Abstract:
A roof rack having movable cross bars that have a low profile when aligned with the side bars, but are raised when generally perpendicular to the side bars. The height variation is achieved using ribs that are provided on a bottom side of the cross bars. When the cross bars are aligned with the side bars, the ribs fit into slots that are provided in the side bars. As a result, each cross bar has a very low profile with respect to the roof of the vehicle. When each cross bar is rotated to a position generally perpendicular to the side bars, the ribs within the cross bar are no longer aligned with the slots in the side bar. Instead, the ribs rest on an upper surface of the side bar, and thus, provide a significant gap between the cross bar and vehicle roof.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The invention is directed to automobile subassemblies or accessories, namely racks placed on the roof of the automobile for securing belongings. 
     2. Description of Related Art 
     Roof racks have been used for years on vehicles to simplify the storage of belongings, including sporting goods, suitcases, and carrying containers. Typical roof racks include a series of side bars that run along the length of the vehicle and cross bars that run across the width of the vehicle. The side bars and cross bars provide support for the belongings being carried and provide points of attachment for ropes and cords used to secure the belongings. 
     To increase vehicle aerodynamics and aesthetics, roof racks have been developed that include cross bars that can be rotated between a first position (typically a position of non-use) that is parallel to the side bars and a second position (typically a use position) that is perpendicular to the side bars. However, within these systems, the height of the cross bars above the vehicle roof does not change when the cross bar is rotated from the first position to the second position. As a result aerodynamics and aesthetics are not maximized. 
     What is desired is a roof rack system with rotatable cross bars wherein when the cross bars are in a stored position, the cross bars have an extremely low profile, and when the cross bars are in a use position, the cross bars are raised and a required minimum clearance is provided between the cross bar and the vehicle roof. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention overcomes deficiencies in the art by providing a roof rack having movable cross bars that have a low profile when aligned with the side bars, but are raised when in a position generally perpendicular to the side bars. The height variation is achieved using ribs that are provided on a bottom side of the cross bars. When the cross bars are aligned with the side bars, the ribs fit into slots that are provided in the side bars. As a result, each cross bar has a very low profile with respect to the roof of the vehicle in this storage position. When each cross bar is rotated or otherwise moved to a position generally perpendicular to the side bars, the ribs within the cross bar are no longer aligned with the slots in the side bar. Instead, the ribs rest on an upper surface of the side bar, and thus, create a significant gap between the cross bar and vehicle roof. 
     Additionally, the roof rack is provided with a plurality of pivot pin/locking mechanisms that lock the cross bar to the side bar when the cross bar is aligned with the side bar. By simply rotating two pivot pin/locking mechanisms until a key on the pivot pin/locking mechanism is no longer in a locking position, but instead a restraining position (aligned with a post on the underside of the side bar) the cross bar can be lifted. By additionally, or alternatively, rotating the pivot pin/locking mechanism until the key is aligned with an aperture protrusion on the side bar, the cross bar, no longer being restrained, can be lifted further such that one or both ends of the cross bar becomes freely removable from the side bar. Typically, one end of each cross bar is removed from the side bar while the second end is unlocked, but kept in a restrained position (key not aligned with protrusion or post) and the first end rotated with the opposite end remaining in contact with the side bar and acts as a pivot point. The pivot pin/locking mechanism on the removed end is then inserted into the vacant spot on the opposite side bar after the second cross bar has been released in a similar manner. After insertion, the pivot pin/locking mechanism is again rotated moving the key to the restrained position, thus, securing the cross bar in a use position. 
     These and other aspects of the invention are herein described in particularized detail with reference to the accompanying figures. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIG. 1  is a side elevational view of a vehicle including a roof rack of the present invention; 
         FIG. 2  is a rear elevational view of the vehicle showing the roof rack in a storage position; 
         FIG. 3  is a perspective view of the vehicle roof showing the roof rack in a storage position; 
         FIG. 4  is a perspective view of the vehicle roof showing the roof rack in a use position; 
         FIG. 5  is an exploded view of a portion of the roof rack showing a cross bar detached from a side bar; 
         FIG. 6  is top view of a portion of the roof rack showing the pivot pin/locking mechanism moving from a locked position to an unlocked, restrained, position; 
         FIG. 7  is a top view of a portion of the roof rack showing the cross bar in a rotated use position; 
         FIG. 8  is a cross-sectional view of a portion of the roof rack showing the cross bar in a storage position; 
         FIG. 9  is a cross-sectional view of a portion of the roof rack showing the pivot pin/locking mechanism in a locked position; and 
         FIG. 10  is a cross-sectional view of a portion of the roof rack showing the pivot pin/locking mechanism in a restrained position. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to the drawings, specifically  FIGS. 1-4 , a preferred roof rack storage system  20  according to the present invention is illustrated on a vehicle  21 . The roof rack system  20  includes first and second side bars  22  and  24 , first and second cross bars  26  and  28  and four pivot pin/locking mechanisms  30 . The cross bars  26  and  28  are rotatable between a storage position that is in line with the side bars  22  and  24  and a use position generally perpendicular to the side bars  22  and  24 . As described in more detail below, the cross bars  26  and  28  can be locked in either position. The invention will be described below, often with regard to only one side bar  22  and one cross bar  26 . However, the second side bar  24  has the same structure as the first side bar  22  and the second cross bar  28 , the same structure as the first cross bar  26 . 
