Abstract:
A cargo carrier mountable to a hitch receiver of a vehicle includes a lightweight, open-air wire basket supported by a tough metal bracket. The bracket is reversible so that the carrier can be attached to different size hitch receivers. To simplify assembly, the mounting hardware for attaching the basket to the bracket is the same regardless of which size receiver is being used. The holes for the mounting hardware are positioned such that the fasteners can avoid carrying most of the cargo&#39;s weight. If the basket is evenly loaded with cargo, it is possible for the fasteners to carry substantially no weight whatsoever. When not in use, the basket is collapsible to lie generally flat against the bracket so that the cargo carrier can be readily stowed.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The subject invention generally pertains to vehicle-mounted cargo carriers and more particularly to one that can be mounted to the hitch receiver of the vehicle. 
     2. Description of Related Art 
     To rig a vehicle for pulling a trailer, the vehicle can be provided with a standard hitch receiver into which a drawbar can be inserted and pinned in place. The drawbar includes a hitch ball upon which a ball-receiving coupler of the trailer can be set, thereby coupling the trailer to the vehicle. Although hitch receivers can be of almost any imaginable shape and size, they are typically a square tube with a 1.25-inch or 2-inch square opening that can receive a similar sized square shank of a drawbar. 
     Hitch receivers can also be used for supporting an outboard cargo carrier as disclosed in U.S. Pat. Nos. 4,813,584; 5,038,983; 6,513,690 and 6,712,248. In these examples, various brackets are used for coupling the cargo carrier to a hitch receiver. Such brackets, however, might not connect to different size receivers without significant modification or replacement of certain parts. 
     One bracket, disclosed in U.S. Pat. No. 6,604,658, is perhaps the most versatile in that the bracket can be reversed to fit either a 1.25-inch or 2-inch receiver. With that design, however, a different set of mounting hardware is used depending on which end of the bracket is inserted into the receiver. Bushings (16) of the &#39;658 patent, for instance, are used with a 2-inch receiver but not a 1.25-inch receiver. If the unused bushings are misplaced while the bracket is inserted in a 1.25-inch receiver, it might be difficult to later switch over to a 2-inch receiver. Or, if the bracket is only used with a 1.25-inch receiver, the bushings can add unnecessary cost to the unit. Moreover, fastener (50) and pin (54) of the &#39;658 patent are relied upon as actual weight-bearing members rather than used for just holding the other more structural members of the unit together. 
     Consequently, a need exists for a simple, robust cargo carrier that can be readily supported by different size receivers. 
     SUMMARY OF THE INVENTION 
     It is an object of the invention to provide a cargo carrier that can be supported by various size hitch receivers. 
     Another object of some embodiments is to provide a cargo carrier with a wire basket that can collapse generally flat and parallel to a bracket that supports the basket so that the cargo carrier can be readily stowed by hanging the collapsed carrier against a wall. 
     Another object of some embodiments is to provide a cargo carrier whose load can be supported by the main structural members of the carrier rather than having to rely heavily on various fasteners to provide weight-bearing support. 
     Another object of some embodiments is to selectively attach a cargo carrier to either a 2-inch or 1.25-inch receiver without having to add or omit parts of the carrier. 
     Another object of some embodiments is to provide a cargo carrier comprising a lightweight wire basket that creates minimal wind resistance and to provide a mounting plate that solidly supports the weight of the basket. 
     Another object of some embodiments is to provide a bracket that elevates a cargo carrier well above a hitch receiver regardless of which end of the bracket is inserted in the receiver. 
     Another object of some embodiments is to provide a cargo carrier with a reversible bracket that includes a large end and a small end for selectively fitting a large receiver or a small receiver respectively, wherein the bracket&#39;s cross-sectional area along most of its length is similar to the bracket&#39;s small end (rather than its large end) to minimize the bracket&#39;s overall size and weight. 
     One or more of these and/or other objects of the invention are provided a cargo carrier that includes a bracket that can selectively fit different size receivers and do so without having to add or omit parts of the cargo carrier. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a rear perspective view of a vehicle with novel cargo carrier. 
         FIG. 2  is a rear perspective view showing a bracket of the cargo carrier being inserted into a hitch receiver of the vehicle. 
         FIG. 3  is a perspective view of the cargo carrier&#39;s bracket. 
         FIG. 4  is a partial end view of the cargo carrier of  FIGS. 1 and 2 . 
         FIG. 5  is similar to  FIG. 4  but showing an alternate end screen. 
         FIG. 6  is a top view of the cargo carrier of  FIG. 1 . 
         FIG. 7  is a rear view of the cargo carrier of  FIG. 1 . 
         FIG. 8  is an end view of the cargo carrier of  FIG. 1 . 
         FIG. 9  is a cross-sectional view taken along line  9 - 9  of  FIG. 8 . 
         FIG. 10  is a cross-sectional view taken along line  10 - 10  of  FIG. 8 . 
         FIG. 11  is an end view similar to  FIG. 8  but showing the bracket inserted into a smaller hitch receiver. 
         FIG. 12  is a cross-sectional view taken along line  12 - 12  of  FIG. 11 . 
