U.S. patent application number 16/055564 was filed with the patent office on 2019-04-04 for crossbar clamp actuator.
This patent application is currently assigned to Yakima Products, Inc.. The applicant listed for this patent is Yakima Products, Inc.. Invention is credited to Gian-Marco D'Angelo, John Mark Elliott, Charles Kraeuter, Scott A. McFadden.
Application Number | 20190100150 16/055564 |
Document ID | / |
Family ID | 57503783 |
Filed Date | 2019-04-04 |
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United States Patent
Application |
20190100150 |
Kind Code |
A1 |
McFadden; Scott A. ; et
al. |
April 4, 2019 |
CROSSBAR CLAMP ACTUATOR
Abstract
A crossbar clamp actuator of a crossbar-to-vehicle coupler may
include a horizontally traveling wedge block having a ramped,
downward-facing first slide surface, and a wedge follower having a
second slide surface in frictional contact with the first slide
surface of the traveling wedge block. Substantially horizontal
repositioning of the traveling wedge block may cause the ramped
first slide surface to urge the wedge follower downward, thereby
actuating a crossbar clamp.
Inventors: |
McFadden; Scott A.;
(Portland, OR) ; Kraeuter; Charles; (Portland,
OR) ; Elliott; John Mark; (Beaverton, OR) ;
D'Angelo; Gian-Marco; (Portland, 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.: |
16/055564 |
Filed: |
August 6, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
15167774 |
May 27, 2016 |
10040403 |
|
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16055564 |
|
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62173333 |
Jun 9, 2015 |
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62175192 |
Jun 12, 2015 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B60R 9/052 20130101;
B60R 9/058 20130101; B60R 2011/0059 20130101; B60R 9/05
20130101 |
International
Class: |
B60R 9/058 20060101
B60R009/058; B60R 9/05 20060101 B60R009/05; B60R 9/052 20060101
B60R009/052 |
Claims
1.-20. (canceled)
21. 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; wherein each coupler includes: a
crossbar clamp having a crossbar seat and a crossbar connector
movable relative to the crossbar seat; and a crossbar clamp
actuator configured to convert horizontal actuation into vertical
clamping of the crossbar connector to the crossbar seat.
22. The rack of claim 21, wherein the actuator comprises: a
horizontally traveling wedge block having a ramped, downward-facing
first slide surface, and a wedge follower coupled to and movable
with the crossbar connector, the wedge follower having a second
slide surface in frictional contact with the first slide surface of
the traveling wedge block, such that substantially horizontal
repositioning of the traveling wedge block causes the ramped first
slide surface to urge the wedge follower downward, moving the
crossbar connector downward relative to the crossbar seat.
23. The rack of claim 22, wherein the first slide surface of the
traveling wedge block is a substantially planar surface.
24. The rack of claim 23, wherein the ramped first slide surface
defines a first ramp angle, and the second slide surface is ramped
at a second ramp angle complementary to the first ramp angle.
25. The rack of claim 22, wherein the actuator further includes a
threaded screw passing through a housing of the actuator and
inserted into an end of the traveling wedge block, such that
rotation of the threaded screw is configured to cause the
horizontal repositioning of the traveling wedge block.
26. The rack of claim 22, wherein each coupler further includes a
vehicle interface configured to releasably secure the coupler to a
corresponding feature of the vehicle.
27. The rack of claim 26, wherein the vehicle interface includes at
least one clip configured to grasp the feature of the vehicle.
28. The rack of claim 22, wherein the crossbar connector includes a
sleeve shaped to slide onto and generally conform to an outer shape
of the crossbar.
29. The rack of claim 22, wherein the crossbar connector includes a
flange configured to slide into a slot of the crossbar, such that
the flange spans a pair of opposing lips of the slot.
30. The rack of claim 22, wherein the traveling wedge block is
horizontally repositionable parallel to the long axis of the
crossbar.
Description
CROSS-REFERENCES
[0001] This application is a continuation of U.S. patent
application Ser. No. 15/167,774 filed May 27, 2016, which claims
priority from 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. The
complete disclosures of each application are hereby incorporated by
reference in their entireties for all purposes.
