US-12617327-B2 - Configurable cargo support structure and method of use

US12617327B2US 12617327 B2US12617327 B2US 12617327B2US-12617327-B2

Abstract

A configurable cargo support structure. The configurable cargo support structure may include foldable support panels, wherein adjacent foldable support panels may be connected via a foldable joint extending along at least a portion of a length of adjacent foldable support panels, and wherein the foldable support panels may be made of at least one of a rigid or semi-rigid material.

Inventors

Richard S. Maxwell

Assignees

Richard S. Maxwell

Dates

Publication Date: 20260505
Application Date: 20220228

Claims (13)

1 . A configurable cargo support structure, comprising: a. a plurality of foldable support panels comprising a first panel, a second panel, a third panel, and a fourth panel, wherein the plurality of foldable support panels are each of the same length in a first state, and are made of at least one of a rigid or semi-rigid material; b. foldable joints, the foldable joints connecting adjacent ones of the plurality of foldable support panels in a foldable manner, the foldable joints extending along at least a portion of a width of adjacent foldable support panels; c. wherein the second, third, and fourth support panels are configurable to rest upon backs of one or more rows of seats in a vehicle when one or more of the one or more rows of seats are in a folded down position, and wherein at least one of the second or third support panels are configured to further be foldable in half lengthwise in a second state converting its length in half, and wherein the foldable one of the second or third support panels is immediately adjacent one of the first panel or the fourth panel; and d. further wherein, in a first stored configuration the first, second, third, and fourth support panels are stackable one on top of the other in a single vertical stack to rest fully in a rear cargo space behind a rear most row of seats; in a second partially deployed configuration the first support panel rests in the cargo space and less than all of the second, third, and fourth support panels are positionable upon the backs of one or more folded down seats to form a substantially flat continuous planer support surface across at least a portion of the cargo area and the backs of the one or more folded down seats upon which they are positioned, and in the event of a gap present between one or more of the folded down seats upon which they are positioned, to also span the gap therebetween; and in a third fully deployed configuration the first support panel rests in the cargo space and the second, third, and fourth support panels are positionable upon the backs of the folded down seats and to form a substantially flat continuous planer support surface across the cargo area and the backs of all the folded down seats, and in the event of a gap present between one or more of the folded down seats upon which they are positioned, to also span the gap therebetween.
2 . The configurable cargo support structure of claim 1 , wherein the foldable support panels comprise an outer covering material.
3 . The configurable cargo support structure of claim 2 , wherein the foldable joints are formed of the outer covering material at a space along the length between adjacent foldable support panels.
4 . The configurable cargo support structure of claim 1 , wherein adjacent foldable support panels are configured to fold atop one another in a folded configuration.
5 . The configurable cargo support structure of claim 4 , wherein the foldable support panels are configurable to fold accordion style in a single stack in the first stored configuration.
6 . The configurable cargo support structure of claim 4 , wherein in the second partially deployed configuration one of the second or third support panels is in its second state and folded in half lengthwise.
7 . The configurable cargo support structure of claim 1 , wherein the foldable support panels all comprise the same width.
8 . The configurable cargo support structure of claim 1 , wherein one or more of the foldable support panels are split widthwise, wherein the one or more split foldable support panels are configurable to be of a full width in a non-split configuration or a partial width in a split configuration.
9 . The configurable cargo support structure of claim 8 , wherein the one or more split foldable support panels each comprise a first split panel and a second split panel, and wherein at least one of the first split panel and the second split panel comprises a flap that overlaps a portion of the other one of the first split panel and the second split panel.
10 . The configurable cargo support structure of claim 1 , wherein a thickness at the foldable joint is less than a thickness of the foldable support panels.
11 . A method of using a configurable cargo support structure, comprising: a. providing a configurable cargo support structure, comprising: i. a plurality of foldable support panels comprising a first panel, a second panel, a third panel, and a fourth panel, wherein the plurality of foldable support panels are each of the same length in a first state, and are made of at least one of a rigid or semi-rigid material; ii. foldable joints, the foldable joints connecting adjacent ones of the plurality of foldable support panels in a foldable manner, the foldable joints extending along at least a portion of a width of adjacent foldable support panels; iii. wherein the second, third, and fourth support panels are configurable to rest upon backs of one or more rows of seats in a vehicle when one or more of the one or more rows of seats are in a folded down position, and wherein at least one of the second or third support panels is configured to further be foldable in half lengthwise in a second state converting its length in half, and wherein the foldable one of the second or third support panels is immediately adjacent one of the first panel or the fourth panel; and iv. further wherein, in a first stored configuration the first, second, third, and fourth support panels are stackable one on top of the other in a single vertical stack to rest fully in a rear cargo space behind a rear most row of seats; in a second partially deployed configuration the first support panel rests in the cargo space and less than all of the second, third, and fourth support panels are positionable upon the backs of one or more folded down seats to form a substantially flat continuous planer support surface across at least a portion of the cargo area and the backs of the one or more folded down seats upon which they are positioned, and in the event of a gap present between one or more of the folded down seats upon which they are positioned, to also span the gap therebetween; and in a third fully deployed configuration the first support panel rests in the cargo space and the second, third, and fourth support panels are positionable upon the backs of the folded down seats and to form a substantially flat continuous planer support surface across the cargo area and the backs of all the folded down seats, and in the event of a gap present between one or more of the folded down seats upon which they are positioned, to also span the gap therebetween; b. adjusting a seat configuration of a vehicle; and c. arranging one or more of the plurality of foldable support panels of the first configurable cargo support structure to substantially match the adjusted vehicle seat configuration.
12 . The method of claim 11 , wherein the plurality of foldable support panels are arranged to substantially cover an expanded vehicle cargo area created by folding down or removing one or more seats during the adjusting of the seat configuration of the vehicle.
13 . The method of claim 12 , wherein the plurality of foldable support panels create a substantially continuous span across the expanded vehicle cargo area.

