Abstract:
A vehicle article carrier adapted for use with outer body surfaces of a vehicle that are curved or non-parallel to one another. The article carrier includes a pair of non-linear slats that are secured in spaced apart relation to one another on the outer body surfaces. A cross bar supporting assembly has a pair of connecting members that support a cross bar at its outermost ends. The connecting members are secured to slider members, and the slider members are adapted to be secured to the slats. The connecting members are secured to the outermost ends of the cross bar and each have bores that enable the outermost ends to be gradually received therewithin as the cross bar is moved along portions of the slats where the distance between the slats decreases, thus effectively shortening the cross bar. Conversely, this coupling enables the length of the cross bar to be effectively lengthened to accommodate increases in the distance between the slats. Each connecting member further includes a slider having a curved face portion which couples to an associated one of the slats and which further helps to prevent jamming of the cross bar as it is moved along the curved or non-parallel slats.

Description:
FIELD OF THE INVENTION 
     The present invention relates to vehicle article carriers. More particularly, the present invention relates to a vehicle article carrier having a cross bar that is capable of being supported from a pair of slats for adjustable movement along the slats, and where the slats are non-linear or are mounted in an slightly non-parallel arrangement on the outer body surface of a vehicle. 
     BACKGROUND OF THE INVENTION 
     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 slats or side rails (i.e. support rails) that are secured to the outer body surface of the vehicle. Usually, the side rails are straight and extend parallel to each other. The side rails are typically secured along a major longitudinal length of the vehicle roof, rear deck lid, or other surface of a vehicle. 
     Usually, at least one cross bar is supported from the two slats or side rails. The cross bar is secured to each support rail by brackets that are rigidly fastened to each end of the cross bar. Each bracket is slidably secured to one of the support rails to allow for adjustable movement of the cross bar along the support rails. 
     Typically, a tap plate extends from each bracket and is disposed within an associated one of the support rails. The tap plate may be threadably engaged with a user actuable, rotatable locking knob or like element that allows the user to effectively lock each end of the cross bar at a desired position along its associated support rail. Thus, the cross bar can be securely positioned as needed to accommodate a variety of articles having many different shapes and dimensions. 
     Current vehicle article racks perform adequately for their intended purpose when both side rails are straight and parallel. However, due to the fixed length of the cross bar, many current vehicle article carrier systems are not suitable for use with support rails that are not spaced parallel to each other. For example, when a cross bar of fixed length is moved along support rails that are not parallel, the support brackets of the cross bar may jam between the support rails as the distance between the support rails decreases. Further, as the cross bar is moved in the direction of increasing distance between the support rails, the support brackets may also jam. 
     Also, current vehicle article carriers are not suitable for use with curved (i.e., bowed) side rails. Specifically, as the cross bar is moved along the curved rails, the cross bar and its associated brackets may become jammed within the side rails at the midpoints of the side rails where the spacing between the side rails is greatest. 
     One system dealing with this problem is disclosed in U.S. Pat. No. 6,279,802, issued Aug. 28, 2001, and assigned to the assignee of the present application, the disclosure of which is hereby incorporated by reference. This system has proven effective for compensating for a degree of non-linearity in the support rails, or non-parallel spacing of the support rails of a vehicle article carrier system. Nevertheless, it would be desirable to provide a vehicle article carrier system that is more specifically intended to accommodate movement of a cross bar along bowed support rails, or along support rails that are non-parallel to one another to a very significant degree. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to a vehicle article carrier having a cross bar support member that is capable of being moved along a pair of supporting rails that are curved (i.e., “bowed”) and/or not parallel to one another. The article carrier is generally comprised of at least two side rails that are adapted to be fixedly secured to an outer body surface of a vehicle, a cross bar, and at least two cross bar support assemblies. The cross bar support assemblies are comprised of a slider and a connecting member. The connecting member secures the cross bar to the slider and the slider is secured to an associated one of the support rails. 
     The cross bar is able to effectively extend and contract in overall length. This is achieved through the use of the connecting member at each end thereof. The connecting members allow end portions of the cross bar to slide into and out of each of the connecting members. For example, as the cross bar is moved to a point where the support rails are spaced closer together, the ends of the cross bar recede within the connecting members. However, as the cross bar is moved along the support rails, as the distance between the support rails is increasing, then the connecting members are able to move apart from one another to effectively lengthen the cross bar. 
