Patent Publication Number: US-2006000860-A1

Title: Rack mount assembly for vehicle roof racks

Description:
FIELD OF THE INVENTION  
      The invention relates generally to roof racks for vehicles and, more particularly, to rack mount assemblies for vehicle roof racks.  
     BACKGROUND  
      Many vehicles come equipped with a roof rack for carrying luggage or various other items, such as skis, snowboards, bicycles, canoes, fishing poles, boxes, containers, and ladders. These items generally must be secured to the roof rack to prevent them from falling off while the vehicle is in motion. For this purpose, a typical roof rack has a pair of spatially separated front and rear crossbars. Each crossbar extends laterally across the top of the vehicle, and items carried on the roof rack can be tied down or clamped to one or both of these crossbars.  
      To assist in securing certain items to roof racks, industry has produced various accessories. Many roof rack accessories are specialized for securing a specific type of item to a roof rack. For example, special locking arms can be attached to the top of the front and rear crossbars for clamping skis and snowboards against the crossbars. However, even with the aid of accessories, securing items to a roof rack can be made difficult by a vehicle&#39;s height. Vans, minivans, and sports utility vehicles (SUVs) are examples of such vehicles with high roofs. The heights of some roofs are greater than an average person&#39;s height. Often a person will need to open a vehicle door and stand on its threshold to reach the roof rack and to secure an item thereto. Then, the person stands awkwardly while lifting the item over his or her head to place it on the roof rack. The roof height of such vehicles, therefore, can make it inconvenient and potentially unsafe to place items on such roof racks. Even for vehicles with lower roof heights, the central regions of the roof rack can still be difficult to reach.  
     SUMMARY  
      In one aspect, the invention features a rack-mount assembly for attaching to a crossbar of a roof rack of a vehicle. The rack-mount assembly includes a rack bar having a substantially planar portion and a downward portion extending at an angle from one end of the planar portion. An attachment assembly is connected at the other end of the planar portion for attaching the rack bar to the crossbar of the roof rack. The planar portion of the rack mount extends above and parallel to the crossbar and the downward portion extends downward along a side of the vehicle when the attachment assembly is attached to the crossbar.  
      In another aspect, the invention features a rack-mount assembly for attaching to a crossbar of a roof rack of a vehicle. The rack-mount assembly includes a rack bar having a substantially planar portion and a downward portion extending at an angle from one end of the planar portion. A roof rack accessory, mounted to a top surface of the rack bar, is for holding a portion of an item to be carried on the roof rack. An attachment assembly, connected at the other end of the planar portion, is for attaching the rack bar to the crossbar of the roof rack. When the attachment assembly is attached to the crossbar, the planar portion of the rack bar extends above and parallel to the crossbar and the downward portion extends downward along a side of the vehicle.  
      In still another aspect, the invention features a roof rack for a vehicle. The roof rack includes spatially separated first and second crossbars, a first rack mount assembly attached to the first crossbar, and a second rack mount assembly attached to the second crossbar. The first rack mount assembly includes a first rack bar with a substantially planar portion and a downward portion extending at an angle from one end of the planar first portion. A first attachment assembly, connected at the other end of the planar portion, attaches the first rack bar to the first crossbar of the vehicle such that the planar portion of the first rack bar extends above and parallel to the first crossbar and the downward portion extends downwards along a portion of a side of the vehicle. A first rack accessory is mounted to a top surface of the first rack bar, for holding a portion of an item on the roof rack. The second rack mount assembly includes a second rack bar with a substantially planar portion and a downward portion extending at an angle from one end of the planar portion. A second attachment assembly, connected at the other end of the planar portion, attaching the second rack bar to the second crossbar of the vehicle such that the planar portion of the second rack bar extends above and parallel to the second crossbar and the downward portion extends downwards along a portion of the side of the vehicle. A second rack accessory is mounted to a top surface of the second rack bar, for holding a portion of an item on the roof rack. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      The above and further advantages of this invention may be better understood by referring to the following description in conjunction with the accompanying drawings, in which like numerals indicate like structural elements and features in various figures. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.  
       FIG. 1A  is a side view of an embodiment of a rack mount of the present invention.  
       FIG. 1B  is a top view of the rack mount of  FIG. 1A .  
       FIG. 1C  is an end view of the rack mount of  FIG. 1A .  
       FIG. 2  is a side view of another embodiment of a rack mount of the present invention.  
       FIG. 3A  is a view of the rack mount attached to a roof rack of a vehicle by a single attachment assembly.  
       FIG. 3B  is a view of the rack mount attached to a roof rack of a vehicle using a plurality of attachment assemblies.  
       FIG. 4A  is a side view of a rack-mount assembly with a plurality of clamps attached to a top surface of the rack mount of  FIG. 1A .  
       FIG. 4B  is a top view of the rack-mount assembly of  FIG. 4A .  
       FIG. 4C  is an end view of the rack-mount assembly of  FIG. 4A .  
       FIG. 5A  is a side view of a rack-mount assembly with plurality of tubes attached to the top surface of the rack mount of  FIG. 1A .  
       FIG. 5B  is a side view of the tubes attached to the top surface of the rack mount.  
       FIG. 5C  is an end view of the rack mount with the tubes attached to the top surface.  
       FIG. 6  is a view of the rack mount assemblies of  FIG. 4A  and  FIG. 5A  attached to a roof rack of a vehicle. 
    
    
     DETAILED DESCRIPTION  
      The invention features a rack-mount assembly that, in effect, extends the mounting structure of a roof rack to one side of the vehicle and lowers the mounting structure along that side for easier reach. Use of the invention is particularly advantageous for vehicles with high roofs, although the rack-mount assembly can be used on vehicles of any height. Customized embodiments of the rack-mount assembly of the invention can be made for attachment to any type of roof rack and for purposes of carrying a variety of items, for example, skis, snowboards, and fishing poles, to the roof rack. In brief overview, each rack-mount assembly includes a rack bar having a planar portion that is attached at one end to a crossbar of the roof rack. The other end of the planar portion may partially extend over one side of the vehicle when the rack bar is secured to the crossbar. A downward portion extends from this other end of the planar portion, downwardly, along a side of the vehicle. This downward portion provides a mounting structure within closer reach than the top of the roof rack. A roof rack accessory mounted on the top surface of this downward portion permits persons to mount and carry items on the roof rack along the side of the vehicle.  
      Referring to  FIGS. 1A-1C , shown is an embodiment of a rack mount  2  having a rack bar  6  and an attachment assembly  10  fastened to one end of the rack bar  6 . In this embodiment, the rack bar  6  extends generally perpendicularly to the attachment assembly  10 . The rack bar  6  includes a substantially planar portion  14 , a downward portion  18  extending from one end of the planar portion  14  at an angle  22 , a top surface  26 , and a bottom surface  30 . In one embodiment, the rack bar  6  is a one-piece anodized aluminum bar. Other materials, such as stainless steel and plastic, can be used to construct the rack bar  6 . The attachment assembly  10  is attached to the bottom surface  30  of the rack bar  6  at the other end of the planar portion  14 . The particular location of the attachment assembly  10  along the rack bar  6  can vary without departing from the principles of the invention. A protective covering  34  (e.g., a rubber cap) covers a free end of the downward portion  18  to mitigate injuring anyone who may inadvertently come into contact with an installed rack mount.  
      The attachment assembly  10  includes top and bottom plates  38 ′,  38 ″ (generally, plate  38 ). Each plate  38  has a flat region  42  on each side of a shallow channel region  46 . The channel region  46  of each plate  38  can be coated with an elastomeric material (e.g., rubber). Fasteners  50  secure the rack bar  6  to the attachment assembly  10 . The fasteners  50  extend through aligned openings in the planar portion  14  and corresponding openings in the top plate  38 ′ of the attachment assembly  10 . Preferably, the fasteners  50  are threaded hex screws and the corresponding openings threaded to receive them. Plates  38  can be made of metal or plastic.  
      To secure the attachment assembly  10  to a crossbar of a roof rack, the top plate  38 ′ is placed on top of and perpendicular to the crossbar, with the channel region  46  of the top plate  38 ′ straddling the crossbar. The lower plate  38 ″ is placed beneath the crossbar in alignment with the top plate  38 ′. Fasteners  54  passing through openings in the flat regions  42  join the plates  38  together and the joined plates  38  clamp the crossbar in between. Preferably, the fasteners  54  are threaded hex screws and the corresponding openings in the flat regions  42  are threaded to receive them. Alternatively, these openings are non-threaded through-holes, and the fasteners  54  are nut-and-bolt assemblies (e.g., wing nuts, locknuts). The length of the fasteners  54  used to clamp the plates  38  can vary based on the thickness of the crossbar. The fasteners  54  are tightened so that the rack mount  2  does not slide laterally, forward, or backward when attached to the crossbar. The elastomeric coating of the plates  38  can prevent the rack mount  2  from scratching the crossbar.  
      Other means can be used to attach the rack bar  6  to the crossbar without departing from the principles of the invention. For example, fasteners can be used to directly connect the rack bar  6  to the crossbar. Such an embodiment may require modifications to a standard roof rack crossbar. In contrast, an advantage of the attachment assembly  10  is that no modifications of the crossbar are necessary. Further, the attachment assembly  10  enables the rack mount  2  to be easily removed from and installed on the roof rack of one vehicle as desired.  
       FIGS. 1A-1C  also show exemplary dimensions of one embodiment of the rack mount  2  of the invention. In this embodiment, the angle  22  is approximately 30 degrees (measured from an axis  58  defined by the top surface  26  of the planar portion  14 ). Also, the planar and downward portions  14 ,  18  are approximately ¼ inch thick, 2 inches in width, and 8 inches and 4 inches, respectively, in length. The attachment assembly  10  is approximately 1.5 inches in width and 5.25 inches in length. The degree of the angle  22 , the dimensions of the planar and downward portions  14 ,  18 , and dimensions of the attachment assembly  10  can vary according to the various types of vehicles and crossbars, which have various thicknesses and widths, to which embodiments of the rack mount  2  can be attached.  