Description

RELATED APPLICATIONS This application claims priority to U.S. patent application Ser. No. 63/161,522, filed Mar. 16, 2021, the disclosure of which is incorporated herein by reference in its entirety. TECHNICAL FIELD The subject matter of the invention relates generally to cargo area liners and more particularly to a configurable cargo support structure and method of use in a cargo area. BACKGROUND The recent market demand for captain seats and third row seating configurations in sport utility vehicles (SUVs) and minivans has created significant drawbacks when trying to use the mixed-use cargo space efficiently. The currently available cargo liners do not meet the full range of needs required by the market. Consumers who favor captain seats and third row seating capacity must sacrifice usable cargo space when the seating configurations are altered. Further, modified seating configurations limit the consumer's ability to protect the vehicle's interior with the cargo liners currently in the market. SUMMARY In one embodiment, a configurable cargo support structure is provided. The configurable cargo support structure may include foldable support panels, wherein adjacent foldable support panels may be connected via a foldable joint extending along at least a portion of a length of adjacent foldable support panels, and wherein the foldable support panels may be made of at least one of a rigid or semi-rigid material. The foldable support panels may include an outer covering material. The foldable joints may be formed of the outer covering material at a space along the length between adjacent foldable support panels. The adjacent foldable support panels may be configured to fold atop one another in a folded configuration. The foldable support panels may be configurable to fold accordion style in a single stack in a fully folded configuration. The foldable support panels may be configurable to lay in a flat planer fashion in a fully unfolded configuration. The foldable support panels may be configurable such that one or more of the foldable support panels may be in a stacked configuration and one or more of the foldable support panels may be in a flat planer configuration in a partially unfolded configuration. The foldable support panels may all be of substantially the same length. The one or more of the foldable support panels may include a different length from one or more of the other foldable support panels. The foldable support panels all may be of about the same width. The one or more of the foldable support panels may be split widthwise, wherein the one or more split foldable support panels may be configurable to be of a full width in a non-split configuration or a partial width in a split configuration. The one or more split foldable support panels each may include a first split panel and a second split panel, and wherein at least one of the first split panel and the second split panel may include a flap that overlaps a portion of the other one of the first split panel and the second split panel. A thickness at the foldable joint may be less than a thickness of the foldable support panels. The one or more unfolded foldable support panels of the foldable support panels may be configured to rest atop one or more folded down seats in a vehicle. In the fully-folded configuration, the one or more panels may be configured to be storable behind a last row of seats of a vehicle with all seats of the vehicle in their unfolded position. In another embodiment, a method of using a configurable cargo support structure in a vehicle is provided. The method may include providing a first configurable cargo support structure. The first configurable cargo support structure may include foldable support panels, wherein adjacent foldable support panels may be connected via a foldable joint extending along at least a portion of a length of adjacent foldable support panels, and wherein the foldable support panels may be made of at least one of a rigid or semi-rigid material. The method may further include, adjusting a seat configuration of a vehicle; and arranging the foldable support panels of the first configurable cargo support structure to substantially match the adjusted vehicle seat configuration. The foldable support panels may be arranged to substantially cover an expanded vehicle cargo area created by folding down or removing one or more seats during the adjusting of the seat configuration of the vehicle. The foldable support panels may create a substantially continuous span across the expanded vehicle cargo area. The method may further include providing a second configurable cargo support structure, wherein foldable support panels of the second configurable cargo support structure may have a width less than that of the foldable support panels of the first configurable cargo support structure. The second configurable cargo support structure may be configurable to substantially cover at least a portion of an expanded vehicl