Note: Descriptions are shown in the official language in which they were submitted.
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TRUCK STORAGE SYSTEM
FIELD OF THE INVENTION
The present invention relates generally to a truck
storage system, and a method of making such a truck storage
system.
BACKGROUND INFORMATION
Existing truck storage systems generally comprise a box
frame or cabinet structure having drawers that is placed
within a truck bed and secured to the truck bed via brackets
and holes drilled in the truck bed. Such storage systems
generally do not extend the full width of the truck bed, thus
not fully utilizing the available storage space, and the
storage systems may create gaps and areas between the storage
systems and the truck bed sidewalls in which various materials
can become trapped and/or lost. Further, the loading and/or
hauling of materials on top of the storage systems is rendered
more difficult and less reliable by such gaps and areas
between the storage systems and the truck bed sidewalls. In
addition, the box frame or cabinet structure may not be
designed to carry heavy loads that would be suitable for the
truck bed alone, and/or the use of the drawers within the
storage systems may be adversely affected by such heavy loads
placed thereon. Moreover, storage systems that may be
designed to carry heavy loads may add excessive weight to the
truck bed, thereby adversely affecting vehicle performance,
such as for example, handling, torque, speed, fuel economy,
and others.
SUMMARY
In accordance with an exemplary embodiment of the present
invention, a vehicle storage system may include a deck
configured to span substantially a total width of a vehicle
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bed, e.g., a truck bed, four support feet, each support foot
situated at a respective corner of the bed and configured to
support the deck, and a center support extending in a
longitudinal direction of the bed between the support feet and
configured to support the deck.
The deck may include two, non-handed deck halves
configured to interleave with each other above the center
support. Outer lateral edges of the deck may be processable
to match sidewall profiles of a plurality of different truck
beds. In addition, the deck may include transverse
reinforcement beams configured to increase strength of the
deck. Further, the deck may be attached to upper surfaces of
the four support feet by fasteners, and to an upper surface of
the center support by protrusions and corresponding
countersunk holes and/or fasteners.
The deck may include four openings, each opening leading
to a compartment defined by an interior of each support foot,
and non-handed covers may cover each of the four openings, an
underside of each cover including cup holders, trays and/or
compartments. A ruler plate may be situated at a rearward
edge of the deck and configured to act as a scuff plate.
The four support feet may include two, non-handed front
support feet and two, non-handed rear support feet. Each
support foot may be attached to existing tie-down points of
the truck bed via J-hooks, brackets and/or fasteners, and each
support foot may be attachable to existing tie-down points of
a plurality of different truck beds.
The center support may act as a load rest without direct
attachment to the truck bed. The center support may stably
support the deck in a plurality of different truck beds.
The deck, the support feet, and the center support may be
made of high density polyethylene.
The storage system may also include at least one drawer
assembly situated between a) a front support foot and a rear
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support foot on one side, and b) the center support on an
other side, the drawer assembly configured to be slidable in
the longitudinal direction of the truck bed via wheels and
corresponding self-centering guide channels. The center
support may include an integral, inner guide channel to
receive an inner front wheel of the drawer assembly, an outer
guide channel may extend in the longitudinal direction of the
truck bed between the front support foot and the rear support
foot and receive an outer front wheel of the drawer assembly,
the center support may include an inner rear wheel, the rear
support foot may include an outer rear wheel, and the drawer
assembly may include integral, lower guide channels to receive
each of the inner and outer rear wheels.
The drawer assembly may include a latch and a lock
configured to interengage with a reinforcement beam on an
underside of the deck. In addition, the drawer assembly may
include a notch, a raised surface and/or a sloped surface on
its rearward, lower surface configured to provide clearance to
a lowered tailgate of the truck bed. The drawer assembly may
include at least two drawer assemblies that are nestable for
packaging, shipping and/or storage. Further, the drawer
assembly may include integral drawer stops configured to
prevent falling out of the drawer assembly from the truck
storage system.
The storage system may be manufacturable in long and
short versions using a single set of tooling and tool inserts.
In accordance with a second exemplary embodiment of the
present invention, the storage system may include a deck
configured to span approximately half a total width of a
vehicle bed, e.g., a truck bed, two support feet on a same
lateral side of the bed, a front support foot situated at a
forward corner of the bed and a rear support foot situated at
a rearward corner of the bed, the two support feet configured
to support the deck, and a center support extending in a
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longitudinal direction of the bed between the support feet and
an opposing side of the bed not spanned by the deck, the
center support configured to support the deck.
The second exemplary embodiment of the storage system may
also include a trim piece configured to interleave with an
edge of the deck above the center support, and to attach to an
upper surface of the center support by protrusions and
corresponding countersunk holes and/or fasteners. In
addition, the second exemplary embodiment of the storage
system may include brackets configured to secure the center
support to the bed via fasteners, for example.
Example embodiments of the present invention are
described in more detail below with reference to the appended
Figures.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 shows a top perspective view of a first
exemplary embodiment of a truck storage system according to
the present invention.
Figure 2 shows a partially exploded view of the first
exemplary embodiment of a truck storage system according to
the present invention.
Figures 3A to 3E show top perspective, bottom
perspective, top, bottom and lateral side views, respectively,
of a left deck half or a right deck half of a truck storage
system according to the present invention.
Figures 4A to 4D show top perspective, top, rear and side
views, respectively, of a reinforcement beam of a truck
storage system according to the present invention.
Figures 5A to 5C show top, bottom and right side views,
respectively, of a ruler plate of a truck storage system
according to the present invention.
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Figures 6A to 6D show top perspective, top, rear and left
side views, respectively, of a center support assembly of a
truck storage system according to the present invention.
