Car top carrier

The invention provides improvements for an enclosed carrier configured for mounting on top of a car.

FIELD OF THE INVENTION

The invention relates to assemblies for carrying cargo on a vehicle. In particular, the invention provides improvements for a box or trunk designed for mounting on top of a car.

BACKGROUND OF THE INVENTION

In recent years car top carriers in the form of boxes or trunks have become quite popular. Enclosed carriers are preferable over conventional open racks for a variety of reasons. Enclosed carriers protect cargo from the elements such as wind, rain, and snow. Enclosed carriers are also more secure from theft or vandalism.

However, some car top boxes have problems which make them difficult or cumbersome to use. For example, some boxes use a labor intensive bracket system to secure the box on to the crossbars of a vehicle roof rack. Bracket systems typically require the installer to reach extensively over the top of the car. Such bracket systems are impractical, particularly for a short person. The installer may have to practically climb into the open box to secure the brackets. This is especially a problem for a user who frequently wants to install or remove the carrier from the car.

Another problem with some enclosed car top carriers is that they can only be accessed from one side. Depending on where or how the vehicle is parked, or who is trying to access the carrier, it may be inconvenient or awkward to always access the box from the same side.

Another problem with car top trunks or boxes is that they are sometimes difficult to open. Typically, there are several latches on the side of the box that opens. The user may have to operate multiple latches simultaneously where the latches are separated by a long distance. This may require substantial strength, dexterity, and reach. Some boxes have an actuator that coordinates simultaneous release of multiple latches but still may require special handling such as lifting of the cover while manipulating the actuator or handle. Accordingly, there is a need for enclosed car top carriers that are easy to mount on a vehicle and easy to use.

SUMMARY OF THE INVENTION

An example of the invention uses a mounting assembly that is quick and easy to install on a car. A preferred design uses a cam-operated clamping device to grip crossbars on a vehicle rack. Another example of the invention uses coordinated hinge/latch devices to permit easy opening of the carrier from either side of a vehicle. Other examples and aspects of the invention are described in detail below.

DESCRIPTION OF THE INVENTION

FIG. 1shows car top carrier20mounted on vehicle22. Car top carrier20includes top24and bottom26mounted on crossbars28on the top of car22.

FIG. 2shows an exploded view of car top carrier or box20. Mounting hardware is provided for easily securing carrier20to the vehicle rack. For example, four mounting mechanisms34a-dmay be provided for this purpose. Each mounting mechanism includes a cam lever for operating a jaw mechanism to clamp around a crossbar, as explained in more detail below. The clamps may be provided completely preassembled with the box. The clamps never need to be disassembled as the carrier is put on and off one or more cars through the life of the product. Each clamp may be adjustable to grip, with variable force, crossbars of different dimensions. The clamps may also be adjustable to different locations on the floor of the box, for example, along an axis parallel to the direction of vehicle travel. The clamps are preferably configured so that once the carrier clamps are adjusted for a particular vehicle configuration, the carrier can be easily installed or removed by simply manipulating each cam lever with a single, one step, switch, toggle, rotation, stroke or other quick-action, for example, with an over-center assist mechanism.

Sets of hinge/latch mechanisms may also be provided on each side of carrier20to allow opening of the carrier from opposite sides. InFIG. 2, hinge/latch mechanisms40a-40care mounted on one side of carrier20to connect top24to bottom26. Similarly, on the other side of carrier20, hinge/latch mechanisms42a-42cconnect top24to bottom26. Actuating bar44is mounted inside carrier20for operating and synchronizing hinge/latch function of mechanisms40a-40c. Actuating bar44may be operated, i.e., moved forward and backward relative to the long axis of carrier20, by manipulating switch, handle, or key device46from the exterior of carrier20. A similar actuating bar (not shown) is used to operate hinge/latch mechanisms42a-cvia switch, handle, or key device50.

Lid supports54aand54bare mounted at the front and back ends of carrier20, connecting top24to bottom26. Lid supports54aand54bstabilize top24when moving between open and closed positions. Lid supports54aand54bmay also limit the extent of potential opening of carrier20. For example, lid supports54a,54b, may limit the extent of opening on either side of carrier20to approximately 16-inches. Longitudinal ribs or indentations58may be formed in carrier top24to provide stiffening and increased strength for carrier20, and may also be desirable aesthetically.

FIGS. 3-7show details of one of the four mounting mechanisms, for example, as shown inFIG. 2.FIG. 3is a side view of one of clamps34, with a portion of bottom26of carrier20cut-away. In closed position, cam lever38seats against floor33of bottom26. Cam lever38acts through cam portion41, shaft member43, bolt45, barrel nut47, and axle49to apply a force holding crossbar28tightly clamped between movable jaw portion51and stationary jaw portion53.

