Abstract:
An article carrier assembly for attachment to a vehicle roof panel comprises two siderails and at least one cross-rail releasably stowed on one of the siderails. Attachment of the cross-rail to the siderails is carried out with the use of latching mechanisms. The mechanism is composed of a stanchion mounted on the cross-rail, with a lever pivotally placed therein, and of a lock plate assembly slidably attached to the siderail. For deployment of the assembly, the stanchion is put on the lock plate assembly which becomes engaged therewith upon turning the lever. The structure of the mechanism contributes to preventing the roof panel from being damaged upon the deployment.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Technical Field  
         [0002]     The present invention relates generally to article carrier assemblies for attachment to a vehicle roof panel with improved styling and functionality, and, more particularly, to the assemblies making use of stowable or removable cross-rails. Even more particularly, the invention relates to the assembly with removable stowable cross-rails and a latching mechanism for the assembly.  
         [0003]     2. Description of the Related Art  
         [0004]     Typical vehicle article carrier assemblies include a pair of siderails mounted to a vehicle roof panel with at least one cross-rail extending therebetween. Retainers on opposing ends of the cross-rail attach the cross-rail to the siderails. The retainers are usually secured to the siderails by latches or other such mechanisms. The retainers, cross-rails and latches, however, create design problems in that such components may be bulky, and it is difficult to combine trim styling with sufficient strength for supporting an article on the carrier assembly. This leads to disadvantages.  
         [0005]     One disadvantage of conventional designs is that the cross-rails create wind noise when the vehicle is driven. Buzz, squeak, and rattle (BSR), as well as noise, vibration and harshness (NVH) associated with the article carrier assembly are inevitable when the article carrier assembly is being used, due to the article itself. Nonetheless, the wind noise is undesirable, especially when the article carrier assembly is not being used. In addition, the cross-rails increase vehicle drag. Finally, it is difficult to provide cross-rails in the form of a trim rail for styling purposes without sacrificing structural integrity. Accordingly, the styling suffers.  
         [0006]     One approach taken in the art to address some of the shortcomings described above involves providing removable cross-rails. In this approach, the cross-rails are removable, and may be stored, for example, in the vehicle owner&#39;s garage or the like when not in use. However, a significant shortcoming of this approach is that the cross-rails are not always with the vehicle. Therefore, on those occasions where use of the article carrier assembly arises unexpectedly, the article carrier assembly cannot be used because the removable cross-rails are not stored with the vehicle.  
         [0007]     Also known in the art are engineering solutions that overcome the above-identified disadvantage. Cross-rails are provided that are stowed in corresponding siderails when they are not needed. This approach reduces both BSR and NVH associated with the article carrier assembly. Such an approach also minimizes vehicle drag. In addition, a fully functional article carrier assembly is self-contained. That is, the cross-rails are always with the vehicle, even when the carrier assembly is not in use. Also, improved styling is accomplished inasmuch as the article carrier assembly, when the cross-rails are stowed, conveys the look of stand-alone siderails.  
         [0008]     This solution, however, is relatively cumbersome, and the use of its locking mechanism is fraught with potential damage of the roof surface during operation. There is therefore a need to provide an article carrier assembly with a locking mechanism that while keeping advantages of the prior art would reduce or eliminate the shortcomings set forth above.  
       SUMMARY OF THE INVENTION  
       [0009]     One object of the present invention is to provide an article carrier assembly that has a ready-to-transform-for-use structure and reduces or eliminates wind noise and vehicle drag when not in use while presenting stylishly.  
         [0010]     Another object of the present invention is to provide an article carrier assembly that, when being deployed, prevents the vehicle roof from damage.  