Figure 7 shows a top perspective view of another
exemplary embodiment of a center support assembly of a truck
storage system according to the present invention.
Figures 8A to 8C show top perspective, rear and side
views, respectively, of a cover plate of a truck storage
system according to the present invention.
Figures 9A to 9D show top perspective, top, front/rear
and lateral side views, respectively, of a front support foot
of a truck storage system according to the present invention.
Figures 10A to 10E show two perspective, two side and
plan views, respectively, of an access hole cover for a front
support foot of a truck storage system according to the
present invention.
Figures 11A to 11D show top perspective, top, front/rear
and lateral side views, respectively, of a rear support foot
assembly of a truck storage system according to the present
invention.
Figures 12A to 12F show top perspective, bottom
perspective, top, bottom, front/rear and lateral side views,
respectively, of a front/rear support foot cover of a truck
storage system according to the present invention.
Figure 13 shows a top perspective of a J-hook assembly of
a truck storage system according to the present invention.
Figures 14A to 14C show top perspective, front/rear and
lateral side views, respectively, of a guide channel of a
truck storage system according to the present invention.
Figures 15A to 15F show top perspective, top, rear,
lateral side, cross-sectional and close-up cross-sectional
views, respectively, of a drawer assembly of a truck storage
system according to the present invention. Figure 15E is a
cross-sectional view along line A-A shown in Figure 15D, and
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Figure 15F is a close-up cross-sectional view of the circled
portion shown in Figure 15E.
Figures 16A to 16D show top perspective, rear, front and
lateral side views, respectively, of a lock of a truck storage
system according to the present invention.
Figures 17A to 17D show top perspective, top, left side
rear and right side rear views, respectively, of a drawer
wheel bracket assembly of a truck storage system according to
the present invention.
Figures 18A to 18D show top perspective, top, front/rear
and lateral side views, respectively, of a drawer divider of a
truck storage system according to the present invention.
Figure 19 shows a close-up, top perspective view of a
latch assembly and lock of a truck storage system according to
the present invention.
Figures 20A to 20C show perspective, rear and lateral
side views, respectively, of a left arm of a latch assembly of
a truck storage system according to the present invention.
Figures 21A to 21C show perspective, rear and lateral
side views, respectively, of a right arm of a latch assembly
of a truck storage system according to the present invention.
Figures 22A to 22C show top perspective, rear and lateral
side views, respectively, of a handle of a latch assembly of a
truck storage system according to the present invention.
Figure 23 shows a top perspective view of a bin tray of a
truck storage system according to the present invention.
Figure 24 shows a top perspective view of a tool tray of
a truck storage system according to the present invention.
Figure 25 shows a top perspective view of a second
exemplary embodiment of a truck storage system according to
the present invention.
Figure 26 shows a partially exploded view of the second
exemplary embodiment of a truck storage system according to
the present invention.
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Figure 27 shows a top perspective view of a trim piece
for the second exemplary embodiment of a truck storage system
according to the present invention.
Figure 28 shows a top perspective view of a bracket for
the second exemplary embodiment of a truck storage system
according to the present invention.
Figures 29A to 29D show top perspective, top, rear and
left side views, respectively, of a center support assembly
having a channel of a truck storage system according to the
present invention.
Figure 30A shows a bottom perspective of a drawer
assembly having and an L-shaped bracket of a truck storage
system according to the present invention. Figure 30C is a
cross-sectional view along line a-a shown in Figure 30B
including the L-shaped bracket shown in Figure 30A.
DETAILED DESCRIPTION
Figure 1 shows a top perspective view and Figure 2 shows
a partially exploded view of a first exemplary embodiment of a
truck storage system 1 according to the present invention. As
shown in Figures 1 and 2, the truck storage system 1 may
comprise a deck 10 including a left deck half 10L and a right
deck half 10R, a center support assembly 20, front support
feet 30, rear support feet 40, foot support covers 50 and
drawer assemblies 60, all of which will be described further
herein. The truck storage system 1 may be sized to fit both
long and short truck beds, and may cover substantially the
full width of the truck bed, as shown in Figure 1, for
example, or only approximately half the width of the truck
bed, as shown in Figure 25, for example.
As used herein, the terms "front," "rear," "left side,"
and "right side" refer to directions with reference to a
vehicle, e.g., a pickup truck, a full-size van, etc. in which
the storage system may be installed. For example, the term
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"front" refers to a forward-moving direction of the vehicle,
the term "rear" refers to a rearward-moving direction of the
vehicle, the term "left side" refers to a driver side of the
vehicle (as commonly used in the U.S.), and the term "right
side" refers to a passenger side of the vehicle (as commonly
used in the U.S.).
Figures 3A to 3E show various views of a left deck half
10L or a right deck half 1OR of a truck storage system 1
according to the present invention.
The left and right deck halves 10L, 1OR may include an
upper surface 11, a lower surface 12, front and rear edges 13,
inner side edge 14, and lateral side edge 15. The deck halves
10L, 1OR may be made of high density polyethylene, other
plastics, metals, or combinations thereof, for example. The
upper surface 11 may include various functional and/or
decorative indicia or surface treatments, such as, for
example, embossing, debossing, texturing (e.g., graining),
engraving, printing, etc. For example, the surface treatment
of the upper surface 11 may provide traction to prevent
slipping and/or sliding of materials placed on the upper
surface 11. As shown in Figures 1 to 3A and 3C, the upper
surface 11 of the deck halves 10L, 1OR may simulate a tire
tread. Additionally, the upper surface 11 may include mounts,
tracks, guides or rails for securing materials placed on the
upper surface 11.
