AU2013251243C1 - Utility Vehicle Tub Canopy Attachment Assembly - Google Patents

Abstract

An assembly for attaching a rim of a canopy shell adjacent to an exterior surface of a vehicle tub, the assembly comprising: at least one rail adapted to be connected to a side-wall of the vehicle tub, the rail having a flange extending towards the exterior surface of the vehicle tub; and at least one bracket having a first portion affixed to the flange and a second portion adapted to be affixed to an inner surface of the canopy shell; wherein the second portion has one or more regions containing adhesive means configured to affix the bracket to the canopy shell. 1 2 2 2 2 1228 10 1718 -24 Figure 1

Description

UTILITY VEHICLE TUB CANOPY ATTACHMENT ASSEMBLY TECHNICAL FIELD

[0001] The present disclosure 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

[0002] 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".

[0003] 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.

[0004] 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.

[0005] Any discussion of documents, acts, materials, devices, articles or the like included in the present specification is not to be taken as an admission that any or all of these matters form part of the common general knowledge in the field relevant to the present disclosure as it existed before the priority date of each of the appended claims.

SUMMARY

[0006] According to some of the disclosed embodiments, there is provided an assembly for attaching a rim of a rigid canopy shell adjacent to an exterior surface of a vehicle tub, the assembly comprising at least one rail adapted to be connected to a side-wall of the vehicle tub, the rail having a flange extending towards the exterior surface of the vehicle tub, and at least one bracket having a first portion secured to the flange to prevent movement of the first portion relative to the flange, and a second portion adapted to be affixed to an inner surface of the canopy shell, wherein the second portion has one or more regions containing adhesive means configured to adhere the bracket to the canopy shell.

[0007] Throughout this specification the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Embodiments will now be described, by way of example only, with reference to the accompanying drawings in which: [0009] Figure 1 is a cross-section view of an assembly connecting a rim of a canopy to a vehicle tub; [00010] Figures 2A & 2B are section detail views of the embodiment shown in Figure 1, viewed from inside and outside of the canopy; [00011] Figures 3A & 3B are cross-section views of an alternative assembly connecting a rim of a canopy to a vehicle tub; [00012] Figure 4 is a cross-section view of a further alternative assembly connecting a rim of a canopy to a vehicle tub; [00013] Figure 5 is a cross-section view of another assembly connecting a rim of a canopy to a vehicle tub; and [00014] 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.

DETAILED DESCRIPTION OF EMBODIMENTS

[00015] The present disclosure relates to an assembly intended to be compatible with a variety of makes, models, sizes and geometries of vehicles and canopies.

[00016] The attachment assembly is adapted for use with vehicles which have a 'tub', which is 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 compatible with the disclosed embodiments. 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.

[00017] The disclosed embodiments are generally 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.

[00018] 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 are typically formed from a rigid material however may also be of fabric or soft materials, or a 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 disclosed embodiments may also be used with flat or tonneau canopies or lids.

[00019] 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.

[00020] In Figure 1 a first 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).

[00021] 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.

[00022] 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.

[00023] 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, 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.

[00024] 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.

[00025] The rail (17) is removably attached to the inner surface (13) of the side wall by any suitable means. In the embodiment shown, 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 inner surface. 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 system can be used to grip the top side (18) of the rail and the upper surface (14) of the side wall.

[00026] The rail (17) is 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 embodiment, the discontinuous lengths 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.

[00027] The attachment assembly (12) has at least one bracket (22) that 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 has a groove (23) adapted to receive the rail flange and abut the top and bottom surfaces of the flange. The groove is formed between two bosses that grip the top and bottom surfaces of the flange at an end portion, and holds the rail firmly in place. The groove may be retained in connection with the rail by friction alone however usually an adhesive or a plurality of rivets or other mechanical fasteners are employed. A combination of such means may also be employed.

[00028] In an alternative embodiment (not shown), the rail and bracket may be a single integrated part, such as formed from an extrusion. This alternative will generally only be appropriate with common models of vehicles, where the geometry of the sidewalls of the tub are known and a unitary bracket and rail can be mass produced.

[00029] The bracket (22) has a first grooved 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. The outer face of the second portion of the bracket abuts and lies against 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 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.

[00030] 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. It is preferable 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 embodiment, adhesive or double sided tape is applied between the canopy's inner face, and the second portion of the bracket (24).

[00031] The outer face of the bracket (24) has a plurality of channels (25, 26) that run along its length, adapted to retain the adhesive means. 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.

