U.S. patent application number 15/170734 was filed with the patent office on 2016-12-15 for slotted crossbar.
This patent application is currently assigned to Yakima Products, Inc.. The applicant listed for this patent is Yakima Products, Inc.. Invention is credited to David Condon, John Mark Elliott, Scott A. McFadden.
Application Number | 20160362055 15/170734 |
Document ID | / |
Family ID | 57503783 |
Filed Date | 2016-12-15 |
United States Patent
Application |
20160362055 |
Kind Code |
A1 |
McFadden; Scott A. ; et
al. |
December 15, 2016 |
SLOTTED CROSSBAR
Abstract
A slotted crossbar may include an upper slot and a lower slot
running continuously across the entire length of the crossbar.
Internal channels associated with the upper and lower slots may be
structurally independent, such that a floor of the upper channel is
spaced from a ceiling of the lower channel. An illustrative slotted
crossbar may be manufactured using an aluminum extrusion
process.
Inventors: |
McFadden; Scott A.;
(Portland, OR) ; Condon; David; (Beaverton,
OR) ; Elliott; John Mark; (Beaverton, OR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Yakima Products, Inc. |
Lake Oswego |
OR |
US |
|
|
Assignee: |
Yakima Products, Inc.
Lake Oswego
OR
|
Family ID: |
57503783 |
Appl. No.: |
15/170734 |
Filed: |
June 1, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62173333 |
Jun 9, 2015 |
|
|
|
62175192 |
Jun 12, 2015 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B60R 9/058 20130101;
B60R 2011/0059 20130101; B60R 9/05 20130101; B60R 9/052
20130101 |
International
Class: |
B60R 9/05 20060101
B60R009/05 |
Claims
1. A crossbar for a vehicle rooftop cargo rack, the crossbar
comprising: an elongate metal body having a first end, a second
end, and an aerodynamic outer profile defining an upper surface and
a lower surface of the body; a continuous first slot running
lengthwise across the upper surface from the first end to the
second end; and a continuous second slot running lengthwise across
the lower surface from the first end to the second end.
2. The crossbar of claim 1, wherein the first slot opens into a
first continuous channel running lengthwise through the body of the
crossbar, the first channel having a floor.
3. The crossbar of claim 2, wherein the second slot opens into a
second continuous channel running lengthwise through the body of
the crossbar, the second channel having a ceiling.
4. The crossbar of claim 3, wherein the floor of the first channel
and the ceiling of the second channel are spaced from each
other.
5. The crossbar of claim 1, further comprising a plurality of
lengthwise internal cavities passing continuously through the body,
the body including a pair of spaced-apart vertical webs spanning an
internal height of the body, such that the plurality of lengthwise
internal cavities includes a forward cavity, a central cavity, and
an aft cavity.
6. The crossbar of claim 1, wherein the first slot is horizontally
offset relative to the second slot. The crossbar of claim 1,
wherein the lower surface of the body is curved.
8. The crossbar of claim 1, wherein a first wall thickness of a top
portion of the body is greater than a second wall thickness of a
leading edge portion of the body.
9. A rack for carrying cargo on top of a vehicle, the rack
comprising: a crossbar and a pair of couplers configured to mount
the crossbar on top of a vehicle such that a long axis of the
crossbar is substantially horizontal and perpendicular to a
longitudinal axis of the vehicle; the crossbar including an
elongate metal body having a first end, a second end, and an
aerodynamic outer profile defining an upper surface and a lower
surface of the body; a continuous first slot running lengthwise
across the upper surface of the body of the crossbar from the first
end to the second end, the first slot opening into a first channel;
and a continuous second slot running lengthwise across the lower
surface of the body of the crossbar from the first end to the
second end, the second slot opening into a second channel; wherein
the first channel and the second channel are structurally
independent from each other.
10. The rack of claim 9, wherein each coupler of the pair of
couplers is configured to be clamped to the second slot of the
crossbar.
11. The rack of claim 9, the crossbar further comprising a
plurality of lengthwise internal cavities passing continuously
through the body of the crossbar, and a pair of spaced-apart
vertical webs spanning an internal height of the crossbar, such
that the plurality of lengthwise internal cavities includes a
forward cavity, a central cavity, and an aft cavity.
12. The rack of claim 9, wherein the first slot is horizontally
offset relative to the second slot.
13. The rack of claim 9, further comprising a first infill member
disposed in the first slot, the first infill member including a
deformable resilient tube.
14. The rack of claim 9, further comprising a second infill member
covering the second slot, the second infill member being
selectively removable from the second slot.
15. A method of manufacturing a crossbar for a vehicle rooftop
cargo rack, the method comprising: extruding an aluminum bar having
a first end, a second end, and an elongated profile defining an
upper surface and a lower surface of the bar; wherein the extruding
step includes forming a plurality of lengthwise internal cavities
passing continuously through the bar, a continuous first slot
running lengthwise across the upper surface of the bar from the
first end to the second end, the first slot opening into a first
channel, and a continuous second slot running lengthwise across the
lower surface of the bar from the first end to the second end, the
second slot opening into a second channel that is structurally
independent from the first channel.
16. The method of claim 15, wherein the first channel has a floor
and the second channel has a ceiling, the floor and ceiling being
generally parallel and spaced from each other.
17. The method of claim 15, wherein the extruding step further
forms a pair of spaced-apart vertical webs spanning an internal
height of the bar, such that the plurality of lengthwise internal
cavities includes a forward cavity, a central cavity, and an aft
cavity.
18. The method of claim 15, wherein the extruding step further
forms a longitudinal ridge protruding from a leading edge portion
of the bar, the ridge being disposed above a vertex of the leading
edge portion.
19. The method of claim 15, wherein a first wall thickness of a top
portion of the bar is greater than a second wall thickness of a
leading edge portion of the bar.
20. The crossbar of claim 15, wherein the elongated profile of the
bar is aerodynamic.
Description
CROSS-REFERENCES
[0001] This application is based upon and claims the benefit under
35 U.S.C. .sctn.119(e) of U.S. Provisional Patent Application Ser.
No. 62/173,333, filed on Jun. 9, 2015, and U.S. Provisional Patent
Application Ser. No. 62/175,192, filed on Jun. 12, 2015, which are
incorporated herein, in their entireties, for all purposes.
[0002] The following related applications and materials are
incorporated herein, in their entireties, for all purposes: U.S.
Pat. No. 6,905,053, U.S. Pat. No. 8,393,508, and U.S. patent
application Ser. No. 15/167,774.