     To even better allow the slider to slide along side rails that are curved, each connecting member is pivotably coupled to its associated slider. Each slider further includes a curved side rail contact portion. Thus, as each slider moves along side rails that are bowed outwardly relative to one another, the connecting members pivot and the cross bar effectively lengthens from the connecting members to follow the curve. As the slider moves along side rails that are bowed inwardly to one another, the connecting members pivot and the cross bar outer ends recede within the connecting members to effectively shorten the cross bar and allow the sliders to follow the curvature of the support rails. The curved support rail contact portion allows the slider to easily follow curved support rails without becoming jammed within the support rails. 
     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, while indicating at least one preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein: 
     FIG. 1 is a perspective view of a vehicle including a vehicle article carrier apparatus in accordance with a preferred embodiment of the present invention; 
     FIG. 2 is a perspective view of a cross bar, a portion of a side rail, and a cross bar assembly of the apparatus of FIG. 1; 
     FIG. 3 is an exploded perspective view of the cross bar and the cross bar support assembly of FIG. 2; 
     FIG. 4 is a perspective view of the vehicle and vehicle article carrier apparatus of FIG. 1 with one cross bar disposed at a point where the spacing between slats of the apparatus is the greatest; and 
     FIG. 5 is a perspective view of the vehicle and vehicle article carrier apparatus of FIG. 1 with one cross bar disposed at a point where the spacing between slats of the apparatus is the smallest. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     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. 
     Referring to FIG. 1, there is shown a vehicle article carrier apparatus  10  in accordance with a preferred embodiment of the present invention. The article carrier apparatus  10  is shown installed on an exemplary motor vehicle, illustrated as a pick-up truck  12 . Specifically, the apparatus  10  is shown installed along the bed walls  14  of a truck bed  16 . While FIG. 1 shows the apparatus  10  secured to bed walls  14 , it will be appreciated that the apparatus  10  can just as readily be secured to a roof area or other area of the vehicle  12  with little or no modification to the apparatus  10 . Also, the illustration of the apparatus  10  being installed for use on a pick-up truck is only for illustrative purposes. The apparatus  10  is suitable for use on virtually any form of vehicle (e.g. sport utility vehicle, station wagon, sedan, etc.) where there is a need for curved or bowed support rails to be employed. The apparatus  10  could also be employed (albeit on a smaller scale) with a little or no modification inside a cargo area of a vehicle if desired. 
     The apparatus  10  generally includes a pair of support rails in the form of elongated slats  18  (only one being visible in FIG.  1 ), at least two cross bar support assemblies  20 , and at least one cross bar  22 . It will be appreciated that in many applications two adjustably positionable cross bars will be used, but that one of the cross bars  22  could just as readily comprise a fixed (i.e., non-movable) cross member. For the purpose of discussion and illustration both of the cross bars  22  are adjustable cross bars. 
     Slats  18  are secured to each bed wall  14  such that the slats  18  extend preferably at least a substantial portion of the length of the bed walls  14 . Each cross bar  22  extends between the slats  18  and is secured to the slats  18  by its associated cross bar support assemblies  20 . 
     It will be appreciated that while the slats  18  have been illustrated as slats attached to interior wall surfaces of the bed walls  14  in FIG. 1, the slats  18  may just as easily be formed as slide rails and supported elevationally above the bed walls  14  by suitable support feet at opposite ends thereof. Thus, the teachings of the present invention are not limited only to the use of slats, but also include the use of side rails that are elevationally positioned over a surface. 
     FIGS. 2 and 3, provide a more detailed view of one of the slats  18  and its associated support assemblies  20 . While FIGS. 2 and 3, and the accompanying description, focus on a single support assembly  20  and a single slat  18 , it will be appreciated that the following description applies equally to both of the slats  18  and support assemblies  20  of the apparatus  10 . 
