Bed rail system

Abstract

An assembly includes a first side rail attached to a first vehicle portion, a second side rail attached to a second vehicle portion, and a first cross rail extending between a first cross rail end and a second cross rail end. The assembly also includes a first retaining portion selectively in contact with the first side rail and the first cross rail end and a second retaining portion selectively in contact with the second side rail and the second cross rail end. The first retaining portion selectively retains the first cross rail so as to permit rotation of the first cross rail relative to the first retaining portion about a first axis. The first retaining portion selectively retains the first cross rail so as to permit rotation of the first cross rail relative to a portion of the first retaining portion about a second axis. The first axis is generally perpendicular to the second axis.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application 60/731,136, filed Oct. 28, 2005, which is incorporated by reference in its entirety.

TECHNICAL FIELD

The disclosure generally relates to article carrier assemblies for vehicles.

BACKGROUND

Typically, article carriers for a roof or bed of a vehicle provide some modular components that may allow a user to attach and store articles while permitting flexibility and removeability. Many article carriers include a pair of side bars and one or more cross bars for securing articles to the vehicle. This flexibility may include cross bars that are removable and stowable, but may occupy undesired space when stowed.

Currently, many truck beds include a tonneau cover that keeps out dirt and debris while protecting articles within the truck bed. These covers are typically attached to upper portions of the truck bed sides. However, many article carriers have not been incorporated into a tonneau cover attachment portions, and the cross rails of these article carriers may not be stowable so as to position the cross bars out of the way for maximum use of the storage area, such as a truck bed.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the drawings, preferred illustrative embodiments are shown in detail. Although the drawings represent some embodiments, the drawings are not necessarily to scale and certain features may be exaggerated, removed, or partially sectioned to better illustrate and explain the present invention. Further, the embodiments set forth herein are not intended to be exhaustive or otherwise limit or restrict the claims to the precise forms and configurations shown in the drawings and disclosed in the following detailed description.

FIG. 1 is a perspective view of a portion of an article carrier assembly, according to an embodiment.

FIG. 2 is a perspective view of another portion of the article carrier assembly of FIG. 1.

FIG. 3 is a top view of a portion of the assembly of FIG. 1, taken along line 3 when a portion of the assembly is in an intermediate stowed configuration.

FIG. 4 is a top view of a portion of the assembly of FIG. 1, taken along line 4.

FIG. 5 is an end view of a portion of the assembly of FIG. 1, taken along line 5 of FIG. 4.

FIG. 6 is an enlarged view of portion 6 of FIG. 1.

FIG. 7 is an enlarged view of portion 7 of FIG. 1.

FIG. 8 is an alternative embodiment of the rail of FIG. 2.

FIG. 9 is a sectional view of the rail of FIG. 1.

FIG. 10 is an alternative embodiment of the rail of FIG. 1.

FIG. 11 is a sectional view taken along sectional line 11-11 in FIG. 2.

FIG. 12 is an alternative embodiment of the sectional view of FIG. 11.

DETAILED DESCRIPTION

Referring now to the drawings, illustrative embodiments are shown in detail. Although the drawings represent the embodiments, the drawings are not necessarily to scale and certain features may be exaggerated to better illustrate and explain an innovative aspect of an embodiment. Further, the embodiments described herein are not intended to be exhaustive or otherwise limit or restrict the invention to the precise form and configuration shown in the drawings and disclosed in the following detailed description.

FIGS. 1 and 2, illustrate an embodiment of an article carrier assembly 20. The article carrier assembly 20 is secured to and extends between a first vehicle portion, or a first side panel assembly, 22 and a second vehicle portion, or a second side panel assembly, 24 of a truck bed TB of a vehicle VE. The article carrier assembly 20 also includes a first cross rail 26 in a deployed, or extended, operational position (configuration) and a second cross rail 28 in stowed position (configuration). The embodiment of the article carrier assembly 20 shown in the detail of FIGS. 1-9 includes the first side rail 30 (FIG. 1), the second side rail 32 (FIG. 2), the first cross rail 26, and the second cross rail 28. The first side rail 30 and the second side rail 32 are substantially identical, configured to be mounted to either of the panel 22 or the panel 24, disposed generally along respective longitudinal axes and transversely spaced apart from each other. As will be described below, side rails 30, 32 are adapted to support the cross rails 26, 28.

