Automobile drivers often find that the interior cargo space of their vehicles is insufficient for transporting recreational equipment, building supplies, or other cargo. Solutions to this problem may include use of a roof mounted cargo box or bag. However, a closed cargo carrier is typically limited by specific volumetric dimensions.
Roof mounted cargo boxes or bags may also block and/or preclude simultaneous use of other rooftop racks. To transport longer loads such as lumber, or specialized loads such as bicycles and boats, the whole cargo carrier must be removed and exchanged for a different rack. A more versatile cargo carrier system is desirable, that can accommodate a variety of cargo and allow concurrent use of other roof-mounted carriers.
A rack for securing cargo on top of a vehicle is disclosed, including a frame structure with a perimetral rail portion having parallel raised side portions. The frame structure comprises a front partial frame structure removably coupled to a rear partial frame structure. Each partial frame structure may include a perimetral rail portion having parallel raised side portions.
The frame structure may be configured to securely carry a load in transit, and may have a longitudinal member configured to extend perpendicular to a crossbar. The rack may further include a clamp device configured to connect the frame structure to a crossbar on top of a vehicle, and the clamp device may be connected to the longitudinal member. The clamp device may also be adjustable along a length of the longitudinal member.
The rack may include a transverse crossbar member mounted on the raised side portions of the frame structure, and generally orthogonal to the raised side portions. The crossbar member may be adjustably moveable along the side portions, and configured to support cargo securing devices. Each of the partial frame structures may include such a transverse crossbar member.
In some examples, each of the partial frame structures may have a tubular end portion, and the rack may include a coupler configured to securely engage the two tubular end portions without a tool. In some examples, the front partial frame structure may include a tubular structure, and the rack may include a fairing expanse that has a coupler configured to reversibly connect the fairing expanse to the tubular structure manually without a tool.
This disclosure provides numerous selected examples of invented devices for transporting cargo on the roof of a vehicle. Many alternatives and modifications which may or may not be expressly mentioned, are enabled, implied, currently possessed, and are supported by the disclosure.
As shown in
Cargo carrier system 10, which may also be referred to as a cargo rack, is shown in more detail in
Cargo rack 10 further includes two pairs of crossbar clamps 28 and 30, each configured to mount the basket portion to a vehicle crossbar. Each pair of clamps includes a left clamp and right clamp, which are adjustable along a length of basket 12. The spacing between clamp pairs may be adjusted to correspond to a spacing between vehicle crossbars. In some examples, additional or alternative mounting hardware may be included. For example, removable or integrated T-track connectors may be included in the cargo rack.
Basket 12 of cargo rack 10, may also be described as a frame structure comprising a front partial frame structure, or forward portion 32 and a separate rear partial frame structure, or rear portion 34. Forward portion 32 may be provided in various lengths, and may be interchangeable with other partial frame portions. A user of system 10 may select a forward portion having a length appropriate to their vehicle or to dimensions of intended cargo. In some examples, basket 12 may include extendable or telescoping elements, and/or may include an additional middle section disposed between rear portion 34 and forward portion 32.
As shown in more detail in
Raised sides 16 of rear portion 34 each include a wall portion 38 with an upper border rail 40. Wall portions 38 are generally solid and curved to conform with the general shape of the basket. The wall portions may include any appropriate material or materials, such as sheet metal, plastic, and/or nylon mesh. Upper border rails 40 are shaped to form gaps 42 between the upper border rail and the outer frame rail. Smaller cutouts 44 are formed in the wall portions proximate the upper border rail, and can be seen more clearly in
Gaps 42 and cutouts 44 may facilitate the passing therethrough of straps, ropes, and the like, e.g., for tying down cargo in the basket. Any number of gaps and/or cutouts may be included, in any pattern. In some examples, alternative tie-down features may be included additionally or in place of the gaps and cutouts. In some examples, wall portions 38 may extend up to outer frame rail 36, without upper border rails 40.
