NESTABLE CARGO BOX FOR A VEHICLE

Abstract

Vehicle rack system with a nestable cargo box, including a kit for constructing the cargo box, and methods of making, packaging, shipping, supplying, and assembling the cargo box. The cargo box may include a base portion and a lid portion that can be arranged in (1) a shipping configuration where the base and lid portions are not operatively connected to each other and one of the portions is inverted and nested in the other portion and (2) an operative configuration in which the base and the lid portions are operatively connected to each other to form a box that can be pivoted open and fastened shut.

Description

CROSS-REFERENCES TO PRIORITY APPLICATIONS

This application is based upon and claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application Ser. No. 61/390,103, filed Oct. 5, 2010; and U.S. Provisional Patent Application Ser. No. 61/454,403, filed Mar. 18, 2011. Each of these provisional patent applications is incorporated herein by reference in its entirety for all purposes.

CROSS-REFERENCES TO OTHER MATERIALS

This application incorporates herein by reference each of the following patent documents in its entirety for all purposes: U.S. Pat. No. 7,416,098; U.S. Pat. No. 7,503,470; U.S. Pat. No. 7,980,436; U.S. Patent Application Publication No. US 2007/0194185; U.S. Patent Application Publication No. US 2010/0084447 A1; and PCT Patent Application Publication No. WO 2011/094724 A1.

INTRODUCTION

Cargo boxes are vehicle top carriers that provide an enclosed storage space above the vehicle. As fuel becomes more expensive, vehicles have become smaller and interior cargo space has decreased, making the demand for reliable, easy-to-use top carriers even greater. Cargo boxes have become quite popular for carrying cargo and are often preferable over conventional open racks for a variety of reasons. For example, cargo boxes protect cargo from the elements, such as wind, rain, and snow, and are more secure from theft or vandalism.

However, cargo boxes are expensive to ship. The costs can mount when a cargo box needs to be shipped from a factory to a distribution center, from the distribution center to a retailer, and then on to a consumer. As a result, there are strong incentives to make cargo boxes less costly to ship. Efforts generally have focused on reducing weight. Constructing a cargo box with less or lighter material can reduce manufacturing and shipping costs, but may produce an inferior product that is less robust.

Cargo boxes typically have a base and a lid that are connected to each other by hinges, latches, and struts to form an enclosure that pivots open and fastens shut. The cargo box is often assembled completely at the factory: the hinges, latches, and struts are fully installed before the cargo box is packaged and shipped. This approach has obvious advantages because it provides a cargo box that is ready-to-use, simplifies construction by minimizing the number of parts, and ensures that hinge, latch, and strut components are positioned precisely and fastened permanently to the lid and the base (such as with rivets). Also, the more difficult aspects of assembly, such as mounting the struts inside the enclosure to both the lid and the base, are of no concern to the consumer. However, complete assembly of the cargo box in the factory produces a bulky product that is expensive to ship.

There is a need for cargo boxes that can be shipped at lower cost without sacrificing product quality. The present disclosure describes a new approach to cargo box assembly in which the base and the lid are connected to each other by the consumer rather than in the factory.

SUMMARY

The present disclosure provides a vehicle rack system with a nestable cargo box, including a kit for constructing the cargo box, and methods of making, packaging, shipping, supplying, and assembling the cargo box. The cargo box may include a base portion and a lid portion that can be arranged in (1) a shipping configuration where the base and lid portions are not operatively connected to each other and one of the portions is inverted and nested in the other portion and (2) an operative configuration in which the base and the lid portions are operatively connected to each other to form a box that can be pivoted open and fastened shut. The base and lid portions may be connected to each other in the operative configuration by snap-fit connections that mount at least part of a hinge assembly, a latch assembly, a strut assembly, or a combination thereof, to the base portion and/or the lid portion of the cargo box.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a view of an exemplary vehicle rack system attached to a roof of a vehicle and including a nestable cargo box mounted to a pair of crossbars in an operative configuration after assembly of the cargo box by a consumer, in accordance with aspects of the present disclosure.

FIG. 2 is an exploded view of the nestable cargo box of FIG. 1 in an exemplary shipping configuration, with a lid of the cargo box turned over and disposed under a base of the cargo box, in accordance with aspects of the present disclosure.

FIG. 3 is a side view of the nestable cargo box of FIG. 1 disposed in the shorter, more compact shipping configuration of FIG. 2, with the base nested in the lid of the cargo box, in accordance with aspects of the present disclosure.

FIG. 4 is a side view of the nestable cargo box of FIG. 1 disposed in the taller, operative configuration of FIG. 1.

FIG. 5 is a top view of the base of the nestable cargo box arranged in the shipping configuration of FIG. 2, taken generally along line 5-5 of FIG. 2.

FIG. 6 is a top view of the lid of the nestable cargo box arranged in the shipping configuration of FIG. 2, taken generally along line 6-6 of FIG. 2.

FIG. 7 is a fragmentary inside view of the cargo box of FIGS. 1 and 2, taken generally along lines 7-7 of FIGS. 5 and 6 toward a strut with the lid disposed above the base and during assembly of the cargo box into the operative configuration by a consumer.

FIG. 8 is another fragmentary inside view of the cargo box of FIGS. 1 and 2, taken generally as in FIG. 7, with a free end of the strut positioned to be mounted to the lid by a snap-fit connection created by mating a strut mount to a lid bracket.

FIG. 9 is yet another fragmentary inside view of the cargo box of FIGS. 1 and 2, taken as in FIG. 8 after the strut mount has been snapped-fitted to the lid bracket to form a snap-fitted assembly that mounts the strut to the lid.

FIG. 10 is a fragmentary inside view of a cargo box, taken generally as in FIG. 8, with another exemplary strut mount aligned with another exemplary lid bracket immediately before the mount and bracket are mated, in accordance with aspects of the present disclosure.

FIG. 11 is another fragmentary view of the cargo box of FIG. 10, taken as in FIG. 10 after the strut mount has been snapped-fitted to the lid bracket to form a snap-fitted assembly that mounts the strut to the lid.

FIG. 12 is a fragmentary cross-sectional view of the lid of FIG. 11, taken generally along line 12-12 of FIG. 11 through the snap-fitted assembly.

FIG. 13 is a fragmentary inside view of the lid of FIG. 6 taken, generally along line 13-13 of FIG. 6, as an upper portion, namely, a catch member, of a prospective hinge/latch assembly is being positioned to be mounted to the lid by a consumer who is assembling the cargo box.

FIG. 14 is a fragmentary inside view of the lid of FIG. 6, taken as in FIG. 13 after the catch member has been mounted to the lid by a snap-fit connection to a factory-mounted lid bracket.

FIG. 15 is a fragmentary sectional view of the lid of FIG. 14, taken generally along line 15-15 of FIG. 14 through a snap-fitted assembly of the lid bracket and catch member.

FIG. 16 is a flowchart illustrating exemplary configurations produced by packaging a nestable cargo box in a shipping configuration at a factory, transporting the packaged cargo box to a consumer, and assembling the cargo box, after purchase, from the shipping configuration into an operative configuration, in accordance with aspects of the present disclosure.

FIG. 17 is a top view of a base of another exemplary nestable cargo box, with the base disposed in an exemplary shipping configuration, in accordance with aspects of the present disclosure.

FIG. 18 is a top inside view of an inverted lid of the nestable cargo box of FIG. 17, with the lid ready to receive and contain the base of FIG. 17 to produce a shipping configuration.

FIG. 19 is a fragmentary inside view of the lid of FIG. 18, taken generally along line 19-19 of FIG. 18 with an upper hinge member positioned by a consumer to be snap-fitted to a factory-mounted lid bracket, in accordance with aspects of the present disclosure.