[0002] The following related applications and materials are
incorporated by reference, in their entireties, for all purposes:
U.S. Pat. No. 6,905,053, and 8,387,839.
FIELD
[0003] This disclosure relates to systems and methods for attaching
cargo racks to vehicles. More specifically, the disclosed
embodiments relate to crossbar-to-vehicle couplers and related
clamping systems.
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 boards, kayaks, and the like. Many such carriers and
accessories are supported on 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.
[0007] With all this variation, rooftop rack systems must typically
incorporate a myriad of components customized to fit each style of
roof and rooftop feature. A need exists for a simplified system of
crossbars, support towers, and connection features, with a
reduction in customized components.
SUMMARY
[0008] The crossbar clamp actuator, as well as related systems and
methods according to the present teachings, allow attachment and
actuation of various crossbar clamps associated with different
crossbars to several coupler styles.
[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; wherein each coupler includes: a
crossbar clamp having a crossbar seat and a crossbar connector
movable relative to the crossbar seat; and a crossbar clamp
actuator comprising a horizontally traveling wedge block having a
ramped, downward-facing first slide surface, and a wedge follower
coupled to and movable with the crossbar connector, the wedge
follower having a second slide surface in frictional contact with
the first slide surface of the traveling wedge block, such that
substantially horizontal repositioning of the traveling wedge block
causes the ramped first slide surface to urge the wedge follower
downward.
[0010] In some embodiments, a coupler for mounting a cargo rack to
a vehicle may include a coupler having a vehicle interface clamp
configured to releasably secure the coupler to a vehicle feature,
and a crossbar clamp actuator including a traveling wedge block
having a ramped first slide surface, and a movable wedge follower
having a second slide surface in frictional contact with the first
slide surface of the traveling wedge block; and a crossbar clamp
having a first clamping portion operatively connected to and
movable with the wedge follower and a second clamping portion fixed
relative to the coupler; wherein repositioning of the traveling
wedge block along a first path causes the ramped first slide
surface to urge the wedge follower along a second path
substantially orthogonal to the first path.
[0011] In some embodiments, a method for attaching a crossbar to a
vehicle may include connecting a crossbar clamp to a clamp actuator
of a coupler assembly, the clamp actuator having a traveling wedge
block operatively connected to a movable wedge follower, such that
a first portion of the crossbar clamp is attached to and movable
with the wedge follower; capturing a crossbar with the first
portion of the crossbar clamp; and clamping the crossbar to the
coupler assembly by repositioning the traveling wedge block in a
first direction across the movable wedge follower, such that the
movable wedge follower is forced in a second direction, urging the
first portion of the crossbar clamp into a clamping position;
wherein the first direction is substantially parallel to a long
axis of the crossbar.
[0012] 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
[0013] FIG. 1 is a schematic block diagram of a rooftop cargo rack
system.
[0014] FIG. 2 is an oblique isometric view of a portion of an
illustrative vehicle showing an illustrative rooftop rack mounted
thereon.
[0015] FIG. 3 is a partially schematic diagram of an illustrative
crossbar-to-vehicle coupler in accordance with aspects of the
present disclosure.
[0016] FIG. 4 is an isometric view of an illustrative crossbar
clamp suitable for round crossbars.
[0017] FIG. 5 is an isometric exploded view of another illustrative
crossbar clamp suitable for slotted crossbars.
[0018] FIG. 6 is an end elevation view of the crossbar clamp of
FIG. 5 assembled and installed in an illustrative slotted
crossbar.
[0019] FIG. 7 is an isometric view of another illustrative crossbar
clamp suitable for aerodynamically shaped crossbars.
[0020] FIG. 8 is an isometric exploded view of an illustrative
crossbar clamp and crossbar clamp actuator assembly in accordance
with aspects of the present disclosure.
[0021] FIG. 9 is a bottom plan view of a traveling wedge block of
the actuator assembly depicted in FIG. 8.
[0022] FIG. 10 is a side elevation view of a wedge follower of the
actuator assembly depicted in FIG. 8.
[0023] FIG. 11 is a top plan view of the wedge follower of FIG.
10.
[0024] FIG. 12 is an end elevation view of the wedge follower of
FIG. 10.
