Field

[0001] The present invention relates to a system and method for opening and closing a rollcover fitted on a cargo bed or tray of a vehicle.

Background

[0002] There are numerous types of truck bed covers used over the utility or cargo bed of a utility vehicle or pickup truck. These products secure and protect the cargo bed, including items disposed therein. Rollcovers, or roll top covers, generally include a motorized or mechanical drive system for operably covering and uncovering the top of an open cargo bed, truck box or the like.

[0003] These prior art rollcovers often incorporate aftermarket key fob remote controllers to operate the roll top cover. That is largely disadvantageous as it requires a vehicle operator to carry an extra key fob just for the rollcover. Key fob remote controllers are also prone to accidental activation by an operator when placed in a pocket/backpack/handbag. Furthermore, key fob batteries need constant replacement and are generally difficult to operate when wearing gloves. The vulnerability of key fobs is also well known in regard to unauthorised or spoofed activation of their transmittal frequencies in order to gain illegal entry into a vehicle.

[0004] Accordingly, an improved way of activating and deactivating the roll over of a vehicle without the use of a key fob is desirable.

Object of the Invention

[0005] It is an object of the present invention to substantially overcome, or at least ameliorate one or more of the above disadvantages or at least provide a useful alternative. Summary of Invention

[0006] In a first aspect, the present invention provides a rollcover mechanism for a rollcover on a vehicle, the rollcover being movable between a fully open position and a fully closed position, the mechanism including: an electric control unit (ECU); a first actuator disposed on the vehicle and operatively connected to the rollcover and the ECU; and a second actuator disposed on the vehicle and operatively connected to the rollcover and the ECU, wherein the ECU is configured to operate the rollcover such that when the rollcover is stationary and partially open, the first actuator initiates movement of the rollcover toward the open position, and the second actuator initiates movement of the rollcover toward the closed position.

[0007] Preferably, the ECU is configured to instantaneously stop the rollcover from moving when either the first actuator or the second actuator is actuated.

[0008] Preferably, a light source is operatively associated with the first actuator and the second actuator, wherein actuation of either the first actuator or the second actuator causes the light source to illuminate for a predetermined time period.

[0009] Preferably, the light source is a light emitting diode.

[00010] Preferably, the first actuator and the second actuator are each a single action switch.

[00011] Preferably, the first actuator and the second actuator are integrated with an exterior portion of the vehicle.

[00012] Preferably, the first actuator and the second actuator are configured such that simultaneous actuation of the first actuator and the second actuator for a predetermined time period initiates a calibration mode. [00013] Preferably, the calibration mode resets the fully open position and the fully closed position of the rollcover.

[00014] Preferably, the mechanism comprises additional actuators for controlling the rollcover.

[00015] Preferably, the first actuator and the second actuator are disposed on a rear corner of the rollcover.

[00016] Preferably, the first actuator and the second actuator are disposed in an interior of the vehicle.

[00017] Preferably, the rollcover mechanism is comprised in a rollcover assembly for operably covering a cargo bed of a vehicle.

[00018] In a second aspect, the present invention provides a method of operating a rollcover on a vehicle, the method comprising: actuating a first actuator, the first actuator disposed on the vehicle and operatively connected to an electric control unit (ECU) operatively connected to the rollcover to control movement of the rollcover, the ECU initiating movement of the rollcover to a fully open position when the rollcover is at least partially closed and stationary; and actuating a second actuator, the second actuator disposed on the vehicle and operatively connected to the ECU, the ECU initiating movement of the rollcover to a fully closed position when the rollcover is at least partially closed and stationary.

[00019] Preferably, the actuating the first actuator or second the actuator when the rollcover is moving instantaneously stops the rollcover from moving.

[00020] Preferably, a light source is operatively associated with the first actuator and the second actuator and actuation of the first actuator or the second actuator causes the light source to illuminate for a predetermined time period.

[00021] Preferably, actuating the first actuator and the second actuator at the same time for a predetermined time period initiates a calibration mode. [00022] Preferably, the calibration mode resets the fully open position and the fully closed position of the rollcover.

[00023] Optionally, a single actuator may be used to operate the rollcover. The single actuator may be programmed to close the rollcover when fully open, and open the rollcover when fully closed.

[00024] Optionally, more than two actuators may be used in the rollcover mechanism.

A third button for example can be used to active the light source, deactivate the light source, initiate calibration mode and pause the movement of the rollcover.

[00025] Optionally, the first actuator and the second actuator may be a joystick switch. The direction of actuation of the joystick switch may determine the movement of the rollcover.

[0010] Optionally, the sets of actuators may be positioned on any exterior surface of the vehicle. Furthermore, the sets of actuators may be placed inside the vehicle. For example, the actuator may be placed on the control panel and/or steering wheel of the vehicle.

