Patent Application
20230303005
The present invention relates generally to a cargo carrier for vehicles. More specifically, the present invention relates to an automated self-loading cargo carrier for vehicles that facilitates loading and unloading of items onto an enclosure, via actuators and a motorized mechanism that may be remotely controlled.
A portion of the disclosure of this patent application may contain material that is subject to copyright protection. The owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyrights whatsoever. Certain marks referenced herein may be common law or registered trademarks of third parties affiliated or unaffiliated with the applicant or the assignee. Use of these marks is by way of example and should not be construed as descriptive or to limit the scope of this invention to material associated only with such marks.
Additional storage space for vehicles is seemingly always desirable. To these ends, numerous different storage racks, storage containers and cargo carriers have been disclosed. In fact, a variety of vehicle roof racks and storage or cargo carrying containers are currently available in the market. Moreover, the prior art is riddled with distinct types of cargo carrying means ranging from modular rack systems, to extendable racks and motorized elevators that can be attached to the rear, the roof or other parts of a vehicle. Nevertheless, despite the variety of disclosed devices, the prior art falls short of addressing several problems common to these known devices.
For example, a common obstacle is where to attach such devices (often including container or platforms for containers) on a vehicle. Sometimes these storage devices are coupled to a side of a vehicle; other times these devices are coupled to a front end or the rear end of a vehicle. Often, cargo carrying devices are coupled or affixed to the roof of a vehicle since the roof offers a wide surface area suitable for sustaining a heftier load. A persisting problem however, is that prior art devices still require a user to lift their cargo up to a platform, storage container, etc. When coupled to the roof, such required lifting may prove prohibitive to most users due to height and strength limitations; multiple users may be required for heavier loads or users may be limited in what items they may store with such devices (i.e. limited by the weight a user may be able to lift rather than the weight capacity of the device itself). While the average SUV has a roof height of 5.8″ and larger vehicles may have a roof height of 6′ or more, and since the device sits on top of the vehicle rack, an additional 3-4″ on top of that is required to practically operate these devices without step ladders or the like. As such, many prior art devices are not used to their fullest potential due to this limitation.
One such device is taught by U.S. Pat. No. 5,348,207 to Frank. Frank describes a carrier apparatus for mounting on a roof of a vehicle. The apparatus includes a housing, magnetic mounts for connecting the housing to the vehicle and for supporting the housing in a horizontal orientation, and a drawer for sliding in and out of the housing. A pivoted connection is provided for connecting the drawer to the housing. When the drawer is retained in the horizontally oriented housing, the drawer is in the horizontal storage mode. When the drawer is pulled out from the housing and hangs down from the housing by the pivoted connection, the drawer is in the vertical access mode. Although the mounts can include a fluid suspension, lifting the cargo up into the container must be done manually, which as mentioned above significantly limits the type and weight limit of the cargo that a user will be able to load using this device.
Another device with a similar limitation is taught by U.S. Patent Publication 2017/0341590 to McLauchlan. McLauchlan describes a roof rack for a vehicle having a roof attachment means, a cargo frame adapted to releasably engage with cargo and a means to enable the cargo frame to be moved between a horizontal position above the roof of a vehicle and a vertical position behind the vehicle. In use, the roof rack is attached to the roof of a vehicle via the roof attachment means wherein a user standing behind the vehicle is able to pull the cargo frame or attached cargo towards himself such that the cargo frame and attached cargo moves from a substantially horizontal position above the roof of the vehicle to a substantially vertical position behind the vehicle so that the user can load and/or unload the cargo. Once this is done, the user can push the cargo frame or attached cargo such that the frame moves from a vertical position behind the vehicle to a horizontal position above the roof of the vehicle. Again, lifting the cargo up to the horizontal position can be difficult for most potential consumers, and as mentioned above significantly limits the type and weight limit of the cargo that a user will be able to load using this device.
Other devices address the problem of having to lift a load up to the roof by implementing a motor. One such device is taught by U.S. Patent Publication 2006/0175368 to Fallis. Fallis describes a cargo container for a vehicle including an enclosure or movable supporting member that is connected by a linkage to the vehicle. The linkage may be used to shift the enclosure between a transport position above the roof and a loading position behind the vehicle. A rearward pivoting member lifts portions of the enclosure behind the forward member upwardly to clear a rear corner of the vehicle as the enclosure is moved between the transport position and the loading position. Although this device appears to implement a motor for lifting the device between the loading position and the transport position, its use appears cumbersome and in order to facilitate the movement of the device, storage space must be substantially limited.
Limited cargo space is yet another problem that has not been adequately addressed, especially by devices that implement motorized lifting mechanisms. One such device is taught by U.S. Pat. No. 3,823,839 to Petzing. Similarly, U.S. Pat. No. 9,463,748 to Presley discloses a powered cargo rack for tall vehicles. Each of these devices fails to disclose an adequate storage space; likely due to their cumbersome lifting mechanisms that take up space otherwise suitable for cargo.
U.S. Pat. No. 5,667,116 to Reinhart forgoes the motorized feature in order to provide a more adequate cargo space, by implementing a two-part or clamshell compartment. As such, although the cargo space is increased, the implementation of clamshell compartments introduces still other setbacks.
For example, clamshells are typically long and narrow. Because of their narrow shape, most consumers install them on one side of their vehicle's roof—otherwise they are unreachable. This creates an unstable load while driving and is therefore undesirable. Moreover, these devices are designed to attach to a cross-member of an SUV's roof rack. For cars that only have longitudinal rails, like most of the newer roof racks, clamshell manufacturers sell their own cross-members and fittings to attach to the factory-installed longitudinal rails.
Newer model clamshells open and lock from either of their longitudinal sides, but the hinging and locking mechanisms, and the cargo containers themselves, are flimsy; consequently, the hinges and locks are prone to breaking, which is a common complaint amongst current clamshell owners. Current devices available on the market are also of limited volume, typically occupying less than 50% of the vehicle roof's area, provoking some users to mount two devices side by side in order to accommodate all of their luggage and equipment. But the most limiting factor of such existing devices is that they are very difficult to load and access, typically requiring a step ladder or other specialized ladders (e.g. one that fits over the rear tire) in order to reach the device once it is mounted on top of the vehicle.
U.S. application Ser. No. 15/972,070 describes a mechanism that raises the entire shell, much like a dump truck, such that the egressing tray will be able to reach the ground, thereby facilitating the loading of heavy wheeled equipment. Although this mechanism provides unique capability, in some situations the equipment stored in the shell may be de-stabilized when the shell is being tilted up unless each item is secured. Other inventions, such as sliding trays currently being marketed, have the drawback of not being able to carry heavy loads due to the resultant significant lever moment; nor are they able to change the angle of the tray's egress in order for it to reach the ground in order to allow for onboarding of wheeled heavy equipment.
Therefore, there exists a previously unappreciated need, and an inadequately addressed problem, requiring a new and improved cargo carrier for vehicles. There is a need for a cargo carrier that addresses the problems mentioned above; enables motorized and automated loading of cargo onto a containment shell or enclosure; employs an enclosure of a durable construction that maximizes a surface area for storage; and is easily utilized by a wide segment of consumers for a wide range of uses. It is to these ends that the present invention has been developed.
To minimize the limitations in the prior art, and to minimize other limitations that will be apparent upon reading and understanding the present specification, the present invention describes an automated self-loading cargo carrier for automobiles that facilitates storing a variety of items.
Generally, the invention involves a cargo carrier for vehicles that facilitates loading and unloading of items onto an enclosure; the cargo carrier may be automated and self-loading via actuators and a motorized mechanism that may be remotely controlled. The actuators may be configured to tilt the enclosure and one or more motors may be configured to deploy a deployable tray housed within the enclosure, which minimizes user loading or unloading labor. As will be apparent from the discussion of various exemplary embodiments, the present invention may be applicable to vehicles employing a roof rack as well as vans, and pick-up trucks. The present invention also solves the lever moment and angle problem within the tray design itself. The present invention provides additional features that, when combined, may transform a pickup bed into a “mobile workshop”.
In some exemplary embodiments, on a front end of the enclosure, one or more actuators may couple the enclosure to a front portion of a vehicle support structure. On a rear end of the enclosure, one or more rear fittings may be configured to couple the enclosure to a rear portion of the vehicle support structure. In some exemplary embodiments, the support structure is a vehicle roof rack. In some exemplary embodiments, the support structure may include a bed of a truck or the interior surface of a van.
