Car top carrier

A car top carrier incorporating improved dual-functioning hinge/latch mechanisms connected by a drive bar that translates pivotal rotation to open and close the carrier.

FIELD OF THE DISCLOSURE

This disclosure relates to car top carriers. More specifically, this disclosure relates to car top carriers having one or more latches and a handle including a lock that interact together to secure cargo for transport in a car top carrier.

BACKGROUND

There are many types of dual-functioning hinge/latch mechanisms used in car top carriers. However, hinge/latch mechanisms often fail to account for variations in temperatures that cause components of the hinge/latch system to expand and contract. Because this problem is not taken into account, car top carriers having multiple latches are often difficult to open and close, particularly in extreme weather conditions. Additionally, some hinge/latch systems allow a user to think the carrier is locked when one or more of the latches are not properly engaged. An improperly latched lid may lead to theft of items stored in the carrier, and may permit the lid to pop open when the vehicle reaches higher speeds.

Examples of car top carriers including box latches are found in the following patents and published applications: U.S. Pat. Nos. 1,313,687; 3,008,177; 3,677,196; 4,217,999; 4,249,684; 4,274,568; 4,406,387; 5,419,479; 5,492,258; 5,546,705; 5,582,313, 5,762,244; 5,823,411; 5,845,828; 5,947,356; 6,145,719; 6,276,311; 6,296,161; 6,296,278; 6,463,627; 2002/0030074; DE2804588; DE19526477; WO04067326; US-2006-0032878-A1 and US-2007-0257075-A1. The patents and publications listed above are incorporated herein by reference in their entirety for all purposes.

SUMMARY

A car top carrier having an improved dual-functioning hinge/latch mechanism is provided. A pair of hinge/latch systems are mounted in the interior of a car top carrier along opposing sides. Each hinge/latch system has a plurality of coordinated hinge/latch mechanisms connected to a handle by a drive bar. The handle is accessible from the exterior of the carrier. When a user rotates the handle, the drive bar rotates causing the hinge/latch mechanism release the lid for opening.

DETAILED DESCRIPTION

This disclosure provides numerous selected examples of invented devices for carrying cargo on or with a vehicle. Many alternatives and modifications which may or may not be expressly mentioned are enabled, implied, currently possessed, and supported by the disclosure.

FIG. 1shows car top carrier10mounted on vehicle12. Carrier10includes top portion14and bottom portion16and opposing lateral sides18. Clamp devices (not shown) are used to attach bottom portion16of carrier10to crossbars20mounted to the top of vehicle12.

FIG. 2shows an end view of carrier10opened alternately from opposing sides18. Carrier10may be opened by a user from a first side and pivot about the opposing side. This feature of carrier10is made possible by dual-functioning hinge/latch mechanisms such as the examples described in detail below.

FIG. 3illustrates latch system22for use in carrier10. Latch system22includes a drive bar24that connects one or more latch assemblies26and a handle assembly28. Latch system22is configured to be attached to the inside portion of carrier10along one of sides18via screws, rivets, or other appropriate fasteners. As described below, portions of handle assembly28may be accessible from the exterior of carrier10so as to be accessible to a user. Latch system22provides a system by which top portion14and bottom portion16of carrier10may be securely engaged for transit and opened by a user to retrieve contents from carrier10.

As shown inFIGS. 3 and 4, and described in more detail below, rotation of handle28around axis AA imparts rotational movement of bar24around axis BB. Axis AA is substantially perpendicular to axis BB.

FIG. 4shows a detailed view of handle assembly28from latch system22ofFIG. 3. Handle assembly28is shown rotating between three positions—closed30, open (or “released”)32, and intermediate (or “partially released”)34positions. Each of the three positions may indicate a different status of latch system22. Handle assembly28may also function as an indicating device. For example, closed position30may indicate latch system22is in the fully latched position, meaning carrier10is closed and latched; open position32may designate that carrier10is open and unlatched; and intermediate position34may indicate that one or more latch assemblies26are latched, but the carrier is not completely engaged or locked.

