface of the flexible cover
material, and a rail capable of being mounted adjacent the edge of
the wall and having an outwardly facing portion defining an
elongated channel portion, wherein the improvement comprises: an
elongated, substantially rigid second fastening means having an
integrally formed fastening surface positioned to engage the first
fastening means, the second fastening means being dimensioned to be
capable of longitudinal slideable engagement with the channel and
also dimensioned to be incapable of lateral movement from the
channel, wherein the second fastening means is prevented from
longitudinal escape from the channel.
2. The cover system of claim 1 wherein two of the side walls have
top edges and two of the side edges of the cover material have
downwardly facing fastening means, and further comprising a second
rail, wherein the two rails are capable of being mounted on the two
top edges.
3. The cover system of claim 1 wherein the first fastening means
and the fastening surface of the second fastening means are
selected from the group consisting of loop bearing material and
hook bearing material.
4. The cover system of claim 2 wherein the rails are made of
materials selected from the group consisting of extruded aluminum
and plastic.
5. The cover system of claim 2 wherein the side rails further
comprise a mounting flange.
6. The cover system of claim 2 wherein the side rails are secured
to the top edges by means selected from the group consisting of
bolts, rivets, screws, and C-clamps.
7. The cover system of claim 1 wherein the channel is substantially
vertical.
8. The cover system of claim 1 wherein the channel is configured in
an inclined orientation.
9. The cover system of claim 1 wherein the second fastening means
is prevented from longitudinal escape by a rivet.
10. In a method of making a cover system for an open top container
or truck box, the system comprising a flexible cover having
dimensions approximately the same as the open top, the flexible
cover material having an upwardly facing surface and a downwardly
facing surface, the flexible cover material having strips of first
fastening material disposed along at least a portion of two side
edges of the downwardly facing surface, the open top container
having strips of second fastening material integrally formed with
an elongated slat mounted on a side rail substantially at a top
edge of a wall of the container or truck box, the first fastening
material and the second fastening material being reversibly
engageable with one another to fasten the cover to the open top,
the improved method of manufacture comprising: first, slideably
introducing the second fastening means into the channel along the
channel's longitudinal axis; and, second, blocking slideable escape
of the second fastening means.
11. The method of claim 10 wherein the slideable escape is
prevented by at least one rivet.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 10/001,384, filed Oct. 31, 2001.
BACKGROUND OF THE INVENTION
[0002] This invention relates to a cover system for an open
compartment. In particular, the invention relates to a cover system
suitable for covering the open box, or cargo compartment, of a
pick-up truck.
[0003] It is known in the art to provide a cover made of a flexible
material and adapted to cover the box of a pick-up truck or the
like, to protect the contents thereof from the elements. Such a
cover can be made of fabric, flexible plastic, or other sheet
material. The cover is commonly secured to a metal frame on the
edge of the box with a method of reversible attachment. Because
pick-up trucks typically are used and stored outdoors, the fabric
and the means of attachment of the fabric to the frame are exposed
to the elements which can include heavy moisture and extreme heat
and cold, as well as dust, mud, rocks and other materials
transported in the box.
[0004] The exposure to the elements creates problems for the
covering and the structure used to reversibly attach the cover to
the frame. Efforts to use convenient structures for attaching the
cover to the metal structure tend to be subject to exposure to the
elements and wear from repetitive use of the attachment means under
those conditions. Moreover, exposure to heat and cold cause the
covering to expand and contract, making the cover either loose and
wrinkled in appearance, or making it difficult to secure the
covering in the closed position.
[0005] A prior art attachment design for convenient reversible
attachment of the covering to the frame uses a hook and loop
fastening system sold under the trademark VELCRO.RTM.. In this
system, strips of hook-bearing material are adhesively attached to
a metal frame secured to the upper edges of the side of the truck
box. Strips of loop-bearing material are permanently affixed to the
downwardly facing surface of the cover material at its side edges
opposite the metal frame. When the cover material is aligned over
the truck box, and the strips of loop-bearing material on the
downwardly facing side edges of the cover are pressed into contact
with the strips of hook-bearing material adhesively fixed to the
outer walls of the frame, such that a reversible yet secure mating
is obtained. Although this system works well when first installed,
it suffers from deterioration over time due to the repetitive
pulling on the VELCRO.RTM. material attached to the frame in a
direction away from the frame, particularly because it also is
exposed to the elements. Specifically, the adhesive that attaches
the hook-bearing strips to the frame will deteriorate over time
because of the pulling motion which occurs when the cover is
detached from the frame, and because of exposure to sun, moisture,
and extreme temperature fluctuations. Moreover, heat or cold can
cause the length and width dimensions of the cover and the frame to
expand and contract, causing stresses in the adhesive bond of the
VELCRO.RTM. material to the frame even when the cover is secured
over the box.
