Abstract: An adaptor for securing a slat of a vehicle article carrier to an outer body surface of a vehicle without the need for drilling holes through the outer body surface. The adaptor comprises a main body portion having a channel formed along the entire length thereof. The channel has a cross-sectional shape which is designed to match the shape of an upwardly protruding lip portion formed within a roof ditch of the vehicle, such that the adaptor can be slid over the upwardly extending metal lip portion and thus attached thereto. At least one threaded bore is provided in the adaptor for enabling a slat to be secured thereto by an external threaded fastening element. A second threaded bore is included for enabling a set screw to be used to secure the adaptor to the metal lip portion so as to prevent sliding movement of the adaptor within the roof ditch. The adaptor thus allows a slat to be secured over a roof ditch without the need for drilling any holes in the roof of the vehicle.

Abstract: A vehicle article carrier which enables a degree of adjustable spacing of the support members used to support a cross bar while preventing the generation of wind noise which might be otherwise caused by wind entering through openings in the support members while the vehicle is moving. The vehicle article carrier includes front and rear cross bar assemblies which are mounted on a pair of slats. The slats may be disposed such that they converge slightly. At least one bracket member of one of the cross bar assemblies includes an elongated slot formed therein and a neck portion of the support member. The neck portion receives one end of one of the cross bars and enables the cross bar to move inwardly or outwardly of the neck as needed, such as when the cross bar is repositioned on a pair of slats which are mounted on a vehicle such that they converge slightly.

Abstract: A blow molding method for use with tubular metal work pieces. The method involves placing a tubular metal component part into a molding tool having an internal molding cavity and at least one access passageway into which the component is inserted. The molding tool is then heated to a temperature between about 1000° F. and 1200° F. and a high pressure gas is injected into the tubular component. The high pressure gas causes the portion of the work component residing within the internal mold cavity of the molding tool to expand and assume the shape of the internal molding cavity. After a cooling period, the component is removed from the molding tool. The process is particularly well suited for forming the end support portions of side rails used with vehicle article carriers, but can be used to form a wide variety of complexly shaped forms from tubular metal workpieces.

Abstract: A roof rail (10), which consists of a side rail (5) and support legs (7, 8). The support legs (6, 7) engage a roof channel (2), which is otherwise closed off by a cover strip (3). The support legs are connected to adaptors (8) at the bottom surface. The connection between the adaptors (8) and the vehicle roof (1) is established by means of threaded bolts (12) which are fastened to the adaptors (8) by means of a threaded portion (14) and to the vehicle roof (1) by means of a second threaded portion (16) with the use of threaded nuts. Each support leg (6, 7) is connected to each respective adaptor in such a manner that it can be loosened, while a bolt (17) with its threaded shaft (21) is screwed into the support leg (6, 7). Here, the bolt head (18) is seated in the adaptor (8) and includes a circular groove (23), one end of which is engaged by a threaded bolt (22) for the purpose of securing it in an axial direction, and where the bolt (22) is extended transversely to the bolt (17).

Abstract: A roof rail for vehicles with a tubular gallery rod (1) and a pair of rail feet (2) which are arranged at its ends, are supported on a vehicle's roof (4). The rail feet (2) are each formed from the same length of material as the gallery rod (1) and consist of bent and flared end sections of the gallery rod (1). The gallery rod (1) has a continuously increasing cross section proceeding from the transition region of one rail foot (2) up to the transition region into the other rail foot (2). A manufacturing process for the roof rail is also disclosed in which a length of extruded material having an expansion fold is formed with arcing end portions. The length of material is then placed in a molding tool and pressurized to expand the material such that it forms a roof rail.

Abstract: A vehicle article carrier having a pair of side rails each including a channel, and an adjustable cross bar disposed between the side rails, wherein the cross bar includes structure for eliminating binding of the cross bar when same is moved along the side rails. The cross bar includes a pair of guide wheel assemblies disposed at opposite ends of a bracket assembly. The bracket assembly is secured to one outermost end of the cross bar. The guide wheel assemblies reside within the channel of the side rail and prevent binding of the structure of the bracket assembly that resides within the channel of the side rail as the cross bar is moved along the side rails and becomes non-perpendicular to the side rails. The guide wheels are disposed generally horizontally and do not perform any load bearing function, but rather enable the bracket assemblies to be moved easily along the side rails without binding.

Abstract: A roof rail for vehicles is described, having a strut (3), which is carried by at least two supporting feet (2), and having a fastening assembly, which is assigned to each supporting foot (2), for fastening it to a non-removable bearing structure (5) on the vehicle, such as a roof channel bottom (6), roof frame, bow or the like. The fastening assembly has a bolt (7) which is arranged on the supporting foot (2), and which is inserted through a hole (8) in the bearing structure (5) and is secured on the bearing structure (5) via a spring element of the fastening assembly. For the purpose of obtaining a simple installation having a snap lock, the bolt (7) to has a radial groove (9) and the spring element (10), which is arranged on the bearing structure (5) and which can be latched into the radial groove (9), to be provided as the fastening means.

Abstract: A vehicle article carrier having a pair of generally parallel disposed side rails and a plurality of mounting support members for securing the side rails fixedly to an outer body surface, wherein each outermost end of each side rail is secured to its associated mounting support member without any fastening element being visible at the areas where each outermost end of the side rail attaches to the mounting support members. A mounting plate is disposed in one tubular end of the side rail such that the ends of the mounting plate engage opposing slots formed in an outermost end of the side rail. A fastening element is inserted through an opening of an internal boss formed within the mounting support member and engages a threaded opening in the mounting plate. The fastener secures the mounting plate, and therefore the outermost end of the side rail, to the mounting support member without the fastening member or mounting plate being visible once these two components are secured together.

Abstract: A vehicle article carrier having a pair of bracket members at the outer ends of a cross bar, where both bracket members can be unlocked from a pair of slats simultaneously through a single actuating member associated with one of the bracket members. In one embodiment an elongated cable extends through the cross bar and couples an actuating member associated with a bracket member at a first end of the cross bar with a locking member associated with a second bracket member at the opposite end of the cross bar. The locking member is biased into a locked position via an independent biasing member which serves to lock both bracket members to their associated slats. Moving the actuating member into an unlocked position allows both bracket members to be placed in unlocked positions simultaneously. Releasing the actuating member allows the biasing member to return both bracket members into locking engagement with their respective slats.

Abstract: A vehicle article carrier incorporating at least one cross bar having a pair of bracket assemblies at each end. Each bracket assembly includes a fixed jaw and a movable jaw. The fixed jaw includes a keyed recess having an internal shoulder portion and a secondary recess. The movable jaw includes a projecting key having a rib and an arm portion having an enlarged outer end. The projecting key engages within the keyed recess and the secondary recess is used to receive the enlarged outer end of the movable jaw to help locate the jaw in precisely the proper position such that the movable jaw is aligned with the fixed jaw during clamping of the bracket assembly to a side rail. Advantageously, the movable jaw can be rotated into a position to be clamped simply by turning a fastening element which secures the fixed and movable jaws together.

Abstract: A sustainer for a roof rail which can be placed on a vehicle will be described. The sustainer includes a hollow sustaining body (1) with a floor plate (3). The floor plate (3) is engaged by a base (6) which is fastened to the floor plate (3) by a fastener (14), whereby the fastener (14) locally lies on the floor plate (3) and locally engages the base (6). They are held together by a threaded bolt (16) pulling the fastener (14) onto the inner surface of the floor plate (3).

Abstract: A vehicle article carrier having a pair of bracket members which are disposed on a pair of slats, and where each bracket member includes a rotatable actuating member incorporating a camming mechanism for allowing each bracket member to be quickly and easily placed in locked and unlocked positions relative to its associated slat. Each bracket member includes a camming member which is threadably engaged with a threaded shaft of the actuating member. A locking member is also operably engaged with the camming member and is moved between locked and unlocked positions by movement of the camming member when an operator rotates the actuating member. The apparatus incorporates a limited number of independent component parts and the majority of the component parts are disposed within a housing of the bracket member so as not to be exposed to rain, ice, snow, etc.

Abstract: A vehicle article carrier having a cross bar which may be locked and unlocked from a pair of side rails from a single side of the cross bar, and which may also be quickly and easily removed from the side rails without disassembly of the cross bar or the side rails. The vehicle article carrier comprises a pair of side rails and at least one adjustably positionable cross bar. The cross bar includes independent first and second components which are disposed at least partially within a sleeve of the cross bar. A single actuating lever having a camming boss extends through portions of each of the first and second components and simultaneously causes the first and second components to be retracted out of locking engagement with their respective side rails, thereby permitting the cross bar to be locked and unlocked relative to the side rails from one side of the vehicle.

Abstract: A vehicle article carrier including a cross bar having a pair of bracket assemblies at each end, where each bracket assembly includes a fixed jaw and a movable jaw which may be cooperatively clamped around a side rail of the article carrier system. The fixed jaw incorporates a keyed recess and the movable jaw incorporates a key. The construction of the keyed recess and the key enable the movable jaw to be pre-positioned so as to not interfere with placement of the cross bar onto the side rails during assembly. Clamping of each bracket assembly to its associated side rail is accomplished simply by turning a threaded fastener engaged with both jaw portions. The movable jaw is rotated automatically into alignment with the fixed jaw and its associated side rail. Further tightening of the fastening member automatically draws the movable jaw into clamping engagement with its associated side rail.

Abstract: An injection mold system and corresponding method that equalizes pressure of flowable plastic dispensed into an injection mold cavity. A gate in communication with the mold cavity introduces a quantity of flowable plastic into the cavity at a predetermined pressure. A gas inlet in communication with the mold cavity at a mold cavity location remote from the gate introduces a gas into the mold cavity to pack the flowable plastic in the mold cavity at a pressure corresponding generally to the predetermined pressure, to thereby minimize the formation of sink marks and warpage on an injection molded part formed therein. The present invention insures formation of the part with a highly finished appearance surface and eliminates the need for painting or otherwise additional finishing of the part.

Abstract: A mounting apparatus adapted to be disposed within a channel formed in an outer body surface of a vehicle, wherein the channel includes a permanently disposed hook portion, for securing a slat to the hook portion without the use of conventional riv-nut fasteners and without requiring holes to be drilled in the outer body surface. The apparatus comprises a mounting bracket having a base portion and a pair of offset arm portions. The base portion is adapted to slide under a lip of the permanently secured hook portion so as to be disposed substantially completely within the channel formed in the outer body surface of a vehicle. The arm portions include threaded openings which allow conventional fastening elements to be used to secure the slat to the mounting bracket. The mounting bracket can be used with or without a conventional resilient mounting pad.

Abstract: A blow molding method for use with tubular metal work pieces. The method involves placing a tubular metal component part into a molding tool having an internal molding cavity and at least one access passageway into which the component is inserted. The molding tool is then heated to a temperature between about 1000.degree. F. and 1200.degree. F. and a high pressure gas is injected into the tubular component. The high pressure gas causes the portion of the work component residing within the internal mold cavity of the molding tool to expand and assume the shape of the internal molding cavity. After a cooling period, the component is removed from the molding tool. The process is particularly well suited for forming the end support portions of side rails used with vehicle article carriers, but can be used to form a wide variety of complexly shaped forms from tubular metal workpieces.

Abstract: A vehicle article carrier 10 forming a low, aerodynamic profile when secured to an outer body surface of the vehicle. The vehicle article carrier includes a pair of slats each having channel portions which are adapted to reside at least partially within channels formed in the outer body surface of the vehicle during manufacture of the vehicle. The low profile of the slats serves to reduce the degree to which a pair of bracket members and at least one cross bar secured to the bracket members projects above the outer body surface, thereby enhancing the aesthetic appeal and improving the aerodynamic efficiency of the vehicle article carrier. In preferred embodiments each slat includes a plurality of tie-down loops integrally formed therewith. The bracket members each incorporate a manually movable locking member adapted to lockably engage with the slat to hold the bracket member at a desired position along the slat.

Abstract: A vehicle article carrier having a pair of bracket members which are disposed on a pair of slats, and where each bracket member includes a rotatable actuating member incorporating a camming mechanism for allowing each bracket member to be quickly and easily placed in locked and unlocked positions relative to its associated slat. Each bracket member includes a camming member which is threadably engaged with a threaded shaft of the actuating member. A locking member is also operably engaged with the camming member and is moved between locked and unlocked positions by movement of the camming member when an operator rotates the actuating member. The apparatus incorporates a limited number of independent component parts and the majority of the component parts are disposed within a housing of the bracket member so as not to be exposed to rain, ice, snow, etc.