The deck halves 10L, 1OR may include a plurality of
reinforcement beams 19, as shown in Figures 3B, 3D, 3E, and 4A
to 4D, for example, that traverse the deck halves 10L, 1OR
transversely from the inner side edge 14 to the lateral side
edge 15. The reinforcement beams 19 may be made of high
density polyethylene, other plastics, metals, or combinations
thereof, for example. The reinforcement beams 19 may be
completely encased within the deck halves 10L, 10R, or
portions of the reinforcement beams 19 may remain exposed.
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For example, the reinforcement beams 19 may be at least
partially exposed on the lower surface 12 of the deck halves
10L, 10R. Further, the reinforcement beams 19 may at least
partially protrude from the lower surface 12 of the deck
halves 10L, 10R. Alternatively or additionally, the
reinforcement beams 19 may traverse the deck halves 10L, 1OR
in directions other than transversely from the inner side edge
14 to the lateral side edge 15. The reinforcement beams 19
may have varying lengths depending on their positions within
the deck halves 10L, 10R. Although shown with a rectangular
cross-section in Figures 4A to 4D, the reinforcement beams 19
may include other cross-sectional shapes that provide
sufficient stiffness and support for the deck halves 10L, 1OR
and materials loaded thereon.
The front and rear edges 13 of the deck halves 10L, 1OR
may be configured to receive a ruler plate 13B, as shown in
Figures 1, 2, and 5A to 5C, for example. For example, the
ruler plate 13B may be attached to the deck halves 10L, 1OR by
fasteners and/or adhesives. The ruler plate 13B may be made
of high density polyethylene, other plastics, metals, or
combinations thereof, for example. The ruler plate 13B may
include measurement indicia, conversion data and other
information, for example, and may be replaceable with various
designs of the ruler plate 13B. In addition, the ruler plate
13B may act as a scuff plate to protect the rearward edge of
the deck halves 10L, 1OR during use, such as during
loading/unloading of materials from the rear of the truck bed.
The inner side edges 14 of the deck halves 10L, 1OR may
include a meandering profile that is identical for each deck
half 10L, 10R, and is configured such that each of the left
and right deck halves 10L, 1OR may be made, at least
initially, in the same shape and/or by using a single mold,
i.e., non-handed deck halves. That is, the right deck half
1OR is rotated 180 degrees from a position of the left deck
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half 10L, such that the inner side edges 14 of the deck halves
10L, 1OR mate without gaps, thereby forming the deck 10.
The inner side edges 14 of the deck halves 10L, 1OR may
also include holes 17 for receiving projections 21 of a center
support assembly 20, as shown in Figures 6A to 7, for example.
The holes 17 may be countersunk on the lower surface 12 of the
deck halves 10L, 1OR in order to receive the projections 21 of
the center support assembly 20. Additionally, fasteners or
adhesives may be inserted in the holes 17 to secure the deck
halves 10L, 1OR to the center support assembly 20. In
addition, the interface of the inner side edges 14 of the deck
halves 10L, 1OR may be configured to prevent the ingress of
water and/or divert such water away from the drawer assemblies
60 and down toward the truck bed.
The lateral side edges 15 of the deck halves 10L, 1OR may
be processed to match the sidewall profiles of the truck bed
in which the truck storage system 1 is to be installed. For
example, the lateral side edges 15 of each deck half 10L, 1OR
may be cut, machined, laser cut, waterjet cut, or otherwise
modified to precisely match the sidewall profiles of the truck
bed, which sidewall profiles differ between various truck
manufacturers and models, and may also differ between left and
right sides on a single truck model.
The deck halves 10L, 1OR may also include foot openings
16 that mate with the front and rear support feet 30, 40, as
shown in Figures 9A to 9D and 11A to 11D, for example. Around
the periphery of each foot opening 16 are provided holes 18
for attachment between the deck halves 10L, 1OR and the front
and rear support feet 30, 40. For example, fasteners and/or
adhesives may be inserted in the holes 18 to secure the deck
halves 10L, 1OR to the front and rear support feet 30, 40.
Figures 6A to 7 show various views of a center support
assembly 20 of a truck storage system 1 according to the
present invention. The center support assembly 20 may be made
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of high density polyethylene, other plastics, metals, or
combinations thereof, for example. As described, the center
support assembly 20 may include projections 21 to mate with
the holes 17 on the lower surface 12 of the deck halves 10L,
10R. In addition, the center support assembly 20 may include
integral drawer wheel channels 22 for guiding wheels 63
provided on a drawer assembly 60, as well as wheels 23, to
facilitate sliding of the drawer assemblies 60, as shown in
Figures 15A to 15F, for example. The integral drawer wheel
channels 22 may include at least one self-centering formation
27 that is configured to maintain wheels 63 provided on a
drawer assembly 60 that roll within the integral drawer wheel
channels 22 in an optimal position, e.g., both vertical
position, as well as horizontal or lateral position, for
smoothly opening/closing a drawer assembly 60. Furthermore,
as shown in Figures 6A to 7, the center support assembly 20
may also include arches 25 and weight reduction holes 26 to
simultaneously reduce weight of the center support assembly 20
while maintaining the strength of the truck storage system 1
to support the weight of materials placed thereon.
The center support assembly 20 may be configured as a
load rest on the truck bed, such that no physical
interconnections or attachments exist between the truck bed
and the center support assembly 20. That is, the center
support assembly 20 may simply rest on the truck bed due to
gravity and/or the weight of any materials placed on the deck
10. Accordingly, the center support assembly 20 may be
installed in the truck bed without requiring structural
modification of the truck bed, such as for example, drilling
holes in or bending/deforming the truck bed.