Typically, the enclosure incudes a front wall, side walls, a top surface, a bottom surface and a rear access door opposite to the front wall of the enclosure. Inside the enclosure, a deployable tray may be slidably housed therein, coupled to one or more motors that may be employed to deploy or slide the deployable tray outside of the enclosure during a loading or unloading sequence. To further assist a user during a loading or unloading sequence, the deployable tray may further include a conveyor mechanism or a means to lowering the tray in a manner that facilitates loading or unloading it.
In exemplary embodiments, a controller may be configured to communicate with a remote control so that a user may control the movement of the enclosure and the deployable tray remotely.
A cargo carrier in accordance with one exemplary embodiment of the present invention, comprises: an enclosure including rear fittings configured to tiltably couple the enclosure to a rear portion of a vehicle roof rack; a pair of actuators housed inside the enclosure, each of the pair of actuators including an extension arm adapted to couple to a front portion of the vehicle roof rack; a deployable tray, slidably housed within the enclosure; one or more motors coupled to the deployable tray; and a controller in communication with the pair of actuators and the one or more motors, the controller configured to: activate the pair of actuators to tilt the enclosure; and activate the one or more motors to slide the deployable tray outside of the enclosure.
A cargo carrier in accordance with another exemplary embodiment of the present invention, comprises: an enclosure defined by a front wall, side walls, a top surface, a bottom surface and a rear access door opposite to the front wall of the enclosure, the enclosure further including rear fittings configured to tiltably couple the enclosure to a rear portion of a vehicle roof rack; one or more actuators, each of the one or more actuators coupled to one of the side walls of the enclosure and including an extension arm configured to couple with a front portion of the vehicle roof rack; a deployable tray, slidably housed within the enclosure; and a controller in communication with the one or more actuators and configured to: draw power from a rechargeable battery housed within the enclosure; and activate the one or more actuators so as to raise the front wall of the enclosure in order to tilt the enclosure.
A cargo carrier in accordance with yet another exemplary embodiment of the present invention, comprises: a cargo carrier adapted to couple to a vehicle roof rack, including: an enclosure adapted to tiltably couple to an aft end of the vehicle roof rack; one or more actuators, each of the one or more actuators coupled to a side wall of the enclosure and including an extension arm, the extension arm adapted to couple to a fore end of the vehicle roof rack; a deployable tray, slidably housed within the enclosure; a first motor coupled to the deployable tray; a second motor coupled to a conveyor mechanism installed on to the deployable tray; and a controller in communication with the one or more actuators, the first motor and the second motor, wherein the controller is configured to: draw power from a rechargeable battery housed within the enclosure; activate the one or more actuators so as to raise a front wall of the enclosure in order to tilt the enclosure; and activate the first motor to deploy the deployable tray outside of the enclosure; and activate the second motor to move the conveyor mechanism installed on the deployable cover; and a remote control configured to remotely control movement of the enclosure and the deployable tray.
In some exemplary embodiments, a cargo carrier is adapted for the bed of a pickup truck. In one version of this exemplary embodiment, the cargo carrier may include: an enclosure including fittings configured to couple the enclosure to a truck bed; a first deployable tray, slidably housed within the enclosure, the first deployable tray including a tiltable surface; one or more actuators, including: at least one actuator adapted to extend and retract the first deployable tray outside and inside the enclosure, respectively; and at least one actuator adapted to tilt the tiltable surface of the first deployable tray; and a controller in communication with the one or more actuators and configured to: activate the one or more actuators to slide the first deployable tray outside of the enclosure; and activate the one or more actuators to tilt the tiltable surface of the first deployable tray.
In another version of this exemplary embodiment, the cargo carrier may include: an enclosure defined by a front wall, side walls, a top surface, a bottom surface and a rear access door opposite to the front wall of the enclosure, the enclosure further including fittings configured to couple the enclosure to a truck bed; a first deployable tray, slidably housed within the enclosure, the first deployable tray including a tiltable surface; one or more actuators, including: at least one actuator housed inside the enclosure adapted to extend and retract the first deployable tray outside and inside the enclosure, respectively; and at least one actuator coupled to a surface of the first deployable tray and adapted to tilt the tiltable surface of the first deployable tray; and a controller in communication with the one or more actuators, the controller configured to: activate the one or more actuators to slide the first deployable tray outside of the enclosure; and activate the one or more actuators to tilt the tiltable surface of the first deployable tray.
In one aspect of the present invention, a cargo carrier may comprise a configuration to address vehicles with a vehicle airfoil. The cargo carrier may comprise: an enclosure adapted to couple to a vehicle roof; a deployable tray, slidably housed within the enclosure; one or more actuators, including: at least one actuator adapted to extend and retract the deployable tray outside and inside the enclosure, respectively; and a controller in communication with the one or more actuators and configured to: activate the one or more actuators to slide the deployable tray outside of the enclosure.
In some exemplary embodiments, the at least one actuator adapted to extend and retract the deployable, is further adapted to move the enclosure over an airfoil of the vehicle.
In some exemplary embodiments, the enclosure is coupled to a translating hinge adapted to facilitate movement of the enclosure over the airfoil of the vehicle. In some exemplary embodiments, the translating hinge is adjustable and further adapted to adjust a distance of the movement of the enclosure over the airfoil of the vehicle.
In some exemplary embodiments, the enclosure is coupled to one or more rollers adapted to facilitate the movement of the enclosure over the airfoil of the vehicle. In some exemplary embodiments, the translating hinge is coupled to one or more rollers adapted to facilitate the movement of the enclosure over the airfoil of the vehicle.
In some exemplary embodiments, at least one of the one or more actuators is adapted to lift or tilt at least a portion of the enclosure. In some exemplary embodiments, the at least one of the one or more actuators is positioned at a fixed angle with respect to the enclosure and lifts or tilts the enclosure at the fixed angle.
In some exemplary embodiments, the at least one of the one or more actuators is positioned at a variable angle with respect to the enclosure and lifts or tilts the enclosure at the variable angle.
In some exemplary embodiments, the deployable tray is adapted to slide out of the enclosure sideways through an opening on a side of the enclosure or through a rear region of the cargo carrier.
In some exemplary embodiments, a cargo carrier in accordance with the present invention may comprise: an enclosure adapted to tiltably couple to a vehicle roof, the enclosure defined by a front wall, side walls, a top surface, a bottom surface and a rear access door opposite to the front wall of the enclosure; a deployable tray, slidably housed within the enclosure; one or more actuators, including: at least one actuator adapted to move the enclosure over an airfoil of the vehicle and extend and retract the deployable tray outside and inside the enclosure, respectively; and a controller in communication with the one or more actuators and configured to: activate the one or more actuators to slide the deployable tray outside of the enclosure.
In some exemplary embodiments, a cargo carrier in accordance with the present invention may comprise: an enclosure adapted to tiltably couple to a vehicle roof, the enclosure defined by a front wall, side walls, a top surface, a bottom surface and a rear access door opposite to the front wall of the enclosure; a translating hinge coupled to the enclosure and the vehicle roof, the translating hinge adapted to facilitate movement of the enclosure over an airfoil of the vehicle; a deployable tray, slidably housed within the enclosure; at least one actuator adapted to lift or tilt at least a portion of the enclosure and move the enclosure over the airfoil of the vehicle and extend and retract the deployable tray outside and inside the enclosure, respectively; and a controller in communication with the one or more actuators and configured to activate the one or more actuators to slide the deployable tray outside of the enclosure.
These features of the present invention are not meant as limiting characteristics, but are described herein with specificity so as to make the present invention understandable to one of ordinary skill in the art.
The cargo carrier as disclosed herein is further described in terms of exemplary embodiments. These exemplary embodiments are described in detail with reference to the drawings, which have not necessarily been drawn to scale in order to enhance their clarity and improve understanding of the various embodiments of the invention. Furthermore, elements that are known to be common and well understood to those in the industry are not depicted in order to provide a clear view of the various embodiments of the invention. These embodiments are non-limiting exemplary embodiments, in which like reference numerals represent similar structures throughout the several views of the drawings. The drawings that accompany the detailed description can be briefly described as follows:
In the following discussion that addresses a number of embodiments and applications of the present invention, reference is made to the accompanying drawings that form a part thereof, where depictions are made, by way of illustration, of specific embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized, and changes may be made without departing from the scope of the invention. Wherever possible, the same reference numbers are used in the drawings and the following description to refer to the same or similar elements.