Referring again to
Spacing between longitudinal members of basket floor 18 may be regular or varied across the width of the basket floor, and may be sufficient to provide an effective support structure while limiting overall weight of the cargo rack. Floor rails 48 may be hollow metal tubing, or may be any appropriate material. In some examples, basket floor 18 may include additional transverse members extending between two or more longitudinal members. In some examples, the basket floor may include additional cargo-securing features such as solid floor panels, or non-slip materials. Additional elements may be spaced from the crossbar clamps, to avoid impeding adjustment of the clamps.
As shown in
In the present example, shown in
Rear portion 34 of basket 12 may be described as having three primary dimensions, a width AA, an upper length BB, and a floor length CC. Floor length CC, which is defined between the rear edge of outer frame rail 36 and transverse forward frame rail 46, is greater upper length BB, which is defined as length of a linear section of outer frame rail 36 proximate a terminal end 56.
Referring again to
An outer frame rail 60 of forward portion 32 is configured to mate with outer frame rail 36 of rear portion 34. Outer frame rail 60 has terminal ends 56 that match with corresponding terminal ends 56 of outer frame rail 36, such that they form a generally continuous outer frame rail for the entire basket. In other words, basket 12 has a perimetral rail portion with raised parallel sides that includes outer frame rails 36 and 60.
Outer frame rail 60 of the forward portion has a curvature proximate front edge 20 of basket 12 that is configured for connection of a fairing. The curvature of outer frame rail 60 accordingly differs from outer frame rail 36 of rear portion 34. In some examples, outer frame rails 36 and 60 may have a matching shape, or may differ in shape at other sections.
As shown in
Distance DD, gap EE, and spacing between any corresponding members may be selected to facilitate a connection type. In some examples, terminal ends 56 of outer frame rails 36, 60 may meet and the left and right clamp rails may each form a gap. Any effective spacing or connection may be used between forward portion 32 and rear portion 34.
Central portion 68 has a length matching gap EE between frame rail ends, shown in
Also shown in
For connection with connector piece 78, terminal ends 56 may each include a vertical member such as a bolt or bar extending through the hollow interior of the outer frame rails. Connector piece 78 may be inserted into terminal ends 56 such that curved channels 80 on each end portion 70 are aligned with the corresponding vertical member. Central portion 68 may be rotated about an elongate axis of connector piece 78, such that the vertical members are urged, by engagement with curved channels 80, along the channels and therefore toward central portion 68. Connector piece 78 may therefore be described as pulling terminal ends 56 toward one another as the connector piece is twisted. In some examples, channels 80 may have alternative shapes such as angled slots or any shape configured to urge the vertical members toward central portion 68.
Curved channels 80 and the vertical members may be dimensioned and/or disposed such that when the vertical members reach an interior end of the channels, central portion 68 is snug against terminal ends 56. In such a configuration, connector piece 78 may resist motion of outer frame rails 36, 60 along the elongate axis of the connector piece relative to one another.
Referring again to
Clamp 28A includes a flexible strap 82, connected to a cam lever 84. To facilitate longitudinal adjustability, clamp 28 includes an upper body portion 86 and a lower body portion 88, which are vertically movable relative to each other. Along a first lateral side of clamp 28A, upper body portion 86 extends out to form an upper jaw 90A and on a second side lateral side the upper body portion extends out to form an upper jaw 92A. Similarly, lower body portion 88 extends out along each lateral side to form lower jaws 90B and 92B, where lower jaw 90B is depicted in
Upper jaw 90A and lower jaw 90B of floor-rail engaging jaws 90 have concave inner surfaces, shaped to conform to a floor rail 48, as shown in
To clamp to a crossbar, a user may release cam lever 84 from the clamp and slide the clamp along the clamp rail to a position above the crossbar, and rest the underside of the clamp on the crossbar. Then, the user may thread the cam lever and strap 82 under the crossbar before mating the cam lever with a recess on the body of the clamp. Rotating the cam lever may tighten strap 82 against the crossbar, securing the clamp to the crossbar. The cam action of lever 84 may also bring upper body portion 86 and lower body portion 88 closer together, securing the clamp to the adjacent clamp rail and floor rail.
