Abstract:
This invention discloses a heavy duty vehicle rack capable of carrying heavy loads and that utilizes fasteners, to attach to the rack to the vehicle&#39;s gutter or drip rails. The heavy duty rack of the present invention has specially shaped cooperating end and clamp portions so that the rack can be attached to a variety of vans made by different manufacturers with different style and shapes gutter/drip rails.

Description:
This invention relates to racks for vehicles and particularly a rack with fastening means to force an end member/clamp specially shaped to grip various shaped gutter or drip rails found on various vehicles. 
     BACKGROUND OF THE INVENTION 
     Heretofore it has been known to provide a rack for a vehicle, such as a van, truck or automobile, for carrying items above the roof of the vehicle or van. Frequently such racks comprised two spaced apart crossmembers which are mounted to the gutters or drip rails of the vehicle. As heavy items, such as ladders, lumber and pipes, are frequently carried on such a rack, it is important that the rack be solidly and strongly connected to the gutters or drip rails. Heretofore it has also been known to provide a connection on each end of each crossmember which utilized one set of fastening means arranged generally horizontally to pull the rack tight against a vertical portion of the drip rail and a second set of fastening means arranged generally vertically to pull the rack tight against a horizontal portion of the drip rail. For example, see U.S. Pat. No. 4,778,092. As there are usually two crossmembers, each with two ends, there were generally at least eight sets of fasteners which are required to be properly horizontally and vertically adjusted and tightened. An alternative was to replace the second sets of vertical fastening means with some sort of pivoting connection, such as formed by a pivoting extension which engages in a formed pivot opening. The provision of such pivoting connection can be more expensive to make as forming dies may be needed to make the pivoting extension and/or pivot opening. Further the pivot type connection can be even more difficult to tighten securely because of “play” and looseness of the pivot connection making the pivot connection less secure to use than the first described sets of horizontal and vertical fastening means, particularly where a rack is to carry heavy items, such as is likely to be used by a tradesman on his/her service van. 
     A strong prior art rack for such purpose is disclosed in my U.S. Pat. No. 5,746,362, which is hereby incorporated by reference. The rack described in my U.S. Pat. No. 5,746,362 comprises two or more crossmembers which are secured at each end thereof by a clamp member held to the end member of the crossmember by a single set of generally horizontal fastening means, with no separate vertical fastening means or pivot connecting means being utilized. A tight connection in both the horizontal and vertical is provided by the single set of generally horizontal fastening means because of this rack&#39;s unique design. The crossmember&#39;s ends and clamps are arranged to be clamped together horizontally by this fastening means, and each has inclined engaging portions to cause the clamp to engage the gutter or drip rail and pull it tight both vertically and horizontally against the crossmember end member. 
     While strong racks and strong fastening means are generally known, such as shown in my U.S. Pat. No. 5,746,362 patent, heretofore it has been necessary to provide custom end members and clamps to fit a plurality of different make vehicles. The result was that the manufacturers had to make and retail outlets had to carry many models to fit the various make vans and vehicles with their different type roof drip and gutter rails constructions. 
     SUMMARY OF THE INVENTION 
     The present improved heavy duty rack invention is particularly suitable for fitting various models of trucks and vans with their various shaped drip or gutter rails. Even though the improved rack of the present invention can fit more than one make or model of van or vehicle, it still is capable of safely carrying very heavy loads, including ladders, lumber, pipes, etc. with a total load weight of up to 1,200 pounds evenly distributed. In fact the rack of the present invention, is capable of lifting the rear of a typical van in the air if a crane is attached to the rack and raised. 
     The heavy duty rack of the present invention for securing such heavy items and carried on the drip rail or gutter of a van or truck, comprises a square or rectangular cross section tubing cross member adapted to extend horizontally across the full width of a van or truck type vehicle roof generally from to or beyond one drip rail to or beyond the drip rail on the opposite side of the van type vehicle roof. The cross member has opposing ends or members defining a length therebetween and is made of steel and/or aluminum having a minimum wall thickness of ⅛ to ¼ inch thick with about {fraction (3/16)} of an inch being preferred. A pair of the unitary one piece end members are secured by welding at each end of said cross member. Each of said end members are bent from flat, compatible material of at least ⅛ to ¼ inch thick, with {fraction (3/16)} of an inch thickness being preferred, of steel or aluminum. Each of the unitary one piece end members extend generally downwardly from the respective end of its said cross member towards its underneath, associated drip rail. Each unitary one end member is bent and its lower portion or particularly lower end is adapted to rest on various types of van or vehicle drip rails. Clamping means are provided for each unitary, one piece end member shorter in height than the unitary, one piece end member. Each clamping means is bent from flat material of ⅛ to ¼ inch thick, with about {fraction (3/16)} of an inch thickness being preferred, and made of steel or aluminum. The lower portions or ends of the clamping means are also specially shaped to cooperate with its end member and secure the rack to various shaped drip or gutter rails found on various make vans or vehicles. Each end member and its associated clamp are adapted to sandwich various portions of the adjacent various shaped van type vehicle drip rails. The clamping means and fastening means, in this instance with one generally extending parallel and the other extending perpendicular to said cross member, pulls the clamping means towards the unitary one piece end member to tightly sandwich the drip rail to hold the heavy duty rack to the van or other type vehicle&#39;s drip rail. The rack of the present invention is especially configured to be attachable to various make truck and van drip molds and gutter rails, such as those found on Ford, Dodge, Chevrolet, GMC and Chrysler. 