[0006] It is thus one object of the invention to provide an
attachment system for use with a cover for a truck box that
provides a reversible yet secure attachment of the cover to the
box, but will be resistant to deterioration as a result of repeated
removal of the cover from the frame and exposure to the
elements.
[0007] It is still another object of the invention to provide an
attachment system for use with a cover for a truck box that
provides an easily attachable and detachable covering without the
prior art disadvantages of deterioration over time as a result of
stresses applied during use.
SUMMARY OF THE INVENTION
[0008] In one inventive aspect of the disclosed subject matter, a
cover system for a truck box or open top container is provided
comprising a flexible cover material of approximately the same
dimensions as the opening of the truck box or container, the
flexible cover material having first fastening means in the form of
strips of loop-bearing material fixedly attached at its sides, side
rails capable of being mounted generally along the upper edges of
the side walls of the truck box, each said side rail having an
outwardly facing surface defining a channel portion, and second
fastening means being in the form of substantially rigid strip
members having strips of hook-bearing material bonded thereto, said
substantially rigid strip members being receivable in laterally
sliding engagement in said channel portions of said side rails, and
obstructed from sliding out.
[0009] The foregoing system eliminates the adhesive mounting of the
second fastening means directly to the frame at the edge of the
truck box, as in prior art systems. By eliminating the adhesive
holding one portion of the hook and loop fasteners to the frame,
the instant invention eliminates wear problems associated with the
repeated force of separating the hook portion from the loop portion
of the connectors, and with poor initial and long term adhesion and
weathering.
[0010] Another inventive feature of the disclosed cover system for
an open top container or truck box comprises a flexible cover of
approximately the same dimensions as the container or truck box,
said flexible cover having a front edge and a rear edge, said front
edge of said flexible cover being affixed to a front header
apparatus, said front header apparatus spanning the width of said
truck box or open top container and being adjustably mounted at the
front end thereof, said rear edge of said flexible cover being
permanently affixed to a rear header apparatus, said rear header
apparatus spanning the width of said truck box or open top
container and capable of being releasably secured to said rear end
thereof, and an adjustable tension control assembly that provides a
forwardly biased force against said front header apparatus to urge
said front header toward the front of the truck box or open
container so as to maintain said flexible cover material in a taut
condition, or to relieve stress due to contraction of the
cover.
[0011] In one embodiment, the side rails are in the form of
aluminum extrusions that provide channel portions to receive said
second fastening means and support members for supporting said
front header apparatus, said rear header apparatus, and said
tension control assembly.
DESCRIPTION OF THE FIGURES
[0012] The following detailed description of the invention can be
better understood with reference to the accompanying drawings,
wherein
[0013] FIG. 1 is an exploded perspective view of a cover system in
accordance with the instant invention, with the flexible cover and
front and rear header illustrated in a rolled-up condition;
[0014] FIG. 2 is a side cross-sectional view of a side rail mounted
on a rim of a truck box in accordance with the instant
invention;
[0015] FIG. 3 is a front elevation view of a segment of a second
fastening means capable of being mounted on a side rail of the
instant invention;
[0016] FIG. 4 is a view along line 4-4 of FIG. 3;
[0017] FIG. 5 is a perspective view of the right front corner of
the cover system of the invention without the flexible cover,
showing the side rail, the front header apparatus, and the tension
control assembly;
[0018] FIG. 6 is an elevation view of a front header apparatus
showing the header guide with respect to the side rail;
[0019] FIG. 7A is a side cross-sectional view of the front header
apparatus showing engagement by the tension control assembly before
the rear header is locked in position; and
[0020] FIG. 7B is a side cross-sectional view of the front header
apparatus showing engagement by the tension control assembly after
the rear header is locked in position.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT
[0021] As illustrated in FIG. 1, a truck box 10 as is well-known in
the art comprises a front wall 12 having a top rim 13, and side
walls 14, 16 having top rims 15, 17, said rims having inwardly
facing downwardly extending lips 18, 19, respectively. Mounted on
side wall top rims 15, 17 are side rails 20, 30, respectively. Side
rail 30 will be described in detail, it being understood that side
rail 20 is a substantially identical mirror image of side rail 30.
