Abstract:
A storage rack assembly in kit form is particularly adapted for use on a vehicle and includes a small number of different types of components to simplify shipping, assembly and installation by a purchaser. The storage rack includes side, front and back generally flat panels connected together to form a generally rectangular structure. Opposed side panels are connected to opposed ends of plural elongated cross members which are arranged in a spaced manner along the length of the rectangular structure and are aligned in a common plane to form a flat support bed in the storage rack. Plural telescoping support/mounting members are each connected to a respective cross member to allow for varying the storage rack&#39;s width depending on vehicle size and are adapted for secure attachment to the vehicle. Incorporating additional interfitting side panels and cross members allows for increasing the storage rack&#39;s length.

Description:
FIELD OF THE INVENTION 
     The present invention relates generally to storage containers and is particularly directed to an adjustable storage rack assembly for mounting to the roof of a vehicle for holding virtually any type of cargo item such as bales of hay on a horse trailer. 
     BACKGROUND OF THE INVENTION 
     Storage racks for vehicles such as cars, trucks and trailers are frequently mounted to the vehicle&#39;s roof and are designed to carry various cargo items. These types of storage racks are typically comprised of high-strength, metal components which are welded together to form a large, unitary structure of fixed dimensions. The storage rack is typically secured to the roof, or upper portion, of the vehicle by weldments or mounting brackets and nut and bolt combinations. The typical roof storage rack is comprised of large components, is of considerable weight, and is cumbersome to pack and ship. Because of its fixed dimensions and mounting arrangement, the typical vehicle storage rack is not adapted for use with vehicles having a range of sizes and roof dimensions. 
     The present invention addresses the aforementioned limitations of prior art vehicle storage racks by providing a storage rack assembly in kit form which is easily shipped, assembled and installed by a purchaser. The inventive vehicle storage rack assembly may be adjusted in all three dimensions, i.e., length, width and height above the vehicle, to accommodate various vehicle sizes and roof configurations and dimensions, as well as large cargo items. 
     OBJECTS AND SUMMARY OF THE INVENTION 
     Accordingly, it is an object of the present invention to provide a roof storage rack assembly for a vehicle, such as an automobile, a truck, or a trailer, which is particularly adapted for manufacture and sale in kit form and is easily assembled and installed. 
     It is another object of the present invention to provide a roof cargo rack for a vehicle which is adjustable in height, width and length to accommodate a wide range of vehicle and vehicle roof sizes and shapes. 
     A further object of the present invention is to provide a lightweight, high-strength roof storage rack which is comprised of small components which are easily shipped, assembled and installed on a vehicle, and easily removed from the vehicle, by a purchaser. 
     A still further object of the present invention is to provide an improved rack for a vehicle which is particularly adapted for carrying hay and other heavy, oversized cargo on the roof of the vehicle, such as a truck or trailer for hauling horses. 
     The present invention contemplates a storage rack assembly for a vehicle comprising at least one each of a forward panel and an aft panel; at least one each of a first side panel and a second, opposed side panel, wherein the forward and aft panels are adapted for coupling to respective forward and aft end portions of the first and second side panels in forming a generally rectangular frame; plural elongated, linear members arranged in a spaced, parallel manner between the forward and aft panels and connected at opposed ends to the first and second side panels; and plural mounting members adjustable in length and attached to at least some of the elongated, linear members for attaching the storage rack assembly to lateral portions of the vehicle and allowing the width of the storage rack assembly to be varied, as desired. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The appended claims set forth those novel features which characterize the invention. However, the invention itself, as well as further objects and advantages thereof, will best be understood by reference to the following detailed description of a preferred embodiment taken in conjunction with the accompanying drawings, where like reference characters identify like elements throughout the various figures, in which: 
         FIG. 1  is a partially exploded perspective view of a storage rack assembly mounted to an upper portion of a vehicle in accordance with one embodiment of the present invention; 
         FIG. 1   a  is an enlarged perspective view of a portion of the storage rack assembly shown in  FIG. 1 ; 
         FIG. 2  is an exploded perspective view of the mounting assembly for securely attaching a storage rack to an upper portion of a vehicle in accordance with the present invention; 
         FIG. 2   a  is an enlarged perspective view showing additional details of a portion of the storage rack mounting assembly illustrated in  FIG. 2 ; 
         FIG. 2   b  is an enlarged perspective view of a portion of a support/mounting member for use in securely mounting a storage rack to an upper portion of a vehicle in accordance with the present invention; 