     In order to accommodate these various drip racks or gutters, the attaching portions of the rack of the present invention is especially formed. Unlike the rack shown in the U.S. Pat. No. 5,746,632 patent which had simple “L” shaped drip rail or gutter engaging portions, the drip rack or gutter engaging portions of the clamp and end member of the rack of the present invention are a series of successive steps, a double step or “W” which can accommodate both the simple “L” shaped gutter or drip rail, and the more complicated wing, successive stepped, or “W” shaped profiles found on some vans or trucks, such as those sold under the “GMC” and “Chevrolet” brands. Thus, with the present invention one style rack can be made to fit several brands of vans and their drip rail and gutter styles. 
     Further, unlike some prior art two bolt (vertical and horizontal) attached racks which have their end pieces at angles to the gutter or drip rail and which tends to increase the outboard or spreading load on the gutter, and thus reduce the carrying capacity, in the present invention the end pieces are located generally vertically so that the load transferred to or imposed on the gutter or drip rail is also generally vertical and can, thus, be safely maximized. Applying the load to the gutter or drip rail vertically permits a greater load to be safely imposed on the gutter or drip rail, and thus the van or vehicle to carry a greater load. Further, rather than have separate end pieces, which permit adjustment for width but could limit load carrying capacity, in the present invention the end members or pieces are solidly welded to the ends of the cross bar or member, and the cross bar itself is made of two heavily constructed pieces which telescope over a length of a few feet, and are welded to the end members to permit a pair of crossbars to safely carry a maximized load, as heavy as 1,200 pounds, evenly distributed. 
     OBJECTS OF THE PRESENT INVENTION 
     It is an object of the present invention to provide a heavy duty vehicle rack for carrying heavy loads, such as ladders, pipe, lumber, etc., weighing up to 1,200 pounds evenly distributed, suitable for use by trades persons. 
     It is another object of the present invention to provide a heavy duty rack which can be easily but strongly attached to a variety of vehicles. 
     Yet another object of the present invention is to provide a heavy duty rack which attaches tightly to a variety of shaped drip rails of various vehicles using portions to fit tightly onto various portions of the various shaped drip rails. 
     These and other objects of the present invention will become apparent from the accompanying drawings and following written description. 
    
    
     DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of the heavy duty rack of the present invention shown mounted to one style drip rails or gutters of one type vehicles, such as a van. 
     FIG. 2 is an enlarged exploded view of one end of the heavy duty rack of the present invention shown in FIG. 2, but shown in an unassembled state. 
     FIG. 3 is an elevational view of the crossmember end blank shown in FIGS. 1 and 2, before being bent to shape. 
     FIG. 4 is a side elevational view of the blank shown in FIG. 3, but after being bent to shape as shown in FIGS. 1 and 2. 
     FIG. 5 is an elevational view of the clamp blank shown in FIGS. 1 and 2, before being bent to shape. 
     FIG. 6 is a side elevational view of the clamp blank shown in FIG. 6, but after being bent to shape as shown in FIGS. 1 and 2. 
     FIG. 7 is a cross-sectional view of the left end of the heavy duty rack shown in FIG. 1, showing how the heavy duty rack is assembled and secured to a vehicle having a left side drip rail of one style. 
     FIG. 8 is a cross-sectional view, similar to FIG. 7, but showing how the heavy duty rack of the present invention can be fitted to another style drip rail on another type/brand vehicle. 
     FIG. 9 is a cross-sectional view similar to FIGS. 7 and 8, but showing how the heavy duty rack of the present invention can be fitted to yet another style drip rail on yet another type/brand vehicle. 