In the following detailed description, numerous specific details are set forth by way of examples in order to provide a thorough understanding of the relevant teachings. However, it should be apparent to those skilled in the art that the present teachings may be practiced without such details. In other instances, well known structures, components and/or functional or structural relationship thereof, etc., have been described at a relatively high-level, without detail, in order to avoid unnecessarily obscuring aspects of the present teachings.
Throughout the specification and claims, terms may have nuanced meanings suggested or implied in context beyond an explicitly stated meaning. Likewise, the phrase “in one embodiment/example” as used herein does not necessarily refer to the same embodiment and the phrase “in another embodiment/example” as used herein does not necessarily refer to a different embodiment. It is intended, for example, that claimed subject matter include combinations of example embodiments in whole or in part.
Conditional language used herein, such as, among others, “can,” “could,” “might,” “may,” “e.g.,” and the like, unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements and or steps. Thus, such conditional language is not generally intended to imply that features, elements and or steps are in any way required for one or more embodiments, whether these features, elements and or steps are included or are to be performed in any particular embodiment.
The terms “comprising,” “including,” “having,” and the like are synonymous and are used inclusively, in an open-ended fashion, and do not exclude additional elements, features, acts, operations and so forth. Also, the term “or” is used in its inclusive sense (and not in its exclusive sense) so that when used, for example, to connect a list of elements, the term “or” means one, some, or all of the elements in the list. Conjunctive language such as the phrase “at least one of X, Y, and Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to convey that an item, term, etc. may be either X, Y, or Z. Thus, such conjunctive language is not generally intended to imply that certain embodiments require at least one of X, at least one of Y, and at least one of Z to each be present. The term “and or” means that “and” applies to some embodiments and “or” applies to some embodiments. Thus, A, B, and or C can be replaced with A, B, and C written in one sentence and A, B, or C written in another sentence. A, B, and or C means that some embodiments can include A and B, some embodiments can include A and C, some embodiments can include B and C, some embodiments can only include A, some embodiments can include only B, some embodiments can include only C, and some embodiments include A, B, and C. The term “and or” is used to avoid unnecessary redundancy. Similarly, terms, such as “a, an,” or “the,” again, may be understood to convey a singular usage or to convey a plural usage, depending at least in part upon context. In addition, the term “based on” may be understood as not necessarily intended to convey an exclusive set of factors and may, instead, allow for existence of additional factors not necessarily expressly described, again, depending at least in part on context.
While exemplary embodiments of the disclosure may be described, modifications, adaptations, and other implementations are possible. For example, substitutions, additions, or modifications may be made to the elements illustrated in the drawings, and the methods described herein may be modified by substituting, reordering, or adding stages to the disclosed methods. Thus, nothing in the foregoing description is intended to imply that any particular feature, characteristic, step, module, or block is necessary or indispensable. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions, and changes in the form of the methods and systems described herein may be made without departing from the spirit of the invention or inventions disclosed herein. Accordingly, the following detailed description does not limit the disclosure. Instead, the proper scope of the disclosure is defined by the appended claims.
Turning now to the figures,
Enclosure 101 may be constructed of a variety of materials without deviating from the scope of the present invention. In exemplary embodiments, enclosure 101 comprises high-density plastic that is rotationally molded, resulting in a completely enclosed shell. In exemplary embodiments, two access openings may be cut out of the single-piece shell to form: (i) an access opening at the forward face or face wall of enclosure 101 providing access to power supply 103 and (ii) another opening opposite to the front wall of enclosure 101 for the rear face access to the interior of the shell, wherein the rear access opening is substantially as wide as a width of enclosure 101 in order to accommodate deployable tray 102 sliding out and back inside enclosure 101 during operation of cargo carrier 100. Enclosure 101 preferably although not necessarily conforms to a vehicle's design such that the enclosure minimizes interference with structural components of the vehicle. This maximizes storage space and, in some embodiments, (i.e. wherein enclosure 101 is coupled to a vehicle rack as depicted in this set of figures) reduces wind turbulence. For example, and without limiting the scope of the present invention, when coupled to a vehicle rack as shown, rather than sit between the longitudinal rails of vehicle rack 108 of vehicle 112, and rather than sitting completely above each of the longitudinal rails, enclosure 101 may include a bottom surface that contours to each longitudinal rail. Storage space is maximized as the width of the shell may be as widened, and this design enables enclosure 101 of cargo carrier 100 to rest closer to the roof of vehicle 112.
Deployable tray 102 is typically a retractable surface or tray that is slidably coupled to an interior of enclosure 101 and slides in and out of enclosure 101 to facilitate loading and unloading of items 106 stored therein. Deployable tray 102 (as will be discussed further below) may implement a conveyor mechanism that facilitates such loading and unloading sequence. Deployable tray 102 may be constructed of a variety of materials without deviating from the scope of the present invention. In exemplary embodiments, deployable tray 102 is made of molded plastic (industrial versions, described below, may have aluminum litters) and may be configured to translate or slide in and out of enclosure 101 on—for example and without limitation—heavy duty ball bearing slides. As mentioned above, deployable tray 102 may be motorized and remotely controlled.
Power supply 103 may be a battery or more specifically a rechargeable battery pack, which in exemplary embodiments is installed at a front end of enclosure 101 so as to provide easy access in case of required maintenance, recharge or replacement. In exemplary embodiments, power supply 103 is configured to receive power from photovoltaic cells disposed on one or more exterior surfaces of enclosure 101. In some exemplary embodiments, the photovoltaic cells or solar panels may be, for example, disposed in a recessed surface or region of the enclosure such that the solar panels are flush with an exterior surface of the enclosure. As such, in some exemplary embodiments, power supply 103 includes a rechargeable battery pack that may be recharged with solar power from the photovoltaic cells as well as power from an external power source. In order to provide easy access to power supply 103, enclosure 101 may include an access door such as access door 103a. In some exemplary embodiments, access door 103a is cut from the front wall or front face of enclosure 101 during construction of enclosure 101. Access door 103a may be hinged at an upper edge of the smaller front opening of enclosure 101 and may include an electric lock attached to a lower edge of access door 103a so that access door 103a may be operated remotely. Moreover, in some exemplary embodiments, access door 103a may be configured for automatically opening and or closing. To these ends, in some exemplary embodiments, access door 103a may implement dual bi-directional linear actuators attached to the interior of enclosure 101. Other known features may be implemented in exemplary embodiments such as implementation of a sealing component or a rubber grommet that may be employed between access door 103a and enclosure 101 to eliminate potential leakage of water into enclosure 101 during inclement weather.
Actuators 104 may be any type of actuators suitable for raising a front end of enclosure 101 of cargo carrier 100, in order to tilt enclosure 101 in the manner depicted in
Actuators 104 may comprise of any type of actuators suitable for tilting a position of enclosure 101. In some exemplary embodiments, actuators 104 comprise of linear actuators that are electrically powered actuators (one on each side of enclosure 101). As will be mentioned in more detail below, each actuator may be coupled to vehicle rack 108 at a front portion 109 of the longitudinal rails of rack 108; when actuators 104 are activated, the front portion of enclosure 101 is raised while one or more aft attach fittings 110 coupling enclosure 101 to a rear portion of rack 108 enable enclosure 101 to rotate about an axis through the two aft attach fittings 110. This may be achieved by coupling aft attach fittings 110 to a portion of longitudinal rails of rack 108 such as horizontal rail 108a via hinges. Accordingly, actuators 104 typically include extension arms 104a that may traverse through a portion of enclosure 101 such as openings 104b situated at a bottom surface 111 of enclosure 101 in order to extend a length of each actuator 104 below the bottom surface 111 of enclosure 101 thereby raising the front end of enclosure 101 as described and exemplarily shown in the figures.