The cross rails 26, 28 are configured to support articles, such as luggage and the like. In a preferred embodiment, the cross rails 26, 28 are made with the use of a lightweight metal, such as 6063-T6 extruded aluminum, to obtain needed strength objectives (i.e., to support articles), while remaining sufficiently light for easy movement. However, any metal, alloys or composites, plastic, polyamide resin and the like with sufficient strength is contemplated. While the embodiment illustrated includes two cross rails 26, 28, it is understood that other embodiments may include a greater or lesser number of cross rails.

As best seen in the enlarged sectional view of FIG. 9, the side rail 30 includes an elongated base portion 38, an upper wall 40, a first side wall 42, a second side wall 44, a lower wall 46, a first top wall portion 48, and a second top wall portion 50. The lower wall 46 extends between the base portion 38 and the second side wall 44. The upper wall 40 extends from the base portion 38 to the first side wall 42. A first hollow area, or first channel, 60 is defined by surfaces of the base portion 38, the upper wall 40, the first side wall 42 the second side wall 44, and the lower wall 46. A second hollow area, or second channel, 62 is defined by surfaces of the base portion 38, the upper wall 40, the first side wall 42, first top wall portion 48, and the second top wall portion 50.

The base portion 38 includes a plurality of mounting apertures 68 (FIGS. 8 and 9) formed therein that permit the side rail 30 to be attached to the side panel 22 of the vehicle VE.

In the embodiment of FIG. 8, the side rail 30 includes a break-away notch 70. In the embodiment illustrated, the notch 70 is located at about the mid point M of the side rail 32 in FIG. 2 to encourage the side rail 30 to break or bend at the beak-away notch 70 during an event, such as a vehicle collision, that would impart a force component in the direction of arrows F and B. Accordingly, the side rails 30, 32 may favorably buckle and absorb energy in a crash, while not undesirably transmitting forces to the passenger area of a vehicle, such as the vehicle VE.

With general reference to FIGS. 1 and 2, the first cross rail 26, illustrated partially in phantom, extends between a first cross rail end 72 and a second cross rail end 74. A first securing mechanism 76 is attached to the first cross rail end 72 and a second securing mechanism 78 is attached to the second cross rail end 74. Similarly, a pair of securing mechanisms such as mechanisms 76, 78 are attached at either end of the second cross rail 28. The channels 60 of each of the first side rail 30 and the second side rail 32 permit gliding movement of the securing mechanisms 76, 78 in the direction of the arrows F and B. In the embodiment illustrated, the securing mechanisms 76, 78 are identical, although the securing mechanisms 76, 78 may incorporate differences.

The securing mechanism 76 includes a stanchion 82, and a wrist member 84 interposed between the stanchion 82 and a first cross rail end. A cross rail end, such as either the first cross rail end 72 or the second cross rail end 74, is rotatably connected to the wrist member 84 about an axis A-A (FIG. 5) by a retaining portion, or retaining assembly, 88, and the stanchion 82 is rotatably connected to the wrist member 84 about an axis B-B (FIGS. 3 and 4) by a lock plate assembly 90 (FIG. 11).

Each of the first cross rail end 72 and the second cross rail end 74 include a cross rail attachment portion 92 and a wrist engaging end 94. The wrist engaging end 94 includes a lower surface 96, a generally opposing upper surface 98, and a wrist engaging aperture 100 (as best seen in FIG. 1) formed therein that extends generally along the axis A-A from the lower surface 96 to the upper surface 98.

As best seen in FIG. 6, the wrist member 84 includes a central body 110, having a lower tongue 112, an upper tongue 114, a first ear 116, and a second ear 118. Each of the lower tongue 112 and the upper tongue 114 have an aperture 120 formed therein. The wrist engaging end 94 is interposed between the lower tongue 112 and the upper tongue 114 such that the apertures 120 of the lower tongue 112 and the upper tongue 114 align with the wrist engaging aperture 100.

As best seen in FIG. 7, the retaining assembly 88 includes a retaining member 124 having a head 126 and an externally threaded bolt 128. The retaining assembly 88 also includes an internally threaded retaining clamp 130. As illustrated, the bolt 128 extends through the apertures 120 of the lower tongue 112 and the upper tongue 114 and the wrist engaging aperture 100. The retaining clamp 130 may be rotated relative the bolt 128 to move the retaining clamp 130 along the axis A-A relative the bolt 128 from a tightened position, where the wrist engaging end 94 is bindingly secured between the lower tongue 112 and the upper tongue 114 such that the wrist portion 84 will not readily rotate relative to the cross rail 26, to an loosened position, where the wrist portion 84 is permitted to rotate relative to the cross rail 26.

Accordingly, when the retaining assembly 88 is in the loosened position, the cross rail 26 will rotate about the axis A-A relative to the side rail 30. Additionally, when retaining assembly 88 is in the tightened position, the cross rail 26 will not readily rotate about the axis A-A relative to the side rail 30. In the embodiment illustrated, the retaining clamp 130 is an internally threaded ‘wing nut’ having flared portions that permit a user to hand-tighten the retaining assembly 88, however, any suitable component may be used, including a lever and the like.

As best seen in FIGS. 3, 4, and 6, the stanchion 82 includes a stanchion base 140, having a pair of stanchion lugs 142 extending therefrom, with each stanchion lug 142 terminating in a stanchion bushing 144. The stanchion base 140 further includes a mounting aperture 146 formed therein (FIG. 11). Each of the stanchion bushings 144 has a stanchion aperture 150 formed therein with each stanchion aperture generally defining a portion of the axis B-B. Each of the first ear 116 and the second ear 118 have an ear aperture 152 formed therein, also generally defining a portion of the axis B-B. The stanchion bushings 144 are interposed between the first ear 116 and the second ear 118 such that the ear apertures 152 and the stanchion aperture 150 are aligned. A stanchion pin 160 is interposed through the ear apertures 152 and the stanchion aperture 150 to permit the wrist portion 84 to rotate relative to the stanchion 82 generally about the axis B-B.

As best illustrated in the embodiment of FIG. 9, the lock plate assembly 90 includes an externally threaded rod 170 extending from a manipulation wheel 172 and a lock plate 176. The lock plate 176 includes an internally threaded aperture 178 that matingly engages the threaded rod 170. The manipulation wheel 172 may be rotated such that the lock plate 176 is urged toward the manipulation wheel 172, thereby bindingly securing the stanchion base 140 to the side rail 30. Additionally, the manipulation wheel 172 may be rotated such that the lock plate 176 is urged away from the manipulation wheel 172, thereby permitting the stanchion base 140 and the side rail 30 to have a gap (not shown) therebetween.

As illustrated, the stanchion 82 of the securing mechanism 76 is attached to the cross rail 26 by the lock plate assembly 90 while a portion of the lock plate assembly 90 is guidingly retained within the channel 60 of the side rail 30 so as to permit the stanchion 82 to be moved in the directions of the arrows F and B.

In the stowed position of a cross rail, such as the position of the cross rail 28 as illustrated in FIG. 1, the cross rail 28 extends in the general direction of the arrows F and B (parallel to the axis B-B), while in the deployed position of a cross rail, such as the position of the cross rail 26 as illustrated in FIGS. 1 and 2, the cross rail 26 extends perpendicular to the general direction of the arrows F and B (perpendicular to the axis B-B).

In operation, a plurality of stanchions 82 with wrist members 84 pivotally attached thereto may be attached to each of the side rails 30, 32 with locking plate assemblies 90, as described herein. A cross rail, such as the cross rail 26, may be then attached to one of the wrist members 84 that is attached to the first side rail 30 such that the first cross rail end 72 is attached adjacent to the first side rail 30. Then the second cross rail end 74, may be then attached to one of the wrist members 84 that is attached to the second side rail 32 such that the second cross rail end 74 is attached adjacent to the second side rail 32. Thus attached, the cross rail 26 will extend from the first side rail 30 toward the second side rail 32 generally perpendicular to the axis B-B. The cross rail (or a plurality of cross rails similarly deployed) may be used to secure articles, or to provide a base for supporting articles.

When a user desires to stow a cross rail that is deployed, that is, when a user desires to reconfigure a cross rail from the deployed position of the cross rail 26 of FIGS. 1 and 2 to the stowed position of the cross rail 28 of FIG. 1, the following steps may be performed. First, the retaining assemblies 88 of the securing mechanisms 76, 78 are loosened such that the bolt 128 is removed from the apertures 120 of the lower tongue 112 and the upper tongue 114 of the second securing mechanism 78, and the cross rail is permitted to rotate relative to the wrist member 84 of the first securing mechanism 76. The cross rail is then rotated about the A-A axis of the first securing mechanism 76 (which is attached to the first side rail 30) as at least one of the stanchions 82 coupled to the first side rail 30 is slid in a direction generally parallel to the axis B-B until the wrist engaging aperture 100 of the securing mechanism that is attached to the first side rail 30 is aligned with the apertures 120 of the lower tongue 112 and the upper tongue 114 adjacent the second cross rail end 74. The bolt 128 is then inserted into the apertures 120 of the lower tongue 112 and the upper tongue 114 adjacent the second cross rail end 74 and the wrist engaging aperture 100 that the bolt was just previously removed from and the retaining clamp 130 is tightened so as to secure the cross rail to the wrist member 84 (as best illustrated in the intermediate stowed configuration of FIG. 3). The cross rail is then permitted to rotate about the axis B-B from the position partially illustrated in FIG. 3 to the position partially illustrated in FIG. 6. This rotation of the cross rail about the axis B-B from the position partially illustrated in FIG. 3 to the position partially illustrated in FIG. 6 will permit the cross rail to at least partially swing out of the way in order to permit the user to utilize a greater amount of width between the side rails 30, 32.

The length of the cross rails 26, 28 may correspond to the span between the side rails 30, 32 that can be achieved either by matching the span by a one-piece cross rail lengthwise or by providing a telescopic cross rail that may be adjusted to span between side rails 30, 32. The option with telescopic cross rails makes it possible to stow more than one cross rail along one side rail. It is also appreciated that having cross rails longitudinally slidable, to thus provide adjustability for the cross rails, has the advantage of reducing the cost of the article carrier assembly. In addition, such an arrangement stimulates the end user to properly load the article carrier assembly (i.e., starting from the forward portion of the carrier assembly).

FIG. 10 illustrates an alternative embodiment of the side rail 30 as a side rail 230. The side rail 230 includes an elongated base portion 238, an upper wall 240, a first side wall 242, a second side wall 244, a lower wall 246 a, first top wall portion 248, and a second top wall portion 250. The lower wall 246 extends between the base portion 238 and the second side wall 244. The upper wall 240 extends from the base portion 238 to the first side wall 242. A first hollow area, or first channel, 260 is defined by surfaces of the base portion 238, the upper wall 240, the first side wall 242 the second side wall 244, and the lower wall 246. A second hollow area, or second channel, 262 is defined by surfaces of the base portion 238, the upper wall 240, the first side wall 242, first top wall portion 248, and the second top wall portion 250.

The base portion 238 includes a plurality of mounting apertures 268 formed therein that permit the side rail 230 to be attached to the side panel 22 of the vehicle VE. Base portion 238 has a raised portion 270.

FIG. 12 illustrates a sectional view of the side rail 32 having a tonneau cover attachment portion 300 attached thereto. As illustrated, the tonneau cover 300 secures a tonneau cover 302 to the side rail 32. Similarly, an additional tonneau cover attachment portion 300 may be attached to the side rail 30 for stretching the tonneau cover 302 between the side rails 30, 32 to cover articles within truck bed TB.

While the assembly 20 is illustrated in the bed of a truck, the assembly 20 is not so limited and may be located in other areas of a vehicle, such on a roof, or within the interior of a vehicle. Additionally, while the first cross rail 26 is illustrated in a deployed position as being generally perpendicular to the first side rail 30 and the second side rail 32, the first cross rail 26 may be in a deployed position where the first cross rail 26 not perpendicular to the first side rail 30 or the second side rail 32. Furthermore, the cross rails 26, 28 may be used for securing articles when in the stowed configuration or in the intermediate configuration.

The preceding description has been presented only to illustrate and describe exemplary embodiments of the methods and systems of the present invention. It is not intended to be exhaustive or to limit the invention to any precise form disclosed. It will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. The invention may be practiced otherwise than is specifically explained and illustrated without departing from its spirit or scope. The scope of the invention is limited solely by the following claims.

Claims

1. An assembly comprising:

a first side rail attached to a first vehicle portion;

a second side rail attached to a second vehicle portion;

a first cross rail selectively extending between a first cross rail end and a second cross rail end in a deployed configuration, having a a first retaining portion selectively in contact with the first side rail and the first cross rail end;

a second retaining portion selectively in contact with the second side rail and the second cross rail end; and

wherein the first retaining portion selectively retains the first cross rail so as to permit rotation of the first cross rail relative to the first retaining portion about a first axis, the first retaining portion selectively retains the first cross rail so as to permit rotation of the first cross rail relative to a portion of the first retaining portion about a second axis, and wherein the first axis is generally perpendicular to the second axis.

2. The assembly of claim 1, wherein the first cross rail is moveable between the deployed configuration and a stowed configuration such that the first cross rail is selectively generally perpendicular to the first side rail in the deployed configuration and the first cross rail is generally parallel to the first side rail in the stowed configuration.

3. The assembly of claim 1, wherein the first cross rail extends generally parallel to the first side rail in a stowed configuration, and the separation between the first cross rail and the second side rail in the stowed configuration is defined by a first distance, the first distance being the closest points between the second side rail and the first cross rail when the first cross rail is in the stowed configuration, and wherein the first cross rail may be rotated generally about an axis to an intermediate configuration where a second distance between the first cross rail and the second side rail is less than the first distance.

4. The assembly of claim 1, further comprising a third retaining portion selectively in contact with the first side rail and the second cross rail end.

5. The assembly of claim 1, wherein the first retaining portion includes a wrist portion pivotally attached to a stanchion, the stanchion is selectively secured to the first side rail, and the wrist portion, at least in part, defines the first axis and the second axis.

6. The assembly of claim 5, wherein the wrist portion rotates relative to the stanchion generally about the second axis.

7. The assembly of claim 5, wherein the wrist portion rotates relative to the first cross rail generally about the first axis.

8. The assembly of claim 1, further comprising a tonneau cover attachment portion attached to at least one of the first side rail and the second side rail.

9. An article carrier assembly for attachment to a vehicle, comprising:

a first cross rail extending between a first cross rail end and a second cross rail end, having a a first retaining portion selectively in contact with the first side rail and the first cross rail end, wherein the first retaining portion is selectively secured to a vehicle portion;

a second retaining portion selectively in contact with the second side rail and the second cross rail end, wherein the second retaining portion is selectively secured to a vehicle portion; and

a third retaining portion selectively in contact with the first side rail and the second cross rail end, wherein the first retaining portion selectively retains the first cross rail so as to permit rotation of the first cross rail relative to the first retaining portion about a first axis, the first retaining portion selectively retains the first cross rail so as to permit rotation of the first cross rail relative to a portion of the first retaining portion about a second axis, and wherein the first axis is generally perpendicular to the second axis.

10. The assembly of claim 8, wherein the first retaining portion includes a wrist portion pivotally attached to a stanchion, the stanchion is selectively secured to the first side rail, and the wrist portion, at least in part, defines the first axis and the second axis.

11. The assembly of claim 10, wherein the wrist portion rotates relative to the stanchion generally about the second axis.

12. The assembly of claim 10, wherein the wrist portion rotates relative to the first cross rail generally about the first axis.

13. The assembly of claim 10, further comprising a third retaining portion selectively in contact with the first side rail and the second cross rail end.

14. The assembly of claim 8, wherein the first cross rail is moveable between the deployed configuration and a stowed configuration such that the first cross rail is selectively generally perpendicular to the first side rail in the deployed configuration and the first cross rail is generally parallel to the first side rail in the stowed configuration.

15. The assembly of claim 8, wherein the first cross rail extends generally parallel to the first side rail in a stowed configuration, and the separation between the first cross rail and the second side rail in the stowed configuration is defined by a first distance, the first distance being the closest points between the second side rail and the first cross rail when the first cross rail is in the stowed configuration, and wherein the first cross rail may be rotated generally about an axis to an intermediate configuration where a second distance between the first cross rail and the second side rail is less than the first distance.

16. The assembly of claim 8, further comprising a second cross rail selectively moveable between a stowed configuration and a deployed configuration.

17. The assembly of claim 8, further comprising a tonneau cover attachment portion attached to at least one of the first side rail and the second side rail.