Brief Description of Drawings

[0011] Preferred embodiments of the invention will be described hereinafter, by way of examples only, with reference to the accompanying drawings, in which:

[0012] Figure 1 shows a partial view of a right rear portion of a cargo bed of a vehicle having a rollcover mechanism in accordance with an embodiment of the present invention;

[0013] Figure 2 shows a rollcover with a light source installed over the cargo bed of the vehicle of Figure 1 ; and

[0014] Figure 3 shows a flow diagram of a functional operation of the rollcover mechanism of Figure 1. Detailed Description of Embodiments

[0015] The present invention relates to a system and method for activation and deactivation of a rolltop cover for a vehicle. Elements of the invention are illustrated in concise outline form in the drawings, showing only those specific details that are necessary to understanding the embodiments of the present invention, but so as not to clutter the disclosure with excessive detail that will be obvious to those of ordinary skill in the art in light of the present description.

[0016] In this patent specification, adjectives such as first and second, left and right, top and bottom, up and down, upper and lower, rear, front and side, etc., are used solely to define one element or method step from another element or method step without necessarily requiring a specific relative position or sequence that is described by the adjectives. Words such as “comprises” or “includes” are not used to define an exclusive set of elements or method steps. Rather, such words merely define a minimum set of elements or method steps included in a particular embodiment of the present invention.

[0017] In Figure 1 there is schematically depicted a rollcover activation button set 12 installed on a vehicle 10 adjacent a cargo bay, according to a preferred embodiment of the invention. The rollcover activation button set 12 operates to open and close a rollcover (such as the rollcover 18 shown in Figure 2) fitted on a cargo bed or tray of the vehicle 10.

[0018] The rollcover activation button set 12 is one of two identical sets of buttons, with one set of buttons being located as shown on an end cap 24 at the right rear corner 24 of the vehicle 10. The rollcover activation button set 12 is conveniently positioned adjacent both a sidewall 22 and a tail gate 23 of the vehicle 10. Another identical rollcover mechanism (not shown) is located on an end cap at the left rear corner of the vehicle 10. Each set of buttons includes a first push button/actuator 14 and a second push button/actuator 16. The two sets of buttons are wired in parallel and so can be used interchangeably. For example:

First button 14 (left hand side) = First button 14 (right hand side) Second button 16 (left hand side) = Second button 16 (right hand side)

[0019] Each set of buttons operate in the same manner. Both buttons 14, 16 initiate movement of the rollcover 18, with the direction of movement depending on the status of the rollcover 18. In this preferred embodiment, the first button 14 is programmed to retract the rollcover 18 to an open position, and the first button 14 on both the left and right side rear corner of the vehicle will initiate retraction of the rollcover 18. Similarly, the second button 16 is programmed to extend the rollcover 18 to a fully closed position, and the second button 16 on both the left and right side will initiate extension of the rollcover 18. In other embodiments, the first button 14 may be programmed to extend the rollcover 18 and the second button 16 may be programmed to retract the rollcover 18.

[0020] The above configuration allows a user to operate the rollcover 18 from either side of the vehicle 10 and is a user-friendly alternative to a key FOB for opening and closing the rollcover.

[0021] The push buttons 14, 16 are fixed to the vehicle 10 using fasteners such as clips. In Figure 1 , the buttons 14, 16 sit within a top plate 20 of the end cap 24 of the vehicle 10. The buttons 14, 16 may be flush with a surface of the top plate 20, or alternatively other suitable button configurations can be used. A three-clip poke-yoke design facilitates easy assembly in the correct orientation.

[0022] The buttons 14, 16 are fully sealed within the plate 20 with a rubber gasket to prevent ingress of water and debris. As will be understood by those having ordinary skill in the art, an electrical control unit (ECU) (not shown) controls a mechanism of the rollcover 18, by sending electrical signals to a drive motor of the rollcover 18. For example, connections connecting each button with the ECU can be routed through side rails 22 of the vehicle.

[0023] Figure 3 is a flow diagram showing the functionality of the rollcover activation button set 12 when operably connected to the rollcover 18. In this embodiment, an actuation, or a press, of one of the buttons 14, 16 may activate or deactivate the rollcover 18. If the rollcover 18 is not fully open and not fully closed, actuation of the first button 14 will initiate movement of the rollcover 18 to the fully open position. Actuation of the second button 16 will initiate movement the rollcover 18 to the fully closed position.

[0024] Furthermore, if the rollcover 18 is in the fully closed position, actuation of the first button 14 will initiate movement the rollcover 18 to the fully open position. If the rollcover 18 is in the fully open position, actuation of the second button 16 will initiate movement the rollcover 18 to the fully closed position.