FIELD
[0003] This disclosure relates to systems and methods for attaching
cargo racks to vehicles. More specifically, the disclosed
embodiments relate to slotted crossbars for vehicle rooftop cargo
racks.
INTRODUCTION
[0004] Popularity of recreational activities continues to grow,
with a corresponding growth in the need for carrying recreational
equipment and cargo on vehicles. Accordingly, various equipment
carriers and accessories have been developed over the years, for
recreational items such as bicycles, skis, surf boards, standup
paddle (SUP) boards, kayaks, and the like. Many such carriers and
accessories are supported on vehicle rooftop racks.
[0005] Meanwhile, the number of different vehicle rooftop
configurations has grown as well, with various shapes, sizes, and
features depending on the make and model of the vehicle. For
example, rooftop rails may be flush on the roof, raised, or not
present at all. Similarly, rooftops themselves may be relatively
flat or curved, and a width of the roof may change from front to
back.
[0006] Rooftop racks typically include crossbars mounted to the
vehicle roof, and the crossbars themselves may be of various shapes
and sizes, from square to round to aerodynamic. Aerodynamic
crossbars may be designed for noise reduction and sometimes include
an upper T-slot for attaching one or more cargo-specific
accessories and/or cargo boxes. Additional features may be machined
into the crossbar to facilitate attachment of supportive
crossbar-to-vehicle couplers.
SUMMARY
[0007] The present disclosure provides systems, apparatuses, and
methods relating to slotted crossbars. Slotted crossbars according
to the present teachings include upper and lower continuous slots
running across the length of the crossbar. Channels associated with
each slot may be structurally independent of each other. Benefits
of crossbars according to the present teachings may include
simplified manufacturability, improved stiffness and strength,
versatility with respect to host vehicle widths, and others.
[0008] In some embodiments, a crossbar for a vehicle rooftop cargo
rack may include an elongate metal body having a first end, a
second end, and an aerodynamic outer profile defining an upper
surface and a lower surface of the body; a continuous first slot
running lengthwise across the upper surface from the first end to
the second end; and a continuous second slot running lengthwise
across the lower surface from the first end to the second end.
[0009] In some embodiments, A rack for carrying cargo on top of a
vehicle may include a crossbar and a pair of couplers configured to
mount the crossbar on top of a vehicle such that a long axis of the
crossbar is substantially horizontal and perpendicular to a
longitudinal axis of the vehicle; the crossbar including an
elongate metal body having a first end, a second end, and an
aerodynamic outer profile defining an upper surface and a lower
surface of the body; a continuous first slot running lengthwise
across the upper surface of the body of the crossbar from the first
end to the second end, the first slot opening into a first channel;
and a continuous second slot running lengthwise across the lower
surface of the body of the crossbar from the first end to the
second end, the second slot opening into a second channel; wherein
the first channel and the second channel are structurally
independent from each other.
[0010] In some embodiments, a method of manufacturing a crossbar
for a vehicle rooftop cargo rack may include: extruding an aluminum
bar having a first end, a second end, and an elongated profile
defining an upper surface and a lower surface of the bar; wherein
the extruding step includes forming a plurality of lengthwise
internal cavities passing continuously through the bar, a
continuous first slot running lengthwise across the upper surface
of the bar from the first end to the second end, the first slot
opening into a first channel, and a continuous second slot running
lengthwise across the lower surface of the bar from the first end
to the second end, the second slot opening into a second channel
that is structurally independent from the first channel.
[0011] Features, functions, and advantages may be achieved
independently in various embodiments of the present disclosure, or
may be combined in yet other embodiments, further details of which
can be seen with reference to the following description and
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a schematic block diagram of a rooftop cargo rack
system.
[0013] FIG. 2 is an oblique isometric view of a portion of an
illustrative vehicle showing an illustrative rooftop rack mounted
thereon.
[0014] FIG. 3 is an isometric view of a portion of an illustrative
slotted crossbar in accordance with aspects of the present
disclosure.
[0015] FIG. 4 is a bottom plan view of the crossbar of FIG. 3.
[0016] FIG. 5 is a top plan view of the crossbar of FIG. 3.
[0017] FIG. 6 is an end elevation view of the crossbar of FIG.
3.
[0018] FIG. 7 is an isometric exploded view of an illustrative
crossbar clamp suitable for a slotted crossbar according to the
present teachings.
[0019] FIG. 8 is an end elevation view of the crossbar clamp of
FIG. 7 assembled and installed in an illustrative slotted
crossbar.
[0020] FIG. 9 is a schematic view showing various possible
combinations of illustrative clamps and couplers with a slotted
crossbar according to the present teachings.
[0021] FIG. 10 is a flow chart depicting steps of an illustrative
method for manufacturing a crossbar in accordance with aspects of
the present disclosure.
DESCRIPTION
[0022] Various aspects and examples of a crossbar having upper and
lower continuous, longitudinal slots, as well as related devices
and methods, are described below and illustrated in the associated
drawings. Unless otherwise specified, a slotted crossbar and/or its
various components may, but are not required to, contain at least
one of the structure, components, functionality, and/or variations
described, illustrated, and/or incorporated herein. Furthermore,
unless specifically excluded, the process steps, structures,
components, functionalities, and/or variations described,
illustrated, and/or incorporated herein in connection with the
present teachings may be included in other similar devices and
methods, including being interchangeable between disclosed
embodiments. The following description of various examples is
merely illustrative in nature and is in no way intended to limit
the disclosure, its application, or uses. Additionally, the
advantages provided by the examples and embodiments described below
are illustrative in nature and not all examples and embodiments
provide the same advantages or the same degree of advantages.
Definitions
[0023] The following definitions apply herein, unless otherwise
indicated.
[0024] "Comprising," "including," and "having" (and conjugations
thereof) are used interchangeably to mean including but not
necessarily limited to, and are open-ended terms not intended to
exclude additional, unrecited elements or method steps.
[0025] Terms such as "first", "second", and "third" are used to
distinguish or identify various members of a group, or the like,
and are not intended to show serial or numerical limitation.
[0026] The terms "inboard," "outboard," "forward," and "aft" (and
the like) are intended to be understood in the context of a host
vehicle on which systems described herein may be mounted or
otherwise attached. For example, "outboard" may indicate a relative
position that is laterally farther from the centerline of the
vehicle, or a direction that is away from the vehicle centerline.