FIGS. 4 and 5show details of clamp34moving to an unclamped position. Cam lever38pivots around shaft member43. The shape of cam portion41and the position of shaft member43causes opening and closing of movable jaw portion51relative to stationary jaw portion53when cam lever38is rotated between different positions as shown inFIGS. 3 to 5. The jaw portions may define openings of different shapes for various purposes. The jaw portions inFIGS. 3-5define an elongate curved opening, or oval shape to accommodate crossbars having different cross-sectional shapes. Cam portion41is shaped so that as lever38rotates around shaft member43the distance between shaft member43and floor33is altered, thus causing corresponding pivotal movement of jaw portion51toward or away from fixed stationary jaw potion53mounted on floor33. An over-center mechanism is used so that a maximum height of shaft member43is reached at an intermediate point, for example, approximately at the location shown inFIG. 4. This way lever38tends to stay locked in the closed position shown inFIG. 3, and tends to spring to the unlocked position when lever38is moved over-center in the opposite direction, as shown inFIG. 5. Movable jaw portion51pivots around axle structure49. Movable jaw portion51is elongate, with an initial portion55angled so as to guide crossbar28into position between movable jaw portion51and stationary jaw portion53. Movable jaw portion51has a concave inner surface57which contacts crossbar28when the jaw is closed, and which is configured for gripping. Concave inner surface57may have a cushion or pad59near axle49. Stationary jaw portion53may have side tabs61to guide movable jaw portion51when clamp34is moved to the closed position.

Clamp34is mounted on floor33of carrier bottom26by bolt45, with barrel nut47serving us an anchor pivot for bolt45. In addition, a first oversize knob63turns bolt45to move barrel nut47closer to or farther away from shaft member43, thereby providing a gross adjustment mechanism for the tightness of the clamping action. Movable jaw portion51clamps around crossbar28. InFIGS. 3-5, arrow64indicates the direction of forward travel of vehicle26. Movable jaw portion51preferably is oriented to open in the forward direction to make carrier20less likely to be dislodged from vehicle22in a high-impact forward collision.

FIG. 6shows a top view of clamp34. Bolt45passes from the inside of car top carrier20to the outside through floor33of carrier bottom26via slot66which is aligned with the long axis of car top carrier20. Slot66allows adjustment of the location of clamp34along the long axis of car top carrier20. Finger tabs68facilitate prying or lifting of cam lever38away from floor33when opening clamp34. Cam lever38is shaped to provide clearance for first oversize knob62when cam lever38is moved between open and closed positions. A second oversize knob70provides for tightening or loosening of fastener72passing through slot66to stationary jaw component53to prevent or allow motion of clamp34in slot66. Floor33of bottom30is shaped in the form of a ridge or rail74to complement the shape of clamp34and to aid in seating cam lever38against floor33when clamp34is in the closed position, thereby providing repeatable and secure alignment.

FIG. 7is an end-on view of clamp34, as shown inFIG. 6. Shaft member43may include curvature away from barrel nut47so as to provide spring action during operation of clamp34.

FIG. 8shows a top view of the interior of car top carrier80including four clamps82a-d. In this example, all four clamps82a-dare ganged by connectors84and86. Ganging clamps allows multiple clamps to be operated with a single movement, step, or manipulation. Ganged clamp configurations may also make it easier to operate clamps located distally from the installer's vantage point.

FIG. 9shows another example. A top view of car top carrier90has two clamps92aand92b. In this example, two clamps92aand92bare located on front and rear crossbars, and are ganged by connector94so that clamps92aand92bopen and close together.

Any number of clamps may be used to fasten a container on a set of crossbars on top of a vehicle. For example, one, two or more clamps may be used to secure a container on a front crossbar. Similarly, one, two or more clamps may be used to secure a container to a rear crossbar. For some purposes a single clamp may be sufficient, for example, on the front crossbar with the container merely resting on the back crossbar. In other instances, a single clamp may be used on each crossbar, or multiple clamps may be used on one or both crossbars.

Any combination of clamps may be ganged. For example, it may be advantageous to have a clamp which is closest to the hinge side of a box (distal clamp) ganged to a clamp on the opening side of the box (proximal clamp) so that operation of the proximal clamp automatically operates a corresponding distal clamp.

It may also be advantageous to have an extended handle or actuator connected to the distal clamp so that the distal clamp can be operated with minimal reaching from the open side of the container.

A clamp, as described above, may also be modified to provide automatic clamping. For example, the movable jaw portion may be spring biased toward the closed position. The lip of the jaw may be configured to cause opening of the jaw as the box slides forward across the top of the crossbars. Once the jaw encompasses the crossbar, it springs back to a secure closed position. The jaw is further configured so that it cannot be opened without a manipulation, for example, switch or lever-operated, action inside the box. This type of fastener may be referred to as “seat belt type engagement.”