Further, the center support assembly 20 may also include
a cover plate 24, as shown in Figures 8A to 8C, for example.
The cover plate 24 may be made of high density polyethylene,
other plastics, metals, or combinations thereof, for example.
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The cover plate 24 may include decorative indicia 28 or other
surface treatment formed by, for example, embossing,
debossing, texturing (e.g., graining), engraving, printing,
etc. In addition, the cover plate 24 may include a bottle
opener 29. For example, the cover plate 24 may be attached to
the center support assembly 20 by fasteners and/or adhesives.
Figures 9A to 9D and 11A to 11D show various views of a
front support foot 30 and a rear support foot assembly 40 of a
truck storage system according to the present invention.
One front support foot 30 may be configured to be
attached to the deck halves 10L, 1OR in each of the front,
driver side corner and the front, passenger side corner of the
truck storage system 1, and one rear support foot assembly 40
may be configured to be attached to the deck halves 10L, 1OR
in each of the rear, driver side corner and the rear,
passenger side corner of the truck storage system 1, as shown
in Figure 2, for example. The front and rear support feet 30,
40 may be made of high density polyethylene, other plastics,
metals, or combinations thereof, for example. The front and
rear support feet 30, 40 may include an upper surface 31, 41
having holes 32, 42 that align with holes 18 of each foot
opening 16 for attachment between the deck halves 10L, 1OR and
the front and rear support feet 30, 40. For example,
fasteners and/or adhesives may be inserted through holes 32,
42, 18 to secure the deck halves 10L, 1OR to the front and
rear support feet 30, 40. The front and rear support feet 30,
40 may also include a lower surface 33, 43 that rests on the
truck bed. Between the upper surface 31, 41 and lower surface
33, 43, the front and rear support feet 30, 40 may define a
compartment 39, 49 in which beverages, tools, fasteners or any
other items may be placed. Further, the upper surface 31, 41
may include drain holes (not shown), e.g., forward and
rearward drain holes, to direct water or other substances away
from the compartment 39, 49 and down toward the truck bed.
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In addition, the front and rear support feet 30, 40 may
include substantially spherical, semispherical or rounded
attachment points 34, 44, and each attachment point 34, 44 may
include a hole 35, 45. The holes 35, 45 are shown as
elongated slots, but may also have other shapes, including
circular or polygonal, for example. The attachment points 34,
44 may be used to secure the front and rear support feet 30,
40 to the truck bed via fasteners, brackets, hooks, etc.
Preferably, the attachment points 34, 44 of the front and rear
support feet 30, 40 may be secured to existing brackets, holes
or tie-down points in the truck bed via a J-hook assembly 54,
as shown in Figure 13, for example. The J-hook assembly 54
may be made of high density polyethylene, other plastics,
metals, or combinations thereof, for example. The J-hook
assembly 54 includes a J-hook 55, a substantially spherical,
semispherical or rounded washer 56, and a locking nut 56a
threaded onto the J-hook 55. The substantially spherical,
semispherical or rounded surface of the washer 56 is
configured to mate with the substantially spherical,
semispherical or rounded attachment points 34, 44 of the front
and rear support feet 30, 40 in order to secure the J-hook
assembly 54 at variously placed existing brackets, holes or
tie-down points of the truck bed. Accordingly, the front and
rear support feet 30, 40 may be installed in the truck bed
without requiring structural modification of the truck bed,
such as for example, drilling holes in or bending/deforming
the truck bed, since the J-hook assembly 54 attaches to
existing brackets, holes or tie-down points of the truck bed.
Additionally, further brackets may be installed in the truck
bed at existing holes or tie-down points to facilitate the use
of the J-hook assembly 54 for securing the front and rear
support feet 30, 40.
Each front support foot 30 may also include an access
hole 37 to provide visibility and facilitate attachment of the
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front support foot 30 to the truck bed using J-hook assemblies
54 extending between attachment points 34 and existing
brackets, further brackets, holes or tie-down points in the
truck bed. Following attachment of the front support foot 30
to the truck bed, the access hole 37 may be covered by an
access hole cover 38, as shown in Figures 10A to 10E, for
example. The access hole cover 38 may be made of high density
polyethylene, other plastics, metals, or combinations thereof,
for example. The access hole cover 38 may include decorative
indicia 38A or other surface treatment formed by, for example,
embossing, debossing, texturing (e.g., graining), engraving,
printing, etc. In addition, the access hole cover may include
at least one snap-in tab 38B and at least one finger access
feature 38C to facilitate snapping-in and removal of the cover
38 to/from access hole 37. Moreover, the substantially square
shape of the access hole 37 and access hole cover 38 may allow
the cover 38 to be snapped into hole 37 in any of four
orientations that are rotated 90 degrees relative to each
other, thereby facilitating ease of use. Alternatively, the
access hole 37 and access hole cover 38 may have shapes other
than the substantially square shape shown in Figures 9A to
10E, for example, such as circular, polygonal or others, while
still maintaining the ease of use.
Further, the front and rear support feet 30, 40 may
include at least one guide channel surface 36, 46 on which a
guide channel 57, as shown in Figures 14A to 14C, for example,
may rest and/or be secured. The guide channel 57 may be made
of high density polyethylene, other plastics, metals, or
combinations thereof, for example. The guide channel 57 may
be attached to the front and rear support feet 30, 40 by
fasteners and/or adhesives, and extend in a front-to-rear
direction between front and rear support feet 30, 40 provided
on a same side (i.e., driver side or passenger side) of the
truck storage system 1, as shown in Figure 2, for example.