FIG. 5shows drive bar24illustrated inFIGS. 3 and 4. Drive bar24may provide a rotational connection between one or more latch assemblies26and handle assembly28. Drive bar24, as shown, may be an elongate tube formed of metal or other rigid material. As shown inFIG. 5, drive bar24may include opposing flat portions36and tabs (ridges, or spines)38formed in the tube. Such a structure may permit latch assemblies26and handle assembly28to slide or adjust along drive bar24due to expansion and contraction due to fluctuations in temperature, while reliably and effectively translating pivotal rotation between latch assembly26and handle assembly28.

FIG. 6shows an exploded view of handle assembly28. Each component of handle assembly28is shown in the latched position, meaning carrier10is closed. Handle assembly28includes lock40, handle42, handle base44, handle driver46, handle spring48, lock cam50, bar driver52, and lock cover or housing54. The components of handle assembly28function to impart rotational movement on drive bar24when handle42is manipulated, specifically rotated. The components, their function, and interaction with one another are discussed in detail below.

Lock40ofFIG. 6may lock and unlock carrier10using a key. When lock40is in the locked position, handle assembly28is prohibited from rotating and carrier10cannot be opened using handle assembly28. However, when lock40is in the unlocked position, handle assembly28operates in the manner described in detail below. In some embodiments, the key may not be removed from lock40unless handle assembly28is in closed position30. This feature prevents a user from unknowingly leaving carrier10open.

As shown inFIG. 6, lock40is disposed in a cavity or channel56formed in handle42. Users may rotate handle42to unlatch and open carrier10. Handle42interacts with other components of handle assembly28to impart rotational movement of drive bar24. The rotational movement imparted on drive bar24is thereafter translated to latch assembly26which causes carrier10to open or close. The manner in which handle assembly28rotates drive bar24will be appreciated with consideration of the description below. Handle42also may indicate whether carrier10is fully latched or un-latched. As noted above, the location of handle42—open position30, closed position32, or intermediate position34—indicates the current status of carrier10.

When handle assembly28is fully assembled, lock40and handle42extend through an aperture58defined in handle base44. Handle base44is connected to the exterior of carrier10making handle42and lock40accessible from the exterior of carrier10. Aperture58may align with an opening in carrier10(not shown) such that lock40and handle42may extend into the interior of carrier10to interact with components of handle assembly28disposed therein.

Handle driver46connects to handle42via aperture58defined in handle base44and carrier10. Handle42is fixedly attached to handle driver46such that handle driver46translates rotation of handle42to components disposed within carrier10. For example, when a user rotates handle42, handle driver46rotates correspondingly.

Handle spring48is connected to handle driver46. Handle spring48is oriented so as to bias handle driver46toward the open or un-latched position. The biasing force imparted by handle spring48may be translated to handle42via the connection between handle driver46and handle42.

Lock cam50is connected to lock40through channel56in handle42and apertures58and60defined in handle base44and handle driver46, respectively. Lock cam50prevents handle42from rotating when lock40is in the locked position, thus preventing a user from opening carrier10using handle assembly28. However, when lock40is in the unlocked position, lock cam50rotates when handle42is rotated by a user. Additionally, when handle42is in the un-latched position, lock cam50may not fully rotate back to the locked position, thereby preventing handle42from returning to the locked position.

Bar driver52includes lateral tab62, down tab64, and channel66through which drive bar24may extend. Bar driver52is configured to impart pivotal rotation on drive bar24when handle42is turned by a user. As will be appreciated with the description below, the rotation imparted on drive bar24is then translated to latch assembly26to open carrier10. Bar driver52is rotated by contact from lock cam50on lateral tab62when handle42is rotated by a user. The rotation forced by lock cam50causes lateral tab62and down tab64to rotate upward. Down tab64is positioned such that lock cam50cannot rotate back to the latched position until bar driver52is rotated back to the latched position. Bar driver52is rotated back to the latched position when latch assembly26—described below with reference to FIGS.7and8—is closed by a user.