         [0011]     The present invention achieves these and other objects, and overcomes the above-referenced shortcomings of conventional article carrier by providing an assembly of siderails and cross-rails, and a latching mechanism therefor, the cross-rails being stowed in corresponding siderails when unneeded. The concept of a stowable system suggested in the present invention allows latching mechanisms, as a whole, not to travel with the cross-rails during operation. Rather, they stay partially attached to the siderails. Therefore, the advantage of using a stowable system can be realized without the concern for the damage of the roof. As prior art designs used mechanisms that travel with the cross-rails, which resulted in the locking feature hanging from the bottom of the stanchion and potentially damaging the roof surface during operation, the latching mechanism according to the present invention uses a lock plate assembly with a stud remaining in the siderail during the stowing or deployment of the cross-rails. The stud has a ball on the end that is used to aid in clamping. The lever/stanchion is dropped over the ball stud and engages therewith when latched. The lock plate assembly with the ball allows the cross-rails to be releasably attached to the siderails and to be removed while the lock plate stays in the siderails. In its entirety, the assembly advantageously protects the vehicle roof from damage when it is being deployed. The assembly also reduces both BSR and NVH associated with the article carrier and minimizes vehicle drag. A fully functional assembly is self-contained, that is the cross-rails can always be with the vehicle, even when the assembly is not in use. Additionally, the present invention provides for improved styling inasmuch as the article carrier assembly, when the cross-rails are stowed, conveys the look of stand-alone siderails. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]     The above objects and other objects, features and advantages of the present invention will be readily apparent from the following detailed description of the best mode of carrying out the invention when read in connection with the accompanying drawings, in which like reference characters refer to like parts throughout the views, and in which:  
         [0013]      FIG. 1  is a perspective view of an article carrier assembly in accordance with the present invention, showing a pair of cross-rails in a stowed position;  
         [0014]      FIG. 2  is a perspective view of the article carrier assembly of  FIG. 1  showing the cross-rails in a partially deployed position;  
         [0015]      FIG. 3  is a perspective view of the article carrier assembly of  FIG. 1  showing the cross-rails in a fully deployed position;  
         [0016]      FIG. 4  is a cross-section view approximately along line  4 - 4  of  FIG. 1  showing a latching mechanism locked onto a siderail;  
         [0017]      FIG. 5  is a perspective view of a lock plate assembly and a lever of the latching mechanism;  
         [0018]      FIG. 6A  is a cross-section view approximately along line  6 A- 6 A of  FIG. 2  showing the latching mechanism in an unlocked position, whereas  FIGS. 6B-6D  schematically illustrate the latching mechanism successively changing through partially locked positions ( FIGS. 6B, 6C ) to a locked one ( FIG. 6D );  
         [0019]      FIG. 7  shows a perspective view of a stanchion of the latching mechanism as viewed from the top thereof; and  
         [0020]      FIG. 8  shows a perspective view of a stanchion of the latching mechanism as viewed from the bottom thereof.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0021]      FIGS. 1-3  show a partial, perspective view of an article carrier assembly  10  according to the present invention. It is secured to a vehicle roof panel  12  and depicted in its stowed position ( FIG. 1 ), in a partially deployed position ( FIG. 2 ) and in a fully deployed position ( FIG. 3 ). The embodiment of the article carrier assembly  10  shown in  FIGS. 1-3  comprises a first siderail  14 , a second siderail  16 , a first cross-rail  18 , a second cross-rail  20 , and four identical latching mechanisms generally designated by a reference number  22 . A body of each of the latching mechanisms  22  is attached to a respective cross-rail, two mechanisms being assigned to each of the cross-rails. The first and second siderails  14 ,  16  are made substantially identical, configured to be mounted to the vehicle roof panel  12 , disposed generally along respective longitudinal axes designated L 1  and L 2 , and transversely spaced apart from each other. As will be described below, siderails  14 ,  16  are adapted to stow and support cross-rails  18 ,  20 . Each of the first and second siderails  14  and  16  is provided with a track, described in greater detail below, for allowing slidable movement of the latching mechanisms  22  along the siderails.  
         [0022]     The cross-rails  18 ,  20  are configured to support articles, such as luggage and the like. In a preferred embodiment, the cross-rails  18 ,  20  are made with the use of a lightweight metal, such as aluminum, to obtain needed strength objectives (i.e., to support articles), while remaining sufficiently light for easy movement. While the embodiments illustrated in  FIGS. 1-3  include two cross-rails  18 ,  20 , it is understood that other embodiments of the present invention may include a greater or lesser number of cross-rails.  
         [0023]     Referring now to  FIG. 4 , which is a cross-section of a portion of the article carrier assembly  10  taken substantially along lines  4 - 4  in  FIG. 1 , the siderail  14  ( 16 ) comprises an L-shaped elongated base portion  24  and an elongated track  26  rigidly fixed within the base portion  24 . It is by the base portion  24  that the siderail  14  ( 16 ) is attached to the roof panel  12  of the vehicle. The track  26  is shaped into a tube of a substantially rectangular profile in a preferred embodiment. It has an upper wall  28 , side walls  30 ,  32 , and a lower wall  34 , the walls in their aggregation defining a hollow  36 . The upper wall  28  is cut lengthwise, edges  38 ,  40  of the cut being bent inwardly and forming a slot  42  therebetween that longitudinally extends through the wall  28 . Whereas the track  26  is made preferably of metal, the base portion  24  can be produced with the use of plastic and/or metal.  
         [0024]     The latching mechanism  22 , which is shown in  FIG. 4  locked onto the siderail  14  ( 16 ), comprises a first member including the body having a stanchion  44  with a lever  46 , as well as a second member including a lock plate assembly  48 . The first member of the mechanism  22  is associated with the cross-rail, whereas the second member of the mechanism  22  is slidably retained within the siderail. The lever  46  best shown in  FIG. 5  is an L-shape element. It has a handle  50  and a base portion  52 , and is provided with pin holes  54  and  54 ′ and a cam pocket  56  made therein. The lever  46  is placed into a lever pocket  58  of the stanchion  44  and pivotally secured to the latter by means of pins  60  visible in  FIG. 1  and passing from the opposite sides of the stanchion  44  through pin holes  62  and  62 ′ of the stanchion  44  and the pin holes  54  and  54 ′ of the lever  46 .  
         [0025]     The lock plate assembly  48  includes a lock plate  64  and a ball stud  66 . The assembly  48  sits in the hollow  36  of the track  26 , with the ball stud  66  projecting therefrom through the slot  42 . The lock plate assembly  48  fulfils the role of a connecting element between the siderail ( 14 ,  16 ) and the body of the latching mechanism  22 , the edges  38 ,  40  of the upper wall  28  of the track  26  acting as stops for the lock plate  64  in the upward-directed movement thereof. It is due to the slot  42  that the assembly  48  (and the locking mechanism  22 ) is slidable longitudinally along axes L 1  and L 2 . The distance l that the assembly  48  can travel vertically between the locked and unlocked positions of the latching mechanism  22  is preferably between 2 and 5 mm, and it is in balance with the difference between the distance a and distance b in  FIG. 5 . The ball stud  66  includes a cylindrical bottom portion  68 , a cylindrical central portion  70 , and a ball-shaped top portion  72 . Respectively, the cam pocket  56  is shaped into a cylindrical channel  74  with an opening  76  and a cut-out  78 . The opening  76  in a bottom  80  of the base portion  52  is made fit for the ball top portion  72 , whereas a cut-out  78  defined by side walls  82  of the base portion  52  is made wide enough to let the central portion  70  of the ball stud  66  pass therethrough and narrow enough not to let the ball top portion  72  of the ball stud  66  pass therethrough.  
         [0026]     As best shown in  FIGS. 7 and 8 , the stanchion  44  of the latching mechanism  22  is composed of a bottom wall  84  and a side wall  86 , preferably U-shaped, defining the lever pocket  58 . There is an orifice  88  made in the bottom wall  84  and symmetrically located with regard to the side wall  86 . The orifice  88  is substantially coaxial with the opening  74  of the lever  46  in the respective position thereof, and it is made large enough to unobtrusively let the ball stud  66  pass therethrough. A connection between the latching mechanism  22  and the cross-rails  18 ,  20  can be realized through the use of any conventional means. In the embodiment under consideration, the connection is made by means of an extension  90  of the bottom wall  84  of the stanchion  22 , to which extension  90  the cross-rail ( 18 ,  20 ) can be attached by bolts, screws; welded, or affixed by any other conventional means. The bottom wall  84  and the extension  90  of the stanchion  22  may be provided with a pad  92  of rubber or plastic to protect the roof panel  12  of the vehicle. In view of the connection between the siderail and lock plate assembly discussed in the above, on one hand, and the connection between the stanchion and the cross-rail, on the other hand, a connection between the siderails  14 ,  16  and cross-rails  18 ,  20  can thus be established with the use of the latching mechanism  22 .  
         [0027]     In the starting position of the article carrier assembly according to the present invention illustrated in  FIG. 1 , the cross-rails  18 ,  20  are stowed onto the siderails  14 ,  16 , respectively, affixed thereto by latching mechanisms  22 , which are in the position best shown in  FIG. 4 . The lock plate assembly  48  of each of the latching mechanisms  22  is its uppermost position, the lock plate  64  meeting the edges  38 ,  40  and the top portion  72  of the ball stud  66  being engaged by the walls  82  of the lever base portion  52 .  
         [0028]     In operation, the lever  46  of one of the latching mechanisms  22 , taken by the handle  50 , is rotated around the pin  60  approximately 90° up (back, toward the plane of the drawing from the position shown in  FIG. 4 ) to disengage the ball stud  66  and the stanchion  44 . Unrestricted anymore by the walls  82 , the lock plate assembly  48  drops down to the lower wall  34  of the track  26 . As a result of the disengagement, the cross-rail and the siderail at this point of connection thereof become disengageable. Similarly released from the siderail at the opposite side thereof, the cross-rail can now be lifted, rotated, placed transversely with regard to the siderails  14 ,  16  and affixed to the siderails, the deployment with the lock plate assembly in the opposite siderail being realized in the order reverse to that discussed in the above. The succession of positions illustrating locking the cross-rail onto the siderail in the course of deploying the carrier is shown in  FIGS. 6A-6D  in greater detail (with portions thereof omitted for clarity). Specifically, the stanchion  44 /lever  46  assembly is placed over the ball top portion  72  of the ball stud  66 . The lever  46  is being rotated down to engage the ball  72  on the stud  66 . The lever then “cams” on the stanchion  44  being turned through approximately 90° and thus raises the lock plate  64  of the lock plate assembly  48  two to five mm to lock onto the siderail.  
         [0029]     The length of the cross-rail has to correspond to the span between the siderails that can be achieved either by matching the span by a one-piece cross-rail lengthwise or by making shorter cross-rails telescopic. The option with shorter cross-rails makes it possible to stow more than one cross-rail along one siderail. It is also appreciated that having cross-rails longitudinally slidable, to thus provide adjustability for the cross-rails, has the advantage of reducing the cost of the article carrier assembly. In addition, such an arrangement stimulates the end user to properly load the article carrier assembly (i.e., starting from the forward portion of the carrier assembly).  
         [0030]     While it is the best mode for carrying out the invention that has been described in detail hereinabove, it is to be understood that this embodiment is given by example only and not in a limiting sense and those familiar with the art to which this invention pertains will recognize various alternative designs and embodiments for practicing the invention without departing from the spirit and scope of the present contribution to the art. For example, as it was briefly mentioned in the above, there can be one cross-rail or more than two cross-rails in the assembly according to the present invention. The whole assembly with one cross-rail in the deployed position may have a U-shape, H-shape, or N-shape in the top view thereof, whereas the assembly with more than two cross-rails may require telescopic cross-rails to be of a lesser length for the stowing position and of a bigger length to span the space between the siderails for the deployment. Accordingly, it is to be realized that the patent protection sought and to be afforded hereby shall be deemed to extend to the subject matter claimed and all equivalence thereof fairly within the scope of the invention.