FIG. 20 is a fragmentary inside view of the lid of FIG. 18, taken generally as in FIG. 19, and of the base of FIG. 17, taken generally along line 20-20 of FIG. 17, after the upper hinge member has been snap-fitted to the lid bracket, and as the upper hinge member is being connected to a lower hinge member with a hinge pin.

FIG. 21 is a fragmentary inside view of the lid and base of FIGS. 18 and 19, taken as in FIG. 20 after the hinge pin has been installed to form a hinge assembly that pivotally connects the lid to the base.

FIG. 22 is a side view of the hinge pin of FIGS. 20 and 21.

FIG. 23 is another side view of the hinge pin of FIGS. 20 and 21, taken generally along line 23-23 of FIG. 22.

FIG. 24 is a fragmentary inside view of the lid of FIG. 18, taken generally along line 24-24 of FIG. 18 as a latch member is being positioned by a consumer to be snap-fitted to a factory-mounted lid bracket.

FIG. 25 is a fragmentary inside view of the lid of FIG. 18, taken as in FIG. 24 after the latch member has been mounted to the lid bracket in a snap-fit connection.

DETAILED DESCRIPTION

The present disclosure provides a vehicle rack system with a nestable cargo box, including a kit for constructing the cargo box, and methods of making, packaging, shipping, supplying, and assembling the cargo box. The cargo box may include a base portion and a lid portion that can be arranged in (1) a shipping configuration where the base and lid portions are not operatively connected to each other and one of the portions is inverted and nested in the other portion and (2) an operative configuration in which the base and the lid portions are operatively connected to each other to form a box that can be pivoted open and fastened shut. The base and lid portions may be connected to each other in the operative configuration by snap-fit connections that mount at least part of a hinge assembly, a latch assembly, a strut assembly, or a combination thereof, to the base portion and/or the lid portion of the cargo box.

The nestable cargo box can be shipped to a consumer in a partially assembled, nested configuration that is more compact at lower cost, and then assembly can be completed by the consumer.

The base portion in the shipping configuration and/or the operative configuration may include a lower shell and any combination (or none) of the following devices/components attached to the lower shell, and/or contained by the lower shell (attached or not attached): one or more clamp devices, one or more hinge assemblies (which may be hinge/latch assemblies) or only a portion thereof (e.g., a lower and/or upper portion), one or more latch assemblies (which may be hinge/latch assemblies) or only a portion thereof (e.g., a lower portion and/or an upper portion), one or more strut assemblies, fasteners that attach any of the assemblies or devices to the lower shell, one or more drive bars that operatively connect latch assemblies (which may be hinge/latch assemblies), one or more user controls (e.g., operatively connected to the drive bars), or the like.

The lid portion in the shipping configuration and/or the operative configuration may include an upper shell and any combination (or none) of the following devices/components attached to the upper shell, and/or contained by the upper shell (attached or not attached): one or more brackets (such as snap-fit brackets), fasteners that mount the brackets to the upper shell, one or more hinge assemblies (which may be hinge/latch assemblies) or only a portion thereof (e.g., an upper portion and/or a lower portion), one or more latch assemblies (which may be hinge/latch assemblies) and/or only a portion thereof (e.g., an upper portion and/or a lower portion), one or more strut assemblies, one or more drive bars that operatively connect latch assemblies, fasteners that attach any of the assemblies or devices to the upper shell, one or more user controls, or the like.

Further aspects of the present disclosure are presented in the following sections:

(I) overview of an exemplary vehicle rack system with a nestable cargo box, (II) nestable cargo box in an exemplary shipping configuration, (III) exemplary snap-fit connection of cargo box components, (IV) exemplary packaging, shipping, and assembly of a cargo box, (V) exemplary nestable cargo box with single-sided opening, and (VI) selected embodiments.

I. Overview of an Exemplary Vehicle Rack System with a Nestable Cargo Box

FIG. 1 shows an exemplary vehicle rack system 40 attached to a roof 42 of a vehicle 44. System 40 may include a pair of crossbars 46 and a top carrier in the form of a nestable cargo box 48 mounted to the crossbars (or other bars/rack structure) above the vehicle, with the cargo box in an operative configuration (interchangeably termed a fully-assembled or operative state).

Vehicle 44 defines a longitudinal axis 49 extending through a front and a rear of the vehicle and corresponding to the vehicle's travel direction. Each crossbar 46 may extend transversely, such as substantially orthogonally, to longitudinal axis 49, to provide a front crossbar and a rear crossbar. Crossbars 46 may be mounted to the vehicle with towers or feet 50, which each may, for example, engage a crossbar and the vehicle and/or a longitudinally extending rail secured to the vehicle's roof.

Cargo box 48 may include a base 52 and a lid 54. (The base interchangeably may be termed a base portion or a bottom portion, and the lid interchangeably may be termed a lid portion or a top portion.) The base provides a lower shell 55, and the lid provides an upper shell 56. The base and the lid (and/or lower shell 55 and upper shell 56) fit together to form an enclosure (interchangeably termed a box or container) 57 to hold cargo. The base and the lid (and/or lower shell 55 and upper shell 56) may be connected to each other along opposing lateral sides 58, 60 with one or more hinges and one or more releasable latches. The hinges and latches may be distinct, dedicated devices or may be integrated with one another in hinge/latch assemblies (e.g., releasable hinges), as described in more detail below. In any event, the hinges and latches allow the base and the lid (and/or the shells) to form a latchable clamshell-style container that opens pivotably on only one side or on both opposing lateral sides and fastens shut. Also, the base and the lid may be connected to each other by one or more struts, which interchangeably may be termed strut assemblies or lid supports and which may have the ability to keep the lid ajar when the cargo box is open. A strut may have any suitable position in the cargo box, such as at least one strut mounted at an end (or a side) of the box, for example, a respective strut mounted at a front end 62 and a back end 64 of the box.

II. Nestable Cargo Box in an Exemplary Shipping Configuration

FIGS. 2 and 3 show respective exploded and side views of an exemplary shipping configuration (or nested configuration) for base 52 and lid 54 of cargo box 48. (For comparison, lid 54 in its usual, operative orientation is shown in phantom outline above base 52 in FIG. 2.) The exemplary shipping configuration nests base 52 in lid 54, with a convex outer surface 70 of the base arranged adjacent and facing a concave inner surface 72 of the lid. Also, a concave inner surface 74 of the base opposes/faces away from a convex outer surface 76 of the lid. Also, inner surfaces 72, 74 face in the same (general) direction, and outer surfaces 70, 76 face in the same (general) direction. Convex outer surfaces 70, 76 are at least generally and/or at least predominantly convex, and concave inner surfaces 72, 74 are at least generally and/or at least predominantly concave. In other embodiments, the lid may be nested in the base. (The shipping configuration interchangeably may be termed a shipping state or a nested state.)

Nesting a first structure (e.g., a base or lid) in a second structure (e.g., a lid or base) means that at least part of the first structure is contained in the second structure. Any suitable amount of the first structure may be contained in the second structure, as determined by height. For example, at least about one-fourth, one-half, three-fourths, or 90%, among others, of the first structure may be contained in the second structure when nested. In some cases, the first structure may be contained at least substantially completely (or completely) in the second structure meaning that at least substantially all (e.g., at least about 95% (or about 100%) by height) of the first structure is contained in the second structure. In FIG. 3, base 52 (and/or lower shell 55) is contained completely in lid 54 (and/or upper shell 56) because none of the base (and/or lower shell) projects from a volume defined by the lid (and/or upper shell).

FIG. 4 shows a side view of cargo box 48 arranged in the taller, operative configuration of FIG. 1 with the cargo box fully assembled. When compared with FIG. 3, it is apparent that the cargo box in the operative configuration has a higher profile, a substantially greater height (i.e., H₂>H₁), and occupies a substantially greater volume than in the shipping configuration. The height of the operative configuration may be at least about 20%, 40%, or 50% greater, among others, than the height of the shipping configuration. As a result, the cargo box in the operative configuration requires a bigger shipping box and takes up more valuable space when transported from the factory to the consumer. The fully-assembled configuration of FIG. 4 thus is substantially more expensive to ship.