As shown in
Clamp 28A is lockable, using a sliding lock cover 102, which travels longitudinally to trap or release the cam lever. The lock cover includes a lock core 104 with an asymmetrical flange 106 at a distal end that interfaces with a corresponding slot 108 in the base of the clamp, as shown in
Also shown in
Strap 82 is anchored at both ends to upper body portion 86. When cam lever 84 and the strap are threaded around a crossbar and cam lever is 224 is used to tighten the strap around the crossbar, lower body portion 88 is sandwiched between the crossbar and the upper body portion. Lower body portion 88 is accordingly pushed up relative to upper body portion 86. Accordingly, the floor rail-engaging jaws and clamp rail-engaging jaws will clamp onto the adjacent floor rail 48 and clamp rail 50, respectively.
As shown in
Each bar in the present example includes a substantially identical end clamp 118 at first and second ends of the bar. A cross-section of one end clamp, along line 12-12 in
An actuator screw 126 passes vertically through the clamp, through an unthreaded aperture in upper jaw 120 and into a threaded aperture in lower jaw 122. Turning the screw may therefore cause the lower jaw to move up and down. To attach an end of accessory bar 26 to outer frame rail 36, a user may turn actuator screw 126 to move lower jaw 122 to admit the outer frame rail between upper jaw 120 and lower jaw 122. With upper jaw 120 seated on top of the outer frame rail, the user may turn actuator screw 126 in the opposite direction to tighten lower jaw 122 against a lower surface of the outer frame rail.
Returning to
As
To remove the clamp, force may be applied to a finger tab 138 extending from an outer side of toothed receptacle 136, prying apart the opening of the receptacle and releasing toothed member 134. Collar clamp 128 is sufficiently flexible that toothed receptacle 136 and toothed member 134 may be urged apart to allow outer rail 60 to pass between, removing the clamp entirely from the rail. Collar clamp 128 may therefore manually be reversibly connected to the outer frame rail without using any tools.
With all collar clamps disengaged from outer rail 60, fairing 24 and the attached collar clamps may be removed from the cargo rack and temporarily stored. Without fairing 24 removed, the cargo rack may be configured for transportation of oversize cargo. Fairing 24 may be reattached to reduce wind noise and drag generated by the cargo rack. Because collar clamps 128 do not require use of tools for installation or removal, the user may quickly and easily reconfigure the cargo rack as needed.
A flexible strap 238 (see especially
Mounting pin 248 is spaced from the shaft portion along a length of the lever plate, facilitating an over-center mechanism when securing the lever plate to body 220. Second end portion 224 of the body includes a slot 250 configured to receive shaft portion 246 of the lever plate for this purpose, such that the lever plate is releasably engageable with the second end portion.
Rotation of dial 234 causes the traveling member to move along rod 232, causing more or less of strap 238 to be housed within body 220, thereby altering the effective length of the strap. This may be done, for example, to adapt strap 238 to differently-sized crossbars. Lever plate 244 is also pivotably transitionable, when shaft portion 246 is seated in slot 250, between an open position 258 and a closed position 260, such that transitioning from the open position to the closed position causes an over-center action and a decrease in the effective length of the flexible strap. This facilitates tightening of the strap around the crossbar.
A cover plate 252 is coupled to first end portion 222 of the body. Cover plate 252 is slidable along the body between a first position 254 and a second position 256. Cover plate 252 blocks lever plate 244 from opening when the lever plate is in closed position 260 and the cover plate is in first position 254. Accordingly, the lever plate is prevented by the cover plate from transitioning to the open position until the cover plate is slid into second position 256. In some examples, respective opposing ends of cover plate 252 and lever plate 244 include finger portions 262 configured to interdigitate when the lever plate is in the closed position and the cover plate is in the first position, such that the cover plate and the lever plate are interlockable. For example, lever plate 244 includes finger portions 264 configured to interlock with finger portions 266 on cover plate 252.
