Abstract:
An article carrier assembly includes a pair of longitudinally laterally spaced siderails, each attachable to a vehicle roof panel, including a track and outboard corner portion. A pair of stanchions are attached to the tracks for slidable movement through a plurality of positions. A first crossrail is pivotally secured to a forward end of one of the siderails, and is movable between a stowed position and a deployed position. In the recessed position, the first crossrail is recessed in the siderail to which the first crossrail is attached. In the deployed position, the first crossrail is supported on both siderails. A second crossrail is pivotally attached to one of the stanchions opposite the siderail to which the first crossrail is attached. The second crossrail is rotatable between a stowed position, and a deployed position. In the stowed position, the second crossrail is recessed in the siderail and in the deployed position, the second crossrail is supported on both stanchions. When stowed, the crossrails generate a reduced amount of wind noise and vehicle drag.

Description:
RELATED APPLICATION 
     This application claims the benefit of U.S. provisional application serial No. 60/156,546 filed Sep. 29, 1999. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Technical Field 
     The present invention relates generally to article carrier assemblies, and, more particularly, to an article carrier assembly for attachment to a vehicle roof panel with improved styling and functionality. 
     2. Description of the Related Art 
     Typical vehicle article carrier assemblies include a pair of siderails mounted to a vehicle roof panel with at least one crossrail extending therebetween. Retainers on opposing ends of the crossrail attach the crossrail to the siderails. The retainers are usually secured to the siderails by latches or other such mechanisms. The retainers, crossrails and latches, however, create design problems in that such components may be bulky, and it is difficult to combine trim styling with sufficient strength for supporting an article on the carrier assembly. This leads to disadvantages. 
     One disadvantage of conventional designs is that the crossrails create wind noise when the vehicle is driven. Wind noise is inevitable when the article carrier assembly is being used, due to the article itself. Nonetheless, this wind noise is undesirable, especially when the article carrier assembly is not being used. In addition, the crossrails increase vehicle drag. Finally, it is difficult to provide crossrails in the form of a trim rail for styling purposes without sacrificing structural integrity. Accordingly, the styling suffers. 
     One approach taken in the art to address some of the shortcomings described above involves providing removable crossrails. In this approach, the crossrails are removable, and may be stored, for example, in the vehicle owner&#39;s garage or the like when not in use. However, a significant shortcoming of this approach is that the crossrails are not always with the vehicle. Therefore, on those occasions where use of the article carrier assembly arises unexpectedly, the article carrier assembly cannot be used because the removable crossrails are not stored with the vehicle. 
     There is therefore a need to provide an improved article carrier assembly that reduces or eliminates one or more of the shortcomings set forth above. 
     SUMMARY OF THE INVENTION 
     One object of the present invention is to provide an article carrier assembly that reduces or eliminates wind noise and vehicle drag when not in use. 
     Another object of the present invention is to provide an article carrier assembly that presents stylishly when not in use. 
     The present invention achieves these and other objects, and overcomes the above-referenced shortcomings of conventional article carrier assemblies by providing crossrails that are stowed in corresponding siderails when the crossrails are not needed. This approach reduces both (i) buzz, squeak, and rattle (BSR), and (ii) noise, vibration, and harshness (NVH) associated with the article carrier assembly. The invention also minimizes vehicle drag. In addition, a fully functional article carrier assembly is self-contained. That is, the crossrails are always with the vehicle, even when the carrier assembly is not in use. Moreover, the present invention provides for improved styling inasmuch as the article carrier assembly, when the crossrails are stowed, conveys the look of stand-alone siderails. 
     A preferred embodiment of the inventive article carrier assembly is adapted for attachment to a vehicle roof panel. The assembly includes a pair of spaced siderails configured to be mounted to the roof panel. A crossrail is also provided, along with a first attachment arrangement. The first attachment arrangement is configured to secure a first end of the crossrail to one of the pair of siderails and allow movement of the crossrail between a stowed position and a deployed position. In the stowed position, the crossrail is stowed in the siderail to which it is attached. Preferably, the crossrail when in the stowed position is recessed in a channel provided in the siderail. In the deployed position, the crossrail is supported on both siderails. 
     In another embodiment, a second end of the crossrail opposite the first end is releasably attached to the other one of the pair of siderails. This attachment may include one of a threaded thumb wheel, a screw, a quarter-turn fastener, and an over-center clamping system. 