As seen in FIG. 2, side rail 30 comprises vertical depending flange
32 of similar dimension to downwardly extending lip 19 and adapted
to abut thereto. A resilient rubber or rubber-like seal 33 such as
a strip of weatherproofing material can be disposed between
downwardly extending lip 19 and vertical depending flange 32 to
provide sealing and slip-resistant contact. While side rail 30 can
be mounted to downwardly extending lip 19 of truck side wall 16 by
known mechanical means such as bolts, rivets, screws, and the like,
a preferred mounting means comprises a plurality of C-clamps, 42,
which do not require holes to be drilled or punched in either lip
19 or side rail vertical flange 32.
[0022] Vertical depending flange 32 is connected by shoulder 34 to
channel portion 36. Channel portion 36 comprises outwardly facing
substantially flat surface 37, terminating at its upper
longitudinal edge at curved surface 38 and terminating at its lower
longitudinal edge at curved surface 39. The surfaces 37, 38, 39
together define a channel capable of receiving a member in the
configuration of an elongated slat. Channel portion 36 is shown as
substantially vertical, although it can also be in an inclined
configuration. Extending inwardly from the lower inwardly facing
surface of channel portion 36 is horizontal support flange 40,
discussed in greater detail below.
[0023] Side rail 30 is preferably made by extrusion, and preferably
is made of a strong, lightweight, rustproof material. Anodized
aluminum has been found suitable for this purpose; certain strong
plastics may also find utility herein.
[0024] FIG. 2 generally illustrates flexible cover material 45
having first fastening means 47 disposed along the downwardly
facing side edges thereof. First fastening means 47 preferably
comprises strips of loop bearing material permanently affixed to
flexible cover material 45 by means such as stitching, adhesives,
chemical bonding, fusion, and the like.
[0025] Further in accordance with the invention, and as illustrated
in FIGS. 3 and 4, second fastening means 50 comprises somewhat
rigid elongated slats 52 having a rear surface 51 and a front
surface 53. Integrally formed on front surface 53 are
longitudinally extending ridges 55, 56 which define surface 53 into
end shoulders 57, 58 and central slot 59. A strip of hook-bearing
material 54 is permanently affixed to central slot 59, such as by
adhesives, chemical bonding, thermal fusion, or the like. Elongated
slats 52 are sized and dimensioned such that shoulders 57, 58 are
received in sliding engagement by curved surfaces 38 and 39 of said
channel portion 36. Somewhat rigid, elongated slats 52 already
having hook-bearing material 54 permanently attached to a surface
thereof are commercially available in roll-form from VELCRO USA. It
is believed that resilient or rigid products having fastening hooks
are sold by VELCRO USA under the trademark SOFT HARDWARE. Suitable
lengths of second fastening means 50 are cut from the roll and slid
into channel portions 36. If desired, the second fastening means 50
can be further secured within channel portion 36 by simple
mechanical means such as a single pop-rivet disposed at about the
longitudinal center of channel portion 36. In this manner, both
second fastening means 50 and channel portion 36 can undergo
expansion and contraction due to fluctuations in ambient
temperature without warping, bending, or otherwise distorting the
substantially flat configuration of second fastening means 50.
[0026] To use the cover system of the invention, the flexible cover
material 45 starts in a rolled-up position adjacent front wall 12
of truck box 10 as shown in FIG. 1. A front header apparatus,
discussed in greater detail below, connects the front edge of
flexible material 45 to the top of front wall 12. The user unrolls
the flexible cover material 45 from the front of the truck box to
the rear of the truck box. The rear edge of the flexible material
45 is connected to a rear header apparatus that snaps into a
locking mechanism at the rear of the truck box, as is known in the
art. After the rear header apparatus is locked into place, the user
simply presses first fastening means 47 located at the side edges
of the downwardly facing surface of flexible material 45 against
second fastening means 50. First fastening means 47 and second
fastening means 50 will engage one another to provide a
weatherproof seal without gaps that will protect the contents of
truck box 10 from rain, wind, and blowing debris. To remove the
cover, the rear header apparatus is unsnapped from the rear locking
mechanism and the flexible cover material 45 is simply rolled up
toward the front of the truck box. There is no need to detach first
fastening means 47 from second fastening means 50 prior to rolling
up flexible material 45. The rolling action of the flexible
material 45 creates a lifting force that serves to detach first
fastening means 47 from second fastening means 50 at the point at
which the flexible material 45 is being rolled along its length.
Advantageously, the fastening system of the instant invention
maintains that portion of flexible material 45 that has not yet
been rolled up in a taut condition. This facilitates rolling of the
flexible material into a neat, tightly wound roll that is easily
stored.
[0027] Although the invention has been described herein with the
hook-bearing material mounted on the frame and the loop bearing
material mounted on the flexible cover, the roles of the hook and
loop bearing materials could be reversed and the system would
achieve substantially the same effect.
[0028] Another aspect of the invention relates to a means for
maintaining the flexible cover material in a taut condition when it
is covering the truck box. The front edge of flexible material 45
is permanently affixed to front header apparatus 65, which extends
substantially the full width of truck box 10. Front header
apparatus 65 includes front header body 67 which is preferably made
of a lightweight, strong, rustproof material such as aluminum or
certain plastics. Anodized aluminum is preferred. The front end of
front header body 67 is provided with header seal 68, which can be
made of a resilient rubber or rubber-like material such as
weather-stripping material. Header seal 68 is sufficiently
resilient to provide a constant seal between front header apparatus
and top rim 13 of front wall 12 of truck box 10, as the position of
front header body is longitudinally adjusted as discussed below. In
the illustrated embodiment, the lateral edge areas of the bottom
surface of front header body 67 rest on the top surface of support
flanges 40 of side rails 20, 30. The bottom surface of front header
body 67 is provided on each side with a header guide 70, only one
of which will be described. Header guide 70 has on its top surface
a protruding lug 72 which extends into cavity 69 on the bottom
surface of front header body 67. The top surface of header guide 70
also has shoulder 74 that defines shelf 75, which fits underneath
the bottom surface of support flange 40 of side rail 30. The header
guides 70 on each side of front header body 67 thereby prevent
front header apparatus 65 from slipping off support flanges 40, and
further maintain front header body 67 in a substantially parallel
position across truck box 10, even as the longitudinal position of
front header body 67 is adjusted as discussed below.
[0029] A tension control assembly 80 is disposed behind each side
of front header body 67. Only one such tension control assembly 80
will be described herein, it being understood that the other
tension control assembly is essentially a mirror image. Tension
control assembly 80 includes a bracket 82 fixedly mounted to
support flange 40 of side rail 30 by means such as bolt 84. Bracket
82 includes internally threaded collar member 86 in which is
mounted spring plunger 88. Bracket 82 and internally threaded
collar member can be formed as separate elements, or can
advantageously be formed as a one-piece extrusion. Spring plunger
88 comprises externally threaded cylinder 92, the threads of which
mate with the internal threads of collar member 86. Seated within
the rear end of threaded cylinder 92 is a spring (not shown) which
at its forward end engages the rear of nose 89. The front of nose
89 engages rearward projection 66 extending from front header body
67. A slot 90 on the rear end of cylinder 92 receives a screwdriver
for manual adjustments.
[0030] In operation, the cover system is unrolled and rear header
94, to which the rear edge of flexible material 45 is permanently
affixed, is positioned over rear header stop 95. The user presses
down on rear header 94 until toggle 96 is fully engaged within
recess 97 on the underside of rear header 94. Rotation of rear
header 94 during closing will pre-tension flexible cover 45 by
means of spring plunger 88. With the cover completely closed, the
flexible material 45 is constantly in tension, and spring plunger
88 provides a forwardly directed linear force to maintain the
flexible material 45 in a taut condition. Spring plunger 88 is also
manually adjustable by using a screw driver in slot 90 to turn
externally threaded cylinder 92, to advance or retract spring
plunger 88 to the needs and desires of a particular user. The
tension also can be adjusted to accommodate expansion or
contraction of the materials of the cover system in response to
climactic conditions. As the tension is controlled by tension
control assembly 80, either automatically by virtue of the inherent
operation of spring plunger 88 or manually by adjustments as
hereinbefore described, front header apparatus 65 will ride either
slightly forward or slightly back along support flanges 40 to
achieve the desired tension. In a preferred embodiment, each
tension control assembly can be adjusted by as much as 0.5 inch,
and provides a force of up to 80 lbs. The two tension control
assemblies on either side of the front header apparatus together
provide a force of up to 160 lbs.
[0031] The foregoing description of a preferred embodiment of the
instant invention is intended by way of illustration and not by way
of limitation. Other modification, adaptations, and equivalents as
will be apparent to those of skill in the art are intended to be
encompassed within the scope of the following claims.
* * * * *