     Each slat  18  includes a bottom wall  24  having one or more spaced apart openings  26 , a first end  28 , a second end  30 , an upper wall  32 , a lower wall  34 , and inwardly turned flanges  36  and  38 . Flanges  36  and  38  extend approximately ninety degrees from the upper wall  32  and the lower wall  34 , respectively, to create upper well  40  and lower well  42 . The wells  40  and  42  help to form a channel  43  along the length of the slat  18 . Slat  18  is secured to the bed wall  14  by way of openings  26  using a plurality of conventional fastening elements such as threaded fasteners (not shown), rivnuts, etc. The first end  28  and second end  30  each include an end cap  44 . End caps  44  may be secured to the first end  28  and the second end  30  in any suitable manner but are preferably secured using suitable threaded fasteners  45  that engage openings  26  via apertures  46  of the end caps  44 . 
     Support assembly  20  comprises a slider  48  and a cross bar connecting member  50 . The slider  48  generally includes an upper portion  52 , a lower portion  54 , a side rail contact portion  56 , and a bore  58  forming a connecting member receipt portion. The upper portion  52  and the lower portion  54  each have vertically aligned apertures  60  for the receipt of a suitable fastening device, such as retaining pin  62 . Connecting member  50  is sized to fit within bore  58  and to be secured within the bore portion  58  by retaining pin  62 . Slider  48  may be made from any suitable material but is preferably manufactured from a polymer of suitable strength and rigidity. 
     Slider  48  is secured to slat  18  by way of tap plate  64 . Tap plate  64  may be made of any suitable material but is preferably made of a metal, and more preferably from steel. The tap plate  64  generally includes a threaded center aperture  66  and two opposing side notches  68 . Tap plate  64  is inserted within the channel  43  and can slide along the length of slat  18  within the wells  40 ,  42 . The tap plate  64  is shaped so as to be convex in its relaxed (i.e. unlocked) position, relative to side wall  24  once installed (i.e., so as to bow away from side wall  24 ). 
     Slider  48  further includes a notched portion  69  having a threaded aperture  70  located within side rail contact portion  56 . Aperture  70  threadably receives a threaded post  72  of a user graspable locking knob  74  which is partially housed in the notched portion  69 . The post  72  extends through, aperture  70  to threadably engage center aperture  66  of the tap plate  64 . Thus, by securing tap plate  64  to the slider  48 , the control knob  74  secures the slider  48  to slat  18 . 
     Actuation of locking knob  74  in a first direction causes tap plate  64  to be drawn towards the side rail contact portion  56  and into contact with flanges  36 ,  38 . This clamps the side rail contact portion  56  against the slat  18  at a given position. In contrast, rotation of control knob  74  in the opposite direction causes tap plate  64  to disengage flanges  36 ,  38  to permit the movement of slider  48 , and thus cross bar  22 , along slat  18 . 
     Slider  48  further comprises a pair of extensions  76 . Each extension  76  forms a boss portion that extends outwardly from the side rail contact portion  56  to engage a respective side notch  68  of tap plate  64 . Extensions  76  prevent the tap plate  64  from rotating during the rotation of locking knob  74 . 
     It will be appreciated that the surface of side rail contact portion  56  is not linear (i.e., not perfectly flat). Rather, the surface of side rail contact portion  56  is rounded or arcuate. This helps to prevent the slider  48  from jamming against slat  18  if slat  18  is curved (i.e., bowed) inwards towards slider  48 . Side rail contact portion  56  is formed with a radius of curvature as needed to ensure that the slider  48  will not jam. In one preferred form the radius of curvature is preferably between 300 cm-400 cm. Slider  48  can also slide along slats  18  that are curved (i.e., bowed) outwardly and away from slider  48  without jamming. 
     Cross bar  22  is secured to its associated support assemblies  20  by connecting members  50 . Each connecting member  50  is an elongated, tubular-like member that can be made of any suitable material, such as a polymer of a suitable strength and rigidity, or from aluminum. The connecting member  50  has a hollow  50   a  to enable receipt of one end of cross bar  22  therein. The connecting member  50  is generally comprised of a first end  78 , a second end  80 , a top portion  82 , and a bottom portion  84 . 
