Abstract:
A collapsible cargo carrier for use with a vehicle tow bar receiver, the cargo carrier comprising: a draw bar having a top side and first and second ends, and a pivot frame having a pin coupled therethrough. In one embodiment, the draw bar is coupleable to a vehicle tow bar receiver at the first end, and the draw bar has a first aperture and a keyway through the top side proximate the second end. The pin has a key thereon, wherein the pin and the key are configured to cooperate with the first aperture and the keyway to removeably couple the pivot frame to the draw bar. A method of manufacturing a collapsible cargo carrier is also provided.

Description:
TECHNICAL FIELD OF THE INVENTION  
       [0001]     The present invention is directed, in general, to cargo carriers and, more specifically, to a collapsible cargo carrier for use with a trailer hitch receiver.  
       BACKGROUND OF THE INVENTION  
       [0002]     The need to carry cargo exceeding the within-vehicle capacity has likely been with mankind since the introduction of vehicles. Numerous approaches have been formulated to address this need. With the introduction of the motor vehicle and its considerable horsepower, the opportunity was met to some degree by coupling a trailer to the towing vehicle.  
         [0003]     However, sometimes it is necessary to carry some cargo that does not warrant the use of a separate trailer, although the towing vehicle is equipped with a tow bar receiver. Some approaches to this problem have been specific to the type of cargo, e.g., golf bags, and are therefore not generally adaptable to miscellaneous cargo. Other approaches provide a container within which the miscellaneous cargo can be stowed. These typically also address access to the vehicle trunk through some type of extension mechanism, and are therefore quite complicated. Another approach provides a fixed platform that couples to the tow bar receiver, thereby being a potential storage problem because of its size. Additionally, there is considerable effort today to downsize vehicles to the minimum size suitable for day to day use and conserving gasoline, thus making the transport of cargo a more difficult problem.  
         [0004]     Accordingly, what is needed in the art is a collapsible cargo carrier that removeably couples to a tow bar receiver that does not suffer from the deficiencies of the prior art.  
       SUMMARY OF THE INVENTION  
       [0005]     To address the above-discussed deficiencies of the prior art, the present invention provides a collapsible cargo carrier for use with a vehicle tow bar receiver, the cargo carrier comprising: a draw bar having a top side and first and second ends, and a pivot frame having a pin coupled therethrough. In one embodiment, the draw bar is coupleable to a vehicle tow bar receiver at the first end, and the draw bar has a first aperture and a keyway through the top side proximate the second end. The pin has a key thereon; the pin and the key are configured to cooperate with the first aperture and the keyway to removeably couple the pivot frame to the draw bar. A method of manufacturing a collapsible cargo carrier is also provided.  
         [0006]     The foregoing has outlined preferred and alternative features of the present invention so that those skilled in the art may better understand the detailed description of the invention that follows. Additional features of the invention will be described hereinafter that form the subject of the claims of the invention. Those skilled in the art should appreciate that they can readily use the disclosed conception and specific embodiment as a basis for designing or modifying other structures for carrying out the same purposes of the present invention. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the invention.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0007]     For a more complete understanding of the invention, reference is now made to the following descriptions taken in conjunction with the accompanying drawing, in which:  
         [0008]      FIG. 1  illustrates an isometric view of one embodiment of a collapsible cargo carrier constructed according to the principles of the present invention;  
         [0009]      FIG. 2  illustrates an isometric view of the draw bar of  FIG. 1 ;  
         [0010]      FIG. 3A  illustrates an isometric view of the main frame;  
         [0011]      FIG. 3B  illustrates an isometric view of the pivot frame;  
         [0012]      FIG. 3C  illustrates an isometric view of the primary support members of  FIG. 1 ;  
         [0013]      FIG. 3D  illustrates an isometric view of the second extenders of  FIG. 1 ;  
         [0014]      FIG. 3E  illustrates an isometric view of the first extenders of  FIG. 1 ;  
         [0015]      FIG. 3F  illustrates an isometric view of the end frames of  FIG. 1 ;  
         [0016]      FIG. 3G  illustrates a close up, plan view of one end frame in relation to a first extender;  
         [0017]      FIG. 4  illustrates an isometric view of the collapsible cargo carrier as it is bundled for shipping and for storage; and  
         [0018]      FIG. 5  illustrates a rear isometric view of the collapsible cargo carrier of  FIG. 1  in its fully collapsed form.  