[0025] FIG. 13 is a partial, sectional, elevation view of an
illustrative coupler and crossbar, showing an actuator and crossbar
clamp in a first, unclamped configuration.
[0026] FIG. 14 is a partial, sectional, elevation view of the
coupler and crossbar of FIG. 13, showing the actuator and crossbar
clamp in a second, clamped configuration.
[0027] FIG. 15 is a schematic view showing various possible
combinations of illustrative crossbars, clamps, and couplers with
an actuator, according to the present teachings.
[0028] FIG. 16 is a flow chart showing steps of an illustrative
method for attaching a crossbar to a vehicle.
DESCRIPTION
[0029] Various aspects and examples of crossbar clamp actuators and
crossbar clamps suitable for use with a variety of
crossbar-to-vehicle couplers, as well as related systems and
methods, are described below and illustrated in the associated
drawings. Unless otherwise specified, a crossbar clamp actuator
and/or crossbar clamp according to the present teachings 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
[0030] The following definitions apply herein, unless otherwise
indicated.
[0031] "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.
[0032] 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.
[0033] The terms "inboard," "outboard," "forward," "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. Terms regarding lateral orientation or positioning may be
considered relative to an imaginary central vertical plane dividing
the vehicle into left and right sides. For example, "outboard" may
indicate a relative position that is laterally farther from the
central vertical plane, or a direction that is away from the
central vertical plane. Conversely, "inboard" may indicate a
direction toward the central vertical plane, or a relative position
that is closer to the central vertical plane. Similarly, "forward"
means toward the front 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.
[0034] Overview of a Roof Rack System
[0035] In general, and with reference to FIG. 1, a vehicle roof
rack system 10 may include any suitable combination of components
configured to removably and securely affix a selected crossbar to a
vehicle rooftop. The crossbar is supported at either end by a pair
of supports having features that facilitate attachment to
corresponding feature(s) on the specific host 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.
[0036] 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 longitudinal axis of a vehicle, across
a rooftop, and to support loads placed thereon. For example, a
crossbar 12 may support a bicycle carrier, ski carrier, kayak
carrier, 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 host 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. Specific embodiments of crossbars 12 are
described in further detail below.
[0037] 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.
[0038] To fasten the outboard ends of the crossbars to features 14,
system 10 may include one or more couplers 16, also referred to as
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
a crossbar 12.
[0039] In some examples, crossbar interface 20 may include a
universal interface for connecting a variety of crossbars. Each
specific crossbar 12 may include or be associated with a crossbar
connector 22 (also referred to as an adapter) configured to
comprise a crossbar-specific bar clamp 24 when combined with a
crossbar seat 26. Crossbar interface 20 may include a threaded bolt
protruding upward from support 16. In this example, crossbar
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. Various crossbar connectors
may each be attachable, interchangeably, to the same threaded bolt
of the interface.
[0040] Bar clamp 24 may be used to removably and securely attach
crossbar 12 to coupler 16. 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.
Illustrative examples of bar clamp actuators 28 are described in
detail below.
[0041] Crossbar connector 22 and/or crossbar seat 26 may be grouped
or provided with crossbar 12 to form a kit suitable for connecting
to remaining elements of crossbar interface 20 of one or more
different couplers 16. In other examples, crossbar connector 22
and/or crossbar 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).
[0042] 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 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.
[0043] 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 in the examples below.
[0044] Accordingly, system 10 may allow a user to choose a 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 clamp
comprising crossbar connector 22 and crossbar seat 26.
[0045] 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 axis 46 generally coinciding with (e.g., running
parallel to) a direction of vehicular travel 48.
[0046] 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. 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.
[0047] Examples, Components, and Alternatives
[0048] The following sections describe selected aspects of
exemplary couplers, crossbar clamp actuators, crossbar clamps, and
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.
[0049] Illustrative Crossbar-to-Vehicle Coupler
[0050] As shown in FIG. 3, this section describes an illustrative
coupler 70 having a crossbar clamp actuator 72. Coupler 70 is an
example of couplers 16 described above. Accordingly, similar
components may be labeled with similar reference numbers.