     In a still further embodiment, a pair of crossrails are provided wherein a first, front crossrail, when in a deployed position, is longitudinally fixed with respect to the vehicle. The rear crossrail, however, is longitudinally adjustable with respect to the vehicle. Providing adjustability for only one of the crossrails (rather than for both crossrails) has the advantage of reducing the cost of the article carrier assembly. In addition, such an arrangement forces the end user to load the article carrier assembly properly (i.e., from the forward portion of the carrier assembly). To provide this adjustability, the article carrier assembly includes a pair of stanchions slidably attached to a track portion of the siderails. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The above objects and other objects, features and advantages of the present invention will be readily apparent from the following detailed description of the best modes of carrying out the invention, when read in connection with the accompanying drawings in which like reference characters refer to like parts throughout the views, and in which: 
     FIG. 1 is a perspective view of an article carrier assembly in accordance with the present invention, showing a pair of crossrails in a stowed and in a partially deployed position; 
     FIG. 2 is a perspective view of the article carrier assembly of FIG. 1 showing the crossrails in a fully deployed position; 
     FIGS. 3-4 are cross-section views showing an attachment arrangement for securing a forward crossrail to a predetermined, fixed position along a first siderail; 
     FIGS. 5-6 are cross-section views of a stowed crossrail, and a deployed crossrail, respectively attached to a movable stanchion; 
     FIG. 7 is a perspective view of a rear crossrail in a stowed position, particularly illustrating a releasable attachment arrangement; 
     FIG. 8 is a perspective view showing the rear crossrail of FIG. 7 in a deployed position attached to a first movable stanchion; 
     FIG. 9 is a top, perspective view showing a second movable stanchion; and, 
     FIG. 10 is a side, perspective view of the first movable stanchion of FIG.  8 . 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     FIG. 1 shows a partial, perspective view of an article carrier assembly  10  secured to a vehicle roof panel  12 . Article carrier assembly  10  includes a first siderail  14 , a second siderail  16 , a first crossrail  18 , a second crossrail  20 , a first attachment arrangement  22 , a second attachment arrangement  24 , a first stanchion  26 , and a second stanchion  28 . 
     First and second siderails  14 ,  16  are configured to be mounted to vehicle roof panel  12 . First and second siderails  14 ,  16  are disposed generally along respective longitudinal axes designated L 1  and L 2 , and are transversely spaced apart, one from the other. As described below, siderails  14 ,  16  are adapted to alternatively “stow” and support crossrails  18 ,  20 . Siderails  14  and  16  are substantially identical. Each siderail  14 ,  16  includes a respective forward and rearward portion. The rearward portion includes a track, described in greater detail below, for allowing slidable movement of stanchions  26 ,  28 . 
     Crossrails  18 ,  20  are configured to support articles, such as luggage and the like. In one embodiment, crossrails  18 ,  20  comprises lightweight metal, such as aluminum, to obtain needed strength objectives (i.e., to support articles), while remaining sufficiently light for easy movement. While the embodiment illustrated in FIG. 1 includes two crossrails  18 ,  20 , other embodiments may include a greater or lesser number of crossrails. 
     First attachment arrangement  22  is configured generally to secure a first end of crossrail  18  to siderail  14  and allow movement, shown generally in the direction of the double-arrowhead line designated“A” in FIG.  1 . In particular, crossrail  18  is allowed to move between a stowed position, designated  18   STOWED  (shown in solid-line), and a deployed position, designated  18   DEPLOYED  (best shown in FIG. 2) away from stowed position  18   STOWED . Crossrail  18  in the stowed position  18   STOWED  is preferably recessed for storage in a channel portion of first siderail  14 . Crossrail  18  may be moved to the stowed position, for example, when the article carrier assembly is not used. FIG. 1 further shows an intermediate position of crossrail  18  (shown in phantom-line format), designated  18   INT , which is between the stowed and deployed positions. 
     Likewise, second crossrail  20 , in combination with stanchion  26 , is configured for movement in the direction of the double-arrowhead line designated“B” in FIG.  1 . Such movement is also between a stowed position, designated  20   STOWED  (shown in FIG. 1 in solid-line format), and a fully deployed position, an exemplary position being designated  20   DEPLOYED(1)  (best shown in FIG.  2 ). Crossrail  20  in the stowed position  20   STOWED  is preferably recessed for storage in a channel portion of second siderail  16 . FIG. 1 further shows an intermediate position of crossrail  20  (shown in phantom-line format), designated  20   INT , which is between the stowed and deployed portions. The movement of crossrails  18  and  20  may be reversed. 