Lock cover or housing54houses each of the components of handle assembly28disposed inside carrier10. Lock cover54may be fastened to the interior or bottom portion16of carrier10. Opposing apertures68are formed in lock cover54to provide bearing surfaces for drive bar24. Apertures68may align with channel66in bar driver52when handle assembly28is fully assembled.

FIG. 7shows latch assembly26in detail. Multiple latch assemblies26may be incorporated into latch system22and may be integrated on each opposing side18of carrier10. Latch assembly26is a dual-function latch and hinge which permits top portion14and bottom portion16to attach and rotate relative to one another. Latch assembly26includes latch catch70, latch housing72, latch clasp74, clasp spring76, trigger78, and trigger spring (not shown). As illustrated inFIG. 7, latch assembly26is shown in the latched or closed position.

Latch catch70, as shown inFIG. 7, may be fastened to the inside of top portion14of carrier10. Latch catch70includes a latch catch pin82that extends between opposing brackets84. Latch catch pin82provides a structure by which latch clasp74—described below—may engage to latch top portion14and bottom portion16. Additionally, latch catch pin82is formed so as to permit pivotal rotation between top portion14and bottom portion16when engaged.

Latch housing72may provide a protective housing for the other components of latch assembly26and may be fastened to the inside of bottom portion16of carrier10. The interior of latch housing72may provide bearing surfaces for drive bar24and trigger78. As shown inFIG. 7, drive bar24may extend though opposing apertures86defined in latch housing72, thus connecting latch assembly26to handle assembly28. Latch housing72also includes opposing guides88—shown in greater detail in FIG.8—to guide latch catch pin82into latch housing72when a user is closing carrier10.

Latch clasp74is housed within latch housing72and includes hook portion90and pin knob92. As shown inFIG. 7, when latch assembly26is in the latched position, hook portion90engages latch catch pin82. Hook portion90prevents latch catch pin82from disengaging, which would cause carrier10to open. Pin knob92interacts with trigger78—as described in detail below—to prevent latch clasp74from moving forward to prematurely engage latch catch pin82.

Latch clasp74also includes a channel94that aligns with apertures86defined in latch housing72. Drive bar24may extend through apertures86and channel94. Channel94may be formed such that latch clasp74may slide along drive bar24while not rotating about it. This connection to drive bar24provides the pivotal rotation connection with handle assembly28. When latch assembly26is in the latched position—as shown in FIG.7—drive bar24causes bar driver52and other components of handle assembly28to rotate to the latched position. Conversely, when a user rotates handle42to open carrier10, bar driver52rotates drive bar24and consequently latch clasp74to the open position—shown in FIG.8—releasing latch catch pin82.

Clasp spring76is disposed about drive bar24. Clasp spring76contacts the interior wall of latch housing72at one end and a tab96formed on latch clasp74at the other end. The orientation of clasp spring76biases latch clasp forward in the direction shown by directional arrow98.

As noted above, trigger78interacts with pin knob92to prevent latch clasp from moving forward until latch catch pin82is sufficiently forced into latch assembly26. Trigger78is rotationally attached to the interior wall of latch housing72. When latch catch pin82is forced into latch housing72by a user closing carrier10, latch catch pin82first contacts the distal end of trigger78. As latch catch pin82is forced downward, trigger78also pivots downward. When latch catch pin82is forced downward to the point at which it clears hook portion90of latch clasp74, pin knob92is released and the bias provided by clasp spring76causes latch clasp74to rotate forward to capture latch catch pin82.