Body 220 includes a pair of side walls 267 extending from the first end portion to the second end portion, the pair of side walls configured to prevent access to threaded rod 232. (Lever plate 244 is also configured to prevent access to the dial and threaded rod). Body 220 may include side tabs 268, e.g., on walls 267. Side tabs 268 may include any suitable protrusions or other structures configured to interface with lower slots 202 on proximate longitudinal members or basket ribs, forming a prismatic or sliding joint. In some examples, side tabs may be reverse-tapered or shaped to facilitate retention of the tabs within the slots. Cover plate 252 may include its own side tabs 270, to retain the cover plate in the slots and to facilitate sliding of the cover plate between first and second positions. This arrangement facilitates adjustability of the position of the clamp device relative to the carrier (or other rack accessory) along a length of the slots. In some examples, only one slot is used. In some examples, only one tab 268 is present.
A locking mechanism 272 is included and configured to selectively lock the cover plate 252 in first position 254. Locking mechanism 272 may be present in any crossbar clamp, but a selected one of the clamps may be sufficient to secure the entire carrier. Locking mechanism 272 may be configured to selectively lock cover plate 252 to lower portion 228 of body 220 (or an extension thereof). For example, as shown in
This section describes additional aspects and features of cargo carrier systems according to the present teachings, and related systems and methods, presented without limitation as a series of paragraphs, some or all of which may be alphanumerically designated for clarity and efficiency. Each of these paragraphs can be combined with one or more other paragraphs, and/or with disclosure from elsewhere in this application, including the materials incorporated by reference in the Cross-References, in any suitable manner. Some of the paragraphs below expressly refer to and further limit other paragraphs, providing without limitation examples of some of the suitable combinations.
A. A rack for securing cargo on top of a vehicle, comprising:
a front portion removably coupled to a rear portion, each having:
A1. The rack of A, wherein each of the front frame portion and the rear frame portion include a curved wall portion spanning between the frame rail and the transverse member.
A2. The rack of A, further including one or more transverse bars configured to selectively clamp to a first raised side portion and a second raised side portion of the outer frame rail.
A3. The rack of A2, wherein the one or more transverse bars each include two end clamps having a first jaw, a second jaw, and a bolt threadingly engaged with the second jaw to draw the second jaw toward the first jaw and secure a portion of the outer frame rail between the second jaw and the first jaw.
A4. The rack of A2, wherein the transvers bars are configured to be used as crossbars to secure rooftop rack accessories to the vehicle.
A5. The rack of A, further including a manually removable fairing configured to be coupled to a front end of the front frame portion.
A6. The rack of A5, wherein the fairing includes a plurality of collar clamps to selectively clamp the outer frame rail, each collar clamp including a toothed opening and a toothed member configured for ratcheting receipt in the toothed opening.
A8. The rack of A, wherein each crossbar clamp includes a strap with a first end coupled to a body of the clamp and a second end coupled to a cam lever, the cam lever being removable from the body of the clamp.
A9. The rack of A8, wherein the strap has an adjustable effective length.
A10. The rack of A, wherein a portion of one of the plurality of spaced apart longitudinal members includes an outer toothed surface configured to engage an inner toothed surface of one of the crossbar clamps.
A11. The rack of A, wherein a first hollow end of the frame rail of the front portion is connected to a second hollow end of the frame rail of the rear portion by an insert having a first connecting portion received in the first hollow end, a second connecting portion received in the second hollow end, and a central portion not received in either hollow end, the central portion having a cross section matching the cross sections of the first and second hollow ends.
B. A rack for securing cargo on top of a vehicle, comprising:
an outer frame rail with parallel and opposing raised side portions;
a plurality of longitudinal members generally parallel the raised side portions, each having a first end fixed to the outer frame rail and a second end fixed to a transverse rail; and
a plurality of crossbar clamps each mounted on a pair of adjacent longitudinal members of the plurality of longitudinal members, each having an open position and a closed position, and each being configured to fix the rack to a crossbar of the vehicle when in the closed position;
wherein the crossbar clamp is movable along the pair of adjacent longitudinal members when in the open position, and is fixed to the pair of adjacent longitudinal members when in the closed position.
B1. The rack of B, wherein the rack includes a front portion and a rear portion, removably coupled together.