The usual, operative configuration of the cargo box differs from the shipping configuration in the arrangement of the inner and outer surfaces. Inner surfaces 72, 74 face each other, and outer surfaces 70, 76 face away from each other. In the shipping or nested configuration compared with the operative configuration, the orientation of the base (or lower shell) with respect to the lid (or upper shell) is inverted: either the base or the lid is upside down, depending on perspective.

FIGS. 2 and 5 show various devices that may be contained in, and/or mounted to, base 52 (and/or lower shell 55) in the shipping configuration. The devices may be configured to be connectable to lid 54 (and/or base 52) by a consumer to provide or enable pivotal opening, latching, and support of the lid (and/or mounting of the lower shell to a vehicle). Each device may (or may not) be pre-mounted (i.e., factory-mounted) inside (or outside) base 52 (and/or lower shell 55), adjacent inner surface 74 (or outer surface 70), with any suitable fasteners, such as with rivets 78 or threaded fasteners.

The devices pre-mounted to the base may include retainers 80 each forming at least part of a prospective hinge/latch assembly 80A. Here, retainer 80 provides a lower portion of hinge/latch assembly 80A. Retainer 80 may be configured to releasably engage an upper portion of prospective assembly 80A, namely, a catch member 81 mounted to the lid in the operative configuration of the cargo box, as described in more detail below. When engaged by retainer 80, catch member 81 may function as a latch that prevents the cargo box from being opened and also may function as a pivot point at which the lid can pivot with respect to the base. Any suitable number of one or more retainers 80 may be pre-mounted inside base 52, to lateral side walls 82, 84 of lower shell 55. Generally, at least two retainers may be mounted to each lateral side wall, with three per side wall shown in the depicted embodiment.

Retainers 80 mounted to each lateral side wall may be operatively connected to each other by a drive bar 86 that pivots and/or slides to coordinately control release (and/or capture) of catch member 81 after the catch member is mounted to the lid. The drive bar, in turn, may be operatively connected to a lockable user control assembly 88, which may be accessed from outside the cargo box. Further aspects of hinge/latch assemblies, drive bars, and lockable user controls that may be suitable are described in the patent documents listed above under Cross-References, which are incorporated herein by reference, particularly U.S. Pat. No. 7,416,098; U.S. Pat. No. 7,503,470; and U.S. Patent Application Publication No. 2010/0084447.

The devices pre-mounted to the base also may include a pair of struts 90, 92, which also may be termed strut assemblies. The struts may be copies of each other or may have a different size, shape, and/or distinct features. Front strut 90 may be mounted to the inside of base 52 at front end wall 94. Rear strut 92 may be mounted to the inside of the base at rear end wall 96. Alternatively, or in addition, one or more struts may be attached to one or both lateral side walls 82, 84. In any event, each strut may have a free end configured to be mounted, by the consumer, to the lid (and/or the base) via a snap-fit connection, as will be described in more detail below. Further aspects of struts that may be suitable are described in the patent documents listed above under Cross-References, which are incorporated herein by reference, particularly PCT Patent Application Publication No. WO 2011/094724 A1.

Base 52 also may be equipped with one or more clamp devices 98. Each clamp device may be attached to lower shell 55, and/or may be disposed under lower shell 55 and/or at a bottom of the base. Each clamp device may be configured to mount the base (and/or lower shell) above a vehicle and/or to attach the base/cargo box/lower shell to a bar of a vehicle rack. Accordingly, the base may include at least one or two clamp devices for attachment to a front crossbar and at least one or two clamp devices for attachment to a rear crossbar of a vehicle rack. The clamp device may have a fixed or adjustable position along the base or lower shell. The clamp devices may be disposed between lower shell 55 and upper shell 56 in the nested configuration (see FIG. 3) without interfering with the ability of the base to be nested in the lid (or upper shell).

Lower shell 55 may define openings 99 configured to receive fasteners 99A that mount the clamp devices to the lower shell. Each opening may permit a fastener to extend through a bottom wall of the shell. The openings may be circular through-holes, elongate through-holes or slots, as shown here, or the like. Fasteners 99A may include knobs, wings, or other the like, to enable adjusting the fasteners by hand. Accordingly, in some cases, clamp devices 98 may be mounted to the lower shell, and adjustably positioned along the lower shell, without the use of tools.

In some embodiments, the clamp devices may not be pre-mounted to lower shell 55 at the factory. In other words, the clamp devices may be mounted to the lower shell by the consumer after receiving the cargo box in a shipping configuration. If not pre-mounted, the clamp devices may be disposed between nested upper and lower shells, may be contained by the lower shell but not operatively connected/mounted to the lower shell, or may be disposed outside of both the upper and lower shells but not operatively connected to either.

A clamp device may be any mechanism that provides at least one clamping member of a clamp assembly capable of opposingly gripping a structure, such as a rail or a bar (e.g., a crossbar). The clamp device may be a discrete device that is attached or attachable to the lower shell. For example, the clamp device may be equipped with a pair of clamping members, such as jaws, that can be urged toward each other and against respective opposing sides of a structure (e.g. a bar) to be clamped. Alternatively, the clamp device may include only one clamping member that cooperates with the lower shell to opposingly grip a structure, such as a bar. For example, in some cases, the clamp device may be a U-bolt or U-shaped bracket that forms a clamp assembly with the lower shell. The bolt or bracket may be configured to be disposed under a crossbar and fastened to the lower shell to opposingly engage the crossbar with the U-bolt/bracket and a bottom outer surface region of the lower shell. Further aspects of clamp devices that may be suitable are described in the patent documents listed above under Cross-References, which are incorporated herein by reference, particularly U.S. Pat. No. 7,416,098 and U.S. Pat. No. 7,503,470.

FIGS. 2 and 6 show snap-fit lid brackets 100, 102 that may be contained in lid 54 (and/or upper shell 56) in the shipping configuration (and the operative configuration). Each lid bracket may be pre-mounted (i.e., factory-mounted) to inner surface 72 of upper shell 56 with fasteners, such as with rivets 78. Each lid bracket may be configured to be mated, by a consumer, with a complementary mounting member to create a snap-fit connection that connects a device to the lid during assembly of the cargo box into the operative configuration. For example, end lid brackets 100 may be utilized to mount struts 90, 92 to the lid (and/or upper shell), and side lid brackets 102 to mount catch member 81 (and/or a hinge member or other latch member) to the lid (and/or upper shell), as described in more detail below.

Brackets 100, 102 may be described as low-profile brackets that do not project very far from the inner surface of the upper shell. For example, each bracket may project less than about two or one centimeters from the inner surface. As a result, each bracket 100, 102 may be disposed between lower and upper shells 55, 56 in the shipping/nested configuration without interfering with the ability of the base to nest in the lid (e.g., see FIG. 3).

FIG. 2 shows catch members 81 disposed above base 52. The catch members may or may not be contained in the base (or the lid) in the shipping configuration, but generally are not mounted to the lid (or the base), until the consumer assembles the cargo box. The catch members are shown here in an orientation in which they may be engaged by retainers 80 arranged along one of the lateral side walls of the base. However, three of the catch members would need to be pivoted about a vertical axis to orient them properly for engagement with retainers 80 along the other lateral side wall. In any event, the catch members may be mounted to the lid before they are engaged by retainers 80, in which case the catch members would need to be turned upside down for mating with brackets 102, if lid 54 is upside down (e.g., as shown here).