[0051] FIG. 3 is an oblique isometric view showing the interface
provided by the coupler and clamp actuator. A bar clamp 74 is shown
schematically, including a bar connector 76 and a bar seat 78, to
illustrate that various such clamp components may be
interchangeably utilized with clamp actuator 72. In similar
fashion, clamp actuator 72 may be incorporated into various
couplers. Accordingly, in some examples, this type of clamp
actuator may be referred to as a universal connector, or the
like.
[0052] As described above, coupler 70 includes a vehicle interface
portion 80, a body 82, and a crossbar interface portion 84. Coupler
70 includes an outer case or housing 86, which in this example
includes a locking feature 88 configured to prevent unwanted access
to internal components. One or more portions of outer housing 86
may be selectively removable by a user.
[0053] As indicated schematically in FIG. 3, crossbar clamp 74 is
configured to be attachable to a threaded member 90 of clamp
actuator 72. Any suitable clamp may be used. In the examples
described here and below, a two-piece clamp is utilized, comprising
bar seat 78 and bar connector 76. In these examples, bar seat 78
includes any suitable structure configured to support the crossbar
and function as an anvil against which the bar is secured (i.e.,
clamped). In some examples, bar seat 78 includes a crossbar-facing
seating surface that conforms to an expected shape of the crossbar.
In some examples, bar seat 78 is configured to nest on, mount to,
or mate with a supporting surface 92 of coupler 62. One or more
retaining features 94 of coupler 62 may be utilized (temporarily or
otherwise) to hold bar seat 78 in place.
[0054] Crossbar connector 76 may include any suitable structure
configured to be securely attachable to coupler 70 (e.g., at
threaded member 90) and to capture, grab, connect with, encompass,
slot into, engage, mate with, latch onto, or otherwise hold a
portion of a crossbar. In some examples, different crossbar
connectors may be provided corresponding to respective different
types of crossbars.
[0055] Clamp actuator 72 includes any suitable structure and/or
mechanism manually or automatically operable to urge bar connector
76 into a clamping position relative to bar seat 78, such that the
connector and the bar seat secure the crossbar when clamped. For
example, a portion of the crossbar may be clamped between the
connector and the bar seat. In some examples, the actuator may pull
the bar connector downward such that the crossbar is pulled with
the connector and secured onto the crossbar seat. In some examples,
actuator 72 may cause a pinching action between the bar connector
and the bar seat, securing a portion of the crossbar. Actuator 72
may be reversibly operable, such that the same actuator may be used
to disengage the clamp from the crossbar. In some examples,
actuator 72 may be used to actively or affirmatively urge connector
76 away from crossbar seat 78. In some examples, actuator 72 may be
used to release a securing force or pressure, such that the
connector and seat can be manually separated.
[0056] In addition to securing clamp 74 to coupler 70, threaded
member 90 may form a part of actuator 72. For example, rotation of
threaded member 90 may, alone or in combination with other
features, result in a clamping action. However, clamp operation via
manipulation of threaded member 90 alone may require continued
access to threaded member 90, which may not be desirable and/or
practical in all operational situations or configurations.
Accordingly, in some examples, clamp 74 is attached to the coupler
and/or actuator by member 90, and actuator 72 includes a separate
and/or related actuation mechanism. For example, a tightening screw
96 may be operatively connected to threaded member 90, such that
rotation of screw 96 causes threaded member 90 to move up and/or
down to actuate clamp 74. As shown in FIG. 3, screw 96 may be
horizontal and accessible from an outboard side of the coupler
(e.g., after removing a panel or other portion of housing 86). A
length of screw 96 may be oriented parallel to a long axis of the
crossbar, i.e., transverse to the longitudinal axis of the
vehicle.
[0057] Illustrative Crossbar Clamps
[0058] As shown in FIGS. 4-7, this section describes three examples
of crossbar clamps. These crossbar clamps are each an example of
crossbar clamps 24 and 74, described above. As such, corresponding
components may be labeled and/or associated with the same or
similar reference numbers.
[0059] FIG. 4 depicts an illustrative clamp 100 suitable for use
with a substantially round crossbar 102. Clamp 100 includes a
crossbar seat 104 and a crossbar connector 106. Crossbar seat 104
may include any suitable structure configured to cradle crossbar
102 on a seating surface 108 that generally conforms to an outer
surface 110 of the crossbar. Crossbar seat 104 may be described as
an anvil or a fixed jaw. In some examples, seating surface 108 may
include a resilient, compressible, and/or compliant layer, such as
a rubber coating, to reduce damage to crossbar 102.