B2. The rack of B1, wherein each of the front portion and the rear portion include two or more crossbar clamps of the plurality of crossbar clamps.
B3. The rack of B, wherein one of each pair of adjacent longitudinal members includes a toothed portion configured to engage a toothed portion of the mounted crossbar clamp.
B4. The rack of B, further including a removable fairing configured for attachment to the outer frame rail.
B5. The rack of B4, wherein the fairing is removable without the use of tools.
B6. The rack of B, further including a pair of transverse bar members configured for selective bridging attachment to different locations along the raised side portions of the outer frame rail.
C. A rack for securing cargo on top of a vehicle, comprising:
a frame including front portion and a rear portion, each having:
a pair of transverse bars configured for selective bridging attachment between a plurality of locations on the outer frame rail of the front portion and the outer frame of the rear portion; and
a removable fairing configured for attachment to the outer frame rail of the front portion.
C1. The rack of C, wherein the fairing is removable without the use of tools.
C2. The rack of C1, wherein the fairing includes a plurality of collar clamps to selectively clamp the outer frame rail for the front portion, each collar clamp including a toothed opening and a toothed member configured for ratcheting receipt in the toothed opening.
C3. The rack of C, wherein each of the pair of transverse bars includes two end clamps having a first jaw, a second jaw, and a bolt threadedly engaged with the second jaw to draw the second jaw toward the first jaw and secure a portion of the outer frame rail between the second jaw and the first jaw.
C4. The rack of C, wherein the transvers bars are configured to be used as crossbars to secure rooftop rack accessories to the vehicle.
D. A rack for securing cargo on top of a vehicle, comprising:
a front partial frame structure removably coupled to a rear partial frame structure, each frame structure including:
D1. The rack of D, wherein the crossbar member is adjustable along the raised side portions.
D2. The rack of D, wherein one of the partial frame structures is interchangeable with a third partial frame structure of a different dimension configured to create vehicle cargo carriers of different sizes.
D3. The rack of D, wherein each partial frame structure has a plurality of spaced apart longitudinal members connected to the rail portion, the longitudinal members being parallel to each other and to the direction of vehicle travel.
D4. The rack of D3, further comprising:
a crossbar clamp device slidably mounted on one of the longitudinal members, and configured to selectively clamp a crossbar of the vehicle.
D5. The rack of D4, wherein the clamp device is mounted on two adjacent longitudinal members.
D6. The rack of D4, wherein said one of the longitudinal members has an array of transverse grooves on a bottom side configured to engage an array of ridges on a top side of the clamp device for fixing a desired longitudinal location of the clamp device along said one of the longitudinal members.
D7. The rack of D4, wherein the clamp device includes a strap having an adjustable effective length.
D8 The rack of D, wherein each of the frame structures has a pair of clamp devices, each clamp device being slidably mounted on a different longitudinal member.
E. A rack for securing cargo on top of a vehicle, comprising:
a frame structure including a perimetral rail portion having parallel raised side portions,
a clamp device configured to connect the frame structure to a crossbar on top of a vehicle, and
a first transverse crossbar member mounted on the raised side portions and generally orthogonal to the raised side portions, the crossbar member being adjustably moveable along the side portions and configured to support cargo securing devices.
E1. The rack of E, further comprising:
a second transverse crossbar member mounted on the raised side portions and generally orthogonal to the raised side portions, the crossbar member being adjustably moveable along the side portions and configured to support cargo securing devices in cooperation with the first transverse crossbar member.
E2. The rack of E, wherein the frame structure includes a front partial frame portion removably coupled to a rear partial frame portion.
F. A rack for securing cargo on top of a vehicle, comprising:
a frame structure configured to securely carry a load in transit, the frame structure having a first longitudinal member configured to extend perpendicular to a crossbar, and
a clamp device connected to the first longitudinal member, configured to couple the frame structure to a crossbar, wherein the clamp device is adjustable along a length of the first longitudinal member.
F1. The rack of F, wherein the first longitudinal member has an array of transverse grooves on a bottom side configured to engage an array of ridges on a top side of the clamp device for fixing a desired longitudinal location of the clamp device along the first longitudinal member.
