Patent ID: 12246681

DETAILED DESCRIPTION

This disclosure details a vehicle roof rack assembly with roof rails that are reorientable and may include modular components. An exemplary roof rack assembly may include endcaps and movable rails with connection features configured to engage with the endcaps. The movable rails may include a base mounting connectable components. These and other features of this disclosure are described in greater detail in the following paragraphs of this detailed description.

FIG.1illustrates a motor vehicle10including a roof rack assembly12configured in a longitudinal configuration. In an embodiment, the vehicle10is a sport utility vehicle (SUV). However, the vehicle10could alternatively be configured as a car, a truck, a van, or any other type of vehicle within the scope of this disclosure. The vehicle10could also be a conventional motor vehicle, a battery powered hybrid or electric vehicle, or an autonomous vehicle (i.e., a driverless vehicle).

The vehicle10includes a roof14that establishes an upper barrier surface for enclosing a passenger cabin16of the vehicle10. The roof rack assembly12is mounted to the roof14and may provide a mounting point for securing cargo on the vehicle.

The roof rack assembly12may include a first endcap18a, a second endcap18b, a third endcap18c, and a fourth endcap18dmounted to the roof14. The endcaps18aand18bare located towards the front of the vehicle10, and the endcaps18cand18dare located towards a rear of the vehicle10. The endcaps18aand18cmay be located towards a first lateral side of the vehicle, in this example the right, or passenger side of the vehicle10. The endcaps18band18dmay be located towards a second lateral side of the vehicle that is opposed to the first side, in this example the left, or driver side of the vehicle10.

The roof rack assembly12may further include a first roof rail20aand a second roof rail20b. In the longitudinal configuration illustrated inFIG.1, the roof rails20a/20bextend longitudinally with respect to the vehicle and therefore extend in parallel with the length of the vehicle10. In this configuration, the first roof rail20aextends between and engages with endcaps18aand18csuch that it is located towards the first lateral side, and the second roof rail20bextends between and engages with the endcaps18band18csuch that it is located towards the second lateral side.

The roof rails20a/20bmay include a square prism shape, i.e. they include a square cross-section, and each may include a flat top surface22. However, other roof rail shapes are further contemplated within the scope of this disclosure. The endcaps18a/18b/18c/18dmay represent any sort of mounting interface or structure. The endcaps18a/18b/18c/18dmay also include flat top portions24that mount longitudinally with respect to the vehicle10. In the longitudinal configuration, the top surface22of the roof rails20a/20band the flat top portion24of the endcaps18a/18b/18c/18dform a substantially continuous top surface26of the roof rack assembly12.

FIG.2illustrates the roof rack assembly12configured in a cross-car configuration. In the cross-car configuration, the roof rails20a/20bmount transversely across the vehicle roof14. In this configuration, the first roof rail20amay mount between and engage with the endcaps18aand18bsuch that it is located towards a front of the vehicle10, and the second roof rail20bmay mount between and engage with the endcaps18cand18dsuch that it is located towards a rear of the vehicle10.

The roof rails20a/20bare movable between the longitudinal configuration illustrated inFIG.1and the cross-car configuration illustrated inFIG.2. In this regard, the roof rails20a/20bmay include a quick-release mechanism28near each of their longitudinal ends. The quick release mechanisms28allow a user to easily disengage the roof rails20a/20bfrom the endcaps18a/18b/18c/18d, reorient the roof rails20a/20bfrom the longitudinal to the cross-car configuration, or vise versa, and then reengage the roof rails20a/20bwith the endcaps.

The longitudinal configuration may be aesthetically preferable to the user and may result in less drag during vehicle travel. However, the cross-car configuration may better enable a user to mount bulkier or longer items to the vehicle10, such as luggage, lumber, camping equipment, bikes, kayaks, etc. The roof rack assembly12allows a user to utilize the advantages of both configurations for a given situation without requiring additional components.

FIG.3illustrates the roof rack assembly12separately from the vehicle10and with the roof rails20a/20bdisengaged from the endcaps18a/18b/18c/18d. The endcaps18a/18b/18c/18dmay each include a pedestal30. The pedestal30is a vertically extending member or pin which is configured to interface with the quick release mechanisms28of the roof rails20a/20bin both the longitudinal configuration and the cross car-configuration. In this example, the distance between the pedestals30of the endcaps18aand18bmay be equal to the distances between the pedestals30of the endcaps18aand18c, the endcaps18band18d, and the endcaps18cand18d. In other words, the pedestals30may be located at the corners of a square.

FIG.4illustrates an isometric cross-section of the quick release mechanism28of one of the roof rails20a/20band the pedestal30of one of the endcaps18a/18b/18c/18d. The quick release mechanism28may include a toggle loop32and a lever34. The toggle loop32may include a flat front loop portion32aand loop ends32bthat are connected to the lever34.

The pedestal30may include a first face30aand a second face30bthat is substantially orthogonal to the first face30a. In an example, the first face30afaces toward the endcap18band the second face30bfaces in a direction towards a lateral side of the vehicle10. The pedestal30may further include an indentation36spanning from the first face30ato the second face30b.

