Patent Publication Number: US-2007110539-A1

Title: Bed rail system

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
      This application claims priority to U.S. Provisional Patent Application 60/731,136, filed Oct. 28, 2005, which is incorporated by reference in its entirety. 
    
    
     TECHNICAL FIELD  
      The disclosure generally relates to article carrier assemblies for vehicles.  
     BACKGROUND  
      Typically, article carriers for a roof or bed of a vehicle provide some modular components that may allow a user to attach and store articles while permitting flexibility and removeability. Many article carriers include a pair of side bars and one or more cross bars for securing articles to the vehicle. This flexibility may include cross bars that are removable and stowable, but may occupy undesired space when stowed.  
      Currently, many truck beds include a tonneau cover that keeps out dirt and debris while protecting articles within the truck bed. These covers are typically attached to upper portions of the truck bed sides. However, many article carriers have not been incorporated into a tonneau cover attachment portions, and the cross rails of these article carriers may not be stowable so as to position the cross bars out of the way for maximum use of the storage area, such as a truck bed. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      Referring now to the drawings, preferred illustrative embodiments are shown in detail. Although the drawings represent some embodiments, the drawings are not necessarily to scale and certain features may be exaggerated, removed, or partially sectioned to better illustrate and explain the present invention. Further, the embodiments set forth herein are not intended to be exhaustive or otherwise limit or restrict the claims to the precise forms and configurations shown in the drawings and disclosed in the following detailed description.  
       FIG. 1  is a perspective view of a portion of an article carrier assembly, according to an embodiment.  
       FIG. 2  is a perspective view of another portion of the article carrier assembly of  FIG. 1 .  
       FIG. 3  is a top view of a portion of the assembly of  FIG. 1 , taken along line  3  when a portion of the assembly is in an intermediate stowed configuration.  
       FIG. 4  is a top view of a portion of the assembly of  FIG. 1 , taken along line  4 .  
       FIG. 5  is an end view of a portion of the assembly of  FIG. 1 , taken along line  5  of  FIG. 4 .  
       FIG. 6  is an enlarged view of portion  6  of  FIG. 1 .  
       FIG. 7  is an enlarged view of portion  7  of  FIG. 1 .  
       FIG. 8  is an alternative embodiment of the rail of  FIG. 2 .  
       FIG. 9  is a sectional view of the rail of  FIG. 1 .  
       FIG. 10  is an alternative embodiment of the rail of  FIG. 1 .  
       FIG. 11  is a sectional view taken along sectional line  11 - 11  in  FIG. 2 .  
       FIG. 12  is an alternative embodiment of the sectional view of  FIG. 11 . 
    
    
     DETAILED DESCRIPTION  
      Referring now to the drawings, illustrative embodiments are shown in detail. Although the drawings represent the embodiments, the drawings are not necessarily to scale and certain features may be exaggerated to better illustrate and explain an innovative aspect of an embodiment. Further, the embodiments described herein are not intended to be exhaustive or otherwise limit or restrict the invention to the precise form and configuration shown in the drawings and disclosed in the following detailed description.  
       FIGS. 1 and 2 , illustrate an embodiment of an article carrier assembly  20 . The article carrier assembly  20  is secured to and extends between a first vehicle portion, or a first side panel assembly,  22  and a second vehicle portion, or a second side panel assembly,  24  of a truck bed TB of a vehicle VE. The article carrier assembly  20  also includes a first cross rail  26  in a deployed, or extended, operational position (configuration) and a second cross rail  28  in stowed position (configuration). The embodiment of the article carrier assembly  20  shown in the detail of  FIGS. 1-9  includes the first side rail  30  ( FIG. 1 ), the second side rail  32  ( FIG. 2 ), the first cross rail  26 , and the second cross rail  28 . The first side rail  30  and the second side rail  32  are substantially identical, configured to be mounted to either of the panel  22  or the panel  24 , disposed generally along respective longitudinal axes and transversely spaced apart from each other. As will be described below, side rails  30 ,  32  are adapted to support the cross rails  26 ,  28 .  