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The guide channel 57 may include at least one self-centering
formation 58 that is configured to maintain wheels 63 provided
on a drawer assembly 60 that roll within the guide channel 57
in an optimal position, e.g., both vertical position, as well
as horizontal or lateral position, for smoothly
opening/closing a drawer assembly 60, as shown in Figures 15A
to 15F, for example.
The rear support foot assembly 40 may further include a
wheel 47 that can be attached to either of two holes 48
provided at a rearward lower portion of the rear support foot
assembly 40. That is, for a rear support foot assembly 40
provided at the rear, driver side corner of the truck storage
system 1, the wheel 47 is attached to one rearmost hole 48,
whereas for a rear support foot assembly 40 provided at the
rear, passenger side corner (i.e., rotated 180 degrees from
the rear, driver side corner position) of the truck storage
system 1, the wheel 47 is attached to the other rearmost hole
48, as shown in Figure 2, for example. The wheels 47 of the
rear support foot assemblies 40 cooperate with the wheels 23
of the center support assembly 20 to facilitate sliding of the
drawer assemblies 60.
The front and rear support feet 30, 40 are configured to
be non-handed, such that a single front support foot 30 design
can be installed in either the front, driver side corner or
the front, passenger side corner rotated 180 degrees relative
to each other. Similarly, a single rear support foot 40
design can be installed in either the rear, driver side corner
or the rear, passenger side corner rotated 180 degrees
relative to each other. For each rear support foot assembly
40, the wheel 47 must be installed in the appropriate hole 48
depending on its position within the truck bed.
Figures 12A to 12F show various views of a front/rear
support foot cover 50 of a truck storage system 1 according to
the present invention. The cover 50 may be made of high
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density polyethylene, other plastics, metals, or combinations
thereof, for example. The cover 50 may be configured to fit
snugly, e.g., by friction fit or snap fit, within openings 16
of the deck halves 10L, 10R, and to mate and/or substantially
seal with upper surfaces 31, 41 of the front and rear support
feet 30, 40. A finger access lip may be provided on an edge
of cover 50, and a corresponding finger access recess may be
provided on deck halves 10L, 1OR to facilitate removal of the
covers 50. An upper surface of cover 50 may include various
functional and/or decorative indicia 51 or other surface
treatment formed by, for example, embossing, debossing,
texturing (e.g., graining), engraving, printing, etc. For
example, the surface treatment of the upper surface of cover
50 may provide traction to prevent slipping and/or sliding of
materials placed on the upper surface. A lower surface of
cover 50 may include cup holders 52 and/or other areas 53 for
the placement of cups, tools, fasteners or any other objects,
when the cover 50 is removed from opening 16 or when the cover
50 is placed upside down within opening 16. All openings 16
may be configured to have the same dimensions, and thus, only
a single design of cover 50 may fit in any opening 16 of the
deck 10.
Figures 15A to 15F show various views of a drawer
assembly 60 of a truck storage system 1 according to the
present invention. The drawer assembly 60 may be made of high
density polyethylene, other plastics, metals, or combinations
thereof, for example. Each drawer assembly 60 may be rated to
carry a payload of about 200 lbs, for example.
The drawer assembly 60 may include a drawer 61, integral
wheel channels 62, wheels 63, wheel bracket assemblies 66,
integral handle 64, lock 65 and latch assembly 70. The drawer
61 may be configured to receive materials therein, and may
include notches or other formations to transversely receive
drawer dividers 68, as shown in Figures 18A to 18D, for
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example, and the drawer 61 may receive a mat along its inner
bottom surface. The drawer dividers 68 may include notches or
other formations 69 to allow the placement of longer items
within drawers 61 when using dividers 68 or to facilitate the
use of ropes, cords or other items for tying down and/or
securing items within the drawers 61. Alternatively, drawer
dividers that extend in a front-to-rear direction of the
drawer 61 may also be provided. In addition, the integral
handle 64 of drawer 61 may be initially molded into the drawer
61 and facilitate opening, closing and/or grasping of the
drawer assemblies 60. An integral handle may also be provided
at opposite end of drawer 61 to facilitate grasping of the
drawer assemblies 60, for example, when removed from the truck
storage system 1. Further, the drawer 61 may be configured to
allow nesting of multiple drawers 61 within each other for
packaging, shipping and/or storage by appropriate design of,
for example, the sidewalls, integral wheel channels 62 and
integral handle 64 of the drawer 61.
The integral wheel channels 62 may receive the wheels 23
of the center support assembly 20 and the wheels 47 of the
rear support foot assembly 40, and the wheels 63 may roll
within integral drawer wheel channels 22 of center support
assembly 20 and guide channel 57 secured to front and rear
support feet 30, 40 to facilitate sliding of the drawer
assemblies 60. The integral wheel channels 62 of the drawer
assemblies 60, may include at least one self-centering
formation 62a that is configured to maintain the drawer
assemblies 60 in an optimal position, e.g., both vertical
position, as well as horizontal or lateral position, for
smooth opening/closing. The integral wheel channels 62 may
end at a position short of the forward end of the drawer 61,
such that the ends of the integral wheel channels 62 act as
integral stops to prevent further opening or falling out of
the drawer assemblies 60. If the user desires to remove the
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drawer assemblies 60, this can be effected by removing the
wheels 23, 47 and then removing the drawer assemblies 60. The
wheels 63 may be attached to the drawer 61 by wheel bracket
assemblies 66 having wheel shafts 67, as shown in Figures 17A
to 17D, for example. The wheel bracket assembly 66 may be a
single, non-handed design that can be used for both wheels 63
of the drawer 61 by using one wheel shaft 67 in one
installation position and the other wheel shaft 67 in the
other installation position, while one or the other wheel
shaft remains unused in each position and extends through the
forward end of the drawer 61, as shown in Figures 15A, 15B,
15D, 17C and 17D, for example.