Conversely, "inboard" may indicate a direction toward the
centerline, or a relative position that is closer to the
centerline. Similarly, "forward" means toward the front portion of
the vehicle, and "aft" means toward the rear of the vehicle. In the
absence of a host vehicle, the same directional terms may be used
as if the vehicle were present. For example, even when viewed in
isolation, a crossbar may have a "forward" edge, based on the fact
that the edge in question would be installed facing the front
portion of a host vehicle.
Overview of a Roof Rack System
[0027] In general, and with reference to FIG. 1, a vehicle roof
rack system 10 may include any suitable combination of components
configured to provide a selected crossbar securely affixed to a
vehicle rooftop. The crossbar may be supported at either end by a
pair of supports having features that facilitate attachment to
corresponding feature(s) on the specific vehicle. The crossbar
supports may also be referred to as towers, feet, or mounts, and
are referred to herein as couplers. A versatile and efficient
system may be provided to fit a selected crossbar to the wide range
of vehicle rooftops present in the marketplace.
[0028] Accordingly, roof rack system 10 may include one or more
types of crossbars 12 suitable for use on a range of vehicles. Each
type of crossbar 12 may include any suitable crossbar configured to
be mounted transverse to the long axis of a vehicle, across a
rooftop, and to support loads placed thereon. For example, a
crossbar 12 may support a cargo box, or a cargo-specific accessory,
such as a bicycle carrier, ski carrier, kayak carrier, and the
like. Crossbars 12 may be referred to as rails, cross-rails
transverse supports, support bars, and/or the like. Crossbars are
typically mounted on a vehicle in pairs, such that a forward and an
aft crossbar are present on the vehicle for proper load carrying.
Crossbars 12 may have any suitable cross section, such as round,
square, teardrop, aerodynamic, and/or any other suitable shape or
combination of shapes. A specific embodiment of crossbar 12 is
described in further detail below.
[0029] Crossbars 12 are supported by attaching or fastening each of
the crossbars to one or more specific vehicle features 14. Vehicles
come in many shapes and sizes, with a corresponding array of roof
topologies. Vehicle features 14, to which the crossbars may be
attached, can include raised rails running along lateral sides of a
rooftop, flush rails with no space between the rails and the roof,
channels or hard points on the roof, side edges or gutters of a
naked roof, and/or the like.
[0030] To fasten the outboard ends of the crossbars to features 14,
system 10 may include one or more crossbar-to-vehicle couplers 16,
also referred to as coupler assemblies, supports, towers, feet, or
mounts, as mentioned above. Each coupler 16 may include any
suitable vehicle interface 18 configured to attach, clamp, and/or
removably connect to one or more vehicle features 14. Each coupler
16 may also include any suitable crossbar interface 20 configured
to provide an attachment point or mount for crossbar 12.
[0031] In some examples, crossbar interface 20 may include a
universal interface for connecting a variety of crossbars. For
example, crossbar interface 20 may include a threaded bolt
protruding upward from support 16. Each specific crossbar 12 may
include or be associated with a bar connector 22 (also referred to
as an adapter) configured to provide a crossbar-specific bar clamp
24 when combined with a bar seat 26. In this example, bar connector
22 may include a threaded portion for receiving the threaded bolt,
as well as a holder portion for gripping, grasping, or grabbing
onto the specific crossbar.
[0032] Bar clamp 24 may be used to removably and securely attach
crossbar 12 to coupler 16. For example, bar connector 22 may
comprise a movable capturing portion configured to secure the
crossbar against seat portion 26. Accordingly, crossbar interface
20 of coupler 16 includes a crossbar (or bar) clamp actuator 28
configured to tighten, draw together, or otherwise cause clamp 24
to securingly engage the crossbar. Bar clamp actuator 28 may
include a manual actuator or manual actuating mechanism.
[0033] Bar connector 22 and/or bar seat 26 may be grouped or
provided with crossbar 12 to form a bar kit suitable for connecting
to remaining elements of crossbar interface 20 of one or more
different couplers 16. In other examples, bar connector 22 and/or
bar seat 26 may be grouped or provided with coupler 16, to form a
customized coupler suitable for connecting to a specific crossbar
12. From these examples, it should be clear that selected
combinations of subcomponents of system 10 may be provided
independently or separately, and combined or assembled as
appropriate (e.g., for a specific vehicle).
[0034] In some examples, coupler 16 may include a body or body
portion 30 providing structural and/or other functional aspects of
the coupler, e.g., locking devices, environmental, aesthetic,
and/or aerodynamic outer housing features, internal and/or external
support structure, etc. Vehicle interface 18 and/or crossbar
interface 20 may be attached, unitary with, and/or coupled to
coupler body portion 30. Alternatively or additionally, crossbar
interface 20 and vehicle interface 18 may be coupled to each
other.
[0035] Vehicle interface 18 may include any suitable structure
and/or device configured to removably attach to a given vehicle
feature (or features) 14. For example, vehicle interface 18 may
include a clamp, hook, bolt, clip, strap, and/or the like, and/or
any combination of these. To provide an efficient and versatile
system, a selected number of vehicle interface types may be
provided, some having modifiable or selectable components for
further customization. Specific examples of vehicle interfaces 18
are mentioned below.
[0036] Accordingly, system 10 may allow a user to choose a type of
crossbar 12, select a coupler 16 having a vehicle interface 18
appropriate for attachment to vehicle feature 14 of the user's
vehicle, and clamp the crossbar to the support using a
corresponding bar connector 22 and bar seat 26.
[0037] Turning to FIG. 2, a specific example of a roof rack 40 is
depicted, attached to an illustrative roof 42 of a vehicle 44. Roof
rack 40 is a selected example of roof rack 10, described above.
Accordingly, similar components may be labeled with similar
reference numbers. Rack 40 may be used for carrying cargo and/or
cargo-specific accessories on top of vehicle 44. Vehicle 44 has a
longitudinal or central axis 46 generally coinciding with (e.g.,
running parallel to) a direction of vehicular travel 48.
[0038] Rack 40 includes a pair of crossbars 50 and 52 having
aerodynamic shapes and attached to flush rail features 54 and 56 of
vehicle roof 42. Each crossbar is supported and mounted on vehicle
44 by a respective pair of couplers configured to mount the
crossbar on top of the vehicle with the crossbar substantially
perpendicular to longitudinal axis 46. Accordingly, crossbars 50
and 52 are substantially parallel to each other and oriented across
a width of the vehicle roof, as generally indicated by a lateral
axis 58 in FIG. 2.