     FIGS. 10A and B are cross-sectional views similar to FIGS. 7-9, but showing how the present invention can be utilized with the heavy duty rack of the construction shown in my prior U.S. Pat. No. 5,746,362 and fitted to two different style drip rails. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to FIG. 1, the vehicle rack  10  of the present invention is shown. The rack  10  includes, at least one and preferably two crossmembers or bars  12  which are held above the vehicle roof  14 , each by its own two end member  16 . Each end member  16  rests upon the vehicle&#39;s gutter or drip rail  18  and is tightly held there by a clamp  20 . As is noted below, the end members and clamps are specially shaped to fit a variety of shapes of drip rails found on various vehicles. The clamp  20  also engages the drip rail and is held to the end member  16  generally by fastening means  22 . In this instance fastening means  22  consists of a set of two bolts and nuts, one set extending generally vertically ( 22   a ) and the other extending generally horizontally ( 22 B). Of course the fastening means  22  could be in other forms, such like that shown in my prior U.S. Pat. No. 5,746,362. If desired, an additional intermediate mount  24  can be provided for the crossmember  12 . Now that the overall construction of the vehicle rack of the present invention has been generally described, the details thereof will be discussed below. 
     Referring to the crossmember  12 , it preferably is made of rectangular, possibly square, cross section steel or aluminum tubing of outside cross sectional dimensions of 4 inches by 4 inches with ½ inch thick wall to 1 inch by 1 inch with ⅛ inch thick wall, with about 1-½ inch by 2 inch with {fraction (3/16)} inch thick wall being preferred. Tubing on or about 1-¾ inches×1-¾×{fraction (3/16)} inch thick or 14 gauge is suitable. Of course, other size or shape tubing could also be used. Preferably the crossmember  12  is made in two parts, an inner part  12 A and a tubular outer part  12 B which telescopes together to provide an exact fit for the width of various vehicles. The crossmember&#39;s  12  outer part  12 A is secured, as by welding to one of the end members  16 , in this instance the right one shown in FIG.  1 . The other end member  16 , the left one in FIG. 1, is secured, as by welding to the inner part  12 B of the crossmember  12 , a stub member, which is of a similar cross section as the outer part of the crossmember  12 A, but of a smaller size so as to telescope inside of the outer part of the crossmember  12 A. The crossmember  12  and its two parts ( 12 A and  12 B) can then be provided in a kit form of a sufficient length, compared to the width of the vehicle roof  14 , desirably to provide a significant overlap of  12 A and  12 B (say at least one foot) and then, if need be, cut to a length to exactly fit the vehicle&#39;s roof width. The stub  12 B and outer portion  12 A of crossmember  12  can then be drilled at a point where they overlap and then secured together with a fastener such as a bolt  31  (FIGS. 1 and 2) and nut, preferably of the self-locking Nylock type. Thus, a single kit for the roof rack and crossmember of the present invention can be easily custom fitted to a variety of width vehicles. Optionally the crossmember could be a single piece of a width to fit across the vehicle and having the end members secured to its respective ends. 
     Each of the two end members  16  is similar to the other, and in essence a mirror image of, in this instance, and identical to one another. The end members  16  are formed from a flat blank  16 ′ shown in FIG.  3  and has an upper portion  16 A with two vertical side wing  16 B. It also includes a tie-down opening  16 C. The blank&#39;s upper portion  16 A is unitary with an intermediate portion  16 D, which includes a stamped hole  16 E, which receives the square portion of a carriage bolt. The intermediate portion  16 D is unitary with a lower portion  16 F which is trapezoidal in shape having a larger bottom edge  16 G to better spread out the imposed load to be carried by the rack onto a length of the drip rail. The lower portion  16 H has a slot  161  for the other carriage bolt  22 B. As is shown in FIG. 4, the blank  16 ′ is transformed into the end  16  as follows: The side wings  16 B are bent, here 90°, to the main portion to stiffen the section. Also as shown in FIG. 4, the intermediate portion  16 D is bent, here about 75°, to the upper portion  16 A, to better transfer the load more perpendicularly onto the drip rail, and the lower portion  16 F is bent, here 90°, to the intermediate portion  16 D. The lower portion  16 F of the end member  16  is generally angled somewhat off of vertical and has the bottom edge  16 G for engaging the horizontal portion  38  of the various “L”, successive stepped, “W” or other shaped drip rail or gutter  18  on the vehicle roof  14 . The upper portion  40  of the end member  16  is also vertical and terminates in an attractive curve  42 . This upper portion  40  forms a cargo stop to keep whatever is placed on the crossmember  12  from shifting and/or falling off. If desired, the opening  16 C in the end  16  can be used to assist securing a tie down rope or device. As was heretofore mentioned, the crossmember  12  or its associated stub  12 A is secured to one or the other end members  16 . 
