Abstract:
In one series of embodiments, a carrier system includes a rack mountable on a vehicle to transport material. The rack includes a frame having one or more suction cups attached to the rear side of the frame, e.g., for attachment to a surface such as the side of the vehicle. A support bar mates with the frame. The support bar and the frame may include attachment configurations which mate with one another to selectively and securely attach the bar to the front side of the frame with the bar extending in a direction away from the one or more cups. With the rack comprising a plurality of suction cups, the frame may be configured as a plate or may comprise a series of arms or connected braces which extend away from a center position to the suction cups.

Description:
RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Patent Application Ser. No. 61/777,008, filed Mar. 12, 2013 of which is incorporated herein by reference. 
    
    
     FIELD OF INVENTION 
     The present invention relates to vehicle mountable rack systems and, more specifically, to removable vehicle mounted rack systems which are easily installed and removed and storable in small vehicle spaces. 
     BACKGROUND OF THE INVENTION 
     Conventional rack systems for trucks and other types of vehicles that transport ladders or other long objects are typically top mount systems (e.g., positioned over the roof of the vehicle) or systems attached to the rear of a vehicle (e.g., via a hitch) to carry the load). The difficulties and inconveniences of lifting, securing and transporting long objects like ladders, lengths of wood and pvc piping on an overhead rack system are arise, in part, because it is often necessary to manually raise the objects to roof height and, when employing a rack, there must be a spatial distribution of sufficient attachment points to provide stability to the cargo. 
     Conventional rack systems for trucks and other types of vehicles that transport ladders or other long objects are typically top mount systems (e.g., positioned over the roof of the vehicle) or systems attached to the rear of a vehicle (e.g., via a hitch) to carry the load). Truck, van, SUV and sedan owners occasionally need to transport lengthy items, but rarely have the capability to do so without securing the item directly to the vehicle, or placing it inside the vehicle itself. Difficulties and inconveniences of lifting, securing and transporting long objects like ladders, lengths of wood and pvc piping on an overhead rack system arise, in part, because it is often necessary to manually lift the objects to roof height. Also, when employing a rack, there must be a spatial distribution of sufficient attachment points to provide stability to the cargo. Typical rack systems, whether aftermarket or factory installed, have narrow cross spans, due in part to relatively short roof lengths. These limit the ability to safely carry many lengthy items. In the case of truck owners, the ability to carry a ladder may require installing overhead rack systems on the truck beds. Ladder racks and other overhead rack systems are expensive, look unattractive, and are relatively permanent. Rack systems may have relatively narrow spans (3-6 feet), in many instances limiting the ability to only carry substantially longer items when the items have internal structural rigidity, e.g., such as ladders. These prior rack systems are not well-suited for carrying long, flexible items, like pvc tubing, crown molding, baseboards, rebar, etc., as these are often sold in 14′-16′ lengths. Securing items directly to the vehicle, either without a rack, or by using a narrow span rack, has involved placing the material in contact with the vehicle roof surface. This increases the risk of damaging the automotive paint finish, side mirrors, and other exterior or interior surfaces. Because risks include marring the vehicle interior, the tasks of carrying long flexible materials are often reserved for occasions when the weather is not inclement. 
     SUMMARY OF THE INVENTION 
     An exemplary vehicle mountable carrier system is disclosed which is easily deployed to carry long items along the side of a pickup truck, van, SUV, sedan or other vehicle. The system comprises a pair of similar rack assemblies made of aluminum, other metals, high impact plastic, or other sturdy material, and the invention also includes methods for securing the rack to the vehicle. These methods may include use of suction cups or tether straps. The various rack parts may be hinged, riveted, welded, screwed, interlocked, integrally formed or otherwise attached. The carrier system may include two or more racks that each attach to a surface of the vehicle, one rack deployed near a forward-most part of the vehicle, e.g., on or in front of a front-most door; and the other rack deployed near the rear of the vehicle, there being a user adjustable span to fit variable applications. 
     In one series of embodiments, a carrier system according to the invention includes at least one rack mountable on a vehicle to transport material. The rack includes a frame having front and rear sides. One or more suction cups are attached to the rear side of the frame so that a suction side of each cup faces away from the frame, e.g., for attachment to a surface such as the side of the vehicle. A support bar mates with the frame. In one embodiment, the support bar and the frame include attachment configurations which mate with one another to selectively and securely attach the bar to the front side of the frame with the bar extending in a direction away from the one or more cups. With the rack comprising a plurality of suction cups, the frame may be configured as a plate or may comprise a series of arms or connected braces which extend away from a center position to the suction cups. 
     The attachment configuration of the frame may include a keyway which extends into or through the frame, e.g., in the form of a slotted opening; and the support bar, also referred to as a rack bar, may include a locking configuration which fits into the keyway to effect securement of the bar at an angle with respect to the frame with the bar extending away from the frame. In one example, the angle may be ninety degrees, but smaller angles are contemplated. More generally, the carrier system may comprise a plurality of racks according to any of multiple embodiments. 