The lock 65 may allow locking of the drawer assembly 60
in the fully closed position. The lock 65, as shown in
Figures 16A to 16D, for example, may include a locking cam 65a
that can rotate between an open position and a closed
position. In an open position, the locking cam 65a allows the
drawer assembly 60 to be pulled out of the truck storage
system 1. In the closed position, the locking cam 65a may
cooperate with structure on the lower surface 12 of the deck
halves 10L, 1OR to prevent pulling out of the drawer assembly
60. For example, the locking cam 65a may engage with a
reinforcement beam 19 that at least partially protrudes from
the lower surface 12 of the deck halves 10L, 10R, thereby not
requiring any additional structural features to be molded into
the deck halves 10L, 1OR to provide the locking function.
Alternatively, the locking cam 65a may engage with other
structure on the lower surface 12 of the deck halves 10L, 10R.
Figure 19 shows a close-up, view of a latch assembly 70
and lock 65 of a truck storage system 1 according to the
present invention. The latch assembly 70 may be made of high
density polyethylene, other plastics, metals, or combinations
thereof, for example.
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The latch assembly 70 may include left and right arms 71,
72, a handle 73, as shown in Figures 20A to 22C, for example,
as well as springs and pins (not shown), as would be
understood by one of ordinary skill in the art. The left and
right arms 71, 72 of the latch assembly 70 may include
latching cams 71a, 72a that can rotate between an open
position and a closed position. In an open position, the
latching cams 71a, 72a allow the drawer assembly 60 to be
pulled out of the truck storage system 1. In the closed
position, the latching cams 71a, 72a may cooperate with
structure on the lower surface 12 of the deck halves 10L, 1OR
to prevent pulling out of the drawer assembly 60. For
example, the latching cams 71a, 72a may engage with a
reinforcement beam 19 that at least partially protrudes from
the lower surface 12 of the deck halves 10L, 10R, thereby not
requiring any additional structural features to be molded into
the deck halves 10L, 1OR to provide the latching function.
Alternatively, the latching cams 71a, 72a may engage with
other structure on the lower surface 12 of the deck halves
10L, 10R.
The handle 73 interconnects the left and right arms 71,
72 of the latch assembly 70, and provides an ergonomical grip
for a user when opening/closing the drawer assembly 60. For
example, the handle 73 may, in cross-section, have a
substantially rounded or semispherical shape, or a D-shape to
provide a comfortable grip to a user. In addition, the
surfaces of the left and right arms 71, 72 and the handle 73
may include various functional and/or decorative indicia or
other surface treatment formed by, for example, embossing,
debossing, texturing (e.g., graining), engraving, printing,
etc. For example, the surface treatment of the handle 73 may
provide grip to provide secure grasping of the handle 73.
Furthermore, the latch assembly 70 may be designed to unlatch,
i.e., open the latching cams 71a, 72a, upon pulling of the
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handle 73 toward the rear of the truck storage system 1, and
the latch assembly 70 may be designed to latch, i.e., close
the latching cams 71a, 72a, upon pushing of the drawer 61
toward the front of the truck storage system 1.
Figure 23 shows a top perspective view of a bin tray 80,
and Figure 24 shows a top perspective view of a tool tray 81
of a truck storage system 1 according to the present
invention. The trays 80, 81 may be made of high density
polyethylene, other plastics, metals, or combinations thereof,
for example. The trays 80, 81 may include a single
compartment or multiple, variously sized compartments for
holding tools, fasteners or any other items. The trays 80, 81
may be configured to rest on upper edges of the drawer
assemblies 60, and may be slidable on the drawer assemblies
60. Further, the trays 80, 81 may be removable in order to
facilitate transport of items held in trays 80, 81 away from
truck storage system 1. The trays are also nestable for
packaging, shipping and/or storage.
Figure 25 shows a top perspective view and Figure 26
shows a partially exploded view of a second exemplary
embodiment of a truck storage system 1' according to the
present invention. As shown in Figures 25 and 26, the truck
storage system 1' may comprise a deck 10 including only one of
a left deck half 10L or a right deck half 10R, a center
support assembly 20, a front support foot 30, a rear support
foot 40, foot support covers 50 and one drawer assembly 60,
all of which are described herein. All components of the
second exemplary embodiment of the truck storage system 1' may
include all of the features described herein with reference to
the first exemplary embodiment of the truck storage system 1.
The truck storage system 1' may be sized to fit both long
and short truck beds, and may cover only approximately half
the width of the truck bed. The truck storage system 1' may
allow the use of an elevated deck 10 and one drawer assembly
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60 covering only approximately half the width of the truck
bed, while maintaining the remaining half of the width of the
truck bed unaltered for, for example, loading larger and/or
taller items in the truck bed.
In addition to the components described above included in
the second exemplary embodiment of the truck storage system
1', the truck storage system 1' may also include a trim piece
90 and one or more brackets 94, as shown in Figures 27 and 28,
for example. The trim piece 90 may include an inner side edge
91, a lateral side edge 92 and holes 93. The inner side edge
91 may include a meandering profile that is identical to the
meandering profile of the inner side edge 14 of the deck half
10L or 10R, and is configured such that the inner side edge 91
mates with the inner side edge 14 of the deck half 10L or 1OR
without gaps, thereby forming the deck 10 of the truck storage
system 1'. The lateral side edge 92 may form a clean edge
without any sharp corners or protrusions, and may form a
smooth transition to, e.g., be flush with, the center support
assembly 20.