[0060] Crossbar connector 106 may include any suitable structure
configured to capture (e.g., grasp or grip) crossbar 102, and to be
movable relative to crossbar seat 104, such that the captured
crossbar can be urged or forced against seating surface 108.
Crossbar connector 106 may be interchangeably referred to as a
crossbar capturing member or crossbar capturing portion of clamp
100.
[0061] In this example, crossbar connector 106 includes a sleeve
portion 112 and a stem portion 114. Sleeve portion 112 is a
substantially cylindrical tube or collar generally conforming to
but slightly larger than an outer diameter of the round crossbar.
Sleeve portion 112 may freely slide on crossbar 102. Stem portion
114 extends or protrudes radially from an outer surface of sleeve
portion 112. Stem portion 114 may include a fastening mechanism,
such as a threaded hole, for attaching connector 106 to a clamp
actuator.
[0062] Crossbar seat 104 includes a block having an aperture 116
running vertically through the block, and through which crossbar
connector 106 can at least partially extend. For example, stem
portion 114 may extend through aperture 116. In some examples, stem
portion 114 may be connectible to an actuator, such that the
actuator can pull crossbar connector 106 downward through aperture
116. As can be seen in FIG. 4, this action causes crossbar 102 to
be pulled down onto crossbar seat 104, thereby arresting the
downward motion of the crossbar connector and clamping the crossbar
in place. As depicted in FIG. 4, a lower inner surface 118 of
sleeve portion 112 may be pulled below seating surface 108. This
may be facilitated by the larger diameter of sleeve portion 112
and/or an elastic deformation of sleeve portion 112 as a downward
force is applied by the actuator. In some examples, crossbar 102
may be a steel crossbar and sleeve portion 112 may comprise
aluminum.
[0063] Crossbar seat 104 also includes a retention ridge 120. A
respective instance of ridge 120 may be present on one or more
surfaces of seat 104, and may be configured to interface with a
corresponding retaining feature, e.g., retaining feature 94
described above with respect to FIG. 3. For example, seat 104 may
click into place with retaining feature 94 grabbing onto ridge 120
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.
[0064] Crossbar seat 104 is supported on the coupler. Accordingly,
a lower mating surface 122 may be shaped to engage or otherwise fit
onto a corresponding support surface of the coupler (e.g., support
surface 90 described above with respect to FIG. 3). As described
below regarding similar crossbar seats, lower mating surface 122
may include one or more additional features, such as discrete
positioning teeth, a selected curvature, etc.
[0065] FIGS. 5 and 6 depict another illustrative clamp 130 suitable
for use with a slotted crossbar 132. FIG. 5 is an exploded
isometric view of clamp 130, and FIG. 6 is an end view of clamp 130
assembled and inserted into a longitudinal bottom slot of crossbar
132, which is shown in section view.
[0066] Clamp 130 includes a crossbar seat 134 and a crossbar
connector 136. Similar to crossbar seat 104, crossbar seat 134 may
include any suitable structure configured to cradle crossbar 132 on
a seating surface 138 that generally conforms to an outer surface
140 of the crossbar. Crossbar seat 134 may be described as an anvil
or a fixed jaw. In some examples, seating surface 138 may include a
resilient, compressible, and/or compliant layer, such as a rubber
coating, to reduce damage to crossbar 132.
[0067] Crossbar connector 136 may include any suitable structure
configured to capture (e.g., grasp or grip) crossbar 132, and to be
movable relative to crossbar seat 134, such that the captured
crossbar can be urged against seating surface 138. Crossbar
connector 136 may be interchangeably referred to as a crossbar
capturing member or crossbar capturing portion of clamp 130. In
this example, crossbar connector 136 may be referred to as a tee or
a mushroom.