         FIG. 2   c  is a perspective view of an end portion of a mounting strip used in securely mounting a storage rack to an upper portion of a vehicle in accordance with the present invention; 
         FIG. 3  is an exploded perspective view of a storage rack in accordance with the present invention; 
         FIGS. 3   a  and  3   b  are enlarged perspective views of two portions of the storage rack shown in  FIG. 3  illustrating additional details of the connections between various storage rack components; 
         FIG. 4  is an upper perspective view of the inventive storage rack assembly mounted to an upper portion of a trailer; 
         FIG. 5  is a partially exploded perspective view of a storage rack and a storage rack extension assembly in accordance with another embodiment of the present invention; and 
         FIG. 6  is an upper perspective view of the extended storage rack assembly shown in  FIG. 5  mounted to an upper portion of a trailer. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to  FIG. 1 , there is shown a partially exploded perspective view of a storage rack assembly  10  mounted to an upper portion of a vehicle  22  in accordance with one embodiment of the present invention.  FIG. 1   a  is an enlarged perspective view of a portion of the storage rack assembly  10  shown in  FIG. 1  illustrating additional details of the structure and coupling between components of the storage rack assembly. Referring to  FIG. 2 , there is shown an exploded perspective view of a mounting assembly  14  attached to an upper portion of the vehicle  22  in accordance with the present invention.  FIGS. 2   a  and  2   b  are enlarged perspective views of portions of the mounting assembly  14  shown in  FIG. 2  illustrating additional details of the structure and connection between various components in the storage rack mounting assembly. Referring to  FIG. 3 , there is shown an exploded perspective view of a storage rack  12  in accordance with the present invention.  FIGS. 3   a  and  3   b  are enlarged perspective views of portions of the storage rack  12  shown in  FIG. 3  illustrating additional details of the structure and coupling between components in the inventive storage rack.  FIG. 4  is an upper perspective view of the inventive storage rack assembly mounted to an upper portion of a trailer. With reference to  FIG. 5 , there is shown a partially exploded perspective view of a combination of a storage rack  102  and storage rack extension assembly  114  in accordance with another embodiment of the present invention.  FIG. 6  is an upper perspective view of the extended storage rack shown in  FIG. 5  mounted to an upper portion of a trailer. 
     Storage rack assembly  10  includes storage rack  12  and mounting assembly  14 . Storage rack  12  is adapted for securely supporting and holding virtually any object sized so as to fit within the storage rack. Storage rack assembly  10  was designed for use on a horse trailer for transporting bales of hay and for providing a multi-purpose cargo storage space. However, the storage rack assembly  10  of the present invention is not limited to use on a horse trailer, as it could be used on virtually any type of vehicle, as shown for trailer  22  in  FIGS. 1 and 2 , for transporting virtually any type of cargo. 
     Storage rack  12  is comprised of left and right lateral panels  16   a  and  16   b  and front and aft panels  18   a  and  18   b . The terms “left” and “right” are used with trailer  22  viewed from the rear looking forward. Lateral panels  16   a ,  16   b  and front and aft panels  18   a ,  18   b  form a generally rectangular structure open at its top and bottom. Front and aft panels  18   a  and  18   b  each include a flange on their opposed ends. Thus, as shown in  FIGS. 3 and 4 , front panel  18   a  includes end flange  82  on one end thereof, with the front panel&#39;s other end flange not shown for simplicity. Aft panel  18   b  similarly includes first and second end flanges  80   a  and  80   b  each disposed on an opposed end of the panel. Each of these end flanges  80   a ,  80   b  includes a pair of spaced apertures, as shown for the case of the second end flange  80   b  as including spaced apertures  81   a  and  81   b . Opposed ends of the left and right lateral panels  16   a ,  16   b  are similarly provided with a pair of spaced apertures  83   a  and  83   b  as shown for the case of the right lateral panel  16   b  in  FIG. 3   a . With apertures  81   a  and  81   b  in aft panel  18   b  respectively aligned with apertures  83   a  and  83   b  in right lateral panel  16   b , a first connecting pin  86   a  may be inserted through aligned apertures  81   a  and  83   a  and a second connecting pin  86   b  may be inserted through aligned apertures  81   b  and  83   b  as shown in  FIGS. 3 and 3   a . Nylon locking nuts  88   a  and  88   b  are then respectively attached to the first connecting pin  86   a  and to the second connecting pin  86   b  for securely attaching adjacent ends of aft panel  18   b  and right lateral panel  16   b . It is in this manner that adjacent ends of the front and aft panels  18   a ,  18   b  and the left and right lateral panels  16   a ,  16   b  may be securely connected together to form a generally rectangular, rigid structure. Each of the left and right lateral panels  16   a ,  16   b  and the front and aft panels  18   a ,  18   b  is preferably comprised of a high strength, lightweight material, such as sheet steel, aluminum, or polyethylene. 
     Disposed in a spaced manner in a lower portion of the storage rack  12  are plural elongated, linear cross support members  20 . Each of the cross support members  20  is preferably in the form of a hollow tube and is comprised of a high strength, lightweight material such as sheet steel, aluminum or polyethylene. Disposed on a lower, inner edge of each of the left and right lateral panels  16   a ,  16   b  is a respective flange  24   a  and  24   b . As shown in  FIG. 3   b  for flange  24   a  in left lateral panel  16   a , each of the lower edge flanges includes plural spaced apertures  26  along the length thereof. Each of the apertures  26  within the lower, inner edge flanges  24   a  and  24   b  of the left and right lateral panels  16   a ,  16   b  is adapted to receive an end of a cross support member  20  as shown in  FIGS. 1   a  and  3   b . More specifically, as shown in  FIG. 3   b , by moving cross support members  20  in the direction of arrow  94 , the ends of each of the cross support members may be positioned within a respective one of apertures  26 . By inserting opposed ends of each of the cross support members  20  in corresponding, aligned apertures within a lower, inner edge flange of the left and right lateral panels  16   a  and  16   b , the cross support members may be securely and fixedly maintained in position within a lower portion of the storage rack  12  for securely supporting cargo disposed therein. While each of the apertures  26  is shown as being generally square in shape and each of the cross support members  20  is shown as having a generally square cross section, the cross support members are not limited to this cross sectional shape and may have virtually any cross sectional shape provided that the apertures within the lower, inner flanges of the right and left lateral panels  16   a ,  16   b  have a corresponding shape and dimensions. 
     The storage rack&#39;s mounting assembly  14  includes forward and aft support/mounting members  32  and  34  as well as first and second mounting strips, where only the first mounting strip  36  is shown in  FIGS. 1 ,  2 ,  2   a  and  2   c  as element  36  and the second mounting strip is shown in  FIG. 4  as element  37 . Each of the forward and aft support/mounting members  32  and  34  is comprised of three connected members. Thus, forward support/mounting member  32  includes first and second curved support braces  44   a  and  44   b  and an intermediate connecting member  46  disposed between and connecting the two curved support braces. Each of the first and second curved support braces  44   a ,  44   b  is tubular in construction as is connecting member  46 . Connecting member  46  is adapted for sliding positioning within each of the first and second curved support braces as shown for the second curved support brace  44   b  in  FIG. 2   b . Connecting member  46  is provided with plural spaced apertures  46   a  along the length thereof. Similarly, the inner ends of each of the first and second support braces  44   a ,  44   b  is provided with a pair of opposed, aligned apertures, where one of these apertures is shown as element  56  in the second curved support brace in  FIG. 2   b . Apertures  56  in the second curved support brace  44   b  when aligned with one of the apertures  46   a  within the connecting member  46  are adapted to receive a coupling pin  48   b  inserted through the aligned apertures. A nylon lock nut  58   b  is positioned on one end of the coupling pin  48   b  for securely maintaining the coupling pin within the telescoping second curved support brace  44   b  and connecting member  46 . A similar arrangement is disposed on a second, opposed portion of the connecting member  46 , where one of its spaced apertures  46   a , when aligned with a pair of aligned apertures in the first curved support brace (which is not shown in  FIG. 2   b  for simplicity), is adapted to receive coupling pin  48   a  for securely maintaining the coupling pin in connection with the first curved support brace as shown in  FIG. 1   a . A second nylon lock nut  50   a  is adapted for positioning on an end of coupling pin  48   a  for securely maintaining connection between the connecting member  46  and the first curved support brace  44   a . By telescopically inserting connecting member  46  within each of the first and second curved support braces  44   a  and  44   b , the length of the forward support/mounting member  32  may be adjusted in accordance with the width of trailer  22  to permit the storage rack assembly  10  to be securely mounted to vehicles of various widths. The aft support/mounting member  34  is similarly provided with third and fourth curved support braces  45   a  and  45   b  as well as connecting member  52  and coupling pins  54   a  and  54   b  to allow the length of the aft support/mounting member to be varied to accommodate a wide range of vehicle widths. 