     Each rack may comprise three spaced-apart suction cups. Each suction cup may be connected to the frame via a tubular post or other stand-off positioned between the frame and the back side of the suction cup, i.e., the opposite the suction side. The afore-mentioned locking configuration may include on the frame a rectangular-like slot extending into or through the frame. The slot may include a circular portion within which a portion of the bar can rotate to place the bar in a secure, locked position or in a position from which the bar can be removed from the frame slot. On the rack bar, the locking configuration may be formed about a first end of the bar and a stop may be formed along an upper surface about a second end of the bar. 
     While carrier systems according to the invention may be deployed on either side of a vehicle, it is intended for deployment to be only on the passenger side of the vehicle. A carrier system may typically comprise at least two similar racks that each mount on any smooth metal or glass surface of the vehicle. In the disclosed embodiments each rack is a single unit comprising 3 main components: 1) a base plate, 2) one or more suction cups, and 3) a horizontal rack bar. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a side a vehicle on which a carrier system according to the invention is installed; 
         FIG. 2A  is a perspective view illustrating the front side of a rack or hanger shown in  FIG. 1 ; 
         FIG. 2B  is a perspective view illustrating the rear side of a rack or hanger shown in  FIG. 1 ; 
         FIG. 3  is a front view of the rack shown in  FIG. 2 ; 
         FIG. 4  provides a side elevation view of the rack shown in  FIG. 2 ; 
         FIG. 5  illustrates components of the rack shown in  FIGS. 2-4  in spaced apart relation prior to assembly; and 
         FIG. 6  illustrates components of the carrier system according to an alternate embodiment which employs a hinge. 
         FIG. 7  is a front view of a rack which, according to another embodiment, comprises a frame formed of brackets in lieu of a flat plate. 
     
    
    
     Like reference numbers are used throughout the figures to denote like components. Numerous components are illustrated schematically, it being understood that various details, connections and components of an apparent nature may not be shown in order to emphasize features of the invention. Various features shown in the figures may not be shown to scale in order to emphasize features of the invention. 
     DETAILED DESCRIPTION OF THE INVENTION 
     Before describing in detail exemplary methods, systems and components according to embodiments of the invention, it is noted that the present invention resides primarily in a novel and non-obvious combination of components and method steps. So as to not obscure the disclosure with details that will be readily apparent to those skilled in the art, certain conventional components and steps have been omitted or presented with lesser detail, while the drawings and the specification describe in greater detail elements and steps pertinent to understanding and practicing the invention. Further, the following embodiments do not define limits as to structure or method according to the invention, but provide examples which include features that are permissive rather than mandatory and illustrative rather than exhaustive. 
     With reference to  FIG. 1  there is shown a carrier system  10  according to an embodiment of the invention. The system  10  comprises one or more hangers, referred to herein as racks  12 . Each rack  12  is shown mounted along a common side  14  of a vehicle  18 . The vehicle is shown positioned above a horizontal ground plane, G with two mounted racks to enable transporting lengths of material  20 . The material may span a portion of, all of or more than the length, L, of the vehicle  18 . The material  20  may be any of a variety of items, including items typically used in home projects, light construction, and sporting activities (e.g., pipes, molding or other types of wood or plastic trim, wood studs, rods, fishing gear, etc.). Generally, the system is suitable for transporting items which are relatively long and narrow, but is not so limited in versatility. Further, the racks can also be mounted on other surfaces of the vehicle, including the rear side, the front side, the roof and the hood, although mounting on the vehicle side  14  may be preferred in most applications. 
     As illustrated in this description, embodiments of the invention are portable, compact, and easy to transport and deploy. System components can be stored in a vehicle when not in use. Additionally, loading material on the carrier system and unloading the material can be relatively quick and simple. For example, the material or other cargo can be attached to and carried by the vehicle at approximately the waist or chest level of a typical person. This is to be contrasted with placement of the material  20  over the roof line of a vehicle, as is common with many carriers. Further, the system can be deployed with sufficient distance between a pair of the racks  12  to support the ends of long flexible materials like pvc pipe, baseboards, crown molding, etc., which are often sold in 10′,12′ and 16′ lengths. Still further, the system can be used to carry long lengths of materials alongside the vehicle without allowing the material to touch and potentially damage the surface of the vehicle side  14 . Moreover, the system can be mounted on the vehicle  18  by one person in less than a few minutes. 