III. Exemplary Snap-Fit Connection of Cargo Box Components

FIG. 7 shows a fragmentary inside view of cargo box 48 taken during assembly of the cargo box by a consumer. In this view, lid 54 is disposed above base 52, with lid bracket 100 disposed above an attached end 104 of strut assembly 90. Attached end 104 may be mounted pivotably to the base with a factory-installed mount 106. (Alternatively, the strut may be mounted to both the lid and the base by the consumer using snap-fit connections.) A free end 108 of the strut assembly may be contained in base 52 before the strut assembly is moved from its shipping configuration. Free end 108 may be pivotably connected to a snap-fit mounting member or mount 110 that is configured to mate with lid bracket 100. Strut assembly 90 may be pivoted, indicated by an arrow at 112, to bring free end 108 out of base 52/shell 55 and into lid 54/shell 56, in preparation for mounting the strut to the lid.

Strut 90 may include a plurality of pivotally connected arms 112A-D that permit the spacing between the ends of the strut to be changed as the cargo box is opened and closed. In some cases, the strut may be a dual-force strut configured to apply an opening force that helps to pivot the lid away from the base as the cargo box is being opened, and a closing force that urges the lid toward the base as the cargo box is being closed. Also, the strut may include a force-adjustment mechanism 112E. Further aspects of a strut that may be suitable are described in the patent documents listed above under Cross-References, which are incorporated herein by reference, particularly PCT Patent Application Publication No. WO 2011/094724 A1.

FIGS. 8 and 9 show strut mount 110 positioned to be mated with lid bracket 100 (FIG. 8), and then mated and locked in place to form a snap-fitted assembly 113 (FIG. 9). The strut mount and the lid bracket may provide respective female and male portions, or vice versa, that are complementary to each other, such that the male portion can be received in the female portion. For example, strut mount 110 may define an opening 114 that can receive a body portion 116 of lid bracket 100. As shown in FIG. 8, the strut mount and the lid bracket may be arranged coaxially, with opening 114 positioned to be received over body region 116. The strut mount may be slidably advanced, indicated by a motion arrow 118 in FIG. 8, into mated engagement with the lid bracket until a snap-fit of the strut mount to the lid bracket is achieved. For example, a detent 120 formed on a resilient tongue 122 of bracket 100 (or mount 110) may be received in a though-hole 124 (or blind hole) of strut mount 110 (or bracket 100) to prevent uncoupling motion of the strut mount (i.e., in the direction reverse to motion arrow 118) (see FIGS. 8 and 9). Also, a stop 126 formed by lid bracket 100 (or mount 110) may be positioned to engage a wall 128 of strut mount 110 (or bracket 100), to block any additional forward motion of the strut mount parallel to motion arrow 118.

The snap-fit may have any suitable properties. Achievement of the snap-fit is generally perceptible, such as by producing a brief, audible sound (e.g., a click) and/or an abrupt movement (and/or stop), among others. In some cases, the snap-fit may be described as a one-time snap-fit, which is configured to be easy to create but very difficult to reverse and thus substantially permanent. For example, detent 120 and tongue 122 may not be accessible to the consumer after the strut mount is locked to the lid bracket. In some embodiments, the strut mount may be snap-fitted to the lid bracket with a twisting motion or any combination of a sliding motion and a twisting motion.

FIGS. 10-12 show another exemplary embodiment of a lid bracket 140 and a strut mount 142, which correspond generally in structure and function to lid bracket 100 and strut mount 110, respectively. Strut mount 142 is configured to be snapped-fitted to lid bracket 140, to form a snap-fit assembly 144 that mounts an upper end of strut 90 to the lid (see FIGS. 11 and 12). Lid bracket 140 and strut mount 142 may provide a male portion 146 and a female portion 148 (see FIG. 10) that are mated with each other in assembly 144 (see FIGS. 11 and 12).

Male portion 146 may be provided by a body or rail region 150 of the lid bracket (see FIGS. 10 and 12). Body region 150 may be wider in cross-section at a position farther from upper shell 56 and narrower at a position closer to the upper shell. For example, the body region in cross-section may form a continuous taper (e.g., a dovetail) or may be stepped (e.g., to form a T-shape in cross section), as shown in FIG. 12. Alternatively, or in addition, one or more grooves 152 may be formed by body region 150 alone or collectively with upper shell 56.

Female portion 148 may define a cavity 154 that is complementary in shape to male portion 146. The cavity may narrow in cross-section toward an inner surface 156 of strut mount 142, which may produce a pair of ridges 158. The ridges or other narrowed structure of strut mount 142 formed adjacent a lateral mouth of cavity 154 may prevent the strut mount from being uncoupled from lid bracket 140 by motion in a direction orthogonal to a local surface region of upper shell 56.

Strut mount 142 may be locked in place by a locking tongue or tab 162 equipped with a detent 164 (see FIGS. 10 and 12), in a manner analogous to that described above for locking of strut mount 110. The locking tongue and detent may be formed by a lateral side region of body region 150 of the lid bracket.

Front and rear strut mounts 142 (or 110) may be connected to their respective lid brackets 140 (or 100) at a point during assembly when it is difficult for the consumer to see inside the cargo box. Accordingly, the consumer may benefit from visual and/or tactile aids that facilitate aligning the mounts and the brackets properly for mating. (The mount and the bracket may be mateable with each other only when aligned and in only one of the two possible alignment orientations.) Toward this end, brackets 140 and/or mounts 142 may be shaped to have a directionality that can be determined by feel and/or by sight under conditions of poor visibility. For example, brackets 140 and mounts 142 may be elongate and oversized (e.g., having a substantially larger footprint than brackets 102), with one of the opposing ends of each forming a wider head 170 and/or tapering to a point 172 (see FIG. 10), which may shape each bracket 140 (or 100) and/or mount 142 (or 110) as an arrow. Each bracket and mount (and/or the arrows they form) may be configured to point in the same direction when correctly positioned to be mated with each other, and may be overlapped and pointing in the same direction when snap-fitted together. During mating of the mount to the bracket, the mount may be moved while the bracket remains generally stationary. Accordingly, the arrows formed by the bracket and mount may both point in the direction that the mount should be moved toward the bracket, optionally with a head/point of the arrow formed by mount 142 adjacent a tail of the arrow formed by bracket 140, when both are positioned correctly for subsequent mating. In some cases, the bracket and/or mount may have an arrow or other direction indicator formed on a surface region of the bracket/mount, rather than or in addition to the mount/bracket being shaped as an arrow.

The brackets and mounts each may have a color that is different than the color of the lid and/or upper shell, such as lighter than the color of the lid, to provide contrast with the lid. The brackets and mounts thus may reflect light more efficiently than the lid. For example, the mounts and/or brackets may be white, yellow, orange, green, blue, or red in color, among others, and the lid and/or upper shell may be black in color.

FIG. 12 shows an exemplary approach for connecting a strut to strut mount 142. The mount may form and/or be connected to a buttressed, projecting receiver 180 defining a bore 182. The upper or free end of the strut may be pivotably connected to receiver 180 with a fastener placed through the free end of the strut and into engagement with the walls of bore 182.

FIGS. 13 to 15 show catch member 81 positioned to be mated with lid bracket 102 (FIG. 13) and then mated and locked in place to form a snap-fitted assembly 200 (FIGS. 14 and 15). The catch member may include a mounting portion 202 connected to a latch portion 204, which may include a pivot/catch pin 206. Catch member 81 may form an upper portion of hinge/latch assembly 80A (see FIG. 2), when the assembly is arranged in the operative configuration of the cargo box, with the cargo box mounted above the vehicle. Pin 206 may be attached to mounting portion 202 at opposing ends of the pin by fingers 208.

Mounting portion 202 and lid side bracket 102 may be configured to mate with each other in a snap-fit connection, in a manner analogous to strut mount 110 (and/or 142) and lid end bracket 100 (and/or 140). Accordingly, mounting portion 202 and lid side bracket 102 may have any combination of features disclosed above for strut mounts and lid end brackets. For example, mounting portion 202 may form a cavity 210 that is received over a body portion or rail 212 formed by lid side bracket 102 (or vice versa), as catch member 81 is placed onto the lid bracket by motion indicated by an arrow at 214 (see FIG. 13). Also, lid bracket 102 may be equipped with a locking tab 216 that includes a detent 218. Further, lid bracket 102 may provide a stop 220 that blocks forward travel of the catch member when being mated with the lid bracket.