     Each of the forward and aft support/mounting members  32 ,  34  is securely attached to an upper, lateral portion of trailer  22  by means of the aforementioned first and second mounting strips  36  and  37 . Each of the forward and aft support/mounting members  32 ,  34 , as well as the aforementioned mounting strips, is comprised of a rigid, high-strength material such as steel, aluminum or polyethylene. The first mounting strip  36  will now be described in detail, it being understood that the second mounting strip  37  is similarly sized and configured to perform the same function as the first mounting strip. 
     Mounting strip  36  is of the double T-slot type, having first and second opposed T-slots  36   a  and  36   b  in opposed lateral portions thereof as shown in  FIG. 2   c . Each of the first and second T-slots  36   a ,  36   b  is adapted to receive in a tight-fitting, sliding manner the head of a bolt so as to prevent rotation of the bolt when a coupling nut is threadably positioned on the bolt. Thus, the second T-slot  36   b  is adapted to receive in a sliding manner first and second mounting pins  58   a  and  58   b  which are inserted through respective apertures  60   a  and  60   b  in the vehicle&#39;s side panel  22   a . With the heads of each of the mounting pins  58   a  and  58   b  tightly positioned within second T-slot  36   b  of mounting strip  36 , nuts (which are not shown in the figures for simplicity) may be tightened on the first and second mounting pins to securely position mounting strip  36  on the outer surface of the vehicle&#39;s side panel  22   a  in a fixed manner. Similarly, the heads of first and second threaded coupling pins  64   a  and  64   b  are tightly positioned within the mounting strip&#39;s first T-slot  36   a  and the threaded shafts of these coupling pins are inserted through respective apertures in first and second L-shaped brackets  62   a  and  62   b . The first and second L-shaped brackets  62   a ,  62   b  are positioned in alignment and in closely-spaced relation with the second curved support brace  44   b . The distal end of the second curved support brace  44   b  is provided with a pair of aligned apertures, where only one of the apertures shown as element  70  is illustrated in  FIG. 2   a . With the second curved support brace  44   b  disposed between the first and second L-shaped brackets  62   a ,  62   b , and with apertures  70  aligned with corresponding apertures in the first and second L-shaped brackets, a third coupling pin  68  may be inserted through the aligned apertures for securely connecting the second curved brace to the trailer  22  by means of mounting strip  36 . First and second threaded coupling pins  64   a  and  64   b  are respectively adapted to receive first and second nylon lock nuts  66   a  and  66   b  for securely connecting the two L-shaped brackets to mounting strip  36 . Similarly, the third coupling pin  68  is adapted to receive a third nylon lock nut  72  for securely connecting the second curved support brace  44   b  to the first and second L-shaped brackets  62   a ,  62   b  and to mounting strip  36 . A similar mounting arrangement  74  is provided on a forward end of the mounting strip  36  for securely attaching the mounting strip to the trailer&#39;s side panel  22   a  along the entire length of the mounting strip as shown in  FIG. 2 . A similar mounting arrangement is provided for the second mounting strip  37  attached to the opposed side panel  22   d  of the trailer  22  as shown in  FIG. 4 . 
     Storage rack  12  is securely attached to mounting assembly  14  by means of four U-shaped threaded couplers  38   a - 38   d . First and second U-shaped threaded couplers  38   a  and  38   d  are positioned upon and engage a first cross member  20   a  disposed in the storage rack  12 . Third and fourth U-shaped threaded couplers  38   b  and  38   c  are positioned upon and engage a second cross member  20   b . First and second U-bolt brackets  40   a  and  40   d  are positioned in contact with a lower surface of the forward support/mounting member  32  and are respectively attached to the first and second U-shaped threaded couplers  38   a ,  38   d  by means of a respective pair of first and second nylon locking nuts  42   a  and  42   b . Similarly, third and fourth U-bolt brackets  40   b  and  40   c  are positioned in contact with a lower surface of the aft support/mounting member  34  and are respectively attached to the third and fourth U-shaped threaded couplers  38   b  and  38   c  by means of respective pairs of first and second nylon locking nuts  42   a  and  42   b . It is in this manner that the storage rack  12  is securely attached to the forward and aft support/mounting members  32 ,  34 . 
     Referring to  FIG. 5 , there is shown a partially exploded perspective view of an extended storage rack  100  in accordance with another embodiment of the present invention. Extended storage rack  100  includes the original storage rack  102  which includes first and second lateral panels  104   a  and  104   b , as well as an aft panel  106 . Plural first cross support members  108  extend between and are connected to the first and second lateral panels  104   a  and  104   b  as in the previously-described embodiment. Extended storage rack  100  further includes an extension assembly  114  which includes third and fourth lateral panels  116   a  and  116   b  connected by means of a forward panel  118  as previously described. Plural second cross support members  120  are attached in a spaced manner between the third and fourth lateral panels  116   a ,  116   b.    