      The cross rails  26 ,  28  are configured to support articles, such as luggage and the like. In a preferred embodiment, the cross rails  26 ,  28  are made with the use of a lightweight metal, such as 6063-T6 extruded aluminum, to obtain needed strength objectives (i.e., to support articles), while remaining sufficiently light for easy movement. However, any metal, alloys or composites, plastic, polyamide resin and the like with sufficient strength is contemplated. While the embodiment illustrated includes two cross rails  26 ,  28 , it is understood that other embodiments may include a greater or lesser number of cross rails.  
      As best seen in the enlarged sectional view of  FIG. 9 , the side rail  30  includes an elongated base portion  38 , an upper wall  40 , a first side wall  42 , a second side wall  44 , a lower wall  46 , a first top wall portion  48 , and a second top wall portion  50 . The lower wall  46  extends between the base portion  38  and the second side wall  44 . The upper wall  40  extends from the base portion  38  to the first side wall  42 . A first hollow area, or first channel,  60  is defined by surfaces of the base portion  38 , the upper wall  40 , the first side wall  42  the second side wall  44 , and the lower wall  46 . A second hollow area, or second channel,  62  is defined by surfaces of the base portion  38 , the upper wall  40 , the first side wall  42 , first top wall portion  48 , and the second top wall portion  50 .  
      The base portion  38  includes a plurality of mounting apertures  68  ( FIGS. 8 and 9 ) formed therein that permit the side rail  30  to be attached to the side panel  22  of the vehicle VE.  
      In the embodiment of  FIG. 8 , the side rail  30  includes a break-away notch  70 . In the embodiment illustrated, the notch  70  is located at about the mid point M of the side rail  32  in  FIG. 2  to encourage the side rail  30  to break or bend at the beak-away notch  70  during an event, such as a vehicle collision, that would impart a force component in the direction of arrows F and B. Accordingly, the side rails  30 ,  32  may favorably buckle and absorb energy in a crash, while not undesirably transmitting forces to the passenger area of a vehicle, such as the vehicle VE.  
      With general reference to  FIGS. 1 and 2 , the first cross rail  26 , illustrated partially in phantom, extends between a first cross rail end  72  and a second cross rail end  74 . A first securing mechanism  76  is attached to the first cross rail end  72  and a second securing mechanism  78  is attached to the second cross rail end  74 . Similarly, a pair of securing mechanisms such as mechanisms  76 ,  78  are attached at either end of the second cross rail  28 . The channels  60  of each of the first side rail  30  and the second side rail  32  permit gliding movement of the securing mechanisms  76 ,  78  in the direction of the arrows F and B. In the embodiment illustrated, the securing mechanisms  76 ,  78  are identical, although the securing mechanisms  76 ,  78  may incorporate differences.  
      The securing mechanism  76  includes a stanchion  82 , and a wrist member  84  interposed between the stanchion  82  and a first cross rail end. A cross rail end, such as either the first cross rail end  72  or the second cross rail end  74 , is rotatably connected to the wrist member  84  about an axis A-A ( FIG. 5 ) by a retaining portion, or retaining assembly,  88 , and the stanchion  82  is rotatably connected to the wrist member  84  about an axis B-B ( FIGS. 3 and 4 ) by a lock plate assembly  90  ( FIG. 11 ).  
      Each of the first cross rail end  72  and the second cross rail end  74  include a cross rail attachment portion  92  and a wrist engaging end  94 . The wrist engaging end  94  includes a lower surface  96 , a generally opposing upper surface  98 , and a wrist engaging aperture  100  (as best seen in  FIG. 1 ) formed therein that extends generally along the axis A-A from the lower surface  96  to the upper surface  98 .  
      As best seen in  FIG. 6 , the wrist member  84  includes a central body  110 , having a lower tongue  112 , an upper tongue  114 , a first ear  116 , and a second ear  118 . Each of the lower tongue  112  and the upper tongue  114  have an aperture  120  formed therein. The wrist engaging end  94  is interposed between the lower tongue  112  and the upper tongue  114  such that the apertures  120  of the lower tongue  112  and the upper tongue  114  align with the wrist engaging aperture  100 .  