     First end  78  is received by connecting member receipt portion  58  of the slider  48 . First end  78  includes a through hole  86  that is aligned with apertures  60  when the first end  78  is, inserted into connecting member receipt portion  58 . Once aligned, pin  62  is inserted through apertures  60  and through hole  86  to pivotally secure connecting member  50  to the slider  48 . The use of pin  62  allows the connecting member  50 , and associated cross bar  22 , to pivot relative to slider  48 . Further, when the cross bar  22  is not in use, the cross bar  22  and connecting member  50  may be separated from slider  48  by removing the pin  62  from slider  48 . 
     First end  78  further includes a tie-down aperture  88 . Tie-down aperture  88  may be used to further help secure articles to the apparatus  10 . The tie-down aperture  88  may be used with any suitable tie-down device, such as a bungee cord, nylon strap, etc., that help secure articles to the cross bar  22 . 
     Generally located between first end  78  and second end  80  is an aperture  90  for receipt of a locking member  92 . Locking member  92  includes a threaded post  94  that extends through aperture  90  and is held in place by fastener  96 . Threaded post  94  engages a threaded aperture  100  of a cross bar tap plate  98 . Cross bar tap plate  98  is seated within tap plate retainer  102 . Retainer  102  includes curved portions  104  that function as springs to bias tap plate  98  against an inside surface of the cross bar  22 , as will be described momentarily. 
     Referring to FIGS. 1 and 3, cross bar  22  is generally comprised of an elongated tubular, oval shaped (in cross-section) member having a top portion  106 , a bottom portion  108 , a first outer most end  110 , and a second outer most end  112  (FIG.  1 ). In FIG. 3, the top portion  106  has a channel  114  that extends the length of the top portion  106 . The channel  114  is bordered by recessed flanges  116 . A majority of the channel  114  is covered by a rubber bumper  118 . The rubber bumper  118  is seated within the recessed flanges  116 . Rubber bumper  118  does not completely extend to the first end  110  and to the second end  112 , thus leaving portions of the channel  114  exposed at ends  110 and  112 . 
     The areas of channel  114  exposed at first end  110  and at second end  112  are inserted within their respective connecting members  50  so that the exposed portions at each end of the channel  114  are located within the connecting members  50 . Tap plate  98  and retainer  102  are disposed within the channel  114  and curved portions  104  of the tap plate serve to hold the tap plate  98  against the recessed flanges  116 . Threaded post  94  extends through channel  114  into engagement with threaded aperture  100 . 
     When the locking member  92  is rotated in a first direction the tap plate  98  is used to clamp the end  106  of the cross bar  22  to the connecting member  50 . The same action occurs at the opposite end  112  of the cross bar  22 . This secures the cross bar  22  in position and prevents it from sliding inwardly or outwardly relative to the connecting member  50 . When the locking member  92  is rotated in a second direction, the tap plate  98  is loosened, thus allowing the ends  110 , 112  of the cross bar  22  to be drawn out from, or to recede within, their respective connecting members  50  as the cross bar  22  is moved along the non-linear slats  18 . 
     Referring to FIG. 4, the apparatus  10  can be seen where one cross bar  22  is disposed at the point where the spacing between the slats  18  is greatest. In FIG. 5, it can be seen how the apparatus  10  allows for the decreasing distance between the slats  18  by enabling the outermost ends  110 ,  112  of the cross bar to be gradually and increasingly received within their respective connecting members  50 . 
     To further enhance sliding movement of the slider  48  along slats  18  that are curved, sliders  48  can each pivot relative to their respective connecting members  50  as side rail contact portions  56  of the slider  48  move along the slats  18 . Thus, as the sliders  48  move along slats  18  that are concave to each slider  48 , the sliders  48  pivot to follow the curvature of its associated slat  18 . As the sliders  48  move along slats  18  that are convex to the sliders  48 , the outermost ends  110 ,  112  of the cross bar  22  recede within their respective connecting members  50  to follow the curvature of the slats  18 . The curved side rail contact portions  56  also help to allow the sliders  48  to follow curved slats or side rails during positioning of the cross bar  22  without becoming jammed between the slats or side rails. 
     The apparatus  10  thus enables a cross bar to be used with nonparallel or bowed support rails. This significantly enhances the utility of the apparatus  10  by allowing it to be used with a wider variety of vehicle body styles where non-parallel or bowed support rails are employed. Most importantly, the cross bars  22  can be slidably adjustably positioned on the slats  18  as needed without jamming or other like interference. 
     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.