     Second attachment arrangement  24  is configured generally to releasably secure crossrail  20  to a forward end of second siderail  16  when crossrail  20  is in the stowed position  20   STOWED . In a preferred embodiment, second attachment arrangement  24  is configured such that crossrail  20  may be alternately secured and released without the use of any tools (i.e., the user can operate the attachment arrangement with his or her hands). Of course, this feature, while advantageous, is exemplary and not limiting in nature. 
     Referring to FIG. 2, stanchions  26 ,  28  are configured generally to support and secure rear crossrail  20  when crossrail  20  is deployed. Stanchions  26 , and  28  are slidably movable with respect to siderails  16  and  14 , respectively. This movement allows crossrail  20  to be positioned at any one of a plurality of positions along the siderails  14 ,  16 . For example, FIG. 2 shows a fully deployed crossrail  20  at a first longitudinal position, designated  20   DEPLOYED(1) , and at a second longitudinal position, designated  20   DEPLOYED(2) . FIG. 2 also shows first crossrail  18  in a fully deployed position,  18   DEPLOYED . 
     FIG. 3 and 4 show siderail  14 , and first attachment arrangement  22  in greater detail. FIG. 3 is a cross-section view taken substantially along lines  3 — 3  in FIG. 1, which is taken through the forward portion of siderail  14 . The forward portion (with respect to the vehicle) of siderail  14  includes an outboard portion  30 . Outboard portion  30  is shaped so as to define a side-opening channel. The side-opening channel is configured so that crossrail  18  may be recessed therein. Outboard portion  30  is formed, in one embodiment, of roll form metal, such as aluminum. Other materials such as plastics and the like may also be used to make siderail  14 . In the illustrated embodiment, the forward portion of siderail  16  is the same as the forward portion of siderail  14 . 
     FIG. 3 also shows, in greater detail, first attachment arrangement  22 . Attachment arrangement  22  includes, in the illustrated embodiment, a threaded fastener such as a bolt  32 , a bushing  34 , and a nut  36 . Bolt  32 , bushing  34  and nut  36  pivotally secure one end of crossrail  18  to siderail  14  at a predetermined, fixed, longitudinal position (with respect to axis L 1 ) along siderail  14 . The predetermined position is near a forward end of siderail  14 . Other known structures for pivotally securing crossrail  18  to siderail  14  may be employed to implement the above-described function. 
     FIG. 4 is a vertical, cross-sectional view taken substantially along lines  4 — 4  in FIG.  2 . As shown, attachment arrangement  22  is configured to allow crossrail  18  to rotate from the stowed position to the deployed position about the predetermined, fixed position on siderail  14 . 
     FIG. 5 is a vertical, cross-sectional view taken substantially along lines  5 — 5  in FIG. 1, which is taken through the rearward portion of siderail  14 . In the illustrated embodiment, the rearward portion of siderail  16  is substantially the same as the rearward portion of siderail  14 . Rearward portion of siderail  14  includes an outboard portion  38 . Outboard portion  38  is shaped so as to form an extension of the above-described side-opening channel. Outboard portion  38  may be made from roll form metal, such as aluminum. In addition, rearward portion of siderail  16  further includes an elongated track  40  having a longitudinally extending slot  42  formed through an upper wall thereof, and a plurality of apertures  44  configured for use in indexing movable stanchion  26  through various positions along siderail  16 . 
     FIG. 6 shows second attachment arrangement  24  in greater detail when crossrail  20  is deployed. Arrangement  24  includes a thumbwheel  46  having a threaded shaft portion thereof and an annular flange portion  47 . Flange  47  bears against a top surface of crossrail  20  when tightened, holding crossrail  20  in place. Since threaded thumbwheel  46 , by its nature, may be tightened or loosened by simply reversing the direction of rotation (e.g., either clockwise (CW) or counter-clockwise (CCW)), it provides the means for releasably securing crossrail  20  to siderail  14 , when crossrail  20  is deployed. It should be understood that variations of arrangement  24  are possible, and which may comprise one of a screw, a quarter-turn fastener, or an over-center clamping system. 
     FIG. 7 shows second attachment arrangement  24  (e.g., thumbwheel  46 ) when crossrail  20  is in the stowed position  20   STOWED . In the stowed position, thumbwheel  46 , particularly threaded shaft portion thereof, cooperates with a threaded nut  48  mounted to siderail  16 , to provide the means for releasably securing crossrail  20  to siderail  16 . 