      As best seen in  FIG. 7 , the retaining assembly  88  includes a retaining member  124  having a head  126  and an externally threaded bolt  128 . The retaining assembly  88  also includes an internally threaded retaining clamp  130 . As illustrated, the bolt  128  extends through the apertures  120  of the lower tongue  112  and the upper tongue  114  and the wrist engaging aperture  100 . The retaining clamp  130  may be rotated relative the bolt  128  to move the retaining clamp  130  along the axis A-A relative the bolt  128  from a tightened position, where the wrist engaging end  94  is bindingly secured between the lower tongue  112  and the upper tongue  114  such that the wrist portion  84  will not readily rotate relative to the cross rail  26 , to an loosened position, where the wrist portion  84  is permitted to rotate relative to the cross rail  26 .  
      Accordingly, when the retaining assembly  88  is in the loosened position, the cross rail  26  will rotate about the axis A-A relative to the side rail  30 . Additionally, when retaining assembly  88  is in the tightened position, the cross rail  26  will not readily rotate about the axis A-A relative to the side rail  30 . In the embodiment illustrated, the retaining clamp  130  is an internally threaded ‘wing nut’ having flared portions that permit a user to hand-tighten the retaining assembly  88 , however, any suitable component may be used, including a lever and the like.  
      As best seen in  FIGS. 3, 4 , and  6 , the stanchion  82  includes a stanchion base  140 , having a pair of stanchion lugs  142  extending therefrom, with each stanchion lug  142  terminating in a stanchion bushing  144 . The stanchion base  140  further includes a mounting aperture  146  formed therein ( FIG. 11 ). Each of the stanchion bushings  144  has a stanchion aperture  150  formed therein with each stanchion aperture generally defining a portion of the axis B-B. Each of the first ear  116  and the second ear  118  have an ear aperture  152  formed therein, also generally defining a portion of the axis B-B. The stanchion bushings  144  are interposed between the first ear  116  and the second ear  118  such that the ear apertures  152  and the stanchion aperture  150  are aligned. A stanchion pin  160  is interposed through the ear apertures  152  and the stanchion aperture  150  to permit the wrist portion  84  to rotate relative to the stanchion  82  generally about the axis B-B.  
      As best illustrated in the embodiment of  FIG. 9 , the lock plate assembly  90  includes an externally threaded rod  170  extending from a manipulation wheel  172  and a lock plate  176 . The lock plate  176  includes an internally threaded aperture  178  that matingly engages the threaded rod  170 . The manipulation wheel  172  may be rotated such that the lock plate  176  is urged toward the manipulation wheel  172 , thereby bindingly securing the stanchion base  140  to the side rail  30 . Additionally, the manipulation wheel  172  may be rotated such that the lock plate  176  is urged away from the manipulation wheel  172 , thereby permitting the stanchion base  140  and the side rail  30  to have a gap (not shown) therebetween.  
      As illustrated, the stanchion  82  of the securing mechanism  76  is attached to the cross rail  26  by the lock plate assembly  90  while a portion of the lock plate assembly  90  is guidingly retained within the channel  60  of the side rail  30  so as to permit the stanchion  82  to be moved in the directions of the arrows F and B.  
      In the stowed position of a cross rail, such as the position of the cross rail  28  as illustrated in  FIG. 1 , the cross rail  28  extends in the general direction of the arrows F and B (parallel to the axis B-B), while in the deployed position of a cross rail, such as the position of the cross rail  26  as illustrated in  FIGS. 1 and 2 , the cross rail  26  extends perpendicular to the general direction of the arrows F and B (perpendicular to the axis B-B).  
      In operation, a plurality of stanchions  82  with wrist members  84  pivotally attached thereto may be attached to each of the side rails  30 ,  32  with locking plate assemblies  90 , as described herein. A cross rail, such as the cross rail  26 , may be then attached to one of the wrist members  84  that is attached to the first side rail  30  such that the first cross rail end  72  is attached adjacent to the first side rail  30 . Then the second cross rail end  74 , may be then attached to one of the wrist members  84  that is attached to the second side rail  32  such that the second cross rail end  74  is attached adjacent to the second side rail  32 . Thus attached, the cross rail  26  will extend from the first side rail  30  toward the second side rail  32  generally perpendicular to the axis B-B. The cross rail (or a plurality of cross rails similarly deployed) may be used to secure articles, or to provide a base for supporting articles.  