[0039] Crossbar 50 is mounted on top of the vehicle by couplers 60
and 62, and crossbar 52 is mounted on top of the vehicle using
couplers 64 and 66. In this example, couplers 60, 62, 64, 66 have a
double-clip style vehicle interface configured to clamp to the
flush bar vehicle features. Other styles may be suitable, and other
vehicle features may be present. In this example, crossbars 50 and
52 are slotted crossbars, each including a lengthwise upper slot
68, 70 and a pair of end caps 72, 74.
Examples, Components, and Alternatives
[0040] The following sections describe selected aspects of
exemplary slotted crossbars as well as related systems and/or
methods. The examples in these sections are intended for
illustration and should not be interpreted as limiting the entire
scope of the present disclosure. Each section may include one or
more distinct inventions, and/or contextual or related information,
function, and/or structure.
Illustrative Slotted Crossbar
[0041] As shown in FIGS. 3-6, this section describes a slotted
crossbar 100 suitable for use in a rooftop rack system (e.g.,
system 10) in accordance with aspects of the present disclosure.
Slotted crossbar 100 is an example of crossbar 12 and of crossbars
50, 52, described above. Accordingly, crossbar 100 shares the
substantially as described above with respect to those crossbars,
and additional details and features are described below.
[0042] FIG. 3 is an oblique isometric view of an end portion of
crossbar 100. FIG. 4 is a bottom plan view of a portion of crossbar
100. FIG. 5 is a top plan view of a portion of crossbar 100. FIG. 6
is an end elevation view of crossbar 100. Given the construction of
crossbar 100, FIG. 6 could also be a cross-sectional view of the
crossbar at any given point along its length.
[0043] Crossbar 100 includes a body 102 having an upper slot 104
and a lower slot 106. Body 102 may include any suitable unitary
structure configured as an elongate bar having sufficient stiffness
and strength to withstand expected environmental forces while
supporting one or more cargo elements coupled thereto or thereon.
In this example, bar 102 is an extruded metal bar having an
aerodynamic outer profile or cross-sectional shape 108, also
referred to as an airfoil-like shape, and a plurality of internal
chambers or cavities defined by internal walls or webs, described
further below. In some examples, body 102 of crossbar 100 is an
extruded aluminum bar.
[0044] Shape 108 is generally configured to reduce the noise
associated with air flow over the crossbar during typical driving
conditions. Shape 108 is loosely based on a standard airfoil shape
developed by the National Advisory Committee for Aeronautics
(NACA). Accordingly, body 102 has a rounded leading edge portion
110 on a forward side of the crossbar, and a tapered trailing edge
portion 112 on a rear or aft side of the crossbar. However, the
shape is modified to reduce noise. For example, a longitudinal
ridge 114 runs along the length of leading edge portion 110,
approximately half way between a forward vertex 116 of the leading
edge and a top portion 118 of the crossbar body. Ridge 114 may also
be referred to as a strip, a trip strip, and/or an air trip strip.
Similar to a stall strip on a wing, ridge 114 causes turbulence in
the air flowing above the crossbar.
[0045] Furthermore, shape 108 is asymmetrical with respect to a
horizontal plane passing through vertex 116, such that an upper
half of the crossbar has a different shape than a lower half of the
crossbar. For example, top portion 118 is flattened, or generally
planar in the vicinity of upper slot 104. This flattened top
portion facilitates mounting of accessories on the crossbar, such
as by bolting or otherwise affixing the accessory in slot 104. This
flattened shape is also distinguished from the generally curved or
curvilinear shape of a bottom portion 120.
[0046] Additionally, shape 108 is further modified from the
symmetrical NACA airfoil by a cutback angle 122 in trailing edge
portion 112. Cutback angle 122 truncates the otherwise long,
symmetrical tapering of the trailing edge of the airfoil at an
oblique angle. This results in an asymmetrical trailing edge
portion 112.
[0047] Together, these asymmetrical features cause air flowing over
the top of the crossbar to behave differently than air flowing
under the bottom of the crossbar. Specifically, the airflow is
changed and/or disrupted, such that harmonics and other
noise-producing airflow phenomena are avoided.
[0048] Internally, body 102 may include a plurality of walls or
webs. Because body 102 may be an extruded structure, these walls or
webs will typically run along the entire length of the crossbar.
The internal walls define internal structures as well as empty or
hollow spaces, referred to as cavities.
[0049] Specifically in this example, two vertical webs, a first
(forward) vertical web 124 and a second (aft) vertical web 126,
connect the upper and lower walls of body 102. Vertical webs 124
and 126 provide structural stiffness and strength to crossbar 100,
and run along the entire length of body 102. In general, forward
vertical web 124 is disposed adjacent leading edge portion 110, and
defines a forward cavity 128. Similarly, aft vertical web 126 is
disposed adjacent trailing edge portion 112, and defines an aft
cavity 130. A central cavity 132 is defined between the two
vertical webs.
[0050] Upper slot 104 may be referred to as an upper T-slot or tee
slot. Slot 104 includes an upper channel 134 formed by vertical web
124, a substantially horizontal floor portion 136, and a
substantially vertical wall portion 138. The gap or opening of slot
104 is formed above upper channel 134 by a pair of overhanging lips
140, 142, having respective distal end portions 144, 146 that are
spaced apart to form a width W of the slot. Distal end portions
144, 146 may be tapered to accommodate an in-fill portion
(described below). Dimensions of upper channel 134 and width W may
be selected to facilitate receiving T-bolts, docking cleats, and
other fasteners typically utilized to attach accessories to T-slot
crossbars. Upper slot 104 may run continuously across the entire
length of crossbar 100. End openings of upper slot 104 may be
covered by removable end caps, such as end caps 72 and 74.
[0051] Lower slot 106 may be referred to as a lower T-slot or tee
slot. Slot 106 includes a lower channel 148 formed by a pair of
vertical walls 150, 152 joined by a substantially horizontal
ceiling portion 154. The gap or opening of slot 106 is formed below
lower channel 148 by a pair of overhanging lips 156, 158, having
respective distal end portions 160, 162 that are spaced apart to
form a width W' of the lower slot. Dimensions of lower channel 148
and width W' may be selected to facilitate receiving a T-connector
or other portion of a clamping assembly used to attach crossbar 100
to a crossbar-to-vehicle coupler. Lower slot 106 may run
continuously across the entire length of crossbar 100. End openings
of lower slot 106 may be covered by removable end caps, such as end
caps 72 and 74.
[0052] A perimeter wall or shell 164 may form shape 108, and may
comprise leading edge portion 110, trailing edge portion 112,
upper/top portion 118, and lower/bottom portion 120. Shell 164 may
have one or more wall thicknesses. For example, leading edge
portion 110 and trailing edge portion 112 may have a first
thickness T. In some examples, webs 124 and 126 may also have
thickness T. In some examples, thickness
[0053] T may be a minimum thickness based on an applicable
extrusion process. Top portion 118 and bottom portion 120, on the
other hand, may have a greater thickness T'. In some examples, T'
is approximately twice as thick as T. In some examples, T' is
greater than twice as thick as T. This may facilitate greater load
bearing capacities in the top and bottom portions, where forces
transverse to the walls are greater and more likely to be
present.
[0054] Upper slot 104 and lower slot 106 may be structurally
independent from each other, such that the two slots do not share
any common walls or other features. For example, the heights (or
depths) of the respective channels are together less than the
overall height of the crossbar. Accordingly, floor 136 of upper
channel 134 is distinct from and spaced from ceiling 154 of lower
channel 148. Central cavity 132 may be at least partially defined
by the space between the two channels.
[0055] Furthermore, upper slot 104 and lower slot 106 may be
horizontally offset from each other. For example, upper slot 104
may be disposed in a suitable location along top portion 118 where
the shell can be substantially flat to receive and support
accessories mounted thereon. Lower slot 106, on the other hand, may
be disposed such that the lower slot is substantially centered on
the curvature of bottom portion 120. This may facilitate the use of
single-design crossbar-to-vehicle couplers, as the symmetrical
curvature around the lower slot permits the same interface to be
used on both left and right sides of the vehicle (i.e., right and
left ends of the crossbar).
[0056] Crossbar 100 may further include an upper infill 166 and a
lower infill 168. Upper infill 166 may include any suitable
resilient structure configured to fit within upper channel 134 and
provide a selectively deformable surface to bridge the gap between
upper lips 140 and 142. Upper infill 166 may include a shaped tube
made of rubber or other resilient material. In the examples shown
in FIGS. 3, 5, and 6, upper infill 166 is a tubular member having a
mushroom-shaped cross section. A pair of lower feet 170, 172 rest
on floor 136 of the upper channel. A stem portion 174 connects the
feet to an upper mushroom head portion 176 that presses into upper
slot 104 from below, exposing an upper surface 178 that is
generally flush with top portion 118. As mentioned above, lips 140
and 142 may be tapered to accommodate mushroom head portion
176.
[0057] Upper infill 166 is configured to remain in slot 104 during
operational use of the crossbar. Infill 166 is deformable and
resilient, which facilitates insertion of T-bolts, docking cleats,
and the like into slot 104 by pushing or otherwise deforming infill
166 downward into channel 134. Upper infill 166 then remains in
position along the remaining length of slot 104 to maintain the
aerodynamic shape of the upper surface of crossbar 100.
[0058] Lower infill 168 may include any suitable structure
configured to removably cover the opening of lower slot 106 and
maintain an aerodynamic bottom surface of the crossbar. In this
example, lower infill 168 is a flexible strip, which may be
resilient, having a pair of flanged protrusions 180, 182.
Protrusions 180 and 182 are spaced apart about the same width as W'
of the lower slot, with flanges or barbs extending forward and aft,
such that the flexible protrusions and flanges hold infill 168 in
the slot (i.e., between lips 156, 158) and resist removal. Lower
infill 168 is configured to be removable and reinsertable, such
that the lower infill may be removed, perhaps sectioned, and
reinserted as desired. For example, attachment of a
crossbar-to-vehicle coupler may include cutting a portion of the
lower infill to create a gap in which the coupler can interface
with lower slot 106. Lower infill 168 may be pressed into the slot
and/or slit in from an open end of the crossbar (i.e., with the end
cap removed). Press-insertion of lower infill 168 into slot 106 may
be facilitated by a tapering of the upper/distal ends of
protrusions 180, 182.
[0059] Upper infill 166 is described here as a "stay-in" type of
infill and lower infill 168 is described as a "pull-out" type of
infill. However, any suitable combination of infill styles may be
used, or none at all. For example, the upper infill and lower
infill may be the same type, or the types may be swapped relative
to how they are described in the present example.
Illustrative Crossbar Clamp
[0060] As shown in FIGS. 7-8, this section describes an
illustrative clamp 230 suitable for use with a slotted crossbar
232. Clamp 230 is a clamp that is connectible to the actuator of a
crossbar-to-vehicle coupler, such that actuating the clamp causes
the crossbar to be fixed to the coupler. Crossbar 232 is an example
of crossbar 100 above, and is substantially identical to crossbar
100. FIG. 7 is an exploded isometric view of clamp 230, and FIG. 8
is an end view of clamp 230 assembled and inserted into a
longitudinal bottom slot of crossbar 232, which is shown in section
view.
[0061] Clamp 230 includes a crossbar seat 234 and a crossbar
connector 236. Crossbar seat 234 may include any suitable structure
configured to cradle crossbar 232 on a seating surface 238 that
generally conforms to an outer surface 240 of the crossbar.
Crossbar seat 234 may be described as an anvil. In some examples,
seating surface 238 may include a resilient, compressible, and/or
compliant layer, such as a rubber coating, to reduce damage to
crossbar 232.
[0062] Crossbar connector 236 may include any suitable structure
configured to capture (e.g., grasp or grip) crossbar 232, and to be
movable relative to crossbar seat 234, such that the captured
crossbar can be urged against seating surface 238. Crossbar
connector 236 may be interchangeably referred to as a crossbar
capturing member or crossbar capturing portion of clamp 230. In
this example, crossbar connector 236 may be referred to as a tee or
a mushroom.
[0063] Crossbar connector 236 includes a flange portion 242, also
referred to as a cap or tee portion, and a stem portion 244. Flange
portion 242 is a substantially planar plate or flange sized to
slide into a lower T-slot 246 (also referred to as a tee slot) of
slotted crossbar 232. As described above with respect to crossbar
100, T-slot 246 runs longitudinally along a length of crossbar 232,
and comprises a pair of lips 248 and 250 defining a gap (i.e., slot
246) therebetween. Flange portion 242 has a width that spans slot
246, such that bottom surfaces of the flange portion may abut upper
surfaces of lips 248 and 250 of the T-slot. Stem portion 244
extends or protrudes orthogonally from flange portion 242. Stem
portion 244 may be sized such that stem portion 244 can extend
through slot 246 when flange portion 242 is inserted in the slot,
as shown in FIG. 8. Accordingly, crossbar connector 236 may freely
slide in a longitudinal direction along slot 246 of crossbar
232.
[0064] Stem portion 244 may include a fastening mechanism, such as
a threaded hole, for attaching connector 236 to a clamp actuator.
