Abstract:
A vehicle article carrier apparatus adapted to be disposed on an outer body surface of a vehicle for supporting articles. The apparatus includes support rails secured to the outer body, a cross bar spanning the support rails, and bracket assemblies secured to the cross bar. The bracket assemblies are coupled to the support rails and include a lower locking clamp pivotally secured to the housing. The lower locking clamp rotates between an open position and a closed position and secures the bracket assembly to the support rail when in the closed position. The open position is approximately 180° from the closed position. A detail within the housing contacts a first face of the lower locking clamp in the open position and a second face of the lower locking clamp in the closed position, thus preventing the lower locking clamp from rotating more than 180° between the open and closed positions.

Description:
FIELD OF THE INVENTION  
         [0001]    The present invention relates to vehicle article carriers. More particularly, the present invention relates to a vehicle article carrier having a bracket assembly with a simplified and improved locking mechanism.  
         BACKGROUND OF THE INVENTION  
         [0002]    Vehicle article carriers are used in a wide variety of applications for supporting and securing articles of various sizes above an outer surface of a vehicle. Typically, vehicle article carriers include a pair of support rails that are secured to the outer body surface of the vehicle. The support rails are typically straight and mounted on the outer body surface to extend parallel to each other. The support rails are usually secured along a major longitudinal length of the vehicle roof, rear deck lid, or truck bed.  
           [0003]    Typically, at least one cross bar extends between the two support rails. The cross bar is secured to each support rail by bracket assemblies that are fastened to each end of the cross bar. Each bracket assembly typically comprises a locking mechanism for releasably securing it to an associated one of the opposing support rails.  
           [0004]    While current vehicle article carriers perform adequately for their intended use they are all subject to improvement. Specifically, the locking mechanisms of many current article carriers typically include a relatively large number of complex parts, thus making the locking mechanisms somewhat difficult and/or costly to assemble. Many such locking mechanisms require one or more independent springs to perform the needed locking action, which can add to the complexity and cost of the locking mechanism. Further, with some article carriers, the locking mechanisms can be difficult to completely disengage from their respective support rails when opened, and thereby prevent one or both of the bracket assemblies from being easily repositioned along its associated support rail or removed from the support rail.  
           [0005]    Consequently, there exists a need for a vehicle article carrier having a cross bar with bracket assemblies at each end thereof that include a simplified locking mechanism that is easier to assemble, more cost efficient to produce, and provides excellent reliability in its locking orientation.  
         SUMMARY OF THE INVENTION  
         [0006]    The present invention fulfills the needs of the prior art by providing a vehicle article carrier apparatus adapted to be disposed on an outer body surface of a vehicle for supporting various articles thereon. The apparatus includes support rails secured to the outer body, a cross bar spanning the support rails, and bracket assemblies secured to the ends of the cross bar. The bracket assemblies are coupled to the support rails and each includes a lower locking clamp pivotally secured to a housing of its respective bracket assembly. A locking lever rotates the lower locking clamp between an open position and a closed position. This secures the bracket assembly to the support rail when the locking lever is in the closed position due to a force applied to the support rails by the lower locking clamp. Once the lower locking clamp has been moved into the closed position, further rotation of the locking lever does not cause further rotation of the lower locking clamp, but does increase the force applied to the support rail by the lower locking clamp. The open position is approximately 180° from the closed position. A surface detail within the housing contacts a first face of the lower locking clamp, when the lower locking clamp is moved to the open position, thus preventing further rotation. A second face of the lower locking clamp contacts the surface detail when the locking clamp is moved to the closed position and thus prevents further rotation of the locking clamp once it is moved into the closed position. The structural detail thus prevents the lower locking clamp from rotating more than 180° between the open and closed positions. This enables the locking clamp to be moved between the full open and closed positions with just rotational movement of the locking lever. Once the locking lever is in its closed position and pre-tightened onto its associated support rail, then the locking lever can be pivoted from a first position, wherein it applies no additional clamping force, to a second position, wherein it applies an additional clamping force to even better secure the bracket assembly to its associated support rail.  