     
    
     DETAILED DESCRIPTION  
       [0019]     Referring initially to  FIG. 1 , illustrated is an isometric view of one embodiment of a collapsible cargo carrier  100  constructed according to the principles of the present invention. The cargo carrier  100  comprises a draw bar  110 , a main frame  121 , a pivot frame  122 , a plurality of first extenders  130 , a plurality of second extenders  140 , and first and second end frames  151 ,  152 . In one embodiment, the draw bar  110  has first and second ends  111 ,  112 , respectively; a draw pin aperture  113 ; a longitudinal axis  114  and a stop block  117 . In a preferred embodiment, the first end  111  is coupleable to a receiver of a towing vehicle (not shown) and secured in place with a draw pin  115  and a security pin  116  that fits through a security pin hole  116   a  in the draw pin  115 . One who is of skill in the art is knowledgeable of how the collapsible cargo carrier  100  is coupled to the receiver of a towing vehicle. In a preferred embodiment, the main frame  121  and the pivot frame  122  are removeably coupleable to the draw bar  110  and perpendicular to the longitudinal axis  114 . The main frame  121  and the pivot frame  122  have first and second opposing ends  123   a ,  123   b ,  124   a ,  124   b , respectively. The collapsible cargo carrier  100  further comprises one or more primary support members  160  and a plurality of flop locks  170 . In the illustrated embodiment, two primary support members  160  are shown. However, one who is of skill in the art will recognize that the number of primary support members  160  may be varied to assure support of a load (not shown) to be carried in the collapsible cargo carrier  100 .  
         [0020]     Referring now to  FIG. 2 , illustrated is an isometric view of the draw bar  110  of  FIG. 1 . In a preferred embodiment, the draw bar  110  comprises 2-inch square aluminum tubing having first and second ends  111 ,  112 , a top wall  211 , a bottom wall  212 , and the stop block  117 . The draw pin aperture  113  is proximate the first end  111 . The draw bar  110  further comprises first, second, third and fourth apertures  201 ,  202 ,  203 ,  204  respectively, through both the top and bottom walls  211 ,  212 , respectively. The fourth aperture  204  is proximate the second end  112  and has a keyway  205  also cut through the top and bottom walls  211 ,  212 . The stop block  117  is welded to the top wall  211  proximate the first end  111  and perpendicular to the longitudinal axis  114 . The inset shows the detail of the fourth aperture  204  and the keyway  205 . In one embodiment, the keyway  205  is offset by an angle α from the longitudinal axis  114 . In one embodiment, the angle a is about 20°. In a preferred embodiment, the angle a is 22.5°.  
         [0021]     Referring now to  FIGS. 3A and 3B , illustrated are isometric views of the main frame  121  and the pivot frame  122 , respectively, of  FIG. 1 . In one embodiment, the main frame  121  and the pivot frame  122  comprise rectangular aluminum tubing. In a preferred embodiment, the main frame  121  and pivot frame  122  comprise 1-inch square, 3/16 inch wall thickness, aluminum tubing having first and second ends  123   a ,  123   b ,  124   a ,  124   b , respectively and a plurality of ball stop apertures  310 . The main frame  121  further comprises a centrally-located, main frame support pin  320 , while the pivot frame  122  further comprises a centrally-located, pivot frame support pin  325 . In a preferred embodiment, the main frame support pin  320  is a smooth, chamfered, aluminum pin of ¾-inch diameter and the pivot frame support pin  321  is a smooth, chamfered, aluminum pin of ¾-inch diameter having a key  322  located thereon proximate a lower end  323  of the pivot frame support pin  321 .  