[0068] Crossbar connector 136 includes a flange portion 142, also
referred to as a cap or tee portion, and a stem portion 144. Flange
portion 142 is a substantially planar plate or flange sized to
slide into a tee slot 146 (also referred to as a T-slot) of slotted
crossbar 132. Tee slot 146 runs longitudinally along a length of
crossbar 132, and comprises a pair of spaced apart lips 148 and 150
defining a gap (i.e., slot 146) therebetween. Flange portion 142
has a width that spans slot 146, such that bottom surfaces of the
flange portion may abut upper surfaces of lips 148 and 150 of the
tee slot. Stem portion 144 extends or protrudes orthogonally from
flange portion 142. Stem portion 144 may be sized such that stem
portion 144 can extend through slot 146 when flange portion 142 is
inserted in the slot, as shown in FIG. 5. Accordingly, crossbar
connector 136 may freely slide in a longitudinal direction along
slot 146 of crossbar 132 when clamp 130 is unclamped.
[0069] Stem portion 144 may include a fastening mechanism, such as
a threaded hole, for attaching connector 136 to a clamp actuator.
Similar to the way sliding sleeve portion 112 onto crossbar 102
captured that crossbar, inserting crossbar connector 136 into tee
slot 146 effectively captures crossbar 132.
[0070] Crossbar seat 134 includes a block having an aperture 152
running vertically through the block, and through which crossbar
connector 136 can at least partially extend. For example, stem
portion 144 may extend through aperture 152, as shown in FIG. 6. In
some examples, stem portion 144 may be connectible to an actuator,
such that the actuator can pull crossbar connector 136 downward
through aperture 152. As can be seen in FIG. 6, this action will
cause flange 142 to exert force on lips 148 and 150, pulling
crossbar 132 down onto crossbar seat 134, thereby arresting the
downward motion of the crossbar connector and clamping the crossbar
in place. (See FIGS. 13-14).
[0071] Crossbar seat 134 may include a pair of guide flanges 154
and 156 protruding from seating surface 138 on opposing sides of
aperture 152. Guide flanges 154 and 156 may include any suitable
structures axially aligned with each other and configured to mate
in sliding engagement with crossbar slot 146. As with flange
portion 142 of crossbar connector 136, guide flanges 154 and 156
may be passed into slot 146 through an end of the crossbar, in an
axial direction with respect to the long axis of the crossbar.
Guide flanges 154 and 156 are positioned on either end of flange
portion 142 of the bar connector when assembled. Guide flanges 154
and 156 may be unitary with crossbar seat 134.
[0072] The guide flanges may function to maintain an orientation of
the crossbar seat with respect to the crossbar slot and/or to keep
seat 134 adjacent to the crossbar, e.g., during assembly and
adjustment. Guide flanges 154 and 156 may not be load bearing
structures. For example, clamping force may be applied to crossbar
132 by drawing bar connector 136 down onto crossbar seat 134.
Flanges 154 and 156 are fixed relative to crossbar seat 134.
Consequently, the guide flanges may not exert any substantive
vertical force on the crossbar during a clamping operation.
[0073] Crossbar seat 134 also includes a retention ridge 158,
substantially similar to ridge 120 described above. As with
crossbar seat 104, a lower mating surface 160 may be shaped to
engage or otherwise fit onto a corresponding support surface of the
coupler (e.g., support surface 90 described above with respect to
FIG. 3). Lower mating surface 160 may include one or more
additional features, such as discrete positioning teeth 162
configured to mate with corresponding teeth or features on the
support surface of the coupler.
[0074] FIG. 7 depicts another illustrative clamp 170 suitable for
use with an aerodynamic (also referred to as "aero") or teardrop
shaped crossbar 172. Aero crossbar 172 may or may not include a
lower T-slot, similar to crossbar 132. However, crossbars having
lower T-slots frequently also have such slots on upper surfaces,
and clamp 170 may interfere with these upper slots. Accordingly, it
may be desirable to use clamp 130 rather than clamp 170 in some
examples, and vice versa.
[0075] Clamp 170 includes a crossbar seat 174 and a crossbar
connector 176, both of which are similar to their corresponding
components in clamp 100. Crossbar seat 174 may include any suitable
structure configured to cradle crossbar 172 on a seating surface
178 that generally conforms to an outer surface 180 of the
crossbar. Crossbar seat 174 may be described as an anvil or a fixed
jaw. In some examples, seating surface 178 may include a resilient,
compressible, and/or compliant layer, such as a rubber coating, to
reduce damage to crossbar 172.