       FIG. 2  shows another embodiment of a rack mount  2 ′. The structural features of this embodiment are, in general, similar to those of the rack mount  2  of  FIGS. 1A-1C , with the exception of the downward portion  18 ′. Here, the downward portion  18 ′ of this embodiment is curved rather than straight, and the angle  22 ′, which, in one embodiment, is approximately 30 degrees, is measured between the axis  58  and a tangent  58 ′ to the downward portion  18 ′.  
      Referring to  FIG. 3A , when the rack mount  2  is secured to a crossbar  80  of a roof rack of a vehicle  84 , the rack bar  6  sits above the crossbar  80 . The planar portion  14  of the rack bar  6  extends parallel to the crossbar  80  to one side of the vehicle  84 . The attachment assembly  10  of the rack mount  2  is mounted near one side of the vehicle  84  so that the downward portion  18  can extend downwards alongside the vehicle  84 . The downward portion  18  does not interfere with opening a vehicle door.  
      As described further below, a variety of items or objects, heavy or light, can be secured to the rack mount  2 . Referring to  FIG. 3B , for heavy items, i.e., those items weighing approximately 20 pounds or more, a second attachment assembly  10 ′ can be used to secure the rack mount  2  to the crossbar  80 . In one embodiment, the second attachment assembly  10 ′ is spatially separated from the first attachment assembly  10  by approximately one inch.  
      Referring to  FIGS. 4A-4C , shown is an embodiment of a rack-mount assembly  100  having the rack mount  2  with a plurality of roof rack accessories  104  mounted to the top surface  26  thereof. In this example, the roof rack accessories  104  are clamps (hereafter clamps  104 ). Clamps  104  are one example of a type of rack accessory  104  that can be mounted on the rack mount  2  of the invention. Here, the clamps  104  are injection-molded plastic padded clamps for holding a fishing rod, such as the UY190 fishing rod holder produced by United Yachting Manufacturing of Milford, Mich. As shown, one clamp  104  is mounted on the downward portion  18  and a pair of clamps  104  is mounted on the planar portion  14 . Each clamp  104  is attached to the rack mount  2  by a plurality of fasteners  108  (e.g., 8/32 hex cap screws).  FIGS. 4A-4C  also show exemplary dimensions of the clamps  104  and spacing between the clamps  104  on the planar portion  14 . Although only one type of clamp is shown in this embodiment, other embodiments of the rack-mount assembly  100  can have different types of roof rack accessories mounted on the same rack mount  2 . Also, although three clamps  104  are shown, as few as one clamp (or more than three clamps) can be used to practice the principles of the invention.  
      Referring to  FIGS. 5A-5C , shown is another embodiment of a rack-mount assembly  150  including the rack mount  2  with a plurality of roof-rack accessories  152  mounted to the top surface  26  thereof. Here, the roof-rack accessories  152  are tubes. These tubes  152  are another example of a type of roof-rack accessory that can be mounted on the rack mount  2  of the invention. Here, the tubes  152  are standard injection-molded poly-tubes, such as the Model ETH-1 rod holders produced by Fentress Marine of Largo, Fla. As shown, one tube  152  is mounted on the downward portion  18  and a pair of tubes  152  is mounted on the planar portion  14 . Each tube  152  is attached to the rack mount  2  by a plurality of fasteners  154  (e.g., flat head 10-24 screws).  FIGS. 5A-5C  also show exemplary dimensions of the tubes  152 . Although three tubes  152  are shown, as few as one tube or more than three tubes can be used to practice the principles of the invention.  
      An advantage of the present invention is that different types of roof-rack accessories can be used to produce customized rack-mount assemblies. A user can then mix and match different rack-mount assemblies to customize a roof rack according to personal preferences. Further, the rack-mount assemblies can be mounted and removed on an as-needed basis without having to modify the existing roof rack on the vehicle. For example,  FIG. 6  shows a customized roof rack  200  in which the rack-mount assembly  100  of  FIGS. 4A-4C  is attached to a front crossbar  204  of a vehicle  208  and the rack-mount assembly  150  of  FIG. 5A-5C  is attached to a rear crossbar  212  of the vehicle  208 . The pair of rack-mount assemblies  100 ,  150  provides a mounting structure near one side of the vehicle. The rack-mount assemblies  100 ,  150  are attached to the respective crossbars  204 ,  212  at approximately the same location so that each clamp  104  of the rack-mount assembly  100  aligns with one of the tubes  152  of the rack-mount assembly  150 . A fishing rod can be secured to the roof rack by each aligned pairing of a clamp  104  and a tube  152 . The same or different rack-mount assemblies can be secured to the other ends of the crossbars  204 ,  212  on the other side of the vehicle  208  for holding additional items. With the rack-mount assemblies  100 ,  150  attached near one or both sides of the roof rack, another advantage of the present invention is that the central portion of the roof rack can still be used to carry additional items, such as a travel box.  
      While the invention has been shown and described with reference to specific preferred embodiments, it should be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention as defined by the following claims.