[00032] The bracket (22) may be made of any suitable material such as steel, plastics or aluminium, and is generally aluminium formed from an extrusion in order to simplify manufacture. The bracket is provided as a continuous strip, but may alternatively be provided as separate strips that abut together. Alternatively, the bracket may be discontinuous and arranged evenly along the edges of the canopy. Gaps may be provided where the sidewall has obstructions, for instance.

[00033] The assembly (12) also 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). The 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.

[00034] 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 adapted to be slidably engaged with the bracket, covering the fasteners to prevent accidental impacts with the fasteners and provide an improved visual appeal.

[00035] 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).

[00036] 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 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.

[00037] 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 embodiments, 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.

[00038] 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), 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 supported above the top surface (14) of the side-wall to support the weight of the canopy and assembly, and is connected to a seal (45) to provide further protection against moisture ingress into the tub.

[00039] 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.

[00040] 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 (50) separated from the flange groove (43) and canopy attachment region by walls, forming an enclosed volume adapted to receive electrical cables and the like. The wiring channel (50) is adapted to receive a cover (52), able to be slidably engaged with the bracket.

[00041] 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.

[00042] 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.

[00043] 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.

[00044] 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) 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.

[00045] It will be apparent that obvious variations or modifications may be made that are in accordance with the spirit of the present disclosure and any such obvious variations or modifications are therefore within the scope of this disclosure.

INDUSTRIAL APPLICABILITY

[00046] The disclosed embodiments 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.

Claims (8)

1. CLAIMS:

   1. An assembly for attaching a rim of a rigid canopy shell adjacent to an exterior surface of a vehicle tub, the assembly comprising: at least one rail adapted to be connected to a side-wall of the vehicle tub, the at least one rail having a flange arranged to extend, in use, towards the exterior surface of the vehicle tub; and at least one bracket having a first portion secured to the flange to prevent movement of the first portion relative to the flange, and a second portion adapted to be affixed to an inner surface of the canopy shell; wherein the second portion has one or more regions containing adhesive means configured to adhere the bracket to the canopy shell.
2. 2. The assembly of claim 1, wherein the first portion has a groove adapted to receive the flange.
3. 3. The assembly of claim 1 or 2, wherein the first portion is secured to the flange by one or more of an adhesive and mechanical fixing.
4. 4. The assembly of any one of the preceding claims, wherein the second portion has two separate regions containing adhesive means.
5. 5. The assembly of claim 4, wherein one of the regions contains a different adhesive means.
6. 6. The assembly of claim 5, wherein the adhesive means are selected from: double-sided tape, adhesive tape, glue and epoxy resin.
7. 7. The assembly of any one of claims 4 to 6, wherein each of the regions defines a channel, wherein the channel of one region contains doublesided tape and the channel of the other region contains glue.
8. 8. The assembly of any one of the preceding claims, wherein the second portion of the bracket is configured to be affixed to the inner surface of the canopy shell in a position spaced apart from the rim, so that the rim is suspended below the bracket. The assembly of any one of the preceding claims, wherein the rail is configured to be directly connected to the side-wall by one or more of an adhesive and mechanical fixing. The assembly of any one of claims 1 to 8, further comprising one or more intermediary components configured to connect the rail to the side-wall. The assembly of claim 10, wherein the one or more intermediary components comprise a second rail, the second rail adapted to be connected to the side-wall. The assembly of claim 11, wherein the rail is configured to connect to the second rail in a plurality of positions relative to the exterior surface of the vehicle tub. The assembly of claim 12, further comprising a fastener for securing the rail to the second rail, and wherein the rail defines an array of first apertures dimensioned to receive the fastener, and the second rail defines a second aperture dimensioned to receive the fastener. The assembly of claim 1, wherein the rail is connected to one or more clamp mechanisms, each clamp mechanism adapted to grip the rail and the tub. The assembly of claim 14, wherein the rail defines one or more apertures, each aperture dimensioned to receive one of the one or more clamp mechanisms. The assembly of any one of the preceding claims, further comprising a first seal affixed to the bracket and arranged to extend between the bracket and the exterior surface of the vehicle tub. The assembly of any one of the preceding claims, further comprising a second seal adapted to be affixed to the inner surface of the canopy shell and extend between the inner surface of the canopy shell and the exterior surface of the vehicle tub. The assembly of any one of the preceding claims, further comprising a third seal affixed to the rail and arranged to extend between the rail and the exterior surface of the vehicle tub. The assembly of any one of the preceding claims, wherein the bracket has a wiring loom channel adapted to receive a cover, the channel defining a volume separated from the first and second portion. The assembly of any one of the preceding claims, wherein each of the rail and bracket are extrusions.