Inserting crossbar connector 236 into T-slot 246 effectively
captures crossbar 232.
[0065] Crossbar seat 234 includes a block having a central aperture
252, through which crossbar connector 236 can at least partially
extend. For example, stem portion 244 may extend through aperture
252, as shown in FIG. 8. In some examples, stem portion 244 may be
connectible to an actuator, such that the actuator can pull
crossbar connector 236 downward through aperture 252. As can be
seen in FIG. 8, this action will cause flange 242 to exert force on
lips 248 and 250, pulling crossbar 232 down onto crossbar seat 234,
thereby arresting the downward motion of the crossbar connector and
clamping the crossbar in place (e.g., by pinching the lips between
flange 242 and seat 234).
[0066] Crossbar seat 234 may include a pair of guide flanges 254
and 256 protruding from seating surface 238 on opposing sides of
aperture 252. Guide flanges 254 and 256 may include any suitable
structures axially aligned with each other and configured to mate
in sliding engagement with crossbar slot 246. As with flange
portion 242 of crossbar connector 236, guide flanges 254 and 256
may be passed into slot 246 through an end of the crossbar, in an
axial direction with respect to the long axis of the crossbar.
Guide flanges 254 and 256 are positioned on either end of flange
portion 242 of the bar connector when assembled. Guide flanges 254
and 256 may be unitary with crossbar seat 234, and may function to
maintain an orientation of the crossbar seat with respect to the
crossbar slot, e.g., during assembly. Guide flanges 254 and 256 may
not be load bearing structures. For example, clamping force may be
applied to crossbar 232 by drawing bar connector 236 down onto
crossbar seat 234. Flanges 254 and 256 are fixed relative to
crossbar seat 234. Consequently, the guide flanges may not exert
any substantive vertical force on the crossbar during a clamping
operation.
[0067] Crossbar seat 234 also includes a retention ridge 258. A
respective instance of ridge 258 may be present on one or more
surfaces of seat 234, and may be configured to interface with a
corresponding retaining feature of the coupler. For example, seat
234 may click into place with a retaining feature grabbing onto
ridge 258 to hold the crossbar seat block in place on the coupler.
Holding the crossbar seat in place may be temporary, as the
crossbar seat is secured in place by subsequent clamping of the
crossbar. A lower mating surface 260 may be shaped to engage or
otherwise fit onto a corresponding support surface of the coupler.
Lower mating surface 260 may include one or more additional
features, such as discrete positioning teeth 262 configured to mate
with corresponding teeth or features on the support surface of the
coupler.
Illustrative Coupler-Crossbar Combinations
[0068] As shown in FIG. 9, this section describes various suitable
combinations of an illustrative two-slotted crossbar 300 with a
crossbar clamp 302 and different coupler styles. Crossbar 300 is an
example of crossbar 100, described above. Clamp 302 is an example
of clamp 230, and includes crossbar connector 304 and crossbar seat
306, both substantially as described above with respect to
connector 236 and seat 234.
[0069] Crossbar 300 is versatile, in that the crossbar is
attachable to several different couplers, such as couplers 312,
314, 316, 318 shown in FIG. 9. Although four such couplers are
shown in FIG. 9 and described below, it should be understood that
attachment of crossbar 300 is optional for any given coupler, and
that more or fewer couplers may be available for such attachment.
In general, a clamp actuator of the coupler includes an attachment
bolt 319 protruding generally vertically from an upper surface of
the coupler. Crossbar connector 304 is attached via this attachment
screw, and seat 306 mates with an upper receiving surface of the
coupler. A tightening screw of the actuator may protrude in an
outboard or downward direction from the coupler.
[0070] As described above with respect to coupler 16, a coupler
according to the present teachings includes any suitable device
configured to mount a crossbar to a vehicle feature. Accordingly,
couplers 312, 314, 316, 318 each include a vehicle interface 18 for
clamping or otherwise connecting the coupler to a vehicle
feature.
[0071] Specifically, coupler 312 is a strap-type coupler suitable
for connecting the coupler to a raised rail feature of a vehicle.
Raised rails generally include a pair of rails or bars each running
parallel to the direction of vehicle travel and spaced above a
respective lateral side of the rooftop. A strap 320 extends from a
body 322 of this coupler, and is configured to pass under one of
the raised rails while body 322 rests on top of the rail.
[0072] Coupler 314 is a fixed-point style of coupler, suitable for
connecting to a base portion fixed to a vehicle rooftop.
Retractable pins in vehicle interface portion 18 of coupler 314
extend into corresponding receptacles in the base (not pictured).
An example of a coupler having this type of vehicle interface is
described in U.S. Pat. No. 6,905,053, the entirety of which is
hereby incorporated herein for all purposes.
[0073] Coupler 316 is a naked-roof style of coupler, suitable for
connecting the coupler to a gutter or other slot running along a
side of the vehicle rooftop. An adjustable clip 324 and rooftop
seat 326 extend from a lower portion of a body 328 of coupler
316.
[0074] Seat 326 sits atop the vehicle roof, while clip 324 grabs
onto the vehicle gutter (or the like).
[0075] Coupler 318 is a two-clip flush rail type of coupler,
similar to the couplers shown in FIG. 2. This style of coupler is
suitable for connecting the coupler to a flush rail feature of a
vehicle. Flush rails generally include a pair of rails or bars each
running parallel to the direction of vehicle travel on respective
lateral sides of the rooftop. In contrast with the raised rail, a
flush rail abuts the vehicle roof such that no gap exists between
the rail and the roof. A pair of clips 330 extend from a body 332
of coupler 318 to grasp the rail (see FIG. 2).
Illustrative Manufacturing Method
[0076] This section describes steps of an illustrative method for
manufacturing a slotted crossbar in accordance with aspects of the
present disclosure; see FIG. 10. Where appropriate, reference may
be made to previously described components and systems that may be
produced or used in carrying out each step. These references are
for illustration, and are not intended to limit the possible ways
of carrying out any particular step of the method.
[0077] FIG. 10 is a flowchart illustrating steps performed in an
illustrative method, and may not recite the complete process or all
steps of the method. FIG. 10 depicts multiple steps of a method,
generally indicated at 400. Although various steps of method 400
are described below and depicted in FIG. 10, the steps need not
necessarily all be performed, and in some cases may be performed in
a different order than the order shown.