Catch member 81 may be configured to slide onto bracket 102 from only one of the opposing ends of the bracket. Arrows 222, 224 may be visible on (e.g., formed on and/or in) outer surface regions of the catch member and bracket to indicate to the consumer how the catch member should be aligned with and slid onto the bracket. The arrows may be formed by any suitable process, such as molding, printing, painting, etching, application of a discrete label, or the like.

Catch members 81 may be mounted to lid side brackets 102 on both opposing lateral sides of the lid. At any given time, each catch pin 206 may act as engageable/releasable latch or a pivot pin for the cargo box based respectively on whether the catch pins on the other lateral side are engaged/trapped by or released from retainers 80 (see FIG. 2).

Each catch pin 206 may be disposed at least partially outside upper shell 56, as shown in FIGS. 13 and 15, or may be contained completely by the upper shell. Generally, having the catch pin positioned outside the upper shell allows more and/or all of the corresponding retainer 80 to be contained in the lower shell (see FIGS. 2, 3, and 5), which may (or may not) decrease the profile of the cargo box in the shipping configuration. In any event, since catch member 81 may be mounted during assembly by a consumer, the catch member can have a substantially higher profile than lid bracket 102, without affecting the ability of the base to nest in the lid in the shipping configuration of the cargo box. For example, as shown in FIG. 15, the catch member may project into upper shell 56 at least about two or three times as far from the upper shell as bracket 102.

IV. Exemplary Packaging, Shipping, and Assembly of a Cargo Box

FIG. 16 shows a flowchart illustrating exemplary configurations produced by packaging cargo box 48, shipping the cargo box, and assembling the cargo box after shipment. The assembly configurations shown may be generated in any suitable order.

A manufacturer and/or supplier of cargo box 48 may arrange components of the cargo box in a shipping configuration 250 as a kit 251 of cargo box components. Base 52 and lid 54 (and/or the lower shell and upper shell) of the partially-assembled cargo box may be nested and packaged in a shipping container 252, such as a shipping box (e.g., a cardboard box). Kit 251 may provide all of the components necessary to assemble a functional cargo box in an operative configuration. Mhe kit may be contained by the shipping container. At least some of the components may be pre-mounted to lower shell 55 (e.g., any combination of retainers, hinge members, struts, drive bars, user control assemblies, and clamp devices) or upper shell 56 (e.g., snap-fit brackets). Other components, such as catch members 81 (and/or hinge members and/or latch members, see below) may not be mounted yet to either shell. The catch members (and/or other unmounted components) may be disposed between the shells and/or contained in the upper and/or lower shell, or may be disposed outside both shells, as shown here, but inside shipping container 252. The shipping container also may contain instructions for assembling the cargo box at home, and/or assembly instructions may be available online, among others. In some cases, the clamp devices may not be pre-mounted to the lower shell. Accordingly, if not pre-mounted, the unmounted clamp devices may be disposed at any suitable position inside or outside the upper and lower shells, such as associated with other unmounted components.

The partially-assembled cargo box in shipping container 252 may be transported, indicated at 254, from the manufacturer/supplier to a consumer. Transporting the cargo box may involve any suitable number of shipping steps, between any suitable number of destinations. For example, the cargo box in shipping configuration 250 may be transported from a factory to a distribution center, from the distribution center to a retail outlet, and from the retail outlet to the consumer's place of residence, among others. In any event, the consumer may receive cargo box 48 in shipping configuration 250.

The consumer may assemble the cargo box from the shipping configuration into a fully-assembled, operative configuration 256, shown at the bottom of FIG. 16. In some cases, the consumer may assemble the cargo box without the use of tools. In any event, the lid, the base, and unmounted components (e.g., catch member 81, upper portions of hinges, upper portions of latches, and/or clamp devices) of the cargo box may be removed from shipping container 252, indicated at 258. The base may be removed (i.e., unnested) from the lid before or after the base and lid are removed from container 252. Unnesting configuration 260 shows the base being removed from the lid, which may be performed by moving the base out of the lid and/or taking the lid off the base, among others.

The relative orientation of the base with respect to the lid may be inverted, as shown in configuration 262. In other words, the base may be turned over with respect to the lid, or the lid may be turned over with respect to the base (and placed on the other side of the base). Inverting the relative orientation of the base with respect to lid generally involves arranging concave inner surfaces 72, 74 of the lid and base (and/or shells thereof) to face each other, so that the base and the lid (and/or shells thereof) can be fitted together and operatively connected to each other to form a box for holding cargo.

Unmounted components of the cargo box (e.g., catch members 81) may be mounted to the lid. Configuration 262 shows a pair of catch members 81 already mounted to the lid by snap-fitting the catch members to side brackets 102. Struts 90, 92 also may be mounted to the lid by making snap-fit connections with end brackets 100 (e.g., see FIGS. 7-9). The struts may be mounted at any suitable time relative to hinge and/or latch members, such as before or after the hinge and/or latch members are mounted. In any event, after the struts and hinge and/or latch members are mounted, the cargo box provides a box that may be pivoted open via hinges, supported by the struts in an open position, and fastened shut with latches. In some cases, the clamp devices may be mounted to the lower shell during assembly, at any suitable time relative to mounting other components. In any event, the assembled cargo box may be mounted above a vehicle.

V. Exemplary Nestable Cargo Box with Single-Sided Opening

FIG. 17 show a top view of a base 280 of another exemplary nestable cargo box 282, with the base disposed in an exemplary shipping configuration. Cargo box 282 may be configured to open pivotably on only one of two opposing lateral sides 284, 286. In particular, the cargo box may be hinged, but not releasably latchable, on lateral side 284, and a releasably latchable, but not hinged, on lateral side 286.

Base 280 may have any of the structures, features, and components described above for base 52 of cargo box 48. The base may include pre-mounted lower portions of hinge assemblies and latch assemblies to achieve hinge and latch functions. The base may have at least two lower hinge members 288 mounted to an inside surface 290 of a lower shell 292 of the base on lateral side 284. Also, at least two latch retainers 294 may be mounted to inside surface 290 of shell 292 on lateral side 286. The latch retainers may be coordinately controlled by a drive bar 296 that moves retainer pins 298 between engaged and released positions.

Base 280 also may include strut assemblies 300, 302 mounted to lower shell 292. The strut assemblies may have any of the structures and features described above for struts 90, 92, including strut mount 110 or 142.

The base may be equipped with clamp devices 304 that allow the base to be mounted to a roof of a vehicle. The clamp devices may, for example, include a U-bolt 306.

FIG. 18 shows a top inside view of an inverted lid 310 of nestable cargo box 282, with the lid ready to receive and contain the base of FIG. 17, to produce a shipping configuration. Lid 310 may have any of the structures, features, and components described above for lid 54. The lid may include an upper shell 312 and a plurality of snap-fit brackets mounted to an inner surface of the upper shell. The brackets may include end brackets 100 for mounting strut assemblies 300, 302 to the lid. Brackets 100 have already been described in detail and will not be addressed further here. The brackets also may include side brackets 314, 316 for mounting respective upper portions of hinge assemblies and latch assemblies to the lid by a snap-fit.

FIG. 19 is a fragmentary inside view of the lid of FIG. 18, taken generally along line 19-19 of FIG. 18 with an upper hinge member 318 positioned to be snap-fitted to lid bracket 314. Upper hinge member 318 may include a mounting portion 320 and a pin-receiving portion 322. The mounting portion may be mated with bracket 314 in a snap-fit, to mount pin-receiving portion to upper shell 312. Bracket 314 and mounting portion 320 may have any of the structures and features described above for other brackets and mounting portions. Bracket 314 also may be visually distinguishable from bracket 316, such as by color, size, shape, and/or indicia 324 thereon, among others. Here, bracket 314 and hinge member 318 are both marked with the word “HINGE” to distinguish them respectively from bracket 316 and a latch member to be described below.