           [0007]    Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the invention. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0008]    The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:  
         [0009]    [0009]FIG. 1 is a perspective view of a portion of a vehicle including a vehicle article carrier apparatus in accordance with a preferred embodiment of the present invention;  
         [0010]    [0010]FIG. 2 is a perspective view of a portion of a cross bar, a portion of a support rail, and a bracket assembly of the apparatus of FIG. 1 in a closed position;  
         [0011]    [0011]FIG. 3 is an exploded perspective view of a portion of a cross bar and one of the bracket assemblies of the apparatus of FIG. 1;  
         [0012]    [0012]FIG. 4 is a side view of the assembled bracket assembly of FIG. 3 showing the bracket assembly in a closed position over a portion of its respective support rail;  
         [0013]    [0013]FIG. 5 is a cross-sectional view taken along section line  5 - 5  in FIG. 4;  
         [0014]    [0014]FIG. 6 is a side view of the bracket assembly of FIG. 4 but with the locking clamp in the fully open position; and  
         [0015]    [0015]FIG. 7 is a cross-sectional view taken along line section  7 - 7  in FIG. 6.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0016]    The following description of the preferred embodiment is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.  
         [0017]    Referring to FIG. 1, a vehicle article carrier apparatus  10  in accordance with a preferred embodiment of the present invention is illustrated. The article carrier apparatus  10  is shown installed on an exemplary motor vehicle  12 . Specifically, the apparatus  10  is shown installed on a roof portion  14  of the motor vehicle  12 . While FIG. 1 shows the apparatus  10  secured to the roof portion  14 , it will be appreciated that the apparatus  10  can just as readily be secured at various other surfaces about an exterior of the motor vehicle  12 . Further, the apparatus  10  is suitable for use on virtually any form of vehicle such as, but not limited to, a sport utility vehicle, station wagon, sedan, etc.  
         [0018]    The apparatus  10  generally includes a pair of elongated support rails  16 , at least two cross bar bracket assemblies  18 , and at least one cross bar  20 . It will be appreciated that in many applications two adjustably positionable cross bars  20  will be used, but that one of the cross bars  20  could just as readily comprise a fixed (i.e. non-movable) cross bar member. For the purpose of discussion and illustration, both of the cross bars  20  comprise adjustable cross bars.  
         [0019]    As illustrated in FIG. 1, the support rails  16  are placed in a generally parallel relationship along opposite sides of the roof  14 . The support rails  16  are supported above the roof  14  by suitable support feet  15 . FIG. 2 provides a more detailed view of one of the support rails  16 , as well as the cross bar  20  and one of the bracket assemblies  18 . As seen in FIG. 2, the support rail  16  is generally comprised of a lower rail surface  24 , an upper rail surface  26 , an inner rail surface  28 , and an outer rail surface  30 .  
         [0020]    With reference to FIG. 3, the cross bar bracket assembly  18  will now be described in detail. It will be appreciated that the bracket assembly  18  at each end of the cross bar  20  is identical in construction. As seen in FIG. 3, the bracket assembly  18  is generally comprised of a housing  32 , a locking lever assembly  33  having a locking lever  34  and a locking pin  36 , and a lower locking clamp  38 . The housing  32  generally includes a neck portion  40 , a clamp portion  42 , an upper recess  44  for receiving the locking lever  34 , and a center through bore  46 .  
         [0021]    The neck portion  40  includes a hollow portion  48 . The hollow portion  48  is shaped complementary to the cross bar  20  (described in detail below) so that the cross bar  20  may be seated securely within the hollow portion  48 . The cross bar  20  is secured within the hollow portion  48  in any suitable manner, such as through the use of threaded fasteners (not shown) to provide a rigid connection between the cross bar  20  and the bracket assembly  18 .  
         [0022]    The clamp portion  42  includes an inner surface  50 , an upper surface  52 , and an outer surface  54 . The shape of the inner surface  50 , the upper surface  52 , and the outer surface  54  complement the shape of the inner rail surface  28 , the upper rail surface  26 , and the outer rail surface  30  respectively so that the clamp portion  42  may sit firmly over the support rail  16 . To cushion the interaction between the clamp portion  42  and the support rail  16 , a rubber or other like pad (not shown) may be secured to the inner surface  50 , the upper surface  52 , and the outer surface  54 .  