Access door 105 may be constructed of the same material as enclosure 101 or may be constructed of a different material altogether without limiting the scope of the present invention. In some exemplary embodiments, access door 105 is cut from the rear face of enclosure 101 during construction of enclosure 101. Access door 105 may be hinged at an upper edge of the rear opening of enclosure 101 and configured for automatically opening and or closing. In some exemplary embodiments, access door 105 may implement dual bi-directional linear actuators attached to the sides and interior of enclosure 101. Access door 105 may include an electric lock attached to a lower edge of access door 105 that can be operated remotely. Other known features may be implemented in exemplary embodiments such as implementation of a sealing component or a rubber grommet that may be employed between access door 105 and enclosure 101 to eliminate potential leakage of water into enclosure 101 during inclement weather.
Items 106 may of course comprise any storable items, including but not limited to typical travel items such as suitcases (as shown), boxes, sports equipment, or other items a user may choose to travel with including but not limited to occupational tools, other equipment, etc. As will be discussed with reference to other figures below, depending on the type or structure of storable items 106, enclosure 101 and or deployable tray 102 may employ components to facilitate the secured storage of such items; the components may include a molded tray suitable for storing tools and equipment having known universal shapes, or clamps for securing items such as skis so that the skis stay secured to a side wall or interior surface of enclosure 101.
In order to control activation of actuators 104 and any motor or set of motors that may be employed by deployable tray 102, a control circuitry may be configured to communicate with each device and may further be configured to communicate with a remote-control device, such as remote control 107 so that a user may control activation of each component remotely. Remote control 107 may facilitate a user to: remotely activate the movement (including the tilting and leveling) of enclosure 101 by activation of actuators 104; remotely activate the movement (including the sliding out and sliding in) of deployable tray 102 by activation of one or more motors coupled to deployable tray 102; and or remotely activate a locking and or opening and closing of access doors such as access doors 103a and 105.
Cargo carrier 100 is attached at four points to the longitudinal rails of rack 108 of vehicle 112: left, right, fore and aft, wherein the two forward attachment points 109 connect actuators 104 (one on each side of enclosure 101) to the forward mounting points on the longitudinal rails of rack 108; and wherein the two aft attach fitting points 110 couple enclosure 101 to a rear portion of longitudinal rails of rack 108 (e.g. in the embodiment of
In the embodiments depicted in
Turning now to the next set of figures,
From these views, enclosure 201, deployable tray 202 and other components of a device in accordance with the present invention may be better appreciated. As mentioned above, the shape of an enclosure for a cargo carrier in accordance with the present invention may be such that aerodynamics of a traveling vehicle are aided by the conforming design of the enclosure. In the current embodiment depicted in these figures, enclosure 201 includes a front wall or face wall 203 that may be slightly slanted (in some embodiments slanted about 30 degrees i.e. to minimize wind loading), a flat top surface 204, flat side walls 205 and a rear opening 206 to which access is controlled via access door 207; moreover, a rear portion of enclosure 201 is slightly slanted albeit less so than face wall 203. The edges of the enclosure may be sharp or rounded as shown without deviating from the scope of the present invention.
In exemplary embodiments, enclosure 201 is a single-piece molded enclosure made of a high-density plastic that is rotationally molded; such rigid single-piece construction facilitates additional storage on the interior and exterior of enclosure 201. Two access openings, a first access opening removably covered with access door 203A (on face wall 203) and a second access opening or rear opening 206 (to which access is controlled via access door 207) are cut out of the single-piece molded enclosure. Access opening 203A is typically a small opening that may measure approximately 12″ wide×8″ tall, is as mentioned above cut from front or face wall 203 of the enclosure 201, and is used to access battery pack 216, typically situated at the front of the enclosure for the reasons stated above, albeit without limiting the scope of the present invention. The second access opening or rear opening 206 is typically a larger opening that may measure approximately 36″ wide and 14″ tall, is cut from the rear face or rear wall of the enclosure 201 and is large enough to allow deployable tray 201 loaded with storable items such as luggage (lying flat) to pass through. Other openings at a bottom surface 212 of enclosure 201 may be implemented for traversing actuator extension arms therethrough; that is, in exemplary embodiments wherein actuators are housed within enclosure 201, openings 213 may be implemented so as to allow extension arms of each actuator to extend from these openings 213. As may be appreciated from the view of
In exemplary embodiments, enclosure 201 occupies an entire area of the roof of the vehicle, which means that enclosure 201 provides more than twice the volume of most known cargo shells installed on vehicle roof racks. In exemplary embodiments, enclosure 201 is conformal to the extent that the front and rear faces of the container are approximately tangent and contiguous with the planes of the windshield and hatchback, respectively (van containers' rear faces will be perpendicular to the roof plane since the rear panels or doors of vans are also perpendicular to the roof plane). As such, in some exemplary embodiments, the rear portion of enclosure 201 is slightly slanted although less so than front face 203.
In some exemplary embodiments, deployable tray 202 is made of molded plastic, aluminum or any other materials with a suitable strength to support storable items, depending on the requirements of deployable tray 202. Moreover, deployable tray 202 may be motorized as mentioned above. Whether or not a conveyor mechanism 208 is implemented, in exemplary embodiments, deployable tray 202 may be slid out and back into enclosure 201 with the aid of a plurality of tracks and a motor to control movement of the deployable tray 202. For example, and as in the shown embodiments of
Movement of deployable tray 202, and more specifically tray surface 209, may be accomplished by a first motor 217. In exemplary embodiments, motor 217 is a pancake-type stepper motor (although other DC motor types may be employed without deviating from the scope of the present invention) attached to the aft end of the inside bottom surface 212 of enclosure 201. Motor 217 may implement a pinion gear attached to it that is meshed with track 211 that is mounted to the underside of tray surface 209, oriented longitudinally along the centerline of deployable tray 202.
Deployable tray 202 may implement low side rails 208b (i.e. in exemplary embodiments, approximately 2″ high) that are horizontally slotted periodically (approximately 18-24″ apart) along the sides of tray surface 209 to accommodate cargo straps to secure the load. As an option, recoiling cargo straps may be attached to one of the side rails 208b of tray surface 209 of deployable tray 202, and hooked into the corresponding slots on the other side of side rails 208b. Of course, other means of mechanizing deployable tray 202 may be achieved without deviating from the scope of the present invention. For example, and without limiting the scope of the invention, deployable tray 202 may employ a ball screw and ball nut mechanism, similar to the way tables on machine tools are moved; such solution may be more rigid and quieter than the rack and pinion option, but also more expensive.
In some exemplary embodiments, as shown, a conveyor mechanism 208 is implemented. For example, and without limiting the scope of the present invention, a motorized conveyor includes a snap-in or bolt-in option that installs inside tray surface 209. The conveyor mechanism may be powered by a second motor, also mounted to the inside bottom of tray surface 209 (at the forward end of tray surface 209). The conveyor's rollers may be belt-driven, coupled to the second motor. This option allows for easier loading by “feeding” pieces of storable items such as luggage, etc. forward from the aft end of the tray surface 209, which in practice will be situated at the lowest point with reference to the ground when enclosure 201 is in an inclined or tilted position. An alternate method for powering the conveyor is to have one or more of the rollers motorized, a slightly more elegant but significantly more expensive solution. In the shown embodiment, conveyor mechanism 208 exemplarily comprises a plurality of rotatable tubes or rollers 208a that lay perpendicular to a length of deployable tray 202 across tray surface 209 and coupled to side rails 208b. Movement of conveyor mechanism 208 may be accomplished via a belt 215 coupled to rollers 208a driven by a motor 214.
Although not shown in the views of
Similarly, in other exemplary embodiments, cargo carrier 200 comprises: an enclosure 201 defined by a front wall 203, side walls 205, a top surface 204, a bottom surface 212 and a rear access door 207 opposite to the front wall 203 of the enclosure 201, the enclosure 201 further including rear hinged attachment fittings 213A configured to tiltably couple the enclosure 201 to a rear portion of a vehicle roof rack 108; one or more actuators 104, each of the one or more actuators coupled to one of the side walls 205 of the enclosure 201 and including an extension arm 104a configured to couple with a front portion of the vehicle roof rack 108; a deployable tray 202, slidably housed within the enclosure 201; and a controller 303 in communication with the one or more actuators 104 and configured to: draw power from a rechargeable battery 216 housed within the enclosure 201; and activate the one or more actuators 104 so as to raise the front wall 203 of the enclosure 201 in order to tilt the enclosure 201.