     Referring to  FIGS. 3 ,  4  and  8  the first side bar  22  and second side bar  24  extend lengthwise along the vehicle roof  32 . A gasket  25  is placed between each side bar  22  and  24  and the roof  32  to prevent damage to an outside surface of the roof  32 . The first side bar  22  has a forward end  36 , a rearward end  40  and a top surface  44 . The second side bar  24  has a forward end  38 , a rearward end  42  and a top surface  46 . Referring to  FIGS. 5 and 8 , slots  48  are shown at the rearward end  40  of the first side bar  22 . In a similar manner, slots  48  are provided in the forward end  36  of the first side bar  22  and the forward and rearward ends,  38  and  42 , of the second side bar  24 . Preferably, the side bar  22  is hollow and includes enclosed pockets  50  beneath the slots  48  in the top surface  44 . Six slots  48  are provided and each has a rectangular shape. The slots  48  are arranged in two rows of three slots across the width of the side bar  22 . The slots  48  are oriented lengthwise along the length of the side bar  22 . The sides of the pocket  50  taper inwardly, becoming smaller, as the pocket  50  extends downwardly. 
     An aperture  54  is located between the two rows of slots  48  on each end of each side bar  20  and  22 . The aperture  54  preferably has a keyhole shape. The protruding portion  56  of the keyhole shaped aperture points toward a lengthwise center line running along the vehicle roof  32 . Preferably, the side bars  22  and  24  are rounded at each end to provide an aesthetic appearance. Referring to  FIGS. 8 and 9 , below the upper surface  44  of the side bar  22 , the pockets  50  extend downwardly, approximately two thirds of the thickness of the side bar  22 . A locking post  62  is provided adjacent to the pockets  50  and also extends downwardly from the top of the side bar  22 . The depth of the locking post  62  is approximately equal to the depth of a pocket  50 . 
     Referring back to  FIGS. 3-5 , each cross bar  26  and  28  is a long straight bar of solid material. Each cross bar  26  and  28  has, respectively, a forward end  64  and  66  and a rearward end  68  and  70  as defined when the length of the cross bar  26  and  28  is aligned with the length of the vehicle  21 . The thickness of the cross bar  26  is generally consistent except at the forward end  64  and rearward end  68 . At each end, the thickness is reduced such that a top surface  72  and  74  of each cross bar  26  and  28  is not flat, but instead includes a single step downward. A bottom surface  76  of each cross bar is flat except for a plurality of ribs  60  that protrude therefrom at each end. Preferably six rectangular ribs  60  protrude in two rows of three ribs each. The pattern of ribs  60  matches the pattern of slots  48  within an adjacent side bar when the side bar  22  and cross bar  26  are aligned. A circular aperture  82  is defined in each cross bar  26  and  28  between the two rows of rectangular ribs  60 . Preferably, the length and width of each rib  60  narrows slightly as the rib  60  extends away from the bottom surface  76  of the cross bar  26 . 
     Referring to  FIGS. 5 and 9 , the pivot pin/locking mechanism  30  is shown. The pivot pin/locking mechanism  30  includes a pivot pin  83  having a first end  84  and a second end  86 . The pin  83  passes through the hole  82  in the cross bar. A small rectangular key  87  protrudes radially from the second end  86  of the pin  83 . A handle  88  is affixed to or integrally formed with the first end  84  of the pin  83 . The handle  88  preferably has an oval shape that fills the stepped end of the cross bar  26  when the handle  88  is aligned length wise with the length of the cross bar  26 . The curves of the handle  88  match the curves within the stepped end of the cross bar  26 . 
     Referring to  FIGS. 3-5 , the side bars  22  and  24  are affixed to the roof  32  of a vehicle  21 . The cross bars  26  and  28  are supported by the side bars  22  and  24 . When a side bar  22  is aligned with a cross bar  26 , the cross bar  26  fully covers the top surface  44  of the side bar  22 . Additionally, the ribs  60  within the crossbar  26  fit into the slots  48  within the side bar  22 . As a result, the cross bar  26  has a low profile when viewed from the side of the vehicle. 