F2. The rack of F, wherein the frame structure includes a front partial frame portion removably coupled to a rear partial frame portion, the first longitudinal member being connected to the front partial frame portion, a second longitudinal member being connected to the rear partial frame portion, each of the first and second longitudinal members having a clamp device adjustably connected to a bottom side.
F3. The rack of F, wherein the clamp device includes a strap having an adjustable effective length.
F4. The rack of F, wherein the frame structure has a second longitudinal member parallel and adjacent to the first longitudinal member, the clamp device being mounted on both of the first and second longitudinal members.
F5. The rack of F4, wherein the clamp device is slidable along the second longitudinal member.
G. A rack for securing cargo on top of a vehicle, comprising:
a front partial frame structure removably coupled to a rear partial frame structure, each of the partial frame structures having a tubular end portion, and
a coupler configured to securely engage the two tubular end portions without a tool.
G1. The rack of G, wherein the coupler has first and second end portions, each end portion being dimensioned to fit inside one of the tubular end portions, and having an angled slot configured to pull the tubular end portions toward each other by manually twisting the coupler.
H. A rack for securing cargo on top of a vehicle, comprising:
a basket assembly configured for attachment to a pair of crossbars on top of a vehicle, the basket assembly having a front frame portion including a tubular structure, and
a fairing expanse having a coupler configured to reversibly connect the fairing expanse to the tubular structure manually without a tool.
H1. The rack of H, wherein the coupler has first and second end portions, each of the end portions having a tab, one of the tabs being configured for connection directly to the fairing expanse, and each of the end portions having ratcheting structure for engaging the other end portion manually without a tool.
It is believed that the disclosure set forth herein encompasses multiple distinct inventions with independent utility. While each of these inventions has been disclosed in its preferred form, the specific embodiments thereof as disclosed and illustrated herein are not to be considered in a limiting sense as numerous variations are possible. The subject matter of the disclosure includes all novel and non-obvious combinations and subcombinations of the various elements, features, functions and/or properties disclosed herein. Similarly, where the claims recite “a” or “a first” element or the equivalent thereof, such claims should be understood to include incorporation of one or more such elements, neither requiring nor excluding two or more such elements.
The various structural members disclosed herein may be constructed from any suitable material, or combination of materials, such as metal, plastic, nylon, plastic, rubber, or any other materials with sufficient structural strength to withstand the loads incurred during use. Materials may be selected based on their durability, flexibility, weight, and/or aesthetic qualities.
Although the present disclosure has been provided with reference to the foregoing operational principles and embodiments, it will be apparent to those skilled in the art that various changes in form and detail may be made without departing from the spirit and scope of the disclosure. The present disclosure is intended to embrace all such alternatives, modifications and variances. Where the disclosure recites “a,” “a first,” or “another” element, or the equivalent thereof, it should be interpreted to include one or more such elements, neither requiring nor excluding two or more such elements. Furthermore, any aspect shown or described with reference to a particular embodiment should be interpreted to be compatible with any other embodiment, alternative, modification, or variance.
It is believed that the following claims particularly point out certain combinations and subcombinations that are directed to one of the disclosed inventions and are novel and non-obvious. Inventions embodied in other combinations and subcombinations of features, functions, elements and/or properties may be claimed through amendment of the present claims or presentation of new claims in this or a related application. Such amended or new claims, whether they are directed to a different invention or directed to the same invention, whether different, broader, narrower or equal in scope to the original claims, are also regarded as included within the subject matter of the inventions of the present disclosure.
This application claims the benefit under 35 U.S.C. § 119(e) of the priority of U.S. Provisional Patent Application Ser. No. 62/452,924, filed Jan. 31, 2017, the entirety of which is hereby incorporated by reference for all purposes. The following related applications and materials are also incorporated by reference, in their entireties, for all purposes: U.S. Pat. No. 9,283,884, and U.S. patent application Ser. Nos. 15/614,515 and 15/614,530.
Number | Date | Country | |
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62452924 | Jan 2017 | US |