       FIGS. 2A and 2B  are front and rear perspective views of a rack  12  as would be deployed when mounted on the vehicle side  14 .  FIG. 3  provides a front elevation view of the rack  12 . As can be seen in the figures, the illustrated embodiment of the rack comprises a plate  24  having a front side  24   f  shown in  FIGS. 2A and 3 , and a rear side  24   r , shown in  FIG. 2B , to which three suction cups  28   a ,  28   b  and  28   c  are mounted in a spaced-apart triangular-like configuration. The suction cups may be made of rubber or other pliant material (e.g., a plastic). The cups  28   a  and  28   b  are positioned along a horizontal line and above the cup  28   c  relative to the ground plane, G. Each cup includes first and second opposing sides  30   s  and  30   m . The side  30   s  is an open suction side which faces away from the plate  24  for contact with a surface to which the cup is to be attached. The side  30   m  is a rear side which faces the plate for attachment thereto through a stand-off  32  in the form of a tubular shaped mounting post. 
       FIG. 4  provides a side elevation view of the rack  12  taken along an edge of the plate  24  to illustrate the stand-offs  32  which space the cups  28   a ,  28   b  and  28   c  away from the plate  24 . Each suction cup  28   a ,  28   b  and  28   c  is connected to the rear side  24   r  of the plate with a conventional fastener that extends from a point of securement within the cup and into or through the plate  24 . For example, to secure each cup to the plate  24 , a machine screw  32 ′ may pass through an aperture in the plate, through a stand-off  32  and into the rear side  30   m  of a cup where it is threaded into a nut (not shown) that is secured within the cup. 
     The plate  24  may be a flat plate of arbitrary shape and of sufficient height relative to the ground plane and sufficient width, in a direction parallel to the ground plane, to accommodate an array of suction cups which provide both vertical and horizontal stability to the mounted rack  12 . Although three cups are illustrated, the number of suction cups attached to each plate  24  is a design choice which depends, in part, on the load to be carried and conditions such as the vehicle speed during transport and the stability of attachment for each cup. 
     The base plate may be made of aluminum, other metal, plastic or another sturdy material. Additionally, the plate  24  may have holes or slots which serve as attachment points for anchor ends of, for example, bungee cords or other means of securing loads to each rack  12 . Appropriate dimensions for the plate  24  are approximately 7 inches in height by 5½ inches in maximum width. The plate thickness may be on the order of ¼ inch. 
     The illustrated stand-offs  32 , in the form of hollow, cylindrically shaped posts, each extend away from the rear side  24   r  of the plate to provide necessary clearance from the vehicle body, e.g., to avoid interference due to contours in the shape of the vehicle side  14 . In other embodiments he stand-offs  32  may be attached to the plate  24  by weld joints, other types of fasteners, or may be integrally formed with the plate  24  (e.g., with injection molding manufacture to create plastic or composites shapes). Nominal dimensions of cylindrically shaped posts which serve as stand-offs are one inch in diameter and one inch in length. 
     The plate  24  may also include one or more additional holes or slots  36  which each serve as an additional attachment point for a tether  40  that provides securement to the vehicle in addition to the suction cups. Each tether may be a conventional strap of suitable width, length and strength, may be constructed of nylon or other flexible synthetic or natural material commonly described as webbing/strapping. A tether  40  may comprise a buckle system for tightening and securing the tether to a mounting point on the vehicle. In this regard, a tether may be threaded through or around any attachment point on the vehicle (e.g. OEM attachment rings in a pickup truck bed or a roof rack on an SUV). Exemplary tether dimensions are 0.75 inch in width, and varied length, e.g., two to six feet. 
     The suction cups  28   a ,  28   b  and  28   c  may be any of a variety of suction cup or vacuum cup designs which readily adhere to the vehicle side  14  or a vehicle window. The suction cups may be of commercial grade to assure provision of sufficient suction to remain stably attached to the vehicle side under specified load conditions. Suitable suction cup dimensions are approximately 3 inches in diameter along the open suction side  30   s  and 1.5 inches in height. 
     A rack bar  44  extends from the plate  24  in a direction away from the suction cups to provide a support to carry and secure the material  20 . In the embodiment illustrated in  FIGS. 2 through 6 , the rack bar  44  is easily attachable to and detachable from the plate  24  when deploying the system  10 . It can be readily removed from the plate  24  to improve compactness of the system for storage purposes. In another embodiment shown in  FIG. 6 , a rack bar  44 ′ and the plate  24  form a foldable assembly where the bar  44 ′ may be attached to the plate  24  with a hinge  45  so it can swing away from the plate to support the load of the material  20  when the system is deployed (e.g., to extend in a direction which is ninety degrees away from the plane in which the front side  24   f  of the flat plate  24  resides). The hinge  45  includes a stop (not shown) which may be an angle bracket positioned along a bottom surface of the rack bar at the first end  46 . The stop limits the range of the angle to which the hinge opens to provide a desired angle between the rack bar  44 ′ and the plate  24 . The hinged bar  44 ′ can also be swung about the hinge angle to rest against the plate when the carrier system is being stored. Although not illustrated, for these and other embodiments, when the carrier system is deployed, the rack bar may extend to less than a ninety degree angle relative to the plate  24 , i.e., to provide a modest vertical incline of the rack bar relative to the plate. This can impart a beneficial positive slope to the rack bar, as a function of distance along a direction away from the plate. In still other embodiments, the rack bar may be permanently affixed to the plate  24  with no freedom to rotate or change the angle of the bar  44  relative to the plate  24 . 