Turning now to the next figure,
Components of cargo carrier 301 include controller 303, which may be any type of controller suitable for communicating with the various actuators and or motors employed by cargo carrier 301. In exemplary embodiments, controller 303 is a multi-phase controller configured to: activate lifting actuator module 304 (which may comprise one or more actuators such as actuators 304A and 304B coupled to vehicle rack 305); activate sliding tray module 306 (which may comprise a motor 306A coupled to deployable tray 307); and activate rolling conveyor module 308 (which may comprise a motor 308A coupled to conveyor 309).
Controller 303 may draw power from a rechargeable battery 310, which may be in turn supplied by power from a solar energy via photovoltaic cells 311. As mentioned above, photovoltaic cells 311 may be disposed on a surface of an enclosure in accordance with the present invention.
In some exemplary embodiments, as shown in this current figure, controller 303 utilizes a receiver or transceiver 312 to communicate with remote control 302 and receive commands therefrom. In some exemplary embodiments, independent rocker-type switches may be employed to hold down in one direction or the other to activate: lifting actuator module 304, sliding tray module 306 and or rolling conveyor module 308. Controller 303 may further communicate with an access door control module 313 including additional open/close actuators and or lock/unlock switches configured to operate access doors of the enclosure. The controller may also be programmable, in the sense that it will have the ability to store multiple pre-set lift angles and shelf extensions to accommodate the various waist heights of different users.
This may be optionally achieved, without limiting the scope of the present invention, via remote control 302. In some exemplary embodiments, remote control 302 includes a controller 314, which may communicate with controller 303 via a transmitter or transceiver 315 using any known technologies including but not limited to a Bluetooth protocol or any other wireless communication protocols known in the art. Remote control 302 typically includes battery 316 as a source of power for controller 314, and a user interface 317. User interface 317 may vary in complexity without deviating from, or limiting the scope of, the present invention. For example, user interface 317 may include a screen display or may be as simple as a few pre-programmed buttons.
Accordingly, in an exemplary embodiment, cargo carrier system 300 comprises a cargo carrier 301 adapted to couple to a vehicle rack 305 of a vehicle, including: an enclosure adapted to tiltably couple to an aft end of the vehicle rack 305; an actuator module 304 including one or more actuators 304A, 304B, each of the one or more actuators coupled to a side wall of the enclosure and including an extension arm, the extension arm adapted to couple to a fore end of the vehicle rack 305; a deployable tray 307, slidably housed within the enclosure; a first motor module 306 including a first motor 306A coupled to the deployable tray 307; a second motor module 308 including a second motor 308A coupled to a conveyor mechanism 309 installed onto the deployable tray 307; and a controller 303 in communication with the one or more actuators 304A, 304B, the first motor 306A and the second motor 308A, wherein the controller 303 is configured to: draw power from a rechargeable battery 310 housed within the enclosure; activate the one or more actuators 304A, 304B so as to raise a front wall of the enclosure in order to tilt the enclosure; and activate the first motor 306A to deploy the deployable tray 307 outside of the enclosure; and activate the second motor 308A to move the conveyor mechanism 309 installed on the deployable tray 307. Furthermore, system 300 may include a remote control 302 configured to remotely control movement of the enclosure and the deployable tray via wireless communication with controller 303.
Turning now to the next set of figures,
More specifically,
For example, contractor modular trays may be highly customizable and re-configurable, based on the needs of each job. This may be accomplished by using latch-in or bolt-in “skids” that fit into the trays. The modular trays may take up the entire length of a deployable tray, or just a portion, to allow for multiple modular trays on a single deployable tray. Attachment features may be incorporated at regular intervals to allow maximum flexibility in configuring the deployable tray with the modular tray. For example, a painting tray may include modular trays for holding five-gallon paint buckets, made of molded plastic, like cupholders (such as apertures 403). Each modular tray for this purpose may hold two to four five-gallon buckets in a side by side configuration. Depending on the needs of the job, multiple trays may be snapped into the deployable tray.
In other embodiments, other components may be provided for such as registering components that hold spool-wire. For example, for electricians, modular trays may accommodate spools of wire that are similarly configurable to the deployable tray. Other modular trays may have multi-deep-drawer cabinets for storing large quantities of the various connectors, and or components often used in that trade.
Moreover, in the shown embodiment of carrier 400, enclosure 410 includes a plurality of photovoltaic cells exposed on an exterior surface 411 of the enclosure 410 and coupled to the rechargeable battery (not shown) of carrier 400. As depicted in
As such, different possibilities including implementation of solar cells and or modular trays may be offered to consumers with diverse needs. Solar panels would minimize having to recharge a battery supplying power to the components of the cargo carrier. Modular trays not only help to organize storable items but maximize a storage space within cargo carrier 400. The next exemplary embodiment achieves a similar goal but utilizing an interior frame and clamp system.
In some exemplary embodiments, such clamps may be of a modular design so that different equipment widths and depths may be accommodated. In exemplary embodiments, such clamps may automatically lock and unlock; this may be achieved with interior wiring communicating these components to a control circuitry of cargo carrier 500, in a manner understood by a person of ordinary skill in the art. These features take advantage of the fact that the enclosure is of sturdy unibody construction and opens only from the rear. Equipment, therefore, may be securely attached, loaded and unloaded from the top side surfaces of enclosure 501 without impeding the loading and unloading of interior contents.
Turning now to the next figures,
In this manner, enclosure 601 better conforms to the vehicle's roof. These recessed channels 604 accommodate the longitudinal rails of the car's roof rack. In exemplary embodiments, recessed channels 604 sit approximately flush with the roof of the vehicle instead of 6″ or more above the roof like known prior art devices; as mentioned above, this helps achieve a more integrated design while significantly reducing wind drag and turbulence. Recessed channels 604 also provide for more rigid and secured attachment, since cargo carrier 600 is attaching directly to the (typically) factory installed longitudinal rails (which are attached directly to the roof), as opposed to prior art devices that typically attach to cross-rails, which are then attached to the longitudinal rails and are therefore more prone to more vibration.
Notably, in the view of
Moreover, as can be appreciated from this view, in this embodiment recessed channel 604 includes a C-shape or even u-shaped construction that completely encompasses or enclosed rail 602 therein. In an alternative embodiment discussed with reference to the next figure, a differently shaped recessed channel 604 may be employed.
Turning now to the next figure,
Although several embodiments have been disclosed above with reference to the figures, other embodiments may be possible without limiting the scope of the present invention. For example, although certain types of motors, components and materials are discussed above, a person of ordinary skill in the art will appreciate that different purposes may call for different types of components such as different materials stronger or more efficient motors, actuators, etc. For heavy duty loads, wherein a cargo carrier in accordance with the present invention is used for professional purposes (i.e. as opposed to recreational or everyday use), motors, actuators and all associated mechanical hardware may be heavier duty than those specified for a consumer version.
Similarly, certain designs may be implemented for other purposes. By way of a non-limiting example, a deployable tray utilized by a contractor may implement a dual, side-by-side tray or multiple horizontal tray system. In such embodiments, each tray may be operated independently, so therefore, each tray may require its own motor, rack and pinion. In such embodiments, each tray may be made out of aluminum instead of plastic, in order to support the added weight, wear and tear. Moreover, the heavier loads may require a telescoping tension tube or spooled tensioner cable to counteract the bending moment associated with a loaded tray when extended from the enclosure. In some exemplary embodiments, these tensioners may be mounted to the insides of the enclosure and the aft ends of the sides of the tray. Typically, embodiments in which multiple horizontal trays may be employed may comprise embodiments for cargo carriers coupled to trucks such as pickup trucks, given that enclosures to those carriers may have as much as twice the height as cargo carriers adapted to couple to a roof of a vehicle.
As mentioned above, although the embodiments shown in the figures largely focus on a cargo carrier that may be installed on a roof of a vehicle, other configurations may be possible. By way of a non-limiting example, in some embodiments a cargo carrier may be coupled to a pick-up truck. In such exemplary embodiments, an enclosure may rest on the front and side walls of a pickup truck bed. The enclosure may include channels to accommodate the sides of the bed, much like the above embodiments include recessed channels to accommodate the longitudinal rails of a roof rack. The front face of the shell may be optionally flat and parallel to the back of the cab of the pickup, and the aft face may be contiguous and tangent to the plane of the tailgate. The bottom of the enclosure may be parallel to the bed of the pickup and at the level of the top of the sides of the bed. In such exemplary embodiments, the enclosure may not require lifting or tilting, but may have accommodations for lifting if attached. Similarly, in other exemplary embodiments, deployable trays may slide out of the enclosure sideways rather through a rear opening.