The trim piece 90 may also include holes 93 for receiving
projections 21 of the center support assembly 20. The holes
93 may be countersunk on the lower surface of the trim piece
90 in order to receive the projections 21 of the center
support assembly 20. Additionally, fasteners and/or adhesives
may be inserted in the holes 93 to secure the trim piece 90 to
the center support assembly 20.
The brackets 94 may be used to secure the center support
assembly 20 of the truck storage system 1' to the truck bed.
Since, as described herein, the center support assembly 20 is
not physically attached to the truck bed but is configured as
a load rest, the truck storage system 1' that spans only
approximately half the width of the truck bed is secured to
the truck bed only via one front support foot 30 and one rear
support foot assembly 40 and the corresponding J-hook
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assemblies 54, brackets, fasteners, adhesives, etc.
Accordingly, it may be necessary to physically secure the
center support assembly 20 of the truck storage system 1' to
the truck bed in order to prevent any movement, e.g., lateral
or vertical movement, of the truck storage system 1' during
vehicle movement. One or more brackets 94 may thus be used to
secure the center support assembly 20 to the truck bed via
holes drilled by a user in the truck bed. Alternatively, if
holes or tie-down points already exist in the truck bed in the
vicinity of the brackets 94, it would be preferable to use
such existing holes or tie-down points.
Figures 29A to 29D show various views of a center support
assembly 20 having a channel 100 of a truck storage system 1
according to the present invention. The channel 100 may be a
drainage channel which receives liquid, transmits liquid,
and/or prevents liquid from reaching at least one drawer
assembly 60 or other parts of the system 1. The channel 100
may be made of high density polyethylene, other plastics,
metals, or combinations thereof, for example. The channel 100
may extend vertically from an upper surface of the center
support 20. As shown, the channel 100 may include two spaced
apart walls or ribs 100A and 100B. Each wall or rib 100A, 100B
may extend vertically from the upper surface of the center
support 20 to a bottom surface of the deck 10, and may extend
in a substantially longitudinal direction of the center
support 20 for a total length of the center support 20.
Alternatively, each wall or rib 100A, 100B may extend
vertically from the upper surface of the center support 20 to
a height below the bottom surface of the deck 10, and may
extend in a substantially longitudinal direction of the center
support 20 for only a portion of the length of the center
support 20. In addition, the channel 100 may have a meandering
pattern which forms sections having different widths, a first
width at a first location 102 and a second width, which is
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narrower than the first width, at a second location 104.
Alternatively, the channel 100 may have a curved path which
forms different sections of various widths. As described, the
center support assembly 20 may include projections 21 to mate
with the holes 17 on the lower surface 12 of the deck halves
10L, 1OR which may interleave with each other above the
channel 100. Projections 21 may extend from within a single
widened section 102 vertically from the upper surface of the
center support 20. Adjacent projections 21 may be separated by
a narrower section 104. Further, the channel 100 may include
two opposing openings 106A and 106B, at least one of which
opens up to an exterior of the system 1. All components of
this exemplary embodiment of the channel 100 of the truck
storage system 1 may be applied to the embodiment of the truck
storage system 1'.
Furthermore, as shown in Figures 29A and 29D, the center
support assembly 20 may also include bottom closeouts 108 and
webbed walls in addition to the arches 25 and weight reduction
holes 26 to simultaneously reduce weight of the center support
assembly 20 while maintaining the strength of the truck
storage system 1 to support the weight of materials placed
thereon.
Figures 30A, 30B, and 30C show various views of a drawer
assembly 60 including an L-shaped bracket 110 of a truck
storage system 1 according to the present invention. The L-
shaped bracket 110 improves the rigidity of the drawer 60 and
reduces drawer deflection. The L-shaped bracket 110 may be
made of high density polyethylene, other plastics, metals, or
combinations thereof, for example. The L-shaped bracket 110
may be a full-length steel L-shaped bracket that is affixed
with, for example, screws 112 and nuts 114 to one or both
underside drawer rails of the drawer 60. The L-shaped bracket
110 may have one or more holes or slots along its length for
attachment to the drawer rails, and may be formed to
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substantially correspond to the shape of the rails of the
drawers 60. The drawers 60 may have components, e.g., holes,
which correspond to the holes that are in the L-shaped bracket
110. In addition, a boss (or bosses) may be formed on at least
a bottom surface of the rails to index the location of the L-
shaped bracket and provide a means to allow for a difference
in thermal expansion between the L-shaped bracket 110 and the
drawers 60. All components of this exemplary embodiment of the
L-shaped bracket 110 of the truck storage system 1 may be
applied to the embodiment of the truck storage system 1'.
Furthermore, one or more braces may be placed laterally
at different locations across a topside of one or both drawers
60. The braces may be a full-width steel brace that is affixed
with, for example, screws and nuts to one or both sides of
the drawers 60. In addition, or alternatively, a brace
may be placed at a frontside of the drawers 60 near the lock
65. In addition, or alternatively, a brace may be placed
toward a backside of the drawers 60 near the wheels 63 of the
drawers 60. The brace may be attached to the drawers 60 via
the wheel bracket assemblies 66.