A jaw member as described above, may have different shapes. For example, the jaw member may be generically shaped to fit around differently shaped or dimensioned crossbars. Alternatively, the jaw member may be custom-shaped to fit around a specific crossbar configuration. For example, the jaw member may have a partially rectangular inner surface for fitting around a rectangular or square cross bar.

Clamping devices should be designed to minimize manufacturing costs and complexity. For example, a rail with a slot, as described above, may be molded into the floor of a box. A stationary jaw portion, movable jaw portion, and cam lever may be separately molded pieces.

Different kinds of actuators may be used to operate the jaw assembly. For example, an actuator may be a differently-shaped cam, or may be a screw mechanism using a threaded member. A cam lever may operate in different directions other than parallel to the long axis of a container as described above. Clamp mechanisms, as described above, may also be implemented to connect other types of apparatus to crossbars on top of a vehicle.

The clamp mechanisms shown and described herein may be implemented on boxes with any type of hinge and/or latch mechanism. For example, the clamping devices may be used on a box with dual functioning hinges that can operate as a hinge or a latch, for example, as described in U.S. Pat. No. 5,823,411 and U.S. Provisional Patent Application No. 60/443,437, each of which is hereby incorporated by reference in its entirety.

FIGS. 10 and 11show end views of car top carrier20opened alternately from opposite sides. This feature of carrier20is made possible by dual-functioning hinge/latch mechanisms such as the examples described in detail below.

FIGS. 12 and 13are side views of a hinge/latch mechanism, for example, like40a-cand42a-cinFIG. 2. Mounting base, platform, or portion110may be securely fastened, for example, by screws to24of carrier20. Receiving portion120may be fastened securely to a corresponding location on bottom26of carrier20. InFIG. 12hinge/latch mechanism40ais oriented in position for securing top32to bottom34when carrier20is closed.FIG. 13shows the orientation of hinge/latch mechanism40when the hinge/latch mechanisms on the opposite side of the box are functioning as a latch. Flared portion140of receiving portion120permits a selected degree of motion of arm portion112relative to receiving portion120.FIG. 14shows hinge/latch mechanism40operating as a latch after enlarged end portion114has been released from receiving portion120.

FIG. 15shows a cut-away view of hinge/latch mechanism40with actuating bar44removed. Plunger150is spring-biased upward against enlarged end portion114. The spring helps the lid to pop up initially when opening the container. As shown, enlarged end portion114has a spherical shape which allows mounting platform110multiple, even infinite, degrees of movement relative to receiving portion120. This feature allows the hinge/latch device, not only the flexibility of acting as a hinge or a latch, but also permits the same hinge/latch configuration to be used on carriers of many different shapes and geometries. When pawl122is rotated in the direction of arrow152and is sufficiently out of the way of enlarged end portion114, plunger150urges enlarged end portion114upward so that it disengages from receiving portion120even when pawl122is permitted to rotate back to its original orientation. The spring and plunger mechanism makes it easier to open the carrier because once the actuating bar has simultaneously pushed multiple pawl members out of the way in each of the coordinated hinge/latch mechanisms, the latches are disengaged without further manual movement or handling relative to carrier top24. To re-engage hinge/latch mechanism40a, enlarged end portion114is forced into receiving portion120until pawl122is pushed aside allowing enlarged end portion114to “snap” into place, as shown inFIG. 15. The springs may be selected such that very little, if any, manual force is required, in addition to gravity, to latch the top closed, somewhat analogous to the closing of a trunk on a car.

FIGS. 16-18show movement of actuating bar44to disengage enlarged end portion114from receiving portion120. As shown inFIG. 16, actuating bar44has a projection160that is normally spaced away from end portion162of pawl member122when hinge/latch mechanism40ais functioning as a hinge. When actuating bar144is moved in the direction of arrow164inFIG. 17, projection160of actuating bar144contacts and pushes end portion162of pawl member122. This eventually causes rotation of pawl member122out of the way of the main receiving channel in receiving portion120, thus allowing enlarged end portion114to disengage receiving portion120, enabling hinge/latch mechanism40ato function as a latch.

FIG. 19shows a lid support, for example, such as54binFIG. 2. First arm202may be connected to bottom26of carrier20. Second arm204may be connected to top24of carrier20. First arm202is pivotally connected second arm204. Spring206is contained in a pocket in first arm202. Spring206acts on slide or cam follower208which moves up and down as second arm204is moved between open and closed positions. Second arm204has a cam portion210than contacts slide208. The shape of cam portion206determines the magnitude and direction of torque exerted on second arm204about pivot point212.

While the present invention has been particularly shown and described with reference to the foregoing preferred embodiments, those skilled in the art will understand that many variations may be made therein without departing from the spirit and scope of the invention as variously described and defined above. The description of the invention should be understood to include all novel and non-obvious combinations of elements described herein.