[0078] Step 402 includes extruding an aluminum (e.g., aluminum
alloy) bar having a first end, a second end, and an elongated
(e.g., aerodynamic) profile defining an upper surface and a lower
surface of the bar. Step 402 further includes forming a plurality
of lengthwise internal cavities passing continuously through the
bar, a continuous first slot running lengthwise across the upper
surface of the bar from the first end to the second end, and a
continuous second slot running lengthwise across the lower surface
of the bar from the first end to the second end. The first slot
opens into a first channel, and the second slot opens into a second
channel that is structurally independent from the first
channel.
[0079] In some examples, the first channel has a floor and the
second channel has a ceiling. The floor and ceiling are generally
parallel (e.g., both horizontal) and spaced from each other.
[0080] In some examples, the extruding of step 402 further forms a
pair of spaced-apart vertical webs spanning an internal height of
the bar. These vertical webs define a forward cavity, a central
cavity, and an aft cavity.
[0081] In some examples, the first slot is horizontally offset
relative to the second slot. For example, the first slot may be
disposed closer than the second slot to a leading edge of the
bar.
[0082] In some examples, the upper surface of the bar is
substantially flat in the vicinity of the first slot.
[0083] In some examples, the lower surface of the bar is
curved.
[0084] In some examples, the extruding of step 402 further forms a
longitudinal ridge protruding from a leading edge portion of the
bar, the ridge being disposed above a vertex of the leading edge
portion.
[0085] In some examples, a first wall thickness of a top portion of
the bar is greater than a second wall thickness of a leading edge
portion of the bar. For example, the first wall thickness may be at
least twice as thick as the second wall thickness.
[0086] Optional step 404 includes inserting a first infill member
in the first slot, the first infill member including a deformable
resilient tube. For example, see infill 166 and corresponding
description above.
[0087] Optional step 406 includes covering the second slot using a
second infill member, the second infill member being selectively
removable from the second slot. For example, see infill 168 and
corresponding description above. In some examples, the second
infill member is a flexible strip having a pair of parallel
protrusions, the protrusions being removably insertable into the
second slot to hold the flexible strip in place.
Additional Examples
[0088] This section describes additional aspects and features of
slotted crossbars in accordance with aspects of the present
disclosure, as well as related systems and methods, presented
without limitation as a series of paragraphs, some or all of which
may be alphanumerically designated for clarity and efficiency. Each
of these paragraphs can be combined with one or more other
paragraphs, and/or with disclosure from elsewhere in this
application, including the materials incorporated by reference in
the Cross-References, in any suitable manner. Some of the
paragraphs below expressly refer to and further limit other
paragraphs, providing without limitation examples of some of the
suitable combinations.
[0089] A0. A crossbar for a vehicle rooftop cargo rack, the
crossbar comprising:
[0090] an elongate metal body having a first end, a second end, and
an aerodynamic outer profile defining an upper surface and a lower
surface of the body;
[0091] a continuous first slot running lengthwise across the upper
surface from the first end to the second end; and
[0092] a continuous second slot running lengthwise across the lower
surface from the first end to the second end.
[0093] A1. The crossbar of A0, wherein the first slot opens into a
first continuous channel running lengthwise through the body of the
crossbar, the first channel having a floor.
[0094] A2. The crossbar of A1, wherein the second slot opens into a
second continuous channel running lengthwise through the body of
the crossbar, the second channel having a ceiling.
[0095] A3. The crossbar of A2, wherein the floor of the first
channel and the ceiling of the second channel are spaced from each
other.
[0096] A4. The crossbar of any of paragraphs A0 through A3, further
comprising a plurality of lengthwise internal cavities passing
continuously through the body, the body including a pair of
spaced-apart vertical webs spanning an internal height of the body,
such that the plurality of lengthwise internal cavities includes a
forward cavity, a central cavity, and an aft cavity.
[0097] A5. The crossbar of any of paragraphs A0 through A4, wherein
the first slot is horizontally offset relative to the second
slot.
[0098] A6. The crossbar of A5, wherein the first slot is disposed
closer than the second slot to a leading edge of the crossbar.
[0099] A7. The crossbar of any of paragraphs A0 through A6, wherein
the upper surface of the body is substantially flat in the vicinity
of the first slot.
[0100] A8. The crossbar of any of paragraphs A0 through A7, wherein
the lower surface of the body is curved.
[0101] A9. The crossbar of any of paragraphs A0 through A8, further
including a longitudinal ridge protruding from a leading edge
portion of the body of the crossbar, the ridge being disposed above
a vertex of the leading edge portion.
[0102] A10. The crossbar of any of paragraphs A0 through A9,
wherein a first wall thickness of a top portion of the body is
greater than a second wall thickness of a leading edge portion of
the body.
[0103] A11. The crossbar of A10, wherein the first wall thickness
is at least twice as thick as the second wall thickness.
[0104] A12. The crossbar of any of paragraphs A0 through A11,
further comprising a first infill member disposed in the first
slot, the first infill member including a deformable resilient
tube.
[0105] A13. The crossbar of any of paragraphs A0 through A12,
further comprising a second infill member covering the second slot,
the second infill member being selectively removable from the
second slot.
[0106] A14. The crossbar of A13, wherein the second infill member
is a flexible strip having a pair of parallel protrusions, the
protrusions being removably insertable into the second slot to hold
the flexible strip in place.
[0107] A15. The crossbar of any of paragraphs A0 through A14,
wherein the body of the crossbar comprises aluminum.
[0108] B0. A rack for carrying cargo on top of a vehicle, the rack
comprising:
[0109] a crossbar and a pair of couplers configured to mount the
crossbar on top of a vehicle such that a long axis of the crossbar
is substantially horizontal and perpendicular to a longitudinal
axis of the vehicle;
[0110] the crossbar including an elongate metal body having a first
end, a second end, and an aerodynamic outer profile defining an
upper surface and a lower surface of the body;
[0111] a continuous first slot running lengthwise across the upper
surface of the body of the crossbar from the first end to the
second end, the first slot opening into a first channel; and
[0112] a continuous second slot running lengthwise across the lower
surface of the body of the crossbar from the first end to the
second end, the second slot opening into a second channel;
[0113] wherein the first channel and the second channel are
structurally independent from each other.
[0114] B1. The rack of B0, wherein each coupler of the pair of
couplers is configured to be clamped to the second slot of the
crossbar.
[0115] B2. The rack of any of paragraphs B0 through B1, the
crossbar further comprising a plurality of lengthwise internal
cavities passing continuously through the body of the crossbar, and
a pair of spaced-apart vertical webs spanning an internal height of
the crossbar, such that the plurality of lengthwise internal
cavities includes a forward cavity, a central cavity, and an aft
cavity.