In yet other exemplary embodiments, a double decker, or two-drawer enclosure, with a lower deck and a drawer having the geometry of the embodiment of
In yet another embodiment, no enclosure is provided, but rather a deployable tray is provided, which may be slidably housed and or secured to an interior support structure of a vehicle. Such exemplary embodiment may include a conveyor mechanism as previously described above. In such embodiment, the deployable tray may be housed in a lightweight aluminum frame of tubular construction. For vans, the frame may attach to the vehicle using four telescoping shafts terminating in suction cups that press up against the interior sidewalls of the vehicle. For vans, the frame may bolt to the floor. Since in such embodiment, the deployable tray will be contained inside the vehicle, a controller for the deployable tray may draw power from an auxiliary power of the vehicle rather than a battery pack. Such embodiment would not require a lift or tilt system, since the deployable tray will be operating at the floor level of the back of the van or SUV (i.e. already at approximately waist height or lower).
In yet other exemplary embodiments, the cargo carriers may be “stackable”, using tubular aluminum columns, approximately 2″ square, which are perpendicular to the floor plane and are attached to the sides of a deployable tray frame. The columns terminate in flat pads, approximately 3″ square, which are capable of being bolted to the floor of the vehicle and to a second frame that is stacked on top of it. These exemplary cargo carriers may also incorporate an option for a ‘false floor” that covers the device when not in use. This cover may be rigid plastic, tri or four-folded, with the folds parallel to the length of the vehicle. The covers may be designed to accurately fit the interior of specific vehicle models and would typically be used in conjunction with a “single stack” device. The cover may attach to the column pads in a similar fashion as a double stack would. These latter described embodiments may implement a dual deployable tray system and heavier duty modular trays, actuators and motors.
Turning now to the next set of figures,
Carrier 700 may exemplarily include enclosure 701, which is coupled to a bed of pickup truck 711 at a front end 707 via actuator arms 704a of actuators 704, and at a rear end 708, typically via hinged attachment fittings that enable enclosure 701 to pivot or tilt in a manner such that deployable tray 702 may be deployed or slid out of enclosure 701 to make contact with the ground. In exemplary embodiments, deployable tray 702 is configured to touch the ground in order to facilitate the loading of heavy equipment.
Although the principal of operation is similar to the embodiments disclosed with reference to other figures, in this exemplary embodiment, the added space of enclosure 701 further allows for implementation of multiple deployable trays. For example, and in no way limiting the scope of the present invention, deployable tray 702 may be a first deployable tray, and deployable tray 703 may be a second deployable tray suitable for added storage.
Each deployable tray 702 and 703 may use similar or different deploying systems. For example, and without limiting the scope of the present invention, deployable tray 702 may include a system similar to that of
Turning now to the next figures,
In this exemplary embodiment, aft or rear attachment points 712 may include a protrusion 715 on a bottom inner surface 716 of enclosure 701 that forms a cavity 712a for housing a hinge 717 that is configured to tilt enclosure 701 whenever actuators 704 are activated. In an exemplary embodiment, hinge 717 is coupled to a bed of the truck 711 via one or more bolts 718.
Turning now to the next set of figures,
The next set of figures disclose yet another exemplary embodiment suitable for retrofitting the bed of a pick-up truck into a type of mobile workshop. In this exemplary embodiment, a molded structure (“shell”) may be configured to fit in the bed of a pickup truck, encompassing the wheel wells. The width of the shell increases at the height of the sides of the pickup bed, whereupon it widens and rests on the top of pickup's side panels. The shell then rises to the height of the cab. The shell may also extend over the cab, which is especially useful in the case of smaller pickup trucks. As in other exemplary embodiments, the shell may be sturdy enough to accommodate attach fittings in order to lash ladders and other equipment to the top and/or sides of the shell.
The interior of the shell may be comprised of one or more trays, whose ingress and egress from the shell may be automated in a similar fashion to other embodiments discussed above. In the following exemplary embodiment(s) as shown and described with reference to
The front and sides of the tray may also fold down to transform the tray into a worktable. In an alternative configuration, a separate sliding worktable may be installed below the load tray so that equipment in the load tray needn't be removed in order to have access to a flat and level work surface. The forward face of the worktable is fitted with electrical outlets that are powered by an inverter in the back of the shell.
In order to angle the load tray to enable it to reach the ground, the tray is made in two pieces, with the back segment remaining attached to the shell as the tray egresses. The front segment of the tray (approximately the forward two thirds of the overall length of the tray), is connected to the rear segment with a piano hinge installed across the width of the bottom of the tray. The rear and forward segments of the tray are further connected with sliding deadbolts on the exterior of the two side walls that traverse the gap between the two segments. The front segment has the previously described actuated telescoping wheeled legs attached to the underside of the tray. When the tray needs to be lowered to the ground, the deadbolts are released, and the leg actuators are retracted until the tray touches the ground. The front face of the tray is also hinged, serving as a tailgate to the tray and a ramp for the onboarding of wheeled equipment. The onboarding of heavy equipment may be facilitated by a winch connected to heavy duty lashing rings that are molded into the back face of the shell.
An additional feature which furthers the pickups transformation into a mobile workshop is a retractable awning that slides in and out of the top part of the shell to provide protection from sun and rain while working at the worktable. The awning slides out in a similar fashion as the other trays. It is configured and operates in a similar fashion as the other trays. The awning may also have telescoping legs that fold out.
As described in the previous patent, the trays may contain customized snap-in molded kits customized for various construction or service trades. For example, a painting contractor may require a kit that has “cupholder” accommodations for five-gallon paint buckets; an electrical contractor may require a kit that accommodates spools of wire.
In some exemplary embodiments as shown in these views, the cargo carrier may include an enclosure 901 that is a single-piece molded shell or enclosure, having a top shell portion 901a and a bottom shell portion 901b, defined by a front wall, side walls, a top surface, a bottom surface and a rear access door 909 opposite to the front wall of the enclosure, the enclosure further including fittings configured to couple the enclosure to a truck bed. This may be achieved via tracks 910 along a side wall of the deployable tray 902 that register with complementary tracks situated in the interior walls of enclosure 901. The deployable tray 902 is typically slidably housed within the enclosure 901 and includes tiltable surface 903, which is typically the interior upper surface of the tray that is closest to the hatch or door 909 of the enclosure 901. In exemplary embodiments, the one or more actuators 904, 905, 907, and 908, are house within the enclosure 901.
By way of illustration only, and in no way limiting the scope of the present invention, at least one actuator 904 housed inside the enclosure may be adapted to extend and retract the deployable tray 902 outside and inside the enclosure 901, respectively. Similarly, least one actuator 905 may be coupled to a surface of the deployable tray 902 and adapted to tilt the tiltable surface 903 of the deployable tray 902 (see also
In some exemplary embodiments, such as the one depicted in these set of figures, cargo carrier 900 may further comprising a second deployable tray 911. Generally, the one of the deployable trays, for example deployable tray 902, is a tray comprising a compartment area at least partially enclosed by side walls, similar to a drawer that may be slid inside enclosure 901 for storage or extended outside of enclosure 901 in order to allow access to the items stored within the deployable tray 902. In exemplary embodiments, the second deployable tray may be a smaller or similar tray to tray 902. In some exemplary embodiments, as shown in these figures, the second deployable tray 911 may be a flat tray without a compartment section, but which provides a flat working surface area 911a. In some exemplary embodiments, deployable tray 911 may include accessories such as a power strip 911b or power supply module for allowing access to auxiliary power. This may be useful for tools or other accessories that user may want to power during use.