         [0022]     Referring now to  FIG. 3C , illustrated is an isometric view of the primary support members  160  of  FIG. 1 . In one embodiment, the support members  160  comprise rectangular aluminum tubing. In a preferred embodiment, the primary support members  160  comprise 1-inch square, ⅛-inch wall thickness, aluminum tubing having first and second ends  331 ,  332 , a top wall  333 , a bottom wall  334 , a support member pin  335  and a plurality of ball stop apertures  310 . The support member pin  335  is a smooth, chamfered, aluminum pin of ¾-inch diameter.  
         [0023]     Referring now to  FIG. 3D , illustrated is an isometric view of the second extenders  140  of  FIG. 1 . In one embodiment, the second extenders  140  comprise rectangular aluminum tubing. In a preferred embodiment, the second extenders  140  comprise ¾-inch square, ⅛-inch wall thickness, aluminum tubing having first and second ends  336 ,  337 , a ball stop  315 , and an end cap  340 . The ball stop  315  may be constructed from a ball plunger (see first inset) comprising a ½-inch ball  316  and a spring  317 . Alternatively, a single end, straight spring leg snap button  318  (see second inset) may also be used. The end cap  340  has a ½-inch aperture  341  formed therethrough.  
         [0024]     Referring now to  FIG. 3E , illustrated is an isometric view of the first extenders  130  of  FIG. 1 . In a preferred embodiment, the first extenders  130  may comprise ½-inch round, solid aluminum having first and second ends  338 ,  339 , and a first cross pin  344  and a second cross pin  345 . The second cross pin  345  extends through the second end  339  and is substantially a length of the inside diagonal of the second extender  140 . Each first extender  130  has a slot  342  in the first end  338  with the flop lock  170  held in the slot  342  by a pivot pin  343 . The flop locks  170  may be of a symmetric, oval shape but weighted in one of the long ends as shown in  FIG. 1 , or may be racetrack shape with a pivot hole off-center, creating two portions so that one portion is longer and therefore heavier than the other portion. The first cross pin  344  extends through the first extender  130  at a point approximately ¾ inch from the inboard end of the slot  342 .  
         [0025]     Referring now to  FIG. 3F , illustrated is a close up, plan view of one end frame  151  in relation to a first extender  130 . In a preferred embodiment, the end frames  151 ,  152  comprise ¾-inch square, ⅛-inch wall thickness, aluminum tubing having a plurality of apertures  351  therethrough. The plurality of apertures  351  allow the flop locks  170  and the first end  338  of the first extenders  130  to pass through.  
         [0026]     Referring now to  FIG. 3G , illustrated is a close up plan view of the assembly of one end frame  151 ,  152  to a first extender  130 . The relationship of the flop lock  170 , slot  342 , pivot pin  343 , aperture  351 , and first cross pin  344  is readily seen. The first cross pin  344  keeps the first and second end frames  151 ,  152  trapped proximate the first end  338  of the first extenders  130 .  
         [0027]     Referring now to  FIGS. 3A-3G  as required, assembly of the collapsible cargo carrier  100  will be discussed. Only one collapsible member  130 ,  140  will be discussed for the purposes of simplicity, it being obvious to one who is skilled in the art to repeat the assembly with the analogous parts. The flop lock  170  may be rotated to align with the centerline of the first extender  130  and then inserted into the second end  337  of the second extender  140  until the flop lock  170  passes through the aperture  341  in the second extender end cap  340 . The first extender  130  is prevented from being withdrawn from the second extenders  140  by the end cap  344  that conforms to the interior rectangular cross section of the second extenders  140 . The second end  337  of the second extender  140  as just assembled is inserted into the first end  123   b  of the pivot frame  122  until the ball stop  315  encounters the pivot frame first end  123   b . The ball stop  315  is then depressed and the remainder of the second extender  140  is inserted into the pivot frame  122 .  