     As mentioned, to hold the end member  16  in place on the drip rails  18 , the clamp  20  is provided. As shown in FIGS. 5 and 6, the clamp  20  is also formed of steel or aluminum of a thickness similar to that of the end members  16 . A shown in FIG. 5, the flat blank  20 A is somewhat triangular in shape having a small trapezoidal portion  20 B on top of a large intermediate trapezoidal portion  20 C, which is integral with  20 B. Also integral with  20 C, is a lower rectangular portion  20 D. As shown, an opening  20 E in the upper portion  20 B is formed for the vertical fastener while a square hole  20 F is formed for the carriage bolt of the horizontal fastener. The flat clamp blank  20 A is bent into the somewhat complicated shape shown in FIG. 6 to form the clamp  20 , as follows: The portion  20 B is generally bent at an angle, here about 90°, to the intermediate portion  20 C. The intermediate portion  20 C, itself is bent below its mid point at about 45°, while the lower portion  20 D is bent into several steps adjacent so as to generally have a several step or “W” shape, having portions  20 H,  201 ,  20 J and  20 K. The clamp  20  has a lower end which is formed in a “W” and this “W”, in turn, at its lower portion includes an “L” shape having a generally vertical part  20 J and a generally horizontal part  20 K. Generally, the cooperating pieces  16  and  20  provide the desired clamping or tightening action between them when they are pulled together by fastening means  22  about a sandwiched drip rail. Generally washers  52  could be provided or eliminated and/or made in the form of a lock washer. Preferably, the nuts  54  are of the self-locking type with a nylon or the like insert so that no lock washer is needed. Preferably to prevent rotation of the bolts, they are of carriage bolt construction having a square shank just below the bolt head which engages a provided square opening to accommodate the carriage bolts and prevent their rotation. See FIG.  7 . 
     As shown in FIG. 1, the intermediate member  24  is formed from a unitary bent rod member  60  which at its upper ends fits about the crossmember and has its lower opposed two ends  62  threaded. The lower legs of the rod members  60  are secured to the crossmember  12  with a cross bar  65  and self-locking nuts  66 . The opening  68  formed between the rod  60  can be provided and used to tie a line or rope or to hold a ladder, lumber and/or a pipe in place. 
     The manner in which the clamp  20  secures the end member  16  and its attached crossmember&#39;s  12  inner and outer parts to the various shaped drip rails  18 A,  18 B and  18 C of the vehicle roofs  14 A,  14 B and  14 C is shown in FIGS. 7,  8 ,  9  and  10 . As is shown, the fastening means  22 A and B forces the clamp  20  tight against the end member  16 . At the same time the lower end (be it one or more of  20 H,  20 I,  20 J and/or  20 K) of the clamp  20  is forced upwardly to sandwich the drip rail against the bottom  16 G of the end member  16 . Thus, no matter what the drip rail shape, be it “L” shaped, “W” shaped, stepped, winged, or some other shape, it can be tightly gripped both vertically and horizontally by the ends  16  and clamps  20  when fastening means  22  (A and B) are secured. 
     The construction of the present invention of course could be adapted to other racks to permit them to be attached to the various shaped gutters or drip rails, such as shown in my prior U.S. Pat. No. 5,246,362 (indicated by the numeral  100 ) or U.S. Pat. No. 4,778,092 as is particularly shown in FIGS. 10A and B wherein two different drip rails styles (indicated by the numerals  102  and  104 ) as shown. In this instance, those portions that are like the U.S. Pat. No. 5,246,362 patent are given reference numbers 100 higher. For example, what was 20 in the U.S. Pat. No. 5,246,362 application is shown as  120  in FIGS. 10A and B. The new portions of the present invention are given reference numbers  200  higher than those portions shown in FIGS. 1-9. It should be understood the rack  100  shown in FIGS. 10A and B are identical, but positioned differently to rails  102  and  104 . 
     While specific angles are shown for shaping the blanks for the end member and clamps, other angles could be used. For example, angles ±15° of the angles set forth could also be used. 
     While a specific fastening means is shown, other type fastening means could be used, and other means of securing the clamp to the end member could also be used. While the special shaped portion was shown on the clamp, it could instead have been provided in the end member. 
     While the preferred embodiment of heavy duty racks of the present invention for use on a vehicle has been illustrated and described, and some of the possible alternatives set forth, from the foregoing it should be understood that other variations, modifications which are equivalent structures are possible, and thereof fall within the scope of the appended claims.