     When a side bar  22  is aligned with a cross bar  26  and the ribs  60  within the slots  50 , the cross bar  26  may be locked in position. The handle  88  is rotated into a locking position wherein the handle is aligned with the length of the cross bar  26  and side bar  22 , such that referring to  FIG. 9 , the key  87  of the locking pivot pin/locking mechanism  30  is trapped beneath the post  62 . Thus, the cross bar  26  is prevented from being lifted until the handle  88  is again rotated and the cross bar  26  unlocked. The cross bar  26  cannot be rotated without first lifting the cross bar  26  because the ribs  60  and pockets  50  will interfere with each other. Referring to  FIG. 8 , the cross bar  26  is also shown in a locked configuration. 
     Referring to  FIGS. 5 ,  6 ,  7 ,  9  and  10 , a preferred method of unlocking the pivot pin/locking mechanism  30  and rotating the cross bar  26  is shown. In no particular order, the four handles  88  of the roof rack system  20  are rotated. The handles  88  are rotated, in this case counter clockwise, but may be rotated in either direction. This rotation moves the key  87  out of alignment with the post  62  and allows the cross bar  26  to be lifted. The cross bar  26  is lifted until the ribs  60  within the cross bar exit the pockets  50  within the side bar  22 . If the key  67  is not aligned with the protrusion  56  of the aperture  54  in the side bar, the pivot pin/locking mechanism is in a restrained position. 
     Additionally, one handle  88  in each cross bar  26  is further rotated, either before or after the cross bar  26  is first lifted, such that the key  87  on the pivot pin  82  is aligned with the protrusion  56  in the aperture  54 . If the handle  88  at the forward end  64  of the first cross bar  26  is rotated to this position, the handle  88  at the rearward end  70  of the second cross bar  28  is also rotated to this position. Alternatively, if the handle  88  at the rearward end  68  of the first cross bar  26  is rotated to this unlocked position, the handle  88  at the forward end  66  of the second cross bar  28  is also rotated to this position. The cross bar  26  is then lifted, at this end, up and out of contact with the side bar  22 . On the opposite end of the cross bar, where the key and protrusion are not aligned and the pivot point/locking mechanism remains in the restrained position, upward movement of the cross bar  26  is limited by the key  87  butting up against the side bar  22 . 
     The cross bars  26  and  28  are then rotated until the cross bars  26  and  28  are oriented generally perpendicular to the side bars  22  and  24 . The handle  88 , at the end of the cross bar that was rotated is then moved until the key  67  is aligned with the protrusion of the aperture on the side bar and the key  67  is inserted into the aperture. The handle  88  is then rotated such that the key  67  is moved back to a restraining position, as shown in  FIG. 10 . The cross bars  26  and  28  are now in a use position. The process is reversed in order to place the cross bars back into a storage position. 
     The pivot pin/locking mechanism  30  may simply act as a locking mechanism. In this manner, to change from a storage configuration to a use configuration, all handles  88  are turned to the unlocked position such that the key  67  on the pin  82  is aligned with the protrusion  56  on the aperture  54  in the side bar  22 . Both cross bars  26  and  28  are then simply lifted off of the side bars  22  and  24  (as illustrated in  FIG. 5 ). The cross bars  26  and  28  are then placed across the side bars perpendicularly after the handles  88  are rotated such that the keys  67  are aligned with the protrusions  56  in the apertures  54 . After the cross bars  26  and  28  are in place, the handles  88  are further rotated so the key  67  moves away from the protrusion  56  and into a retaining position, thus, the cross bar  26  is secured to the side bar  22 . 
     More than two side bars may be used in the roof rack. Additional side bars are placed between the first and second side bars. The cross bars do not lock into the additional sidebars, but may be supported by the additional side bars. Preferably, the slots are pockets formed in a hollow side bar. Alternatively, the slots are simple apertures cut into the top of a hollow bar. The slots are shown having a rectangular shape, but may be any shape such as square or oval. The protruding portion of the keyhole shaped aperture may point in any direction, not just toward the lengthwise center line of the vehicle roof. The roof rack may be provided as original equipment on the vehicle or as an after-market accessory. 
     Although the invention has been shown and described with reference to certain preferred and alternate embodiments, the invention is not limited to these specific embodiments. Minor variations and insubstantial differences in the various combinations of materials and methods of application may occur to those of ordinary skill in the art while remaining within the scope of the invention as claimed and equivalents.