     FIGS. 5 and 6 also show stanchion  28  in greater detail, with portions thereof omitted for clarity. As described above, stanchions  26 ,  28  are movably attached to respective siderails  14 ,  16 , which provide a mechanism for adjusting the longitudinal position of the rear crossrail  20 . Stanchions  26  and  28  are substantially identical in one embodiment. Unless described to the contrary, the description of stanchion  28  applies equally to stanchion  26 . Stanchion  28  includes a main body portion  52  (best shown in FIG.  9 ), a foot portion  54 , a land portion  56  (best shown in FIG.  9 ), a fastener, such as a press-fit nut  58  , and releasable locking means  60  having a locked position  62  and an unlocked position  64  comprising an over-center clamping system. Means  60  may include a hand-actuated handle  66 , a pivot  68 , (best shown in FIG.  9 ), a jaw assembly  70 , and a torsion spring  72  (best shown in FIG.  10 ). 
     Body portion  52  may comprise thermoplastic material such as, for exemplary purposes only, thermoplastic olefin (TPO) material, but can be made of a wide variety of materials. Foot portion  54  is configured in shape and size to be received in slot  42  of track  40  to thereby allow slidable, generally longitudinal movement of stanchion  28  through a plurality of positions along siderail  14 . Land portion  56  is configured generally to support crossrail  18  in the stowed position  18   STOWED , as shown in FIG.  5 . Land portion  56  is also configured to support crossrail  20  in the deployed position  20   DEPLOYED , as shown in FIG.  6 . 
     Means  60  is configured for releasably locking stanchion at a fixed position along a siderail. For indexing stanchion  28  along siderail  16 , handle  66  is pivotally mounted to body portion  52  at pivot pin  68  (best shown in FIG. 9) to effect a generally upward and downward movement of jaw assembly  70 . In order to secure stanchion  28  to track  40 , handle  66  is moved to the locked position  62 . In locked position  62 , the distal portion of jaw assembly  70  engages predetermined apertures  44 . To disengage stanchion  28  to thereby allow slidable movement of stanchion  28  along siderail  14 , handle  66  is moved relatively in a downward direction. This downward movement is against a built-in spring bias provided by torsion spring  72  (best shown in FIG.  10 ). When handle is moved downward, a distal portion of jaw assembly  70  assumes unlocked position  64 , shown in dashed-line format in FIG.  5 . In unlocked position  64 , stanchion  28  may be moved along track  40 , generally in a direction along axis L 1 , to any desired position. 
     FIG. 8 shows a feature of stanchion  26  not provided on stanchion  28  in the illustrated embodiment, a generally fixed pivoting arrangement. In particular, threaded nut  58  is configured to mesh with the corresponding outside threaded portion of a fastener, such as a bolt  74  or the like. A bushing  76  is also provided to lessen friction during rotation. The arrangement of bolt  74 , bushing  76 , and nut  58 , in stanchion  26 , is operative to pivotally attach crossrail  20  to stanchion  26 . The nature of the attachment is such that a pivoting action is permitted to allow crossrail  20  to be moved between deployed and stowed positions. This function is similar to that performed by first attachment arrangement  22  with respect to crossrail  18 . 
     FIG. 5 shows a further attachment arrangement, which is applied for releasably attaching crossrail  18  to stanchion  28 . In the illustrated embodiment, such arrangement comprises a thumbwheel  78 . Thumbwheel  78  includes an annular flange portion  80  that bears on an upper surface of crossrail  18 . The thumbwheel  78  further includes a lower, shaft portion  82  having outside threads configured to mesh with the inner threads of nut  58 . This arrangement is shown for when crossrail  18  is stowed. When crossrail  18  is deployed, thumbwheel  78  cooperates with nut  48  (FIG. 7) to releasably secure crossrail  18  to the siderail. Like thumbwheel  46  of second attachment arrangement  24 , thumbwheel  78  is configured such that crossrail  18  may be alternately secured and released without the use of any tools (i.e., the user can operate the attachment arrangement with his or her hands). Of course, other arrangements, such as a screw, a quarter-turn fastener, on an over-center clamping system may be employed to achieve the same functionality. In such alternative embodiments, stanchion  28  may not require threaded nut  58 . 
     An article carrier assembly according to the invention reduces wind noise and vehicle drag when not in use by providing a stowing feature, where the two crossrails are stowed in respective siderails, generally out of sight. When needed, each crossrail may be rotated to a deployed position supported on both siderails. In this way, the crossrails may be kept with the vehicle, allowing full use of the carrier assembly at all times. 
     While the best mode for carrying out the invention has been described in detail, those familiar with the art to which this invention pertains will recognize various alternative designs and embodiments for practicing the invention within the scope of the appended claims.