FIGS. 20 and 21 show connection of the lid to the base with a hinge. FIG. 20 shows base 280 and lid 310 after upper hinge member 318 has been snap-fitted to bracket 314, and as the upper hinge member is being connected to lower hinge member 288 with a hinge pin 326. The hinge pin may be placed through bores 328, 330 defined by lower hinge member 288 and upper hinge member 318. The hinge pin may be inserted from either end of bore 330. FIG. 21 shows base 280 and lid 310 after hinge pin 326 has been placed through coaxially arranged bores 328, 330 to form a hinge assembly 332 that connects the lid to the base.

FIGS. 22 and 23 show side views of hinge pin 326. The pin may include a head 334 connected to a shaft 336. Head 334 may have a larger diameter than bore 330 to block advancement of the pin through the bore (see FIGS. 20 and 21). Shaft 336 may be sized to be received in bores 328, 330. A leading end of the shaft may be forked to produce a pair of tabs 338 each including a detent 340. The tabs may be resilient enough to be urged toward each other, to allow travel through the bores, and then may spring apart slightly when detents 340 emerge from bore 330, such that the detents block removal of the hinge pin from the bores.

FIGS. 24 and 25 show an inside view of lid 310, taken as a latch member 350 is being positioned to be snap-fitted to lid bracket 316 (FIG. 24) and after the snap-fit connection has been made (FIG. 25). The latch member may include a mounting portion 352 and a catch portion 354. Lid bracket 316 and mounting portion 352 may have any of the structures and features described above for other brackets and mounting portions. However, lid bracket 316 may be shaped and/or sized differently from bracket 314, to prevent inadvertently mounting hinge member 318 or latch member 350 on the wrong lateral side of lid 310. In other words, hinge member 318 can only be mounted on bracket 314, and latch member 350 can only be mounted on bracket 316. Also, bracket 314 and hinge member 318 may have matching indicia (e.g., “HINGE”) and/or color, as may bracket 316 and latch member 350 (e.g., “LATCH” and/or a different matching color from that of the other bracket/member).

Latch member 350 may be releasably engageable by latch retainer 294 (see FIGS. 17 and 24). The catch portion of the latch member may form a notch 356 (and/or a hook) that receives retainer pin 298 of the latch retainer to fasten the lid to the base. Drive bar 296 may be slidable by a user to move both pins 298 into and out of the notches of their associated latch members. (The terms “consumer” and “user” are interchangeable in the present disclosure.)

VI. Selected Embodiments

This section describes selected embodiments of the present disclosure, presented as a series of numbered paragraphs.

1. A method of assembling a top carrier for a vehicle, comprising: (A) receiving a base portion and a lid portion each having an inner surface and an outer surface, the base portion and the lid portion being arranged in a nested configuration having the outer surface of one of the portions facing the inner surface of the other portion; (B) connecting the base portion to the lid portion using one or more hinge assemblies, to form a cargo box having the inner surfaces facing each other when the box is closed and that opens by pivoting the lid portion away from the base portion; and (C) mounting the cargo box above a vehicle.

2. The method of paragraph 1, wherein the step of connecting includes a step of creating a plurality of snap-fit connections.

3. The method of paragraph 2, wherein the lid portion in the nested configuration includes an upper shell and a plurality of brackets mounted to the upper shell, and wherein the step of creating a plurality of snap-fit connections includes a step of snap-fitting an upper portion of each hinge assembly to a bracket of the plurality of brackets.

4. The method of paragraph 1, wherein each hinge assembly is a hinge/latch assembly, wherein the box has opposing lateral sides, and wherein the lid portion can be pivotably opened and releasably latched on each of the opposing lateral sides after the step of connecting.

5. The method of paragraph 1, further comprising a step of connecting the base portion to the lid portion with one or more strut assemblies.

6. The method of paragraph 5, wherein the step of connecting the base portion to the lid portion with one or more strut assemblies includes a step of mounting a strut assembly to at least one of the portions with at least one snap-fit connection.

7. The method of paragraph 6, wherein the lid portion includes an upper shell and a pair of brackets mounted to an inner surface of the shell, wherein the step of mounting a strut assembly includes a step of mounting each strut assembly of a pair strut assemblies to the lid portion by making a snap-fit connection to each bracket of the pair.

8. The method of paragraph 1, further comprising a step of mounting an upper portion of a latch assembly to the lid portion with a snap-fit connection, wherein the box has opposing lateral sides and opens and releasably latches on only one of the opposing lateral sides after the steps of connecting and mounting.

9. The method of paragraph 1, wherein the base portion, the lid portion, and the hinge assemblies are disposed inside a shipping container when received, and wherein the shipping container has a height that is less than a height of the cargo box.

10. The method of paragraph 9, wherein the shipping container is a cardboard box.

11. The method of paragraph 1, wherein the base portion is nested in the lid portion in the nested configuration.

12. The method of paragraph 11, wherein the base portion includes a lower shell, and wherein the lower shell is at least substantially completely contained in the lid portion in the nested configuration.

13. The method of paragraph 1, wherein the base portion includes a lower shell, and wherein at least one strut assembly is mounted to the lower shell in the nested configuration.

14. The method of paragraph 1, wherein the base portion includes a lower shell, and wherein a lower portion of each of the hinge assemblies is already mounted to the lower shell when the base portion is received.

15. The method of paragraph 14, wherein the hinge assemblies are hinge/latch assemblies, and wherein the lower portions of the hinge/latch assemblies are already connected to each other by a drive bar when the base portion is received.

16. The method of paragraph 1, wherein the steps of receiving, connecting, and mounting are performed by a consumer, and wherein the lid portion and the base portion are arranged in the nested configuration before the base portion and a lid portion are received by the consumer.

17. The method of paragraph 1, further comprising a step of inverting a relative orientation of the base portion with respect to the lid portion before the step of connecting.

18. The method of paragraph 1, further comprising a step of arranging the base portion and a lid portion such that the inner surfaces face each other before the step of connecting.

19. The method of paragraph 1, wherein the base portion includes a lower shell, and wherein one or more clamp devices configured to mount the base portion above a vehicle are already attached to the lower shell when the base portion is received in the nested configuration.

20. The method of paragraph 19, wherein the base portion includes a lower shell, wherein the lid portion includes an upper shell, and wherein the one or more clamp devices are disposed between the lower shell and the upper shell when the base portion and the lid portion are received in the nested configuration.

21. The method of paragraph 1, further comprising a step of attaching one or more clamp devices to the base portion after the step of receiving, wherein the step of mounting is performed by engaging one or more crossbars with the one or more clamp devices.

22. The method of paragraph 1, wherein each of the inner surfaces is concave and each of the outer surfaces is convex.

23. A kit for constructing a top carrier for a vehicle, comprising: (A) a base portion including a lower shell; (B) a lid portion including an upper shell; (C) one or more clamp devices configured to mount the base portion above a vehicle; and (D) components of a plurality of hinge assemblies; wherein the lower shell and the upper shell each have an inner surface and an outer surface, wherein the lower shell and the upper shell are nested in the kit with the outer surface of one of the shells facing the inner surface of the other shell, and wherein the base portion and the lid portion are configured to be connected to each other with the hinge assemblies, to form a cargo box having the inner surfaces facing each other when the cargo box is closed and that opens by pivoting the lid portion away from the base portion.

24. The kit of paragraph 23, wherein the base portion, the lid portion, the clamp devices and the components of a plurality of hinge assemblies are contained in a shipping box, and wherein the shipping box has a height that is less than a height of the cargo box.

