A retractable pickup truck box cover system includes a pivot joint with improved strength, durability, and manufacturability between panels of a panel assembly of the cover system. A sealing system between the panels and along ends of the panel assembly provides improved weather resistance to the co
A retractable pickup truck box cover system includes a pivot joint with improved strength, durability, and manufacturability between panels of a panel assembly of the cover system. A sealing system between the panels and along ends of the panel assembly provides improved weather resistance to the cover system. A lateral support system provides resistance to binding loads when opening and closing the panel assembly. The lateral support system may also aid installation of the cover system. A ramp adjustment system allows fine tuning of the ramps that guide folding and unfolding of the panel assembly. An improved locking system and the pivot joints allow more compact storage of the panel assembly. The improved locking system includes lock rods that engage rails of the cover system. Connecting structures connect adjacent panel pairs when the cover system is deployed and do not connect the adjacent panels when the cover system is stowed.
대표청구항▼
1. A pivoting joint of a retractable cover system for covering an opening of a pickup truck box, the pivoting joint of the retractable cover system comprising: a first bracket member that is fixed to an end portion of a first panel of the retractable cover system, the first bracket member including
1. A pivoting joint of a retractable cover system for covering an opening of a pickup truck box, the pivoting joint of the retractable cover system comprising: a first bracket member that is fixed to an end portion of a first panel of the retractable cover system, the first bracket member including an aperture defining a pivot surface;a second bracket member that is fixed to an end portion of a second panel of the retractable cover system, the second bracket member including a through hole defining a piloting portion;a monolithic shaft extending along an axis from a first end to a second end, the axis defining a pivot axis of the pivoting joint, the monolithic shaft including a pilot mounted within the piloting portion, and a radially-extending spacer portion fixedly positioned on the monolithic shaft between the first bracket member and the second bracket member thereby spacing the first bracket member and the second bracket member from each other, the monolithic shaft including a pivoting portion disposed at the first end coaxially received within the aperture and rotatably connected to the pivot surface of the first bracket member, and the monolithic shaft including a guide element mount disposed at the second end; anda guide element mounted on the guide element mount of the monolithic shaft;wherein the spacer portion abuts and is fixedly mounted to the second bracket member;wherein the guide element and the spacer portion are positioned on opposite sides of the second bracket member from each other; andwherein the guide element guides the axis of the monolithic shaft along a path as the retractable cover system is moved between a deployed configuration and a stowed configuration. 2. The pivoting joint of the retractable cover system of claim 1, wherein the monolithic shaft is permanently fixedly mounted to the second bracket member. 3. The pivoting joint of the retractable cover system of claim 2, wherein the monolithic shaft includes a weld portion welded to a weld portion of the second bracket member. 4. The pivoting joint of the retractable cover system of claim 3, wherein the weld portion of the monolithic shaft is stud welded to the weld portion of the second bracket member. 5. The pivoting joint of the retractable cover system of claim 1, wherein the pivot axis is positioned below a top surface of the first panel and below a top surface of the second panel when the retractable cover system is covering the opening of the pickup truck box. 6. The pivoting joint of the retractable cover system of claim 1, wherein the first bracket member is positioned generally behind the second bracket member when the retractable cover system is covering the opening of the pickup truck box. 7. The pivoting joint of the retractable cover system of claim 1, wherein the second bracket member is positioned generally behind the first bracket member when the retractable cover system is covering the opening of the pickup truck box. 8. The pivoting joint of the retractable cover system of claim 1, wherein the first bracket member is an inner member and the second bracket member is an outer member. 9. The pivoting joint of the retractable cover system of claim 8, wherein the second panel of the retractable cover system includes a pair of the outer members and wherein the first panel of the retractable cover system is trapped along a pivoting axis of the pivoting joint between the pair of the outer members. 