FIG.5illustrates the quick release mechanism28engaging the pedestal30in the longitudinal configuration of the roof rail20b, andFIG.6illustrates the quick release mechanism28engaging the pedestal30in the cross-car configuration of the roof rail20b. As can be appreciated, the indentation36of the pedestal30is configured to receive the flat front loop portion32aof the toggle loop32in both orientations. Specifically, the flat front loop portion32amay engage a first portion36aof the indentation36that is disposed on the first face30aof the pedestal30in the longitudinal configuration and may engage a second portion36bof the indentation36that is disposed on the second face30bof the pedestal30in the cross-car configuration.

Referring now toFIGS.4-6, the lever34is actuatable to fasten the toggle loop32to the pedestal30. The loop ends32bmay be rotatably mounted to the lever34, and the lever34is rotatable about a pivot point38. When the lever34is pivoted down in a direction D, loop ends32bare translated away from the pedestal30such that the flat front loop portion32ais forced against and received within the indentation36. When the lever34is pivoted up in a direction U, or released, the loop ends32bare translated towards the pedestal30such that the flat front loop portion32ais removable from the indentation36. In both the longitudinal configuration and the cross-car configuration, the roof rails20a/20bmay include toggle loops32that engaged pedestals30on both of their longitudinal ends to secure the roof rails20a/20bin place.

Although in the illustrated example the quick release mechanisms28are located at the ends of roof rails20a/20band pedestals30are located on the endcaps18a/18b/18c/18d, in other example the roof rails20a/20bmay include pedestals30at their longitudinal ends which are configured to engage with quick release mechanisms28that are located on the endcaps18a/18b/18c/18d.

The quick release mechanism28allows for easy adjustment between configurations without the need for any additional tools or hardware. The indentation36aligns the toggle loop32vertically on the pedestal30and facilitates a secure attachment of the roof rails20a/20bto the pedestals30. The inclusion of a flat front portion32aon the toggle loop32that is adapted to engage first and second substantially orthogonal faces30a/30bof the pedestal30increases the surface area of the connection and also aids in constraining and affixing the roof rails20a/20bin place.

FIGS.7-9schematically illustrate another example roof rail120that could be utilized as part of the roof rack assembly12, for example. In this disclosure, like reference numerals designate like elements where appropriate and reference numerals with the addition of one-hundred or multiples thereof designate modified elements that are understood to incorporate the same features and benefits of the corresponding elements.

The roof rail120may include a base40configured to mount one or more quick-connect components. The base40and the quick-connect components are configured such that a user can easily add or remove components to the base40. In one example, the base40may include an inverted T-shaped slot configured to receive quick-connect components with T-shape flanges. In this example, the T-shaped flange of a quick-connect component may slide into, or be removed from, the inverted T-shaped slot of the base40at an opening at a longitudinal end of the base40. The quick-connect components may then be slid to a desired location on the base40and fastened. In another example, the base40may include a plurality of longitudinally spaced receptors configured to receive quick-connect components with a turn-pin, or bayonet mount attachment feature. In this example, a quick connect component may be inserted within a receptor of the base40at a desired location and then rotated such that the turn-pin attachment feature locks the component in place. In another example, the quick-connect components may be attached to the base40via a snap-fit buckle mechanism. The above examples should be construed to be non-limiting, and the base40and quick-connect components may be configured in any manner that allows a user to easily add and remove components from the base40.

In the example ofFIG.7, a first rotatable member42a, a second rotatable member42b, and a divider44are quick-connect components that may be mounted to the base40.FIG.7illustrates the first and second rotatable members42a/42bin a stowed position wherein they are substantially parallel to the base40. The divider44may be mounted to the base40between the first and second rotatable members42a/42b. In the stowed position, the divider44and the rotatable members42a/42bform a substantially continuous top surface45of the roof rail120.

FIG.8illustrates the roof rail120when the first and second rotatable members42a/42bare rotated about pivot points46from the stowed position to a vertically extending position. The pivot points46may each include a stop47which may be a slanted surface of the base40configured to constrain additional rotation of the rotatable members42a/42bpast the vertically extending position. At the vertically extending position, the rotatable members42a/42bmay each form an obtuse angle α relative to the base40.

When the rotatable members42a/42bare rotated out to the vertically extending positions, the rotatable members42a/42band bases40may form a V-shaped support. When two roof rails120are oriented in a cross-car configuration with their rotatable members42a/42bin the vertically extending positions, the roof rails120can support cargo48(e.g., kayaks or other relatively long cargo) schematically illustrated inFIG.8extending longitudinally between the rails120and laterally constrained between the rotatable members42a/42b. The angle α of the rotatable members42a/42bin the vertically extending positions allows the cargo48to be mounted at an angle to better fit on the roof14.

FIG.8further illustrates that the rotatable members42a/42band/or the divider44may include a retractable tie-down cordage mechanism50. The retractable tie-down cordage mechanism50includes a retractable spool of cordage52that a user may unravel to secure the cargo48to the roof rail120. The cordage52may be rope, cable, bungee cord, or any other appropriate tie-down material. In the example ofFIG.8, the cordage52extends out of the divider44to anchor points54located at the ends of the rotatable members42a/42b. Alternatively, the cordage52could extend from the ends of the rotatable member42a/42bto anchor points located on the divider44.

FIG.9illustrates the base40of the roof rail120without the quick connect components, e.g. with the rotatable members42a/42band the divider44removed. Removal of these components may advantageously decrease the overall weight of the roof rail120. Further, removal of the quick connect components may provide access to a valley portion56of the base40extending between ridge portions58at the longitudinal ends of the base40. The valley portion56may provide an ideal surface for stacking cargo48(e.g., lumber or other cargo) extending between two roof rails120in the cross-car configuration. The ridge portions58serve to laterally constrain cargo48within the valley portion56.

FIG.9further illustrates that the retractable tie-down cordage mechanism50described above may also be located in one of the ridge portions58of the base40. In this example, cordage52extends from one of the ridge portions58to an anchor point54on the other ridge portion to secure cargo48within the valley portion56.

FIG.10illustrates another example roof rail220that could be utilized as part of the roof rack assembly12, for example. Roof rail220includes a telescoping function with an inner rail portion260and an outer rail portion262. Both the inner rail portion260and the outer rail portion262include a quick release mechanism28at the longitudinal ends of roof rail220. Inner rail portion260is slidably housed within outer rail portion262, and may be extended in a direction D to increase the overall length of roof rail220. A spring264may be included within the outer rail portion262to bias the inner rail portion260in the direction D with a spring force F.

Roof rail220allows for non-equidistant positioning of the pedestals30of endcaps18a/18b/18c/18d. Accordingly, in one example, a cross-car distance between the pedestals30of front endcaps18aand18band rear endcaps18cand18dmay be less than a longitudinal distance between the pedestals30of right-side endcaps18aand18cand left-side endcaps18band18d. In this example, when the roof rail220is oriented in the cross-car configuration, the inner rail portion260is more retracted within the outer rail portion262to decrease the overall length of the roof rail220, and engagement of the quick release mechanisms28with the pedestals30keeps the spring264compressed. When the roof rail22is oriented in the longitudinal position, the spring264biases the inner rail portion260to extend further out from the outer rail portion262to increase the overall length of the roof rail220to span the longitudinal distance. Alternatively, the cross-car distance may be longer than the longitudinal distance.

FIG.11, with continued reference toFIGS.1-10, illustrates a method200for reorienting the roof rack assembly12from the longitudinal configuration to the cross-car configuration. At step301, a user may release the levers34of the quick release mechanisms28located on both ends of the first roof rail20ato disengage toggle loops32from the pedestals30of endcaps18aand18c, and similarly may release the levers34of the quick release mechanisms28located on both ends of the second roof rail20bto disengage toggle loops32from the pedestals30of endcaps18band18d. At step302, the user may maneuver the roof rails20a/20bsuch that the toggle loops32no longer surround the pedestals30and the roof rails20a/20bare fully removed from the end caps18a/18b/18c/18d. At step303, the user may reorient the roof rails20a/20band position the first roof rail20asuch that its toggle loops32surround the pedestals30of endcaps18aand18b, and position the second roof rail20bsuch that its toggle loops32surround the pedestals30of endcaps18cand18d. At step304, the user may actuate the levers34of the quick release mechanisms28of both the first and second roof rail20a/20bsuch that flat front portions32aof the toggle loops32are forced against and fastened within indentations36of the pedestals30that the toggle loops32surround to secure the roof rails20a/20bin place. The roof rack12may be reoriented from the cross-car configuration to the longitudinal configuration using similar steps.

The disclosed roof rack assembly12allows a user to utilize roof rails in a longitudinal and a cross-car configuration without requiring the purchase of additional components. The roof rack assembly12decreases part complexity from a traditional cross-car set up, which has typically included cross-car rails mounted to longitudinal rails, to a single mechanism that covers both longitudinal and cross-car use cases. Accordingly, the roof rack assembly12provides a simple and cost-effective solution that improves a user's experience with vehicle10.

Although the different non-limiting embodiments are illustrated as having specific components or steps, the embodiments of this disclosure are not limited to those particular combinations. It is possible to use some of the components or features from any of the non-limiting embodiments in combination with features or components from any of the other non-limiting embodiments. In other words, the placement and orientation of the various components of the roof rack assembly12are shown schematically and could vary within the scope of this disclosure. In addition, the various figures accompanying this disclosure are not necessarily drawn to scale, and some features may be exaggerated or minimized to emphasize certain details of a particular component.

It should be understood that like reference numerals identify corresponding or similar elements throughout the several drawings. It should be understood that although a particular component arrangement is disclosed and illustrated in these exemplary embodiments, other arrangements could also benefit from the teachings of this disclosure.

The foregoing description shall be interpreted as illustrative and not in any limiting sense. A worker of ordinary skill in the art would understand that certain modifications could come within the scope of this disclosure. For these reasons, the following claims should be studied to determine the true scope and content of this disclosure.