         [0028]     Referring now to  FIG. 4 , illustrated is an isometric view of the collapsible cargo carrier  100  as it is bundled for shipping and for storage. The collapsible cargo carrier  100  in this configuration may be conveniently held together with straps  410  around the bundle and secured end to end with hook and pile fasteners  420 . The bundle may then be stowed into a storage bag  430  of similar size to those currently used for folding chairs. The bag  430  may then be closed with drawstrings  440  or zipper (not shown). This entire light weight, bagged assembly may be conveniently stored behind a seat of vehicles and readily assembled at any location when additional cargo space is needed.  
         [0029]     Referring now to  FIGS. 1, 2  and  3 A- 3 F, assembly of the collapsible cargo carrier  100  will now be discussed. The first end  111  of the draw bar  110  is inserted into the vehicle receiver (not shown), a draw pin  115  is inserted through the receiver and through the draw pin aperture  113 . The security pin  116  is then inserted through the aperture  116   a  in the draw pin  115 . The main frame  121  is then placed on the draw bar  110  with main frame support pin  320  inserted into first aperture  201 . The stop block  117  keeps the main frame  121  normal to the draw bar  110 . Two primary support members  160  are placed on the draw bar  110  with support member pins  335  inserted into the second and third apertures  202 ,  203 .  
         [0030]     Pivot frame  122  is placed on the draw bar  110  at the fourth aperture  204  with the pivot frame  122  at an angle so as to align the key  322  of pivot frame support pin  321  with the keyway  205 . With the pivot frame support pin  321  all the way through the fourth aperture  204 , the pivot frame  121  is rotated clockwise to a position substantially normal to the draw bar  110  and substantially parallel to the primary support members  160  and the main frame  121 . This position for the pivot frame  122  causes the key  322  to be below the bottom wall  212  and out of alignment with the keyway  205 , thereby preventing removal of the pivot frame  122 .  
         [0031]     The first and second extenders  130 ,  140  are withdrawn from the main frame  121 , pivot frame  122  and the primary support members  160  until the second cross pins  345  contact the end caps  340  and the ball stops  315  engage the apertures  351 . The flop locks  170  are substantially aligned with the first extenders  130  and inserted through apertures  351  of the end frames  151 ,  152  and released. The flop locks  170 , with the assistance of gravity, lock the end frames  151 ,  152  onto the first extenders  130 . With the end frames  151 ,  152  in place, the pivot frame  122  is prevented from rotating thereby locking all of the parts together. The collapsible cargo carrier  100  is ready for use. If desired, cargo containers may be placed directly in and secured by tie downs to the expandable cargo carrier  100 . A panel (not shown) may be placed within the collapsible cargo carrier  100  and on the primary support members  160 . Cargo containers may then be placed thereon and the cargo secured to the expandable cargo carrier  100  with tie downs (not shown). To break down the collapsible cargo carrier  100 , the above steps are reversed.  
         [0032]     Referring now to  FIG. 5 , illustrated is a rear isometric view of the collapsible cargo carrier  100  of  FIG. 1  in its fully collapsed form. The collapsible cargo carrier  100  may be used in this configuration for reasonably small loads while retaining the opportunity to extend the first and second extenders  130 ,  140  for additional capacity.  
         [0033]     Thus, a collapsible cargo carrier  100  has been described for use with a conventional towing vehicle. The collapsible cargo carrier  100  is conveniently expanded to a size capable of carrying considerable cargo while enabling the breakdown and packaging of the cargo carrier  100  in a reasonably small, lightweight package.  
         [0034]     Although the present invention has been described in detail, those skilled in the art should understand that they can make various changes, substitutions and alterations herein without departing from the spirit and scope of the invention in its broadest form.