10. The pivoting joint of the retractable cover system of claim 9, wherein the second panel of the retractable cover system includes a pair of the monolithic shafts respectively mounted to the pair of the outer members, wherein the pivoting portions of the monolithic shafts extend inwardly toward each other, and wherein the pivoting axis is coaxial with the axes of the monolithic shafts. 11. The pivoting joint of the retractable cover system of claim 9, wherein the first and the second panels of the retractable cover system can move relative to each other along the pivoting axis of the pivoting joint by a predetermined amount. 12. The pivoting joint of the retractable cover system of claim 1, wherein the path is a straight path that extends in a fore-aft direction of the pickup truck box. 13. The pivoting joint of the retractable cover system of claim 1, wherein the guide element is a separate piece mounted to the guide element mount of the monolithic shaft. 14. The pivoting joint of the retractable cover system of claim 13, wherein the guide element mount of the monolithic shaft is a roller mount, wherein the separate piece is a roller, and wherein the roller is mounted to the roller mount. 15. The pivoting joint of the retractable cover system of claim 14, wherein the roller is mounted to the roller mount by a press fit. 16. The pivoting joint of the retractable cover system of claim 15, wherein the roller includes an inner race, the roller mount includes a mounting surface, and the inner race is mounted to the mounting surface by the press fit. 17. The pivoting joint of the retractable cover system of claim 16, wherein the inner race yields upon being mounted to the mounting surface by the press fit. 18. The pivoting joint of the retractable cover system of claim 17, wherein a diametral interference between the mounting surface and the inner race is accommodated by the inner race yielding and wherein the diametral interference is in a range of 0.0005 inch and 0.0065 inch. 19. The pivoting joint of the retractable cover system of claim 14, wherein the roller mount is outwardly spaced from the spacer portion of the monolithic shaft and thereby positions the roller as an outer roller of the retractable cover system and wherein the outer roller thereby does not enter a ramp structure of the retractable cover system. 20. The pivoting joint of the retractable cover system of claim 14, wherein the roller mount is coaxial with the axis of the monolithic shaft. 21. The pivoting joint of the retractable cover system of claim 13, wherein the separate piece is a guide block, and wherein the guide block is mounted to the guide element mount. 22. The pivoting joint of the retractable cover system of claim 1, wherein at least one of the first bracket member and the second bracket member is a separate piece from a respective panel of the first panel and the second panel and is fastened to the respective panel by a fastening arrangement. 23. The pivoting joint of the retractable cover system of claim 22, wherein the fastening arrangement includes an upset protrusion engaging a hole and a fastener fastening the separate piece to the respective panel. 24. The pivoting joint of the retractable cover system of claim 23, wherein the upset protrusion is included on the separate piece and the hole is included on the respective panel. 25. The pivoting joint of the retractable cover system of claim 23, wherein the fastener is a rivet. 26. The pivoting joint of the retractable cover system of claim 22, wherein the fastening arrangement includes a pair of upset protrusions engaging a pair of holes and a pair of fasteners fastening the separate piece to the respective panel. 27. The pivoting joint of the retractable cover system of claim 26, wherein the pair of the upset protrusions is included on the separate piece and the pair of the holes is included on the respective panel. 28. The pivoting joint of the retractable cover system of claim 26, wherein the pair of the fasteners are rivets. 29. The pivoting joint of the retractable cover system of claim 26, wherein any shear loads between the separate piece and the respective panel are substantially carried by the pair of the upset protrusions engaging the pair of the holes. 30. The pivoting joint of the retractable cover system of claim 29, wherein the pair of the fasteners compresses the separate piece and the respective panel together and thereby keeps the pair of the upset protrusions engaged with the pair of the holes. 31. The pivoting joint of the retractable cover system of claim 1, wherein the first bracket member and the first panel are fastened together by a first fastening arrangement and the second bracket member and the second panel are fastened together by a second fastening arrangement. 32. The pivoting joint of the retractable cover system of claim 1, wherein the pivoting joint is arranged in an ordered sequence with the first bracket member in a first position, the first panel in a second position, the second bracket member in a third position, and the second panel in a fourth position. 