All components of the truck storage systems 1, 1' may be
made in long and short versions that correspond to long truck
bed designs of approximately 6.5 feet and short truck bed
designs of approximately 5.5 feet. For example, components
such as the deck halves 10L, 10R, center support assembly 20,
guide channels 57, drawer assemblies 60, and trim piece 90 may
be manufactured in long and short versions. Only one set of
tooling may be needed for these components, in which tool
inserts may be inserted/removed for manufacturing long vs.
short versions. Thus, long and short variations of the truck
storage systems 1, 1' may be economically manufactured with
one set of tooling. Moreover, the non-handedness of many of
the components of the truck storage systems 1, 1', such as for
example, the deck halves 10L, 10R, front support feet 30, rear
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support feet assemblies 40, foot covers 50, guide channel 47,
and drawer assemblies 60, may further allow for economical
manufacture of the storage systems 1, 1'.
Furthermore, all components of the truck storage system
1, 1' may be designed to fit within myriad truck bed designs
of truck manufacturers. For example, the truck storage system
1, 1' may be designed to accommodate seventeen of the eighteen
series of full-sized pickup trucks sold in the U.S. since
2000. For example, lateral side edges 15 of the deck halves
10L, 1OR may be processed to fit within any one of the myriad
truck bed designs. In addition, the center support assembly
may be designed to rest securely within any one of the
myriad truck bed designs. In this respect, truck beds
generally have an undulating surface from the driver side to
15 the passenger side of the truck bed, e.g., an alternating
series of upstanding and downstanding beads. As a result, the
width of the lower surface of the center support assembly 20
may be designed to rest securely on the variously designed
undulating surfaces of any one of the myriad truck bed
20 designs, e.g., on one upstanding bead, or on two upstanding
beads and straddling one downstanding bead. Similarly, the
front and rear support feet 30, 40 may be designed to rest
securely on the variously designed undulating surfaces of any
one of the myriad truck bed designs. Further, the front and
rear support feet 30, 40 may be designed to interface with
existing holes, brackets or tie-down points of any one of the
myriad truck bed designs.
In addition, the bottom surface of the drawers 61 may be
designed with a notch, a raised surface and/or a sloped
surface configured to provide clearance to a lowered tailgate.
Truck bed and tailgate designs of various truck manufacturers
provide different angles of inclination, i.e., tailgate ramp
angle, of the lowered tailgate with respect to the plane of
the bottom surface of the truck bed, and the largest of the
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different angles of inclination is approximately 2.5 degrees.
Thus, in order to provide clearance for fully opening the
drawer assemblies 60, a notch, a raised surface and/or a
sloped surface may be provided on the bottom surface of the
drawer 61, such that a single drawer design can be used in any
one of myriad truck bed designs. Accordingly, a single design
of truck storage systems 1, 1' can be used by owners of any
one of the myriad truck bed designs of truck manufacturers.
As a result, if an owner has installed the truck storage
system 1, 1' in an old truck, but then sells the old truck and
purchases a new, different truck, the owner can simply remove
the existing truck storage system 1, 1' from the old truck,
purchase only new deck halves 10L, 1OR having lateral side
edges 15 processed to fit within the new truck, and reinstall
all other components of the existing truck storage system 1,
1' in the new truck with the new deck halves 10L, 10R.
All components of the truck storage systems 1, 1' may be
configured to nest within each other for packaging, shipping
and/or storage, for example. As described herein, the drawer
assemblies 60 may nest within each other. In addition,
components such as front support feet 30, rear support feet
40, foot covers 50, lock 65, drawer dividers 68, latch
assembly 70, trays 80, 81, wheels, J-hook assemblies 54,
fasteners, brackets, and/or adhesives, and any other small
parts may be placed within nested drawer assemblies 60. The
remaining components, such as the deck halves 10L, 10R, center
support assembly 20, guide channels 57, and any other large
parts may be packaged together with the nested drawer
assemblies 60. Alternatively, the deck halves 10L, 1OR may be
packaged and/or shipped separately from the remaining
components.
All components of the truck storage systems 1, 1' may be
made of high density polyethylene, other plastics, metals, or
combinations thereof, for example. Since the storage systems
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1, 1' are to be installed in truck beds that are typically
exposed to the environment and may encounter heavy loads and
rough use, it may be advantageous to use materials that have
high corrosion resistance. For example, high density
polyethylene (HDPE) may be particularly advantageous for
providing high strength, low weight and good corrosion
resistance. Thus, the storage systems 1, 1' may have a long
useful service life, and may be rated for carrying heavy loads
suitable for the truck bed alone without adding excessive
weight that may adversely affect the performance of the
vehicle.
The long version of the truck storage system 1 (spanning
substantially a total width of a truck bed) that corresponds
to long truck bed designs of approximately 6.5 feet may weigh
approximately 195 lbs, and the short version of the truck
storage system 1 (spanning substantially a total width of a
truck bed) that corresponds to short truck bed designs of
approximately 5.5 feet may weigh approximately 168 lbs.
Further, the long version of the truck storage system 1'
(spanning approximately half a total width of a truck bed)
that corresponds to long truck bed designs of approximately
6.5 feet may weigh approximately 108 lbs, and the short
version of the truck storage system 1' (spanning approximately
half a total width of a truck bed) that corresponds to short
truck bed designs of approximately 5.5 feet may weigh
approximately 93 lbs.
In addition, the truck storage system 1 (spanning
substantially a total width of a truck bed) can support
approximately 2000 lbs of load on its deck 10, and the truck
storage system 1' (spanning approximately half a total width
of a truck bed) can support approximately 1000 lbs of load on
its deck 10.
Although the present invention has been described with
reference to particular examples and exemplary embodiments, it
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should be understood that the foregoing description is in no
manner limiting. Moreover, the features described herein may
be used in any combination.
28