     For the embodiment illustrated in  FIGS. 3 and 4 , the rack bar  44  and the plate  24  are shown in a deployed configuration of the system  10  where the plate is in a vertical position and the rack bar is approximately in a horizontal position with respect to the ground plane. The rack bar  44  is of a generally rectangular shape, having a nominal height (i.e., shown in a vertical direction with respect to the ground plane) of about 1¼ inches, a width (i.e., along a horizontal direction) of about ½ inch and a length, measured between first and second opposing ends  46 ,  48 , of 5½ inches. The rack bar includes features formed about the first and second opposing ends  46 ,  48 . See  FIG. 5 . To effect selectable securement of the rack bar  44  to the plate, the plate  24  includes a keyway  52  sized to accept a mating feature  54  formed about the first end  46  of the rack bar  44 . The exemplary keyway  52  is a combination of a rectangular shaped slot, which extends through the plate  24 , and a circular cutout  52   c  which widens a center region of the slot to permit rotation of the mating feature  54  when placed in the keyway  52 . The opening provided by the keyway  52  extends a sufficient length and width in the vertical and horizontal directions to receive the nominal dimensions of the rack bar end  46 . 
     In the illustrated embodiment the mating feature  54  includes keyway cutouts  56  which leave a rectangular segment  54   a  at the end  46  suitable for insertion through the keyway. As shown in the figures, the segment  54   a  may be the full nominal height and width of the rack bar. The keyway cutouts  56  leave a small, recessed rectangular segment  54   b  in the center region of the rack bar, i.e., which does not extend the full height of the rack bar. The small segment  54   b  connects the segment  54   a  to the rest of the rack bar  44 . When the rectangular segment  54   a  at the end  46  is inserted through the keyway  52 , the smaller rectangular segment  54   b , having nominal height and width dimensions of ½ inch, resides in the slot. The diameter of the circular cutout  52   c , enables rotation of the rack bar when the larger rectangular segment  45   a  is extended through the keyway to the rear side  24   r  of the plate. For example, the cutout  52   a  may have a ¾ inch diameter. Once the rack bar is rotated into a desired rotational position, it is slid downward in the keyway to secure the rack bar in a lower rectangular portion of the keyway slot, i.e., below the circular cutout. 
     A second feature of the rack bar  44  is provision of a stop  58  at the second end  48 , along an upper surface  60  thereof. The stop impedes movement of the material off the end  48  when being placed on the surface  60 . The combination of the stop  58  and any slope provided to the rack bar also help keep the material in place during transport. To impart a slope to the installed rack bar, relative to the plate  44 , the mating feature may be formed at an angle with respect to the vertical orientation of sides of the cutout. 
     The rack bar  44  may be made of aluminum, other metal, a plastic or a composite material. Further, the rack bar may have holes in the bottom or sides to provide anchor points for rope, straps, bungee cords or other means to secure the load to the rack. An exemplary rack bar is 5½ inches long, ½ inch thick and 1¼ inches wide. 
     According to still another embodiment,  FIG. 7  is a front view of a rack  12 ′ which, in lieu of a frame formed in the shape of the flat plate  24 , comprises an assembly  65  of interconnected brackets or arms  64  which extend in different directions from a center position  66 , with each of three suction cups  28   a ,  28   b  and  28   c  connected to an arm  64 . The brackets or arms  64  may be formed of injection molded plastic. The center position  66  includes a surface  66   s  along which the keyway  52  or other mating feature may be formed or positioned to interface with a mating feature of the rack bar. 
     While this written description and the drawings enable one of ordinary skill to make and use what is believed to be the best mode for practicing the invention, those of ordinary skill will understand and appreciate the existence of variations, combinations, and equivalents of the disclosed embodiments, methods, and examples described herein. For example, a carrier system may utilize an integrated unit of cup, post and plate fabricated in an injection molding or machining process. The integrated unit may comprise vacuum cups of the type which apply suction via a lever on the cup. An advantage of using vacuum cups is that these types of cups are more capable of lifting heavy objects like glass or pulling dents. Such cups may be produced as part of an integrated assembly to make a “handle-type” device, and are manufactured by companies such as Tooluxe. In such a design, one or more vacuum cups would be designed into a fully integrated unit where the cups, post and plate are formed together. The invention is therefore not limited by the described embodiments, but only by the scope and spirit of the claims which now follow.