Enclosure 901 is configured to couple to a bed of a pickup truck, thus typically a bottom region 901c of the enclosure 901 will include sections 901d and 901e that are adapted to contour or register with the wheel wells of a pickup truck. This may be appreciated, for example, from the views of
Turning now to the next set of figures,
The upper shell 901a is defined by a front surface and two side surfaces, a top surface, bottom surface, and rear surface. The front surface is typically parallel to and approximately coincident with the rear of the pickup cab. The top surface is typically parallel to and approximately coincident with the roof of the pickup cab, but may extend over the cab to make use of space above the cab. The side surfaces are typically parallel to and approximately coincident with the exterior of the side panels of the truck. The bottom surface is essentially a lip that is parallel (i.e., horizontal) to the top surface of the pickup truck bed's side walls (and is of the same approximate width) and rests on that surface. The rear surface is parallel and approximately coincident with the tailgate of the pickup truck. The rear surface is cutout to accommodate an access door 909. The access door 909 may be hinged across the top with a piano hinge or other such hinge type which enables the access door to open horizontally and upwardly. In some exemplary embodiments, access door 909 may be automated by attaching two bi-directional linear actuators on either side of the door. Access door 909 may include electric locks attached either to the sides or the bottom of the upper shell 901a and may be operated remotely. In some exemplary embodiments, the access door 909 may include a sealing component or rubber grommet to prevent leakage of water into the enclosure 901.
Turning now to the next set of figures,
More specifically, from these views, it may be appreciated that the lower shell 901b consists of a front surface, two side surfaces and a bottom surface that are generally defined by the walls and floor of the pickup bed. The sides and floor surfaces are indented to accommodate the wheel wells of a pickup truck. The rear of the lower shell 901b is open to accommodate the tailgate of the pickup truck when the tailgate is closed. If the enclosure 901 is made in two pieces the lower shell 901b will also include a horizontal lip at the upper surface that is parallel to and rests on top of the lip previously described in the upper shell 201. In instances where the enclosure 901 is made in two pieces, the lips of the upper shell 901a and lower shell 901b may be spot-welded or otherwise fastened to each other to secure the upper shell 901a to the lower shell 901b before installation into the bed of the truck.
In
As mentioned above, deployable tray 902 may be configured so that it is tiltable and has a tiltable surface 903; tiltable surface 903 may be appreciated from the perspective view of the truck and cargo carrier 900 shown in
In
From each of the figures discussed above, it may be appreciated that in some exemplary embodiments there are several deployable trays within enclosure 901 that perform different functions.
Turning now to the next set of figures,
The workbench 911 is an important feature of this invention because it provides a working surface for performing work tasks for construction and service vehicles on the job site. The workbench 911 is located near the bottom of the enclosure 901 below the main load tray assembly 902. The workbench tray 911 slides out of enclosure 901 in a similar fashion as the load tray 902. Although described earlier with reference to
As mentioned above, a power strip 911b may be built into the front face of frame in order to supply electrical power for power tools. The power strip may be connected to an inverter in the back of enclosure 901. The workbench tray 911 may be manually pulled out via a handle on the front face of the frame.
Also mentioned above, and viewable in
In some exemplary embodiments, as may be gleaned from
Tray 901 may include folded telescoping wheel system 922 attached to the underside of its front section. As tray 901 extends sufficiently past the exterior of enclosure 901, as determined by a Hall's Effect switch connected to a controller, rotary actuator 923 rotates a rotator arm 924 which is attached to linear rotator link 925 which is in turn attached at its other end to rotator cam 926 which rotates the leg 924 of the two wheels 912 towards the ground. Each leg 927 contains an in-line linear actuator 928 which extends each leg 927 until it reaches the ground as detected by ultrasonic sensors attached to the actuated ends of actuators. Tray 902 may also have a mercury switch located along and parallel to the base of the tray 902, which is connected to the controller that controls the in-line actuators 928, thereby allowing the tray to maintain a level attitude on uneven ground.
Another important feature (in some exemplary embodiments) is the ability to tilt the extended tray to the ground in order to easily load heavy, wheeled equipment into the enclosure. In the current embodiment, this is achieved splitting tray 902 into two segments across its width. The fixed (aft) segment or stationary surface 913 and a tiltable (forward) segment or tiltable surface 903 are connected by a hinge 915, which may be a piano hinge that spans the width of the floor of the two tray segments or surfaces. The folded telescoping actuated wheel assembly 922 may be attached to the underside of the tiltable surface 903. The two tray segments 913 and 903 are secured in an un-tilted position by two deadbolts 929 that may be located on the exterior sides of tray 902 and span the gap between the fixed segment 913 and the tiltable segment 903. When the tray 902 is extended from the enclosure 901 and the wheel assembly 922 has been extended as previously described, the tiltable portion of the tray may be lowered to the ground by retracting the deadbolts 929 and retracting the leg actuators 928. The front face of tiltable tray segment 903 is also hinged to allow it to fold down and serve as a ramp. The process may be further automated by connecting linear actuators to the deadbolts 929, bringing the entire process of extending the tray, extending the legs until the wheels touch the ground, and then tilting the tray down the ground under controlled automation.
The rooftop version of the Automated Self-Loading Cargo Carrier for Vehicles as described in U.S. Pat. Nos. 10,286,853 and 11,214,202 have a design limitation that precludes its unencumbered operation with many of the more recent SUV designs. That is, most later model SUVS contain a factory-installed airfoil that is mounted to the aft body of the SUV, horizontally flush with the roof of the vehicle. The airfoil extends rearward approximately 6-12″ over the vehicle's hatchback. The aforementioned patents describe a tiltable shell which rotates upward about a pair of hinges affixed to the rear of longitudinal rails located on either side of the roof. The hinges are located as close as possible to the rear of the vehicle to avoid interference with the roof when the carrier is raised. As previously described, an internal tray extends outward from the rear of the carrier. The addition of the airfoil on later model SUVs may interfere with the extension of the tray once the carrier shell is raised.
Accordingly, in some exemplary embodiments, this interference may be addressed in several ways. For example, in one exemplary embodiment, the rear of the carrier may be raised several inches upward via solenoids or actuators before tilting the box rearwards. This enables the tray, once deployed, to “clear” the foil as the tray extends. There are a few drawbacks to this solution: firstly, the tilting of the box is less stable because the hinges are suspended on actuators and not securely fastened to the roof structure of the vehicle; secondly, this solution adds two additional actuators and addition motion synchronization complexity to the invention.
In some exemplary embodiments, a set of wheels or movable tracks may be attached to an axel oriented horizontally across the bottom rear of the cargo carrier. The axel and wheels may be embedded in the shell of the carrier and extend only slightly from slats or openings at the bottom rear of the shell to enable the wheels to maintain contact with the roof of the SUV. The wheels serve dual purposes. First, as the previously described actuators (which may be oriented at an approximately 45° angle to the roof of the SUV and attached to the roof of the shell) may be extended to raise the shell, the horizontal component of the actuator force vector causes the box to initially roll rearward until an adjustable mechanical stop is reached. Second, the vertical component of the force vector of the extending actuators now tilts the box upward as the wheels now serve as a hinge to rotate the box upward. The advantages of this embodiment are threefold: 1) The additional actuators or solenoids required in previous embodiments are obviated; 2) the tilting mechanism is much sturdier since the wheels that the box is now tilting upward about are in direct contact with the roof of the SUV; 3) the forces needed to translate the box rearward and then tilt the box upward and rearward are both achieved by the same actuators in a combined and synchronous motion.
In some exemplary embodiments, an automated locking mechanism may be employed. For example, and without limiting the scope of the present invention, an exemplary embodiment may include a pair of solenoids on either side of the shell that secures it to the longitudinal rails when the shell is in a horizontal position (i.e., resting on the roof of the SUV). The solenoid may be activated through one of the channels on the multichannel controller that controls all of the other various actuators. In order to lock the shell in place, the solenoids may extend pins into molded cavities designed into the shell. The molded cavities may have, for example, cone shaped metal inserts to accept the solenoid pins while allowing for some accumulation of tolerances in the mechanism manufacture and installation.
Four additional solenoids may be employed to allow for a quick release of the shell from the vehicle roof. This becomes particularly useful when employing yet another enhancement, which automates the lifting of the shell from the vehicle, ideally via a garage hoist system that suspends the cargo carrier from the roof of a garage. This capability is facilitated by hoist rings that may be provided in exterior recesses in the four corners of the shell.