     Extension assembly  114  is connected to the original storage rack  102  by means of first and second extension mounting brackets  122   a  and  122   b . Each of the first and second extension mounting brackets  122   a ,  122   b  include plural spaced apertures  128  as shown in the second extension mounting bracket. Adjacent ends of the first and second lateral panels  104   a  and  104   b  of the original storage rack  102  are provided with a pair of spaced apertures as shown for the case of apertures  130   a  and  130   b  in the first lateral panel. Similarly, adjacent distal ends of the extension assembly&#39;s third and fourth lateral panels  116   a  and  116   b  are each provided with a pair of spaced apertures, as shown for the case of apertures  132   a  and  132   b  in the third lateral panel. Extension assembly  114  is attached to the original storage rack  102  by positioning distal ends of the first and second lateral panels  104   a  and  104   b  respectively in contact with the distal ends of the third and fourth lateral panels  116   a ,  116   b . The first extension mounting bracket  122   a  is positioned over the inner surfaces of adjacent ends of the first and third lateral panels  104   a  and  116   a  which are in abutting contact. Similarly, a second extension mounting bracket  122   b  is positioned over adjacent distal ends of the second and fourth lateral panels  104   b  and  116   b  which are also in abutting contact. A pair of vertically aligned apertures  128  in the first extension mounting bracket  122  are positioned in alignment with first and second apertures  130   a  and  130   b  in the fourth lateral panel  104   a . A second pair of vertically aligned apertures in the first extension mounting bracket  122   a  are positioned over vertically aligned apertures  132   a  and  132   b  in the third lateral panel  116   a . A carriage bolt  124  is inserted through each pair of aligned apertures in the first extension mounting bracket  122   a  and the first and third lateral panels  104   a  and  116   a  for connecting the two adjacent, abutting lateral panels. A nylon locking nut  126  is attached to the inner end of each of the carriage bolts  124  for securely maintaining the bolts in position in the first extension mounting bracket  122 . Similarly, a pair of vertically aligned apertures in the second extension mounting bracket  122  are positioned in alignment with a pair of apertures in each of the second and fourth lateral panels  104   b  and  116   b . Carriage bolts, which are not shown in the figures for simplicity, are then inserted through each of the aforementioned aligned apertures in the second extension mounting bracket  122  and the second and fourth lateral panels  104   b ,  116   b  for securely connecting this pair of lateral panels. Nylon locking nuts (also now shown in the figures for simplicity) are then attached to the aforementioned carriage bolts for securely maintaining the bolts in position in connecting the two adjacent lateral panels. By incorporating one or more extension assemblies in the original storage rack, the length of the storage rack of the present invention may be increased, as desired, to accommodate longer vehicles and/or additional articles for storage. 
     Referring to  FIG. 6 , there is shown an upper perspective view of the extended storage rack  100  mounted to an upper portion of a trailer  142 . Extended storage rack  100  includes first, second, and third support/mounting members  130   a ,  130   b  and  130   c . The first support/mounting member  130   a  is attached to a first cross support member  134   a  by means of first and second U-shaped threaded couplers  136   a  and  136   b . A second support/mounting member  130   b  is attached to a second cross support member  134   b  by means of third and fourth U-shaped threaded couplers  138   a  and  138   b . Finally, the third support/mounting member  130   c  is attached to a third cross support member  134   c  by means of fifth and sixth U-shaped threaded couplers  140   a  and  140   b . Each of the aforementioned U-shaped threaded couplers is maintained in position on and coupled to an associated support/mounting member and cross support member by means of a respective pair of nylon locking nuts as disclosed in the previously described embodiment, which are not shown in  FIG. 6  for simplicity. Each of the first, second, and third support/mounting members  130   a ,  130   b  and  130   c  is securely mounted to an upper portion of the trailer  142  by means of a pair of mounting strips, where one of the mounting strips is shown as element  132  in  FIG. 6 . 
     While particular embodiments of the present invention have been shown and described, it will be obvious to those skilled in the relevant arts that changes and modifications may be made without departing from the invention in its broader aspects. Therefore, the aim in the appended claims is to cover all such claims and modifications as fall within the true spirit and scope of the true invention. The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only and not as a limitation. The actual scope of the invention is intended to be defined in the following claims when viewed in their proper perspective based on the prior art.