33. The pivoting joint of the retractable cover system of claim 32, wherein the fourth position is positioned outward on the retractable cover system from the first position and the pivot surface of the first bracket member is thereby positioned inward on the retractable cover system from the spacer portion of the monolithic shaft. 34. The pivoting joint of the retractable cover system of claim 33, wherein the spacer portion of the monolithic shaft is positioned partially within a relief portion of the first panel. 35. The pivoting joint of the retractable cover system of claim 33, wherein the spacer portion spaces the second bracket member from the first panel and thereby allows the first panel and the second panel to pivot about the axis of the monolithic shaft without the first bracket member and/or the first panel contacting the second bracket member and/or the second panel. 36. The pivoting joint of the retractable cover system of claim 32, wherein a fastener flange is arranged in the ordered sequence between the second position and the third position, wherein the spacer portion spaces the second bracket member from the first panel and thereby allows the first panel and the second panel to pivot about the axis of the monolithic shaft without interference from the fastener flange. 37. The pivoting joint of the retractable cover system of claim 36, wherein the fastener flange is included on a fastener that joins the first bracket member to the first panel. 38. The pivoting joint of the retractable cover system of claim 36, wherein the fastener flange is included on a fastener that joins the second bracket member to the second panel. 39. The pivoting joint of the retractable cover system of claim 32, wherein the first panel includes a first notch to receive the first bracket member at the first position and a first flange at the second position. 40. The pivoting joint of the retractable cover system of claim 39, wherein the second panel includes a second flange at the fourth position and a second notch to receive the first bracket member at the first position, the spacer portion of the monolithic shaft at the second position, and the second bracket member at the third position. 41. The pivoting joint of the retractable cover system of claim 40, wherein the second notch further receives a portion of the spacer portion of the monolithic shaft between the second position and the third position. 42. The pivoting joint of the retractable cover system of claim 40, wherein the second notch allows a sub-assembly including the second bracket member and the monolithic shaft to be rotated away from the second flange of the second panel while assembling the sub-assembly to the retractable cover system. 43. The pivoting joint of the retractable cover system of claim 42, wherein the first bracket member is preassembled to the first panel before the sub-assembly is assembled to the retractable cover system. 44. The pivoting joint of the retractable cover system of claim 42, wherein rotating the sub-assembly away from the second flange of the second panel allows the pivoting portion of the monolithic shaft to be inserted into the pivot surface of the first bracket member. 45. The pivoting joint of the retractable cover system of claim 42, wherein rotating the sub-assembly away from the second flange of the second panel is needed for an upset protrusion of a fastening arrangement between the second bracket member and the second panel to be inserted into a hole of the fastening arrangement. 46. The pivoting joint of the retractable cover system of claim 42, wherein rotating the sub-assembly away from the second flange of the second panel is needed for an upset protrusion of the second bracket member to be inserted into a hole of the second panel. 47. The pivoting joint of the retractable cover system of claim 42, wherein rotating the sub-assembly away from the second flange of the second panel is needed for a pair of upset protrusions of the second bracket member to be inserted respectively into a pair of holes of the second panel. 48. The pivoting joint of the retractable cover system of claim 1, wherein the radially-extending spacer portion extends circumferentially around the monolithic shaft. 49. A pivoting joint of a retractable cover system for covering an opening of a pickup truck box, the pivoting joint of the retractable cover system comprising: a first bracket member that is fixed to an end portion of a first panel of the retractable cover system, the first bracket member including an aperture defining a pivot surface;a second bracket member that is fixed to an end portion of a second panel of the retractable cover system, the second bracket member including a through hole defining a piloting portion;a shaft extending along an axis from a first end to a second end, the axis defining a pivot axis of the pivoting joint, the shaft including a pilot mounted within the piloting portion, and a radially-extending spacer portion fixedly positioned on the shaft between the first bracket member and the second bracket member, the shaft including