25. The kit of paragraph 23, wherein the kit provides the clamp devices pre-attached to the lower shell.

26. The kit of paragraph 23, wherein the clamp devices are configured to be attached to the lower shell, and wherein the kit provides the clamp devices not attached to the lower shell.

27. The kit of paragraph 23, wherein the hinge assemblies are hinge/latch assemblies each having an upper portion and a lower portion, and wherein the kit provides the lower portion of each hinge/latch assembly pre-mounted to the lower shell.

28. The kit of paragraph 27, wherein the kit provides the upper portion of each hinge/latch assembly not operatively mounted to the upper shell.

29. The kit of paragraph 28, wherein the lid portion includes a plurality of brackets pre-mounted to the upper shell, and wherein the upper portion of each hinge/latch assembly is configured to be operatively mounted to the upper shell by making a snap-fit connection to a bracket of the plurality of brackets.

30. The kit of paragraph 23, wherein the kit provides the base portion nested in the lid portion.

31. The kit of paragraph 30, wherein the clamp devices are disposed between the lower shell and the upper shell in the kit.

32. The kit of paragraph 30, wherein the lid portion includes a plurality of snap-fit brackets pre-mounted to the upper shell, further comprising one or more strut assemblies pre-mounted to the lower shell in the kit, wherein each strut assembly includes a mounting member configured to form a snap-fit connection with a snap-fit bracket to mount the strut assembly to the lid portion.

33. The kit of paragraph 23, wherein the lower shell is contained at least substantially completely in the upper shell in the kit.

34. A cargo carrier for a vehicle, comprising: (A) a base portion equipped with one or more clamp devices configured to mount the base portion above a vehicle; (B) a lid portion fitted together with the base portion to form a box; (C) one or more strut assemblies connecting the base portion to the lid portion; (D) one or more hinge assemblies pivotably connecting the base portion to the lid portion; and (E) one or more latch assemblies releasably fastening the base portion to the lid portion, wherein each strut assembly, hinge assembly, and latch assembly is mounted to the lid portion, the base portion, or to both the lid portion and the base portion by at least one snap-fit connection.

35. The cargo carrier of paragraph 34, wherein an upper portion of each strut assembly, hinge assembly, and latch assembly is mounted to the lid portion by a snap-fit connection.

36. The cargo carrier of paragraph 34, wherein each hinge assembly is a hinge/latch assembly, and wherein each latch assembly is a hinge/latch assembly.

37. The cargo carrier of paragraph 36, wherein the hinge assemblies and the latch assemblies are substantial copies of each other.

38. The cargo carrier of paragraph 34, wherein the box has opposing lateral sides, and wherein the box opens and releasably fastens on only one of the opposing lateral sides.

39. The cargo carrier of paragraph 34, wherein the box has opposing lateral sides, and wherein the box opens and releasably fastens on each of the opposing lateral sides.

40. The cargo carrier of paragraph 34, wherein the lid portion includes an upper shell and a plurality of snap-fit brackets mounted inside the upper shell, and wherein each strut assembly, hinge assembly, and latch assembly forms a snap-fit connection with a snap-fit bracket mounted inside the shell.

41. The cargo carrier of paragraph 34, wherein the base portion includes a lower shell, wherein the lid portion includes an upper shell, and wherein the lower shell taken in isolation is nestable in the upper shell taken in isolation such that the lower shell is substantially completely contained by the upper shell.

42. The cargo carrier of paragraph 41, wherein the lower shell attached only to the clamp devices is nestable in the upper shell taken in isolation such that the lower shell is substantially completely contained by the upper shell.

43. The cargo carrier of paragraph 41, wherein the lid portion includes a plurality of snap-fit brackets mounted to the upper shell, wherein the lower shell taken in isolation is nestable in the upper shell mounted only to the snap-fit brackets such that the lower shell is substantially completely contained by the upper shell.

44. A method of shipping a cargo carrier for a vehicle, comprising: (A) forming a package containing a base portion nested with a lid portion, one or more clamp devices configured to mount the base portion above a vehicle, and components of one or more hinge assemblies; and (B) shipping the package, wherein the base portion is configured to be connected to the lid portion after the step of shipping using the one or more hinge assemblies, to form a cargo box that opens by pivoting the lid portion away from the base portion.

45. The method of paragraph 44, wherein the lid portion includes an upper shell, further comprising a step of mounting a plurality of snap-fit brackets to the upper shell before the step of shipping.

46. The method of paragraph 44, wherein the base portion includes a lower shell, further comprising a step of mounting a lower portion of each of the one or more hinge assemblies to the lower shell before the step of shipping.

47. The method of paragraph 44, wherein the base portion and the lid portion are not operatively connected to each other in the package.

48. The method of paragraph 44, wherein the base portion includes a lower shell, further comprising a step of mounting a lower portion of a strut assembly to the lower shell before the step of shipping.

49. A kit for constructing a cargo carrier for a vehicle, comprising: (A) a base portion; (B) one or more clamp devices configured to mount the base portion above a vehicle; (C) a lid portion; (D) components of one or more hinge assemblies; and (E) components of one or more latch assemblies, wherein the base portion and the lid portion are disposed in a nested configuration in which one of the portions is contained at least substantially completely in the other portion, and wherein the base portion and the lid portion are configured to be unnested and connected to each other with each of the hinge and latch assemblies such that a relative orientation of the base portion with respect to the lid portion is inverted from the nested configuration to form a cargo box capable of pivoting open and fastening shut.

50. A kit for constructing a cargo carrier for a vehicle, comprising: (A) a base portion; (B) one or more clamp devices attached or attachable to the base portion and configured to mount the base portion above a vehicle; (C) a lid portion; (D) components of one or more hinge assemblies; (E) components of one or more latch assemblies; and (F) one or more strut assemblies, wherein each of the base portion and the lid portion has a concave inner surface and a convex outer surface, wherein the base portion and the lid portion are disposed in a nested configuration in which the outer surface of one of the portions faces the inner surface of the other portion, and wherein the base portion and the lid portion are configured to be arranged such that the inner surfaces of the base portion and the lid portion face each other and to be connected to each other with each of the hinge, latch, and strut assemblies by making at least one snap-fit connection for each assembly such that the base portion and lid portion form a cargo box capable of pivoting open to a supported position and fastening shut.

51. A shipping configuration for a vehicle top carrier, comprising: (A) a lid portion including an upper shell and a plurality of snap-fit brackets mounted inside the shell; (B) a base portion equipped with one or more clamp devices configured to mount the base portion above a vehicle, wherein each of the lid portion and the base portion has a convex outer surface and a concave inner surface, the base portion being nested in the lid portion with the outer surface of the base portion facing the inner surface of the lid portion; (C) a lower portion of a hinge/latch assembly mounted to the base portion; and (D) a strut assembly including first and second ends, the first end being mounted to the base portion and the second end including a snap-fit mounting member, wherein the base portion and the lid portion are configured to be unnested and arranged to form a box having the inner surfaces facing each other when the box is closed, and wherein the second end of the strut assembly and an upper portion of the hinge/latch assembly are configured to be mounted to the lid portion by making respective snap-fit connections of the mounting member and the upper portion with a pair of the brackets.

52. A method of assembling a vehicle top carrier, comprising: (A) receiving a base portion nested in a lid portion such that respective concave inside surfaces of the lid portion and the base portion are not facing each other, the base portion being equipped or equippable with one or more clamp devices configured to mount the cargo box above a vehicle; (B) arranging the lid portion and the base portion to form a cargo box with the inside surfaces facing each other when the box is closed; and (D) connecting the lid portion to the base portion.