Finally, a universal telescoping rail may be described which replaces the factory installed rail(s). The universal rails eliminate the variability of the various rail designs of different SUV OEMs (Original Equipment Manufacturers) which enables a common design for attaching the cargo box to the rails. The universal rails also contain the necessary accommodations to attach the actuators, solenoids and hardware described herein. Regarding SUVs that do not come with factory installed rails, the OEMs provide factory installed mounting points in the roof structure for bolting said rails on the roof, regardless of whether the rails are installed by the OEM at the time of initial vehicle sale.
Turning now to the next set of figures,
In some exemplary embodiments, such as the one depicted in these views, the adjustable translating hinge 164 consists of a set of semi-soft rubber wheels 154 approximately 3″ in diameter and 1″ wide, coincident with an axel 169 that is affixed to the rear of enclosure 153. The lower aft edge of enclosure 153 may be filleted such that the axis of the fillet is coincident with the axis of the wheels 154 and axel 169. The radius of the fillet may be slightly less than the radius of the wheels, such that the wheels protrude slightly from slats cut into the filleted lower aft edge of the enclosure as illustrated in
In an exemplary embodiment, the opposite end of the ball joint rods 170 may be internally threaded and may be attached to externally threaded connecting rods 166. Each of the connecting rods 166 may be adapted to pass through connecting rod mounted bearings 168 that may be affixed to the longitudinal rails 108 as illustrated in
Accordingly, in some exemplary embodiments, a cargo carrier in accordance with the present invention may comprise: an enclosure 153 adapted to couple to the roof of vehicle 151; a deployable tray (see for example 102), slidably housed within the enclosure 153; one or more actuators 161, including: at least one actuator adapted to extend and retract the deployable tray outside and inside the enclosure, respectively; and a controller (see for example 303) in communication with the one or more actuators 161 and configured to: activate the one or more actuators 161 to slide the deployable tray outside of the enclosure.
In some exemplary embodiments, the at least one actuator adapted to extend and retract the deployable, is further adapted to move the enclosure over an airfoil 152 of the vehicle 151.
In some exemplary embodiments, the enclosure 153 is coupled to a translating hinge 164 adapted to facilitate movement of the enclosure over the airfoil 152 of the vehicle 151. In some exemplary embodiments, the translating hinge 164 is adjustable and further adapted to adjust a distance of the movement of the enclosure 153 over the airfoil 152 of the vehicle 151.
In some exemplary embodiments, the enclosure 153 is coupled to one or more rollers (for example wheels 154 or filleted regions of the enclosure 153 as described above) adapted to facilitate the movement of the enclosure over the airfoil 152 of the vehicle 151. In some exemplary embodiments, the translating hinge 164 is coupled to one or more rollers (for example wheels 154 or filleted regions of the enclosure 153 as described above) adapted to facilitate the movement of the enclosure 153 over the airfoil 152 of the vehicle 151.
In some exemplary embodiments, at least one of the one or more actuators 161 is or are adapted to lift or tilt at least a portion of the enclosure 153. In some exemplary embodiments, the at least one of the one or more actuators is positioned at a fixed angle with respect to the enclosure 153 and lifts or tilts the enclosure 153 at the fixed angle.
In some exemplary embodiments, the at least one of the one or more actuators is positioned at a variable angle with respect to the enclosure and lifts or tilts the enclosure 153 and lifts or tilts the enclosure 153 at the variable angle.
In some exemplary embodiments, the deployable tray is adapted to slide out of the enclosure sideways through an opening on a side of the enclosure or through a rear region of the cargo carrier.
In some exemplary embodiments, a cargo carrier in accordance with the present invention may comprise: an enclosure 153 adapted to tiltably couple to a roof of a vehicle 151, the enclosure 153 defined by a front wall, side walls, a top surface, a bottom surface and a rear access door opposite to the front wall of the enclosure 153; a deployable tray, slidably housed within the enclosure 153; one or more actuators 161, including: at least one actuator adapted to move the enclosure 153 over an airfoil 152 of the vehicle 151 and extend and retract the deployable tray 102 outside and inside the enclosure 153, respectively; and a controller 303 in communication with the one or more actuators 161 and configured to: activate the one or more actuators to slide the deployable tray 102 outside of the enclosure 153.
In some exemplary embodiments, a cargo carrier in accordance with the present invention may comprise: an enclosure 101 adapted to tiltably couple to a vehicle roof, the enclosure 101 defined by a front wall 203, side walls 205, a top surface 204, a bottom surface 212 and a rear access door 207 opposite to the front wall 203 of the enclosure 101; a translating hinge 164 coupled to the enclosure 101 and the vehicle roof, the translating hinge 164 adapted to facilitate movement of the enclosure 101 over an airfoil 152 of the vehicle; a deployable tray 202, slidably housed within the enclosure 101; at least one actuator 161 adapted to lift or tilt at least a portion of the enclosure 101 and move the enclosure over the airfoil 152 of the vehicle 151 and extend and retract the deployable tray 202 outside and inside the enclosure 101, respectively; and a controller 303 in communication with the one or more actuators 161 and configured to activate the one or more actuators 161 to slide the deployable tray 202 outside of the enclosure.
Turning now to the next set of figures,
In the previous vehicle rooftop embodiment, when the cargo carrier 100 is activated, actuator 104 is extended from the front portion of longitudinal rails 108, thereby tilting enclosure 101 upward about hinges 110 affixed to the rear portion of longitudinal rails 108. In the current embodiment, the actuators 254 are attached to rails 253 that are oriented laterally instead of longitudinally with respect to the width and length of the vehicle, respectively as illustrated in these figures, see for example
In some exemplary embodiments, there are multiple trays 255, each with its own actuator 257, as illustrated in
Accordingly, in some exemplary embodiments, a cargo carrier 251 may include an enclosure 251 adapted to tiltably couple to the roof of vehicle 250, the enclosure 251a defined by a front wall, side walls, a top surface, a bottom surface and a side access door 251b opposite to one of the side walls of the enclosure 251a; one or more deployable trays 252 slidably housed within the enclosure 251a; one or more actuators 254, 257 adapted to extend and retract the one or more deployable trays 255 outside and inside the enclosure, respectively; a controller, f example controller 303, in communication with the one or more actuators 254, 257 and configured to: activate at least one actuator, for example actuator 254 adapted to lift or tilt at least a portion of the enclosure 251a to facilitate access to the one or more deployable trays on a curbside of the vehicle 250; and activate at least one actuator, for example actuators 257 adapted to slide the one or more deployable trays outside of the enclosure 251a to the side of the vehicle by way of side access door 251b.
In some exemplary embodiments, cargo carrier may further comprise of an actuator (for example actuators 257) for each deployable tray 255 housed inside the enclosure 251a. In some exemplary embodiments, each of the actuators 257 for each deployable tray is coupled to lateral supports 253 oriented laterally across the roof of vehicle 250. In some exemplary embodiments, at least one actuator, for example actuator 254, may be positioned at a fixed or variable angle with respect to the enclosure and lifts or tilts the enclosure at the fixed or variable angle.
A cargo carrier including an automated self-loading cargo carrier for automobiles has been described. The foregoing description of the various exemplary embodiments of the invention has been presented for the purposes of illustration and disclosure. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching without departing from the spirit of the invention.
The present application is a continuation-in-part application of U.S. Non-Provisional patent application with Ser. No. 17/533,812, filed on Nov. 23, 2021, which is a continuation of and claims priority under 35 U.S.C. § 120 to U.S. Non-Provisional patent application with Ser. No. 17/151,619, filed on Jan. 18, 2021, which is a continuation-in-part of and claims priority under 35 U.S.C. § 120 to U.S. Non-Provisional patent application with Ser. No. 17/053,017, filed on Nov. 4, 2020, which is a National Phase Application of International Application No. PCT/US2019/030485, filed on May 2, 2019, which claims priority to U.S. Non-Provisional patent application with Ser. No. 15/972,070, filed on May 4, 2018, the disclosure of which are incorporated herein by reference in their entirety.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 17151619 | Jan 2021 | US |
| Child | 17533812 | US | |
| Parent | 15972070 | May 2018 | US |
| Child | 17053017 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 17533812 | Nov 2021 | US |
| Child | 18203602 | US | |
| Parent | 17053017 | Nov 2020 | US |
| Child | 17151619 | US |