a pivoting portion disposed at the first end coaxially received within the aperture and rotatably connected to the pivot surface of the first bracket member, and the shaft including a roller mount disposed at the second end; anda roller mounted to the roller mount of the shaft;wherein the spacer portion abuts and is fixedly mounted to the second bracket member;wherein the roller and the spacer portion are positioned on opposite sides of the second bracket member from each other;wherein the first bracket member is a first separate piece from the first panel and the second bracket member is a second separate piece from the second panel;wherein the pivoting joint is arranged in an ordered sequence along the axis of the shaft with the first bracket member in a first position, the first panel in a second position, the second bracket member in a third position, and the second panel in a fourth position;wherein the first panel includes a first notch to receive the first bracket member at the first position and a first flange at the second position;wherein the second panel includes a second flange at the fourth position and a second notch to receive the first bracket member at the first position, the spacer portion of the monolithic shaft at the second position, and the second bracket member at the third position; andwherein the second notch is configured to allow a sub-assembly including the second bracket member and the monolithic shaft to be rotated away from the second flange of the second panel while assembling the sub-assembly to the retractable cover system. 50. The pivoting joint of the retractable cover system of claim 49, wherein the shaft is a monolithic shaft that includes the spacer portion. 51. The pivoting joint of the retractable cover system of claim 49, wherein the radially-extending spacer portion includes a weld portion welded to a weld portion of the second bracket member. 52. The pivoting joint of the retractable cover system of claim 49, wherein the radially-extending spacer portion extends circumferentially around the shaft. 53. A pivoting and guiding joint of a retractable cover system for covering an opening of a pickup truck box, the pivoting and guiding joint of the retractable cover system comprising: a first bracket member that is fixed to an end portion of a first panel of the retractable cover system, the first bracket member including an aperture defining a pivot surface;a second bracket member that is fixed to an end portion of a second panel of the retractable cover system, the second bracket member including a through hole defining a piloting portion;a guide member that kinematically follows a path that extends along a rail of the retractable cover system; anda monolithic shaft extending along an axis from a first end to a second end, the axis defining a pivot axis of the pivoting and guiding joint, the monolithic shaft including:a pilot mounted within the piloting portion;an integral radially-extending spacer portion positioned between the first bracket member and the second bracket member;an integral pivoting portion coaxially received within the aperture and rotatably connected to the pivot surface of the first member and positioned between the integral spacer portion and the first end of the monolithic shaft; andan integral guide mount on which the guide member is mounted and which thereby guides the monolithic shaft along the path that extends along the rail, the integral guide mount positioned between the integral spacer portion and the second end of the monolithic shaft;wherein the spacer portion abuts and is fixedly mounted to the second bracket member; andwherein the guide member and the spacer portion are positioned on opposite sides of the second bracket member from each other. 54. The pivoting and guiding joint of the retractable cover system of claim 53, wherein the guide element guides the axis of the monolithic shaft along the path as the retractable cover system is moved between a deployed configuration and a stowed configuration. 55. The pivoting and guiding joint of the retractable cover system of claim 54, wherein the mount is a roller mount and the guide element is a roller. 56. The pivoting joint of the retractable cover system of claim 55, wherein the roller is mounted to the roller mount by a press fit. 57. The pivoting joint of the retractable cover system of claim 56, wherein an inner race of the roller yields upon being mounted to a mounting surface of the roller mount by the press fit. 58. The pivoting and guiding joint of the retractable cover system of claim 54, wherein the guide element is a guide block. 59. The pivoting and guiding joint of the retractable cover system of claim 53, wherein the integral spacer portion includes a weld portion welded to a weld portion of the second bracket member. 60. The pivoting and guiding joint of the retractable cover system of claim 53, wherein the integral radially-extending spacer portion extends circumferentially around the monolithic shaft.
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