53. A method of assembling a top carrier for a vehicle, comprising: (A) receiving a base portion and a lid portion each having a convex outer surface and a concave inner surface, the base portion and the lid portion being disposed in a nested configuration in which the base portion is nested in the lid portion such that the outer surface of the base portion faces the inner surface of the lid portion, the base portion being equipped with one or more clamp devices configured to mount the base portion above a vehicle; (B) arranging the lid portion and the base portion with the inside surfaces facing each other to form a box; and (C) making one or more snap-fit connections that connect the base portion to the lid portion.

54. A method of assembling a cargo box, comprising: (A) receiving a base portion and a lid portion each having a convex outer surface and a concave inner surface, the base portion and the lid portion being disposed in a nested configuration in which the base portion is nested in the lid portion such that the outer surface of the base portion faces the inner surface of the lid portion, the base portion being equipped or equippable with one or more clamp devices configured to mount the base portion above a vehicle; (B) arranging the lid portion and the base portion with the inside surfaces facing each other to form a box; and (C) mounting a strut assembly to the lid portion, the base portion, or to the lid portion and the base portion with a snap-fit connection.

55. The method of paragraph 54, wherein the strut assembly is mounted to the lid portion and not the base portion by a snap-fit connection.

56. A top carrier for a vehicle, comprising: (A) a base portion and a lid portion that collectively form a box, the lid portion including an upper shell and a bracket mounted inside the upper shell, the base portion being equipped with one or more clamp devices configured to mount the base portion above a vehicle; and (B) a strut assembly including a mounting member snap-fitted to the bracket to mount the strut assembly to the lid portion.

57. The top carrier of paragraph 56, wherein the mounting member and the bracket are both shaped like an arrow.

58. The top carrier of paragraph 57, wherein the arrows are overlapped.

59. The top carrier of paragraph 57, wherein the arrows point in the same direction.

60. The top carrier of paragraph 56, wherein the mounting member and the bracket each are more reflective than the upper shell.

61. The top carrier of paragraph 60, wherein the upper shell is black, and wherein the mounting member and the bracket are each red.

While methods/devices for making, packaging, shipping, assembling, and using a nestable cargo box have been particularly shown and described, many variations may be made therein. This disclosure may include one or more independent or interdependent embodiments directed to various combinations of features, functions, elements and/or properties. Other combinations and sub-combinations of features, functions, elements and/or properties may be claimed later in a related application. Such variations, whether they are directed to different combinations or directed to the same combinations, whether different, broader, narrower or equal in scope, are also regarded as included within the subject matter of the present disclosure. Accordingly, the foregoing embodiments are illustrative, and no single feature or element, or combination thereof, is essential to all possible combinations that may be claimed in this or a later application. Each example defines an embodiment disclosed in the foregoing disclosure, but any one example does not necessarily encompass all features or combinations that may be eventually claimed. Where the description recites “a” or “a first” element or the equivalent thereof, such description includes one or more such elements, neither requiring nor excluding two or more such elements. Further, ordinal indicators, such as first, second or third, for identified elements are used to distinguish between the elements, and do not indicate a required or limited number of such elements, and do not indicate a particular position or order of such elements unless otherwise specifically stated.

Claims

1. A method of shipping a cargo carrier for a vehicle, comprising:

creating a package containing a base portion nested with a lid portion such that an outer surface of one of the portions faces the inner surface of the other portion, and also containing one or more clamp devices configured to mount the base portion above a vehicle, and components of one or more hinge assemblies; and

shipping the package,

wherein the base portion is configured to be connected to the lid portion after the step of shipping using the one or more hinge assemblies, to form a cargo box having inner surfaces of the base and lid portions facing each other when the box is closed and that opens by pivoting the lid portion away from the base portion.

2. The method of claim 1, wherein the lid portion includes an upper shell, further comprising a step of mounting a plurality of snap-fit brackets to the upper shell before the step of shipping.

3. The method of claim 1, wherein the base portion includes a lower shell, further comprising a step of mounting only a portion of each of the one or more hinge assemblies to the lower shell before the step of shipping.

4. The method of claim 1, wherein the base portion and the lid portion are not operatively connected to each other in the package.

5. The method of claim 1, wherein the base portion includes a lower shell, further comprising a step of mounting an end of a strut assembly to the lower shell before the step of shipping.

6. The method of claim 5, wherein the end of the strut assembly is a first end, wherein the strut assembly has an opposing second end connected to a snap-fit mounting member configured to be snap-fitted to the lid portion after the package is shipped.

7. The method of claim 1, wherein the base portion is nested in the lid portion in the package.

8. The method of claim 7, wherein the base portion is at least substantially completely nested in the lid portion in the package.

9. A method of assembling a top carrier for a vehicle, comprising:

receiving a base portion and a lid portion each having an inner surface and an outer surface, the base portion and the lid portion being arranged in a nested configuration having the outer surface of one of the portions facing the inner surface of the other portion;

connecting the base portion to the lid portion using one or more hinge assemblies, to form a cargo box having the inner surfaces of the base and lid portions facing each other when the box is closed and that opens by pivoting the lid portion away from the base portion; and

mounting the cargo box above a vehicle.

10. The method of claim 9, wherein the step of connecting includes a step of creating a plurality of snap-fit connections.

11. The method of claim 10, wherein the lid portion in the nested configuration includes an upper shell and a plurality of brackets mounted to the upper shell, and wherein the step of creating a plurality of snap-fit connections includes a step of snap-fitting an upper portion of each hinge assembly to a bracket of the plurality of brackets.

12. The method of claim 9, wherein each hinge assembly is a hinge/latch assembly, wherein the cargo box has opposing lateral sides, and wherein the lid portion can be pivotably opened and releasably latched on each of the opposing lateral sides after the step of connecting.

13. The method of claim 9, further comprising a step of connecting the base portion to the lid portion with one or more strut assemblies after the step of receiving.

14. The method of claim 13, wherein the step of connecting the base portion to the lid portion with one or more strut assemblies includes a step of mounting a strut assembly to at least one of the portions with at least one snap-fit connection.

15. The method of claim 9, wherein the base portion, the lid portion, and the hinge assemblies are disposed inside a shipping container when received, and wherein the shipping container has a height that is less than a height of the cargo box.

16. The method of claim 9, wherein the base portion includes a lower shell, and wherein the lower shell is at least substantially completely contained in the lid portion in the nested configuration.

17. The method of claim 9, wherein the base portion includes a lower shell, and wherein only a lower portion of each of the hinge assemblies is already mounted to the lower shell when the base portion is received.

18. A kit for constructing a top carrier for a vehicle, comprising:

a base portion including a lower shell;

a lid portion including an upper shell;

one or more clamp devices configured to mount the base portion above a vehicle; and

components of a plurality of hinge assemblies;

wherein the lower shell and the upper shell each have an inner surface and an outer surface, wherein the lower shell and the upper shell are nested in the kit with the outer surface of one of the shells facing the inner surface of the other shell, and wherein the base portion and the lid portion are configured to be connected to each other with the hinge assemblies, to form a cargo box having the inner surfaces facing each other when the cargo box is closed and that opens by pivoting the lid portion away from the base portion.

19. The kit of claim 18, wherein the hinge assemblies are hinge/latch assemblies each having an upper portion and a lower portion, and wherein the kit provides the lower portion of each hinge/latch assembly pre-mounted to the lower shell.

20. The kit of claim 18, wherein the kit provides the upper portion of each hinge/latch assembly not operatively mounted to the upper shell, wherein the lid portion includes a plurality of brackets pre-mounted to the upper shell, and wherein the upper portion of each hinge/latch assembly is configured to be operatively mounted to the upper shell by making a snap-fit connection to a bracket of the plurality of brackets.

21. The kit of claim 18, wherein the kit provides the base portion nested in the lid portion, wherein the lid portion includes a plurality of snap-fit brackets pre-mounted to the upper shell, further comprising one or more strut assemblies pre-mounted to the lower shell, wherein each strut assembly includes a mounting member configured to form a snap-fit connection with a snap-fit bracket to mount the strut assembly to the lid portion.