         [0023]    The upper recess  44  is located on a surface of the housing  32  opposite the clamp portion  42 . The recess  44  is of a depth and contour such that when the locking lever  34  is seated flat within the recess  44  (FIG. 2), the locking lever  34  does not protrude from the recess  44 . The recess  44  preferably includes a bore  56  for receipt of an optional fastener (not shown) that cooperates with a similar bore (not shown) within the upper rail surface  26  to secure the bracket assembly  18  at a particular position on the support rail  16 .  
         [0024]    The center through bore  46  extends through the housing  32  from the recessed portion  44  to an undersurface  58  of the housing  32 . As seen in FIGS. 5 and 6, the center through bore  46  includes a detail (i.e., rib or protrusion)  59  that protrudes from an interior wall of the center through bore  46 . The detail  59  includes a first face  60  and a second face  61 .  
         [0025]    The locking lever  34  is an elongated lever having a first end  64  and a second end  66 . The first end  64  includes a retention area  68  for receiving a portion of the locking pin  36 , and a camming surface  67 . The retention area  68  includes a first aperture  70  and a second aperture  72  within opposite sides of the lever  34 . Between the first aperture  70  and the second aperture  72  is a well  74  having a center slit  76 . The second end  66  preferably includes a raised portion  78  to permit easy actuation of the locking lever  34  by one or more fingers of an operator.  
         [0026]    The locking pin  36  has a vertical shaft portion  80  and a head portion  82 . The shaft portion  80  has a first end  84  and a second end  86 . The second end  86  is threaded to threadly engage with the lower locking clamp  38 . The head portion  82  is positioned at the first end  84  and is ninety degrees to the vertical shaft portion  80  to provide the locking pin  36  with a “T” shape.  
         [0027]    The lower locking clamp  38  includes a planar support rail contact portion  88  and a boss surface portion  90 . The support rail contact portion  88  has an upper surface  92  and a lower surface  94 . The upper surface  92  is planar to complement the lower rail surface  24 , which is also planar. The boss portion  90  extends from the upper surface  92  and is circular. Extending through the center of the boss portion  90  is a threaded through hole  96 .  
         [0028]    The boss portion  90  includes a lower circular base portion  98  and an upper portion  100 . The upper portion  100  is comprised of a first semi-circular portion  102  and a second semicircular portion  104 . The first semi-circular portion  102  has a diameter that is equal to the base portion  98 . The second semi-circular portion  104  has a diameter that is less than the first semi-circular portion  102 . Due to the difference in diameters between the first portion  102  and the second portion  104 , a first face  106  and a second face  108  (see also FIG. 5) of the first semi-circular portion  102  are created.  
         [0029]    With further reference to FIGS. 1 through 3, the cross bar  20  will now be described in detail. The cross bar  20  generally includes an elongated tubular, preferably oval shaped (in cross-section), member having a top portion  110 , a bottom portion  112 , a first outer most end  114 , a second outer most end  116 , and a central region  118 . One of the bracket assemblies  18  is disposed at both the first outer most end  114  and the second outer most end  116  with a portion of both the first outer most end  114  and the second outer most end  116  secured within its respective hollow portion  48  of its respective bracket assembly  18 .  
         [0030]    [0030]FIGS. 4 and 5 illustrate the components of FIG. 3 as installed with the bracket assembly  18  in a closed position such that it is securely seated upon, and clamped to, one of the support rails  16 . As seen in FIG. 4, in the closed position the locking lever  34  is seated horizontally within the upper recess  44 . The head portion  82  of the locking pin  36  is seated within the retention area  68  such that the head portion  82  extends from the first aperture  70  to the second aperture  72 . The vertical shaft portion  80  extends through the center slit  76 . The locking pin  36  remains in the horizontal position as shown in FIG. 4 until an upward force is applied to the locking pin  36 , due to an over-center locking action between a planar base portion  120  of the locking lever  34  and the recessed portion  44 .  