[0116] B3. The rack of any of paragraphs B0 through B2, wherein the
first slot is horizontally offset relative to the second slot.
[0117] B4. The rack of B3, wherein the first slot is disposed
closer than the second slot to a leading edge of the crossbar.
[0118] B5. The rack of any of paragraphs B0 through B4, wherein the
upper surface of the body of the crossbar is substantially flat in
the vicinity of the first slot.
[0119] B6. The rack of any of paragraphs B0 through B5, wherein the
lower surface of the body of the crossbar is curved.
[0120] B7. The rack of any of paragraphs B0 through B6, the
crossbar further including a longitudinal ridge protruding from a
leading edge portion of the body of the crossbar, the ridge being
disposed above a vertex of the leading edge portion.
[0121] B8. The rack of any of paragraphs B0 through B7, wherein a
first wall thickness of a top portion of the body is greater than a
second wall thickness of a leading edge portion of the body.
[0122] B9. The rack of B8, wherein the first wall thickness is at
least twice as thick as the second wall thickness.
[0123] B10. The rack of any of paragraphs B0 through B9, further
comprising a first infill member disposed in the first slot, the
first infill member including a deformable resilient tube.
[0124] B11. The rack of any of paragraphs B0 through B10, further
comprising a second infill member covering the second slot, the
second infill member being selectively removable from the second
slot.
[0125] B12. The rack of B11, wherein the second infill member is a
flexible strip having a pair of parallel protrusions, the
protrusions being removably insertable into the second slot to hold
the flexible strip in place.
[0126] B13. The rack of any of paragraphs B0 through B12, wherein
the body of the crossbar comprises aluminum.
[0127] C0. A method of manufacturing a crossbar for a vehicle
rooftop cargo rack, the method comprising:
[0128] extruding an aluminum bar having a first end, a second end,
and an elongated profile defining an upper surface and a lower
surface of the bar;
[0129] wherein the extruding step includes forming a plurality of
lengthwise internal cavities passing continuously through the
bar,
[0130] a continuous first slot running lengthwise across the upper
surface of the bar from the first end to the second end, the first
slot opening into a first channel, and
[0131] a continuous second slot running lengthwise across the lower
surface of the bar from the first end to the second end, the second
slot opening into a second channel that is structurally independent
from the first channel.
[0132] C1. The method of C0, wherein the first channel has a floor
and the second channel has a ceiling, the floor and ceiling being
generally parallel and spaced from each other.
[0133] C2. The method of any of paragraphs C0 through C1, wherein
the extruding step further forms a pair of spaced-apart vertical
webs spanning an internal height of the bar, such that the
plurality of lengthwise internal cavities includes a forward
cavity, a central cavity, and an aft cavity.
[0134] C3. The method of any of paragraphs C0 through C2, wherein
the first slot is horizontally offset relative to the second
slot.
[0135] C4. The method of C3, wherein the first slot is disposed
closer than the second slot to a leading edge of the bar.
[0136] C5. The method of any of paragraphs C0 through C4, wherein
the upper surface of the bar is substantially flat in the vicinity
of the first slot.
[0137] C6. The method of any of paragraphs C0 through C5, wherein
the lower surface of the bar is curved.
[0138] C7. The method of any of paragraphs C0 through C6, wherein
the extruding step further forms a longitudinal ridge protruding
from a leading edge portion of the bar, the ridge being disposed
above a vertex of the leading edge portion.
[0139] C8. The method of any of paragraphs C0 through C7, wherein a
first wall thickness of a top portion of the bar is greater than a
second wall thickness of a leading edge portion of the bar.
[0140] C9. The method of C8, wherein the first wall thickness is at
least twice as thick as the second wall thickness.
[0141] C10. The method of any of paragraphs C0 through C9, further
comprising inserting a first infill member in the first slot, the
first infill member including a deformable resilient tube.
[0142] C11. The method of any of paragraphs C0 through C10, further
comprising covering the second slot using a second infill member,
the second infill member being selectively removable from the
second slot.
[0143] C12. The method of C11, wherein the second infill member is
a flexible strip having a pair of parallel protrusions, the
protrusions being removably insertable into the second slot to hold
the flexible strip in place.
[0144] C13. The crossbar of any of paragraphs C0 through C12,
wherein the elongated profile of the bar is aerodynamic.
Advantages, Features, Benefits
[0145] The different embodiments and examples of the slotted
crossbars described herein provide several advantages over known
solutions. For example, illustrative embodiments and examples
described herein provide an aerodynamic, aesthetically pleasing,
and quiet crossbar, having enhanced stiffness and strength.
[0146] Additionally, and among other benefits, illustrative
embodiments and examples described herein have different wall
thicknesses in different portions of the crossbar, such that
non-load bearing surfaces are thinner than load bearing surfaces,
thereby reducing material usage.
[0147] Additionally, and among other benefits, illustrative
embodiments and examples described herein have structurally
independent upper and lower T-slots, such that the slots can be
offset from each other and/or run the entire length of the
crossbar. Separate channels associated with the slots may provide
additional structural support to the crossbar.
[0148] Additionally, and among other benefits, illustrative
embodiments and examples described herein have a continuous lower
slot across the entire width of the crossbar, facilitating (a)
improved manufacturability, as the crossbar can be extruded in its
final form (i.e., eliminating the need for partial-width lower
slots to be machined into the bar); and (b) versatility, as the
crossbar can be used for a wide range of vehicle widths, because
crossbar-to-vehicle couplers can be attached to the lower slot at
any point along the length of the crossbar.
[0149] No known system or device can perform these functions.
However, not all embodiments and examples described herein provide
the same advantages or the same degree of advantage.
CONCLUSION
[0150] The disclosure set forth above may encompass multiple
distinct examples with independent utility. Although each of these
has been disclosed in its preferred form(s), the specific
embodiments thereof as disclosed and illustrated herein are not to
be considered in a limiting sense, because numerous variations are
possible. To the extent that section headings are used within this
disclosure, such headings are for organizational purposes only. The
subject matter of the invention(s) includes all novel and
nonobvious combinations and subcombinations of the various
elements, features, functions, and/or properties disclosed herein.
The following claims particularly point out certain combinations
and subcombinations regarded as novel and nonobvious. Other
combinations and subcombinations of features, functions, elements,
and/or properties may be claimed in applications claiming priority
from this or a related application. Such claims, whether broader,
narrower, equal, or different in scope to the original claims, also
are regarded as included within the subject matter of the present
disclosure.
* * * * *