      When a user desires to stow a cross rail that is deployed, that is, when a user desires to reconfigure a cross rail from the deployed position of the cross rail  26  of  FIGS. 1 and 2  to the stowed position of the cross rail  28  of  FIG. 1 , the following steps may be performed. First, the retaining assemblies  88  of the securing mechanisms  76 ,  78  are loosened such that the bolt  128  is removed from the apertures  120  of the lower tongue  112  and the upper tongue  114  of the second securing mechanism  78 , and the cross rail is permitted to rotate relative to the wrist member  84  of the first securing mechanism  76 . The cross rail is then rotated about the A-A axis of the first securing mechanism  76  (which is attached to the first side rail  30 ) as at least one of the stanchions  82  coupled to the first side rail  30  is slid in a direction generally parallel to the axis B-B until the wrist engaging aperture  100  of the securing mechanism that is attached to the first side rail  30  is aligned with the apertures  120  of the lower tongue  112  and the upper tongue  114  adjacent the second cross rail end  74 . The bolt  128  is then inserted into the apertures  120  of the lower tongue  112  and the upper tongue  114  adjacent the second cross rail end  74  and the wrist engaging aperture  100  that the bolt was just previously removed from and the retaining clamp  130  is tightened so as to secure the cross rail to the wrist member  84  (as best illustrated in the intermediate stowed configuration of  FIG. 3 ). The cross rail is then permitted to rotate about the axis B-B from the position partially illustrated in  FIG. 3  to the position partially illustrated in  FIG. 6 . This rotation of the cross rail about the axis B-B from the position partially illustrated in  FIG. 3  to the position partially illustrated in  FIG. 6  will permit the cross rail to at least partially swing out of the way in order to permit the user to utilize a greater amount of width between the side rails  30 ,  32 .  
      The length of the cross rails  26 ,  28  may correspond to the span between the side rails  30 ,  32  that can be achieved either by matching the span by a one-piece cross rail lengthwise or by providing a telescopic cross rail that may be adjusted to span between side rails  30 ,  32 . The option with telescopic cross rails makes it possible to stow more than one cross rail along one side rail. 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).  
       FIG. 10  illustrates an alternative embodiment of the side rail  30  as a side rail  230 . The side rail  230  includes an elongated base portion  238 , an upper wall  240 , a first side wall  242 , a second side wall  244 , a lower wall  246  a, first top wall portion  248 , and a second top wall portion  250 . The lower wall  246  extends between the base portion  238  and the second side wall  244 . The upper wall  240  extends from the base portion  238  to the first side wall  242 . A first hollow area, or first channel,  260  is defined by surfaces of the base portion  238 , the upper wall  240 , the first side wall  242  the second side wall  244 , and the lower wall  246 . A second hollow area, or second channel,  262  is defined by surfaces of the base portion  238 , the upper wall  240 , the first side wall  242 , first top wall portion  248 , and the second top wall portion  250 .  
      The base portion  238  includes a plurality of mounting apertures  268  formed therein that permit the side rail  230  to be attached to the side panel  22  of the vehicle VE. Base portion  238  has a raised portion  270 .  
       FIG. 12  illustrates a sectional view of the side rail  32  having a tonneau cover attachment portion  300  attached thereto. As illustrated, the tonneau cover  300  secures a tonneau cover  302  to the side rail  32 . Similarly, an additional tonneau cover attachment portion  300  may be attached to the side rail  30  for stretching the tonneau cover  302  between the side rails  30 ,  32  to cover articles within truck bed TB.  
      While the assembly  20  is illustrated in the bed of a truck, the assembly  20  is not so limited and may be located in other areas of a vehicle, such on a roof, or within the interior of a vehicle. Additionally, while the first cross rail  26  is illustrated in a deployed position as being generally perpendicular to the first side rail  30  and the second side rail  32 , the first cross rail  26  may be in a deployed position where the first cross rail  26  not perpendicular to the first side rail  30  or the second side rail  32 . Furthermore, the cross rails  26 ,  28  may be used for securing articles when in the stowed configuration or in the intermediate configuration.  
      The preceding description has been presented only to illustrate and describe exemplary embodiments of the methods and systems of the present invention. It is not intended to be exhaustive or to limit the invention to any precise form disclosed. It will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. The invention may be practiced otherwise than is specifically explained and illustrated without departing from its spirit or scope. The scope of the invention is limited solely by the following claims.