A trigger spring, which is not shown, biases trigger78upward in the direction shown by directional arrow100. The biasing provided by the trigger spring causes latch catch70and consequently top portion14of carrier10to “pop” open when opened. The trigger spring also provides the force that holds pin knob92in place until trigger78has been sufficiently rotated.

FIG. 8shows latch assembly26ofFIG. 7in the un-latched or open position. As seen inFIG. 8, latch clasp74has disengaged latch catch pin82permitting it to be lifted from latch assembly26. Latch catch pin82is shown resting on the upper side of trigger78which is forcing latch catch pin82upward due to the biasing provided by the trigger spring. Latch clasp74is held in the back or disengaged position by a hook102(FIGS. 9 and 10) formed in trigger78that engages pin knob92on latch clasp74.

It should be appreciated that in latch system22incorporating multiple latch assemblies26, carrier10will not close unless each latch assembly26is fully latched. Specifically, handle42will not rotate to closed position30until drive bar24rotates back to the closed position. Because drive bar24is connected to each latch assembly (three per side, for example)26incorporated in latch system22, drive bar24will not rotate until each latch clasp76has either (1) engaged latch catch pin82to close carrier10, or (2) released latch catch pin82to open carrier10.

FIGS. 9 and 10show a cross-sectional side view of the interaction between latch clasp74and trigger78.FIG. 9illustrates latch assembly26in the un-latched or disengaged position.FIG. 10shows latch assembly26in the latched or fully engaged position.FIGS. 9 and 10also show trigger pivot axis104and latch catch pivot axis106along with directional arrows108and110indicating the direction in which trigger78and latch clasp74are biased. The cross-hatched portion of trigger78indicates raised contours formed in the side of trigger78. Specifically, the raised contours form hook102that interacts with pin knob92to hold back or release latch clasp74to engage latch catch pin82.

FIG. 9shows latch catch pin82initially contacting the upper surface of trigger78. As latch catch pin82is forced downward, pin knob92moves upward relative to hook102on trigger78. Hook102and pin knob92are formed such that pin knob92is fully released when latch catch pin82clears the distal end of hook portion90formed in latch clasp74. As pin knob92is released from hook102, latch clasp74moves forward to engage latch catch pin82because of the biasing provided by clasp spring76. Pin knob92slides along a rail112formed in trigger78until latch clasp74eventually engages latch catch pin, as shown inFIG. 10.

While embodiments of a box latch system have been particularly shown and described, many variations may be made therein. This disclosure may include one or more independent or interdependent inventions directed to various combinations of features, functions, elements and/or properties, one or more of which may be defined in the following claims. Other combinations and sub-combinations of features, functions, elements and/or properties may be claimed later in this or a related application. Such variations, whether they are directed to different combinations or directed to the same combinations, whether different, broader, narrower or equal in scope, are also regarded as included within the subject matter of the present disclosure. Accordingly, the foregoing embodiments are illustrative, and no single feature or element, or combination thereof, is essential to all possible combinations that may be claimed in this or a later application. Each claim defines an invention disclosed in the foregoing disclosure, but any one claim does not necessarily encompass all features or combinations that may be claimed. Where the claims recite “a” or “a first” element or the equivalent thereof, such claims include one or more such elements, neither requiring nor excluding two or more such elements. Further, ordinal indicators, such as first, second or third, for identified elements are used to distinguish between the elements, and do not indicate a required or limited number of such elements, and do not indicate a particular position or order of such elements unless otherwise specifically stated.

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.

Many useful modified combinations of the devices disclosed may be implemented. Numerous elements of the disclosed devices may be interchanged or reversed. For example, the coordinating bar connecting latch/hinge devices may be carried on the lid instead of the bottom of a carrier. For a given latch/hinge device, the trigger and latch assembly may be mounted on the lid with a corresponding pin mounted on the bottom of a carrier. Any number of latch/hinge devices may be engaged on a single coordinating bar. Similar latch systems to those described and illustrated may be implemented on a carrier that only opens on one side.