[0076] Crossbar connector 176 may include any suitable structure
configured to capture (e.g., grasp or grip) crossbar 172, and to be
movable relative to crossbar seat 174, such that the captured
crossbar can be urged against seating surface 178. Crossbar
connector 176 may be interchangeably referred to as a crossbar
capturing member or crossbar capturing portion of clamp 170.
[0077] In this example, crossbar connector 176 includes a sleeve
portion 182 and a stem portion 184. Sleeve portion 182 is a
substantially teardrop-shaped or airfoil-shaped tube or collar
generally conforming to but slightly larger than an outer shape of
the aero crossbar. Sleeve portion 182 may freely slide on crossbar
172. Stem portion 184 extends or protrudes outward from an outer
surface of sleeve portion 182. Stem portion 184 may include a
fastening mechanism, such as a threaded hole, for attaching
connector 176 to a clamp actuator.
[0078] Seating surface 178 of crossbar seat 174 may include two
raised wall portions 186, 188 defining a central channel 190, and
may have an aperture 192 passing vertically through the crossbar
seat. Crossbar connector 176 can at least partially extend through
aperture 192, and sleeve 182 may be nestable in channel 190, as
shown in FIG. 7. Stem portion 184 may extend through aperture 192
when clamp 170 is assembled.
[0079] In some examples, stem portion 184 may be connectible to an
actuator, such that the actuator can pull crossbar connector 176
downward through aperture 192. As can be seen in FIG. 7, this
action will cause crossbar 172 to be pulled down onto crossbar seat
174, thereby arresting the downward motion of the crossbar
connector and clamping the crossbar in place. As depicted in FIG.
7, a lower inner surface 194 of sleeve portion 182 may be pulled
below seating surface 178. This may be facilitated by the larger
diameter of sleeve portion 182 and/or an elastic deformation of
sleeve portion 182 as a downward force is applied by the actuator.
In some examples, crossbar 172 may be a steel crossbar and sleeve
portion 182 may comprise aluminum.
[0080] Crossbar seat 174 also includes a retention ridge 196. A
respective instance of ridge 196 may be present on one or more
surfaces of seat 174, and may be configured to interface with a
corresponding retaining feature, e.g., retaining feature 94
described above with respect to FIG. 3. For example, as with other
crossbar seats, seat 174 may click into place with retaining
feature 94 grabbing onto ridge 196 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.
[0081] Crossbar seat 174 is supported on the coupler. Accordingly,
a lower mating surface 198 may be shaped to engage or otherwise fit
onto a corresponding support surface of the coupler (e.g., support
surface 90 described above with respect to FIG. 3). As described
above, lower mating surface 198 may include one or more additional
features, such as discrete positioning teeth, a selected curvature,
etc.
[0082] Illustrative Crossbar Clamp Actuator
[0083] As shown in FIGS. 8-14, this section describes an
illustrative clamp actuator (also referred to as an actuator
mechanism or actuator assembly) suitable for use in a coupler to
tighten crossbar clamps similar to those described above. The clamp
actuator described in this section is an example of crossbar clamp
actuator 28, described above, and is similar to actuator 72 shown
in FIG. 3. As such, corresponding components may be labeled and/or
associated with the same or similar reference numbers.
[0084] As described above, actuation of crossbar clamps such as
clamps 100, 130, and 170 includes repositioning of a portion of the
clamp (e.g., a clamp jaw or crossbar connector) in a substantially
downward direction, e.g., along a vertical path. For example, clamp
100 is actuated by applying a downward force to (e.g., pulling
downward on) stem portion 114, thereby drawing bar connector 106
down with respect to bar seat 104. Because crossbar 102 is captured
by the encircling bar connector 106, crossbar 102 is pinned against
bar seat 104 as a result. Similarly, clamp 130 is actuated by
applying a downward force to stem portion 144, thereby drawing bar
connector 136 down with respect to bar seat 134. Because crossbar
132 is captured by bar connector 136 being inserted in slot 146,
crossbar 132 is pinned against bar seat 134 as a result. This
downward-force style of actuation may also be true for other types
of clamps.
[0085] Accordