Patent Document

CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of application Ser. No. 14/315,151, filed Jun. 25, 2014, which is a continuation of application Ser. No. 12/781,075, filed May 17, 2010, and claims the benefit of is related to and claims priority from earlier filed provisional application Ser. No. 61/179,163, filed May 18, 2009, the entire contents thereof of each of the aforementioned applications is incorporated herein by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    This invention relates generally to equipment for vehicles, such as pickup trucks, and more particularly to a releasably attachable and adjustable rack system having sliding connections and many other accessories for attaching to the overhead rack of the vehicle. 
         [0003]    Vehicle racks and systems are very well known in the art. They can connect to various parts of the vehicle such as a cab and side walls of a truck bed. The rack systems that typically connect to a truck bed include a frame-like structure that includes a connection for attaching the rack to a vehicle as well as a structure for receiving accessories for customizing the rack system. For example, the rack system commonly includes a base or footing, a vertical tube or post, a cross-rail and a structure for connecting these components together. 
         [0004]    For example,  FIGS. 1-4  illustrate a known prior art rack system  10 .  FIGS. 1-4  are of interest because they employ components that are permanently welded together and use gusseted braces  12  to form the desired configuration. As in  FIG. 1 , the base  14  is welded to the bottom of an upright member  16 , which is further reinforced by the gusseted brace  12 . The top of the tube is also welded to a top saddle member  18 , which is also further reinforced by a gusseted brace  12 . As a result, a unitary rack member, that includes a base  14 , an upright tube  16  and a saddle  18 , is provided. This general construction can be seen in U.S. Pat. No. 7,014,236. This patent is of interest for its teachings of a vehicle rack system  10  that uses gusseted braces  12  to better secure rack members relative to each other and to provide a more rigid joint connection. 
         [0005]      FIG. 2  is a close-up view of a prior art rack system  10  that includes a horizontal base member  14  that is clamped to the side wall  20  of a vehicle, such as a pick up truck. A vertical member  16  is permanently welded to the horizontal member  14  to provide an upright structure. A top saddle  18  is also permanently attached to the top of the vertical member  16  for receipt of a top rail  22  and other accessories thereon, as is well known in the art. Such a known construction can be seen in  FIG. 3  where a top rail  22  can support equipment, such as ladders, and the like. The clamps  24  are adjustable to permit the horizontal member  14 , and thereby the vertical member  16 , to permit a customized installation, as can be seen in  FIG. 4 . Typically, a set of four horizontal members  14  and associated vertical members  16  are used to provide a pair of top rails  22  for location at a desired distance D from each other, as can be seen in  FIG. 4 . This construction is so well known in the art that further discussion herein is not required. 
         [0006]    Although the prior art systems function acceptably as rack systems, they suffer from a number of disadvantages that make them undesirable. For example, a base horizontal member  14 , a vertical upright member  16  and top saddle  18  are typically welded together, which results in a structure that is unacceptably large in size, which makes shipping very difficult because a large box must be used. This oversize packaging adds costs to shipping and, as a result, adds to the cost of the rack system. Also, such a prior art structure is very labor intensive because parts must be welded together. Such welding requires expensive parts and components and is a time consuming and expensive manufacturing process. Missed weld locations will also make the rack “non functional” out of the box forcing customer to return the product. Moreover, welded products add weight to the overall package thereby adding cost and, unfortunately, welds, best seen as  26  in  FIG. 4 , are susceptible to failure over time. If there is a failure, it is very difficult and expensive to replace only a portion of the entire welded structure. So, as a result, wasteful replacement of the entire welded unitary structure is typically required. 
         [0007]    Also, a structure that is welded requires cumbersome gusseted braces  12  to supplement the welds so that acceptable rigidity can be achieved. These braces  12  add cost and further increase manufacturing time thereby further adding to the overall costs of production. 
         [0008]    A permanently welded structure takes away most if not all of the customization options because the horizontal member, the vertical member and saddle are permanently fixed to each other in a given configuration. Thus, such a permanently welded structure makes it more difficult to provide options and flexibility for the user. As a result, prior art rack systems  10  are not conducive to a desirable modular rack system. 
         [0009]    Finally, the permanent welds  26  and cross-braces  12  and gussets  12  of a rack system  10  are very unattractive in appearance as these welds  26  and braces  12  are readily visible. 
         [0010]    In view of the foregoing, there is a demand for a rack system that eliminates welds to increase manufacturing capacity by removing the tedious welding process. There is a demand to directly cast in the reinforcing geometry into the base and the saddle to obviate the need for gusseted braces. There is a demand for a rack system that is even stiffer without gusseted braces by using a component that is thicker in the existing welded locations from the prior art rack system  10 . There is also a need for a system that is modular so the user can customize and configure the system to what they need by mixing and matching horizontal bases, vertical upright members and top saddles, as well as top rails and accessories. A new rack system is desired that does not use a unitary welded structure to enable different variations of the horizontal member, vertical member and top saddle to be used and to obviate the need for expensive welding. Also, there is a need for a modular system so if one part of the system fails, only one small component is replaced rather than a larger unitary welded part. There is a also a need for a rack system that is more attractive and sleek in appearance and one that looks like a unitary structure but is actually a modular bolted component system. 
       SUMMARY OF THE INVENTION 
       [0011]    The present invention preserves the advantages of prior art rack systems, such as those used in vehicles. In addition, it provides new advantages not found in currently available systems and overcomes many disadvantages of such currently available systems. 
         [0012]    A modular rack system, for adjustably attaching equipment to a vehicle, includes a base mountable on a side wall of the vehicle. The rack system has a first wall that is disposed on and upwardly emanating from the top surface of the base that defines a lower seat. One end of a vertical member resides in the lower seat and is secured thereto. The other end of the vertical member resides in an upper seat defining by a downwardly depending wall from a saddle and is secured thereto. The first and second walls laterally stabilize the vertical member relative to the base and saddle to permit the base to be mounted to a side wall of a vehicle and a top rail to be secured to the saddle without the use of gussets or cross-braces. 
         [0013]    Therefore, an object of the present invention is to provide a modular rack system that eliminates welds to increase manufacturing capacity by removing the tedious welding process. 
         [0014]    Another object of the invention is to provide a rack system that directly formed, such as by casting or extrusion or the like, the required reinforcing geometry into the base and the saddle to obviate the need for gusseted braces. 
         [0015]    A further object of the present invention is to provide a modular rack system that is even stiffer without gusseted braces by using a component that is thicker in the existing welded locations from the prior art rack system  10 . 
         [0016]    Yet another object of the present invention is to provide a rack system that is modular in nature so the user can customize and configure the system to suit their current needs by mixing and matching horizontal bases, vertical upright members and top saddles, as well as top rails and accessories. 
         [0017]    Another object of the present invention is to provide a modular rack system that is devoid of any welding to reduce the overall costs of production of the rack system. 
         [0018]    An object of the present invention is to provide a modular system so if one part of the system fails, only one small component will need to be replaced rather than one large unitary welded part. 
         [0019]    Yet another object of the present invention is to provide a rack system that is more aesthetically appealing than prior art rack systems. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0020]    The novel features which are characteristic of the present invention are set forth in the appended claims. However, the invention&#39;s preferred embodiments, together with further objects and attendant advantages, will be best understood by reference to the following detailed description taken in connection with the accompanying drawings in which: 
           [0021]      FIG. 1  is rear perspective view of a prior art rack system that with a top rail that is reinforced by a gusseted brace; 
           [0022]      FIG. 2  is a close up view of a base of a prior art rack system that is reinforced by a welded gusseted brace; 
           [0023]      FIG. 3  is a prior art rack system rear perspective view of a base that is reinforced with a welded gusseted brace; 
           [0024]      FIG. 4  is rear perspective view of another prior art rack system that uses gusseted brace reinforcement for the base and rails; 
           [0025]      FIG. 5  is a diametric perspective view of the modular rack system of the present invention; 
           [0026]      FIG. 6  is an elevational view of the modular rack system of  FIG. 5 ; 
           [0027]      FIG. 7  is a an exploded perspective view of the horizontal base member, tubular vertical member and top saddle construction; 
           [0028]      FIG. 8  is a perspective view of a vertical tube used in the invention of  FIG. 5 ; 
           [0029]      FIG. 9  is a end perspective view of the vertical tube of  FIG. 7 ; 
           [0030]      FIG. 10  is a front elevational view of the vertical tube of  FIG. 7 ; 
           [0031]      FIG. 11  is a front perspective view of sliding lock assembly in accordance with the modular rack system of the present invention; 
           [0032]      FIG. 12  is a rear perspective view of the sliding lock assembly; 
           [0033]      FIG. 13  is a right elevational view of the sliding lock assembly; 
           [0034]      FIG. 14  is a front elevational view of the sliding lock assembly; 
           [0035]      FIG. 15  is a perspective view of the base of the sliding lock assembly; 
           [0036]      FIG. 16  is a front side elevational view of the base of the sliding lock assembly; 
           [0037]      FIG. 17  is a top view of the base of the sliding lock assembly; 
           [0038]      FIG. 18  is a bottom view of the base of the sliding lock assembly; 
           [0039]      FIG. 19  is a top perspective view of the saddle of the modular rack system of the present invention; 
           [0040]      FIG. 20  is a front view of the saddle; 
           [0041]      FIG. 21  is a side view of the saddle; 
           [0042]      FIG. 22  is a bottom perspective view of the saddle; 
           [0043]      FIG. 23  is a top view of the saddle; 
           [0044]      FIG. 24  is a perspective view of a top rail secured to a vertical tube using the unique saddle of the present invention; 
           [0045]      FIG. 25  is a bottom perspective view of the interconnection of  FIG. 24 ; 
           [0046]      FIG. 26  is a perspective view of a top rail used with the present invention; 
           [0047]      FIG. 27  is a perspective view of a saddle, shown in shadow for illustrative purposes, attached to a vertical tube; and 
           [0048]      FIG. 28  is a side view of the saddle and vertical tube of  FIG. 26 . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0049]    The modular rack system  100  of the present invention is shown in detail in  FIGS. 5-28 . 
         [0050]    Generally,  FIGS. 5 and 6  show the overall new modular rack system  100  while  FIGS. 8-10  show the structure of unique vertical upright tubular member  116  and  FIGS. 11-18  show the horizontal base member  114  and its interconnection to the vertical upright tubular member  116 .  FIGS. 19-23  show the structure of the top saddle  118  in detail.  FIGS. 24-28  show the interconnection of the top saddle  118  to the top rail  122  to complete the rack system  100  of the present invention. The top rail  122  is preferably of a length that can span across the distance between two side walls  20  of a vehicle. For example, the top rail  122  may be of a length of  65 ″ inches to  69 . 5 ″ inches, but can be any length to meet the given application at hand.  FIG. 7  shows an exploded view of the three components of the horizontal base member  114 , the vertical tubular member  116  and top saddle  118 . 
         [0051]    Referring first to  FIGS. 5 and 6 , the overall rack system  100  is shown to include a horizontal member  114  that serves as a base that communicates with a clamp assembly  124  to secure the rack system  100  to a support, such as a side wall  20  of a truck bed, as can be seen in  FIG. 3 . Any type of clamp system  124  may be employed by the present invention as long as the horizontal base member  114  is secured to the side wall  20 . Preferably, the clamp system  124  is releasably secured to the side wall  20  of a vehicle so that the horizontal base member  114  can be positioned at any desired location along the length of the side wall  20 . However, the frontmost vertical members  116  are recommended to sit as far forward as possible behind a rear window of a vehicle and the rearmost vertical members  116  to sit as far back as possible to optimize structural rigidity. Further, this enables the opposing horizontal base members  114  to also be adjusted so that the location of the entire rack structure  10  can be located where desired along the length of the side walls  20 . In turn, an assembled rack  100  can be located where desired. 
         [0052]    Details of the horizontal base member  114  will be discussed below in connection with  FIGS. 11-18 . 
         [0053]    Still referring to  FIGS. 5-7 , a vertical upright member  116 , such as in the form of a tube, is received in and secured to the horizontal base member  114  at its bottom end  116   a.  It should be noted that both ends of the vertical upright members  116   a,    116   b  are identical to facilitate installation. Details of the vertical upright member  116  will be discussed in detail below in connection with  FIGS. 8-10 . 
         [0054]    The top end  116   b  of the vertical upright member resides in and is secured to a top saddle  118 . Details of the top saddle  118  will be discussed in detail below in connection with  FIGS. 19-22 . The interconnection of the vertical upright member  114  to the top saddle will be discussed in connection with  FIGS. 24-28  below. 
         [0055]    As can be best seen in  FIGS. 5-7 , a top rail  122  is releasably connected to a top saddle  118  to complete one half of the modular rack system of the present invention. The opposing side of the rack system  100  is constructed in the same fashion and is a mirror image thereof. Therefore, one half of a rack includes two horizontal base members  114 , two vertical upright members  116  and two top saddles  118  and one top rail  122  spanning thereacross. It should also be understood that at least two entire racks are preferably used in spaced apart relation to each other to provide at least two top rails  122 .  FIG. 5  shows two racks with two top rails  122  to form the rack system  100  of the present invention. This general configuration is well suited to provide a support for items on the top surface  122   a  of the top rails  122 . Additional accessories (not shown) can also be attached to the top surface  122   a  and bottom surface  122   b  of the top rails  122 . For ease of discussion herein, the weldless and modular interconnection of a single horizontal base member  114 , single vertical upright member  116  and top saddle  118  will be addressed herein. It should be understood that the other connections to complete and entire rack system  100  are the same and, therefore, need not be discussed, although are covered by the present invention. 
         [0056]    First, the construction of the vertical upright member  116  will be discussed in detail.  FIG. 8  shows the unique vertical upright member  116  of the present invention. A tubular construction is preferably formed by extrusion but can be formed by other processes, such as casting, and the like. As can best be seen in  FIGS. 9 and 10 , the tubular vertical member  116  is not merely a hollow or solid tube as in the prior art but rather a preferably extruded part. The walls of the extrusion are preferably 0.080″ on the perimeter, 0.080″ on the support ribs and 0.140″ around the female threads but may be any desired thickness. This vertical member  116  is preferably extruded from aluminum but may be formed of any material. The vertical upright member  116  preferably has a general rectangular cross-sectional shape with the short sides of the rectangular profile being rounded. The rounded profile provides an attractive aesthetic appearance. As in  FIGS. 9 and 10 , the height of the vertical member  116  is preferably 3.000″ inches and the width is preferably 1.250″ inches. 
         [0057]    Use of an extrusion process enables a uniquely configured part to be provided that has a number of apertures formed, generally referred to as  128 , that longitudinally run throughout the entire length of the part. This construction permits large voids  130  to be formed to reduce the overall weight of the part, which results in a large cost savings. Further, the longitudinally running circular apertures  132  are well-suited to be tapped to receive fasteners therein. 
         [0058]    For this purpose, preferably, a pair of such circular apertures  132  are provided that are tapped using known methods to turn the extruded apertures into females threaded bores  132  that are suitable for receipt of fasteners  134 , such as bolts , as will be described below. 
         [0059]      FIGS. 11-18 , along with  FIG. 7 , show the interconnection of a horizontal base member  114  to the extruded tubular vertical member  116 . Turning first to  FIGS. 15-18 , the horizontal base member  114 , in which the tubular vertical member  116  will be installed, has an upstanding wall  114   a  that defines a seat  114   b,  which defines a floor  114   c  for receipt of a first end  116   a  of the tubular vertical member  116  therein. The upstanding wall  114   a  is dimensioned to accommodate the size and configuration of the cross-sectional profile of the bottom end  116   a  of vertical member  116  shown in  FIGS. 9 and 10 . The appearance of the interconnection of the vertical member  116  into the upstanding wall  114   a,  as in  FIG. 11 , has a very aesthetically pleasing appearance, particularly because it is devoid of any welds and all fastening connections are completely hidden. This also eliminates the need for a gusset. 
         [0060]    The horizontal member  114  includes a primary plate  114   d  to support the upstanding wall  114   a  and provide a floor  114   c  upon which the lower end  116   a  of the vertical member  116  will sit. This primary plate  114   d  may be of any size and configuration as long as it can sit on top of a side wall  20  of a vehicle and be secured thereto. For example, the length of the primary plate is preferably 16.0″ inches but can be of any length, as desired. A secondary plate  114   e  is optionally included, which downwardly depends from the edge of the primary plate  114   d  that facing toward the center of the vehicle. This secondary plate  114   e  helps secure the horizontal member  116  in place on the top of a side wall  20  of a vehicle. 
         [0061]    As seen in  FIGS. 17 and 18 , a pair of pass-through apertures  136  is provided through the floor  114   c  of the primary plate  114   d  that resides within the upstanding wall  114   a.  This pair of apertures  136  matches with the threaded bores  132  on the end of the vertical upright member  116 . The floor  114   c  is configured at an angle, preferably 13.5 degrees, so that the vertical upright  116  closely matches the cab angle of the truck. Also, this angled positioning provides a stronger geometry than if the uprights were at 90 degrees. 
         [0062]    An end of the vertical upright member  116  is inserted into the seat  114   b  defined by the upstanding wall  114   a  to effectuate matching of the respective apertures  136  and threaded bores  132 . Referring to  FIG. 11 , bolt fasteners  134  are inserted up through the pass-through apertures  136  in the primary plate  114   d  and into threaded engagement with the threaded bores  132  in the end  116   a  of the vertical upright member  116 . The male threaded bolts  134  are tightened to secure the horizontal base member  114  to the vertical upright member  116  without welding. In fact, this connection and all connections are preferably carried out by the end user. 
         [0063]    As can be best seen in  FIG. 18 , the bottom side of the primary plate  114   d  of the horizontal member  114  has countersunk holes  136  so that the head  134   a  of the bolt  134  residing therein is flush with or below the bottom surface of the base  114 . Preferably, a C′ sink hole with flat head cap screws are preferably used to achieve self-alignment with the casting and the mating features. So, as in  FIG. 14 , the base  114  can rest against the top of a side wall of a truck bed or other support surface without interference. A number of clamps  124 , such as 8 clamps per rack, are preferably used, as to secure the base to the top edge of wall of truck bed. A C-clamp construction  124  with a threaded bolt  124   a  and foot  124   b  can be used. The clamps  124  shown are by way of example only. Any type of suitable clamping system may be used. In this particular example, a channel  114   f  can be formed in the top surface of the primary plate  114   d  to receive a top pad  124   c  of the C-clamp  124  to help secure the C-clamp  124  in place. This structure can be seen in  FIGS. 11, 12, 15-17 . 
         [0064]    The horizontal base member  114  is preferably cast but can be formed by any process. The horizontal base member includes a geometry about the seat  114   b  that has, preferably, an upward sloping configuration toward the seat  114   b  (downwardly sloping away from the seat) to provide lateral stability and rigidity. This allows for gussets to be completely eliminated overcoming a disadvantage in the prior art. The upstanding wall  114   a  preferably positions the vertical upright member  116  at an angle less than 90 degrees to add further strength to the overall construction  100 . For example, an angle of 76.5 degrees is preferably used. As a result of the geometry of the upstanding side wall  114   a  and the thickness of the seat  114   b  of the horizontal base member  114 , there is no need for additional gusseted braces. In general, the width of the upstanding wall  114   a  of the horizontal base member  114  is preferably larger at its bottom than at its top. 
         [0065]    Both ends  116   a  and  116   b  of the tubular vertical member  116  are equipped with tapped holes  132 . As above, a first, lower end  116   a  is secured to the horizontal base member  114 , as seen in  FIG. 7, 11-13 , for example.  FIGS. 24-28  show the interconnection of the second, upper end  116   b  of the vertical tubular member  116  to a top saddle  118 . As will be discussed in detail below, a top rail  122  is then attached to top saddles  118  to complete the rack system  100 . 
         [0066]    Turning next to  FIGS. 19-23 , details of the construction of the saddle  118  is shown. The top saddle  118  is provided as an upper interconnection interface between the tubular vertical member  116  and the top rail  122 . In similar fashion to the horizontal base member  114 , the top saddle  118  includes a wall  118   a  to define a seat  118   b  that receives the top end  116   b  of the tubular vertical member  116  so that the tapped holes  132  on the top end  116   b  of the tubular vertical member  116  align with the pass through holes  140  shown in  FIG. 22 . This is very similar to the structure for securing the bottom end  116   a  of the vertical tubular member  116  into the seat  114   b  on the horizontal base member  114 .  FIGS. 19 and 23  show the opposing side of the top saddle  118  where the apertures  140  have a countersunk configuration so the heads  134   a  of the fastening bolts  134  remain flush to or sit below the opposing surface, which is configured to receive and secure to a top rail  122 . C′ Sink holes with flat head cap screws are preferably used to allow the bolt to self align with the casting and mating features.  FIGS. 27 and 28  illustrate a side view of the interconnection of a top saddle  118  to the upper end  116   b  of the tubular vertical member  116 . 
         [0067]    The seat  118   b  is formed by a downwardly depending wall  118   a  that is similar to the upstanding wall  114   a  found on the horizontal base member  114 . The downwardly depending wall  118   a  is dimensioned to accommodate the size and configuration of the cross-sectional profile of the top end of the vertical member  116   b  shown in  FIGS. 9 and 10 . The appearance of the interconnection of the vertical member  116  into the downwardly depending wall  118   a , as in  FIG. 25 , has a very aesthetically pleasing appearance, particularly because it is devoid of any welds and all fastening connections are completely hidden. This also eliminates the need for a gusset. The angle of the positioning of the downwardly depending wall  118   a  is preferably complementary to the angle of the upstanding wall  114   a  so that top surface  118   c  of the top saddle  118  remains parallel to the ground so that a top rail  122  mounted thereto also remains positioned parallel to the ground. Different combinations of angles are possible although a top rail  122  that is parallel to ground is preferred. 
         [0068]    With the top saddle  118  (and top saddle  118  on the opposing side of the rack) secured to the upper end  116   b  of the tubular vertical member  116 , the top rail  122  may be installed. The interconnection of the top rail  122  to the top saddles  118  is illustrated in connection with  FIGS. 24-26 .  FIG. 26  shows a perspective view of the top rail  122  that is preferably used in the present invention. As can be seen, a channels  122   a  runs longitudinally along the length of the top rail on both the top and bottom sides thereof. A bolt  142  is partially threaded into a nut  144  and then the nut  144  is slid laterally into the channel  112   a  on the bottom side of the top rail  122  with the head of the bolt  142  located within a bolt seat  146  on the top saddle  118 . A second bolt  142  and nut  144  are threaded and similarly threaded into the channel  122   a  on the opposing side of the top rail  122  with the head of a bolt  142  residing in the bolt seat  146  on that opposing top saddle  118 . The opposing top saddle  118  is also similarly configured. At this point, the top rail  122  can still freely slide along the top saddles  118 . The grooving  118   d  on the top surface of the top saddle  118  is configured to be complementary to the grooving  122   b  on the outer surface of the top rail  122  to help secure the top rail  122  in place, particularly during initial installation. Once the position of the top rail  122  is desired relative to the top saddles  118 , the rail bolts  142  can be tightened thereby pulling the top rail  122  into secure engagement with the top saddles  118 . Accessories can be attached to this bottom channel  122   a  or to the channel  122   a  on the top side of the top rail  122  using the same interconnection construction as the top saddle  118  to the bottom surface of the top rail  122 . 
         [0069]    Finally, a cosmetic end cap  146  is installed onto the free ends of the top rail  122 . This end cap  146  can be secured in many different ways, such as by providing a tab with a female threaded bore that emanates from the end cap to engage with a bolt that passes through the top rail itself (not shown). The cosmetic end caps  146  also help prevent accessories from falling out with any item held within the channel  122   a.    
         [0070]    Although preferred in accordance with the present invention, the above structure for interconnecting the tubular vertical member  116  to a saddle  118  is one of many that can be employed. Other interconnection structures are considered within the scope of the present invention. 
         [0071]    The sides of the top saddles  118  are configured with a geometry profile, in similar fashion to the horizontal base member  114  as above, to obviate the need for gusseted braces. The profiling is preferably similar to that of the horizontal base members  114  but may be modified to suit the application at hand. The horizontal base members  114  and top saddles  118  are configured for left and right hand location, as can be seen in  FIG. 7  to provide both sides of the support for top rail  122 . 
         [0072]    The horizontal base members  114  and the top saddles  118  are preferably made of cast aluminum and the vertical tubular members and the top rails  122  are preferably made of extruded aluminum. However, other suitable materials can be used and still be within the scope of the present invention. 
         [0073]    Generally, the interconnection of the horizontal base member  114  to the bottom end  116   a  of the extruded tubular vertical member  116  and the top saddle  118  to the top end  116   b  of the extruded tubular vertical member  116  are similar although the overall configuration of the horizontal base member  114  and the top saddle  118  are different as they interconnect to different structures. The horizontal base member  114  is preferably elongated because it typically rests on the elongated top edge of the side wall  20  of a truck bed. The top saddle  118  includes a top surface that is well suited to receive a top rail  122  that can support and receive accessories, and the like. 
         [0074]    The rail system  100  of the present invention enables a modular construction that can ship to the point of purchase or to the consumer in a compact package where the horizontal base members  114 , tubular vertical members  116 , top saddles  118  and top rails  122  (and other parts) are separate pieces and in an unassembled form. 
         [0075]    In view of the foregoing, the unique modular rack system  100  of the present invention does not include welded parts, gussets or braces. Welds are eliminated to increase manufacturing capacity by avoiding the tedious welding process. Reinforcing geometry is cast into the horizontal base member  114  and the top saddle  118  to obviate the need for separate gusseted braces. The rack system  100  of the present invention is even more stiff that the prior art racks with gusseted braces by using a component that is thicker in the existing welded locations from the prior art rack system  10 . In the present invention, thicker areas on the saddle  118  and the horizontal base  114  are provided to the needed support and rigidity to obviate the need for gussets. This is in contrast to the same regions in prior art constructions that are not thicker but are simply welded. However, the prior art welded constructions are still not strong enough thereby still requiring the use of gussets and braces. Thus, the configuration of the present invention, with its thicker regions, is a significant advance over prior art constructions. 
         [0076]    The rack system  100  of the present invention is modular so the user can customize and configure the system to what they need by mixing and matching bases, tubes and saddles (as well as top rails and accessories). In the event one part of the system fails, only one small component is replaced rather than the larger unitary welded part. The rack system  100  of the present invention is more attractive and sleek in appearance than prior art devices. Moreover, the inventive rack system  100  has the appearance of a unitary structure but is actually a modular bolted component system. 
         [0077]    It would be appreciated by those skilled in the art that various changes and modifications can be made to the illustrated embodiments without departing from the spirit of the present invention. All such modifications and changes are intended to be covered by the appended claims.

Technology Category: b