[0025] Actuation of the first button 14 when the rollcover 18 is fully opened will not move the rollcover 18 in any direction. Similarly, actuation of the second button 16 when the rollcover is fully closed will not move the rollcover 18 in any direction.

[0026] When actuation of the buttons 14, 16 causes movement, a light source 26, preferably in the form of an LED lamp, will be illuminated for a predetermined time (see Figure 2). The predetermined time period may be, for example, from 1 - 300 seconds. Alternatively, the light source 26 may be configured for example to switch on until the rollcover 18 is closed.

[0027] If the rollcover 18 is moving in either direction (toward the fully open or fully closed position), actuation of either the first button 14 or the second button 16 will stop the rollcover 18 instantaneously at its current location.

[0028] The rollcover activation button set 12 is also configured to calibrate the rollcover 18. A calibration mode is activated when the rollcover 18 is stationary, and both buttons 14, 16 are pressed simultaneously for a predetermined time period. This predetermined time period may range, for example, from 5-60 seconds. For example, the calibration mode may be required if the stop positions of the rollcover 18 are no longer accurate and thus prevent the rollcover 18 from opening or closing fully.

[0029] The calibration mode comprises the following steps: a) Using the first button 14 to retract the rollcover 18 to a position where the rollcover 18 cannot be retracted anymore. This position defines a fully open position. b) Using the second button 16 to extend the rollcover 18 until the rollcover 18 cannot be extended anymore. This position defines a fully closed position. c) The electric control unit (ECU) receives feedback from a motor and limit switches to determine the fully open position and the fully closed position. The ECU can use for example hall sensor (encoder) counts to register a position. d) The ECU saves the new fully open and fully closed position.

[0030] Once a calibration operation is completed the rollcover 18 will configure back to normal operation. The ECU will maintain the new fully open and fully closed positions for use during normal operation. Advantageously, the configuration of the calibration mode enables the use of the ECU to be generic across multiple vehicle product lines, and compensates for manufacturing tolerances concerning the rollcover 18.

[0031] During operation of the calibration mode any anti-pinch function generally is disabled.

[0032] A further embodiment of the present invention provides an anti-tamper mode if either button 14, 16 is actuated an excessive number of times within a short period.

The anti-tamper mode pauses movement of the rollcover 18 at its current location and deactivates all buttons (in all button sets) for a predetermined period of time. For example, an excessive amount of presses may be considered as more than five presses of the first button 14 and/or second button 16 in less than 10 seconds. The predetermined time period during which the first and second buttons 14, 16 will remain deactivated may be, for example, from 5-600 seconds.

[0033] In a preferred embodiment the first button 14 and the second button 16 may be linked with the central locking system of the vehicle 10 when the vehicle 10 is unlocked, and the rollcover 18 is operable with the first button 14 and the second button 16 of the rollcover activation button set 12. If the vehicle 10 is locked, the rollcover activation button set 12 is deactivated, and the rollcover 18 is inoperable. Furthermore, when the vehicle 10 is locked the light source 26 will not energise. [0034] As will be understood by those skilled in the art, the first button 14 and second button 16 may be fully sealed IP 67 units. In a preferred embodiment the visual components of the rollcover activation button set 12 are made with a UV stable glass filled Nylon bezel and a TPV material with UV stabilizer additives.

[0035] Advantages of the present invention include that the buttons 14, 16 are integrated into the vehicle 10’s central locking system via the rollcover ECU. Thus when the vehicle 10 is locked the buttons 14, 16 are automatically rendered non- operational. Further, during opening or closing of the rollcover 18, the buttons 14, 16 can stop the rollcover at any position (partially opened/closed). Further, the single action buttons 14, 16 enable multiple functions in a compact design. Further, the calibration mode enables convenient setting of the open and closed positions of the rollcover 18, which enables elimination of any vehicle and/or rollcover manufacturing tolerances.

[0036] Those skilled in the art will appreciate that not all of the above advantages of the present invention are necessarily included in all embodiments.

[0037] Those skilled in the art will appreciate that various embodiments of the present invention can be made of various materials, or a combination of various materials, including steel, steel alloys, other metal alloys or even high strength plastics or composites.

[0038] The above description of various embodiments of the present invention is provided for purposes of description to one of ordinary skill in the related art. It is not intended to be exhaustive or to limit the invention to a single disclosed embodiment. Numerous alternatives and variations to the present invention will be apparent to those skilled in the art of the above teaching. Accordingly, while some alternative embodiments have been discussed specifically, other embodiments will be apparent or relatively easily developed by those of ordinary skill in the art. Accordingly, this patent specification is intended to embrace all alternatives, modifications and variations of the present invention that have been discussed herein, and other embodiments that fall within the spirit and scope of the above described invention.