         [0031]    The vertical shaft portion  80  of the locking pin  36  extends through the center through bore  46  and is engaged within the threaded through hole  96 . The locking pin  36  secures the entire boss portion  90  to the housing  32 . The boss portion  90  is secured within an enlarged recess  105  and coaxially aligned with the through bore  46 , as shown in FIG. 4. The boss portion  90  is secured within the recess  105  such that the detail  59  within the housing  32  is positioned between the first face  106  and the second face  108 . In the closed position illustrated in FIG. 4 and FIG. 5, the lower locking clamp  38  is orientated such that the upper surface  92  of the support rail contact surface  88  abuts the lower rail surface  24 . As seen in FIG. 5, when the lower locking clamp  38  is in the closed position the first face  106  of the first semi-circular portion  102  abuts the first face  60  of the detail  59  to limit rotational movement in one direction such that the lower locking clamp  38  is precisely positioned under the support rail  16 . Thus, as the locking pin  36  is rotated in a first (i.e., tightening) direction, from an unclamped position, the lower locking clamp  38  moves initially into the clamped position and is then stopped by first face  60  from rotating further. The slight frictional engagement of the threaded portion of the second end  86  in contact with the threaded hole  96  provides for initial rotational movement of the lower locking clamp  38 .  
         [0032]    [0032]FIGS. 6 and 7 illustrate the components of FIG. 3 as installed with the bracket assembly  18  in an open position so that the bracket assembly  18  may be freely placed upon, or removed from, the support rail  16 . In the open position the lower locking clamp  38  is positioned out from underneath the lower rail surface  24  (i.e., positioned 180° from its orientation of FIG. 4). The boss portion  90  of the locking clamp  38  is orientated such that the second face  108  of the first semi-circular portion  102  abuts the second face  61  of the detail  59  to hold the lower locking clamp  38  in the fully open position where the bracket assembly  18  can be easily lifted off of the support rail  16 .  
         [0033]    Movement of the bracket assembly  18  from the closed position of FIGS. 4 and 5 to the open position of FIGS. 6 and 7 will now be described in detail. The locking lever  34  is first lifted to its raised position as seen in FIG. 6. The locking lever  34  is lifted by the operator who preferably engages the raised portion  78  using his/her finger to lift the lever  34 . This removes a portion of the clamping force applied by lever  34 , locking pin  36  and lower locking clamp  38 . Once the lever  34  is raised, the operator rotates the lever  34  180° (i.e., counterclockwise in FIG. 3) so that the lower locking clamp  38  is no longer positioned beneath the lower rail surface  24  (FIG. 4) but is rather clear of the lower rail surface  24  to permit the bracket assembly  18  to be removed from the support rail  16  (FIG. 6). Accordingly, the detail  59  stops rotation of the lower locking clamp  38  at a predetermined point where the bracket assembly can be lifted off.  
         [0034]    To return the bracket assembly  18  to the closed position and secure the bracket assembly  18  to the support rail  16 , the locking lever  34  is again rotated 180° (this time clockwise in FIG. 3). The support rail contact portion  88  of the lower locking clamp  38  is then initially moved underneath the support rail  16  and second face  108  of boss portion  90  abuts the detail  59 . Once the lower locking clamp  38  is in position to abut the lower rail surface  24 , the user may tighten the grip of the lower locking clamp  38  against the lower rail surface  24  by further rotating the locking lever  34  clockwise. As the lower locking lever  34  is rotated further, the contact between the second face  108  of the knob portion and the second face  61  of the detail  59  prevents the lower locking clamp  38  from rotating further, but permits the locking pin  36  to advance further into the threaded through hole  96 . As the locking pin  36  is advanced further into the through hole  96 , the lower locking clamp  38  is pulled upward toward, and into contact with, the lower rail surface  24  to thus further tightly clamp the bracket assembly  18  to the support rail  16 . The locking lever  34  is then turned downward so that it is secured in a horizontal position within the recessed portion  44 . The camming surface  67  and the over center action of the locking lever  34  maintains the locking lever  34  in the downward position, thus holding it in the locked position, while providing a small additional degree of clamping force over the support rail  16 .  
         [0035]    It will be appreciated however, that the open and closed positions could be set at less than 180° apart, depending on the width of the contact portion  88  and the positioning of the boss portion  90  thereon. However, generally at least a 90° range of movement will be required between the open and closed positions, with 180° being more preferred to ensure easy removal of the bracket assembly  18 .  
         [0036]    The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.