         FIG. 13  is a cross-sectional view taken along line  13 - 13  of  FIG. 11 . 
         FIG. 14  is a cross-sectional view taken along line  14 - 14  of  FIG. 8 . 
         FIG. 15  is a cross-sectional view similar to  FIG. 14  but showing a second embodiment. 
         FIG. 16  is a cross-sectional view similar to  FIG. 14  but showing a third embodiment. 
         FIG. 17  is a cross-sectional view similar to  FIG. 14  but showing a fourth embodiment. 
         FIG. 18  is a cross-sectional view similar to  FIG. 14  but showing a fifth embodiment. 
         FIG. 19  is a cross-sectional view similar to  FIG. 14  but showing a sixth embodiment. 
         FIG. 20  is a cross-sectional view taken along line  20 - 20  of  FIG. 21   
         FIG. 21  is a side view of the large end of a bracket inserted in a large receiver. 
         FIG. 22  is a cross-sectional view taken along line  22 - 22  of  FIG. 23 . 
         FIG. 23  is a side view of the large end of a bracket inserted into a large receiver according to another embodiment. 
         FIG. 24  is an end view similar to  FIG. 11  but showing the cargo carrier removed from the vehicle. 
         FIG. 25  is an end view similar to  FIG. 24  but showing the end screens being removed from the rest of the basket. 
         FIG. 26  is an end view showing the basket being collapsed in a generally flat configuration. 
         FIG. 27  is an end view showing the collapsed basket being hung on a wall-mounted hook. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     A cargo carrier  10 , shown in  FIGS. 1 ,  2 ,  4 ,  6 - 8 ,  11  and  20 - 23  can be reconfigured to mount to at least two different size receivers of a vehicle  12 . Although receivers can be of almost any size and shape, carrier  10  will be described, for sake of example, as being selectively mountable to either a receiver  14  ( FIGS. 11 and 12 ) having a substantially 1.25-inch square opening  16  or a larger receiver  18  ( FIGS. 1 ,  2  and  6 - 9 ) having a substantially 2-inch square opening  20  (1.25 and 2 are nominal values, and their exact dimensions may vary). 
     In a currently preferred embodiment, cargo carrier  10  includes a wire basket  22  comprising a bottom screen  24 , two side screens  26 , and two end screens  28 . Screens  24 ,  26 , and  28  are each primarily constructed of a network of substantially round wires  30 . A spiral wire binder  32  ( FIGS. 7 ,  8  and  22 ) pivotally attaches the lower edge of each side screen  26  to bottom screen  24 . To attach end screens  28  and to provide basket  22  with structural support, narrow rods  34  ( FIGS. 8 and 21 ) extending downward from end screens  28  are inserted into sleeves  36 , which are welded to side screens  26 . A wire clip  38  can be used to help hold end screens  28  in position relative to bottom screen  24 . The assembled basket  22  is a box-like structure that is open at the top for loading and removing cargo. 
     The actual construction of basket  22  may vary.  FIG. 5 , for instance, shows an alternate end screen  40  that includes slots  41  for holding horizontally elongate items such as ski equipment, fishing rods, pipe, lumber, etc. 
     Referring further to  FIG. 3 , a reversible bracket  42  for supporting basket  22  comprises a nominal 1.25-inch square tube  44  that includes a relatively small end  46  adapted to fit within the 1.25-inch receiver  14  and a relatively large end  48  for the 2-inch receiver  18 . Referring to  FIG. 8 , tube  44  is formed such that ends  46  and  48  lay along two spaced-apart lines  50  and  52  that are substantially parallel to each other. While one end  46  or  48  is inserted into receiver  14  or  18 , the other end of bracket  42  is attached to the bottom of basket  22 . A mounting plate  54 , a backup plate  56 , and basket fasteners  58  and  60  help fasten bottom screen  24  to bracket  42 . A hitch fastener  62 , such as a common hitch pin, can help hold the opposite end  46  or  48  of bracket  42  within receiver  14  or  18 . 
     When cargo carrier  10  is mounted to the 2-inch receiver  18 , as shown in FIGS.  1  and  6 - 10 , basket fasteners  60  extend through one or more generally vertical holes  64  (first generally vertical hole) in small end  46  to clamp mounting plate  54  to a first weight bearing surface  66  of end  46 , and basket fastener  58  clamps bottom screen  24  between plates  54  and  56 , thereby fastening basket  22  to small end  46  of bracket  42 . Any number of holes and corresponding fasteners  58  and  60  can be used. Meanwhile, hitch fastener  62  extends through a generally horizontal hole  68  (second generally horizontal hole) in large end  48  and also extends through a generally aligned hole in the 2-inch receiver  18 , thereby fastening large end  48  of bracket  42  to receiver  18 . 
     When cargo carrier  10  is mounted to the 1.25-inch receiver  14 , as shown in  FIGS. 11-13 , basket fasteners  60  extend through one or more generally vertical holes  70  (second generally vertical hole) in large end  48  to clamp mounting plate  54  to a second weight bearing surface  72  of end  48 , and basket fastener  58  clamps bottom screen  24  between plates  54  and  56 , thereby fastening basket  22  to large end  48  of bracket  42 . Again, any number of holes and corresponding fasteners  58  and  60  can be used. At the other end of bracket  42 , hitch fastener  62  extends through a generally horizontal hole  74  (first generally horizontal hole) in small end  46  and also extends through a generally aligned hole in the 1.25-inch receiver  14 , thereby fastening small end  46  of bracket  42  to receiver  14 . 
     Switching bracket  42  between the positions of  FIGS. 8 and 11  involves rotating bracket  42  180 degrees about a horizontal axis  75 , as shown in  FIG. 3 . In either position, weight bearing surfaces  66  and  72  each face vertically but in opposite directions (upward or downward). It should also be noted that regardless of whether bracket  42  is in the 1.25-inch position of  FIG. 11  or in the 2-inch position of  FIG. 8 , cargo carrier  10  uses the same set of hardware (plate  54 , plate  56  and fasteners  58  and  60 ) for fastening basket  22  to bracket  42 . Moreover, the weight of basket  22  and its cargo is primarily carried by main structural members (e.g., mounting plate  54  and bracket  42 ), and fasteners  58  and  60  are primarily used for just holding the main structural members together. 
     There are infinite ways of providing a bracket with a large end that can fit snugly into a nominal 2-inch square opening of a receiver. Some of the better examples include, but are not limited to, the designs shown in  FIGS. 14-23 . 
     In  FIG. 14 , large end  48  is created by welding a spacer such as a ¾″×2″ channel  76  to a 1.25″ square tube  44 . The welded structure, comprising tube  44 , channel  76  and a metal weld bead  78 , defines a square outer periphery  80  that can snugly fit into a nominal 2-inch opening of a receiver, wherein the term, “snugly fit” refers to a longitudinal sliding fit between two parts while the clearance between the two is sufficiently small to limit their relative rotation. Although hole  68  is shown extending only through tube  44 , it would also be well within the scope of the invention to enlarge the hole&#39;s diameter or raise the hole&#39;s position such that hole  68  breaks through an upper surface  82  of tube  44  and cuts into a lower surface  84  of spacer  76 . 
     In  FIG. 15 , a nominal 2-inch large end  48   a  is created by welding ¾″×2″ spacer  86  to a 1.25-inch square tube  44 . 
     In  FIG. 16 , a nominal 2-inch large end  48   b  is created by welding a 1.25-inch square tube  90  inside a 2-inch square tube spacer  88 . In this example, a hole  92  for a hitch pin breaks through an upper surface  94  of tube  90 . As an alternative to breaking through upper surface  94 , tube  90  can be inserted just short of hole  92  so that the hitch pin lies just beyond the end of tube  90  rather than passing through it (similar to  FIGS. 20 and 21 ). 
     In  FIG. 17 , a nominal 2-inch large end  48   c  is created by welding two L-shaped spacers  94  to a 1.25-inch square tube  96 . 
     In  FIG. 18 , a nominal 2-inch large end  48   d  is created by welding two ⅜-inch spacers  98  to the lateral sides of a 1.25-inch square tube  100 . 
     In  FIG. 19 , a nominal 2-inch large end  48   e  is created by welding two ⅜-inch spacers  102  to the upper and lower sides of a 1.25-inch square tube  104 . 
     For the embodiment shown in  FIGS. 20 and 21 , a nominal 2-inch large end  110  is created by welding a 1.25-inch square tube  112  centrally within a 2-inch square tube spacer  114 . A metal weld bead  116  extends completely or partially around tube  112 . In this example, tube  112  is inserted just short of the hitch pin hole so that hitch pin  62  lies just beyond an end  112 ′ of tube  112  rather than passing through tube  112 . 
     Alternatively, a nominal 2-inch large end  118  can be created by welding a 1.25-inch square tube  120  to a bottom or any other surface of a 2-inch square channel spacer  122 . One or more weld beads  124  can be applied at one or both ends and/or along the length of tube  120 . In this example, tube  120  is inserted just short of the hitch pin hole so that hitch pin  62  lies just beyond an end  120 ′ of tube  120 . 
       FIGS. 24-27  show how cargo carrier  10  can be partially disassembled and collapsed to a relatively flat configuration that makes carrier  10  easy to stow.  FIG. 24  shows carrier  10  separated from receiver  14 .  FIG. 25  shows end screens  28  being removed after disengaging clips  38 .  FIG. 26  shows side screens  26  pivoting downward and end screens  28  being tucked between bottom screen  24  and side screens  26 . A clip  106  on one of the side screens can be latched onto bottom screen  24  to hold basket  22  in the relatively flat configuration of  FIG. 27  such that screens  24 ,  26  and  28  are generally parallel to weight bearing surfaces  66  and  72 . Once in the generally flat configuration, cargo carrier  10  can be readily hung on a wall-mounted hook  108 . 
     Although the invention is described with reference to a preferred embodiment, it should be appreciated by those of ordinary skill in the art that various modifications are well within the scope of the invention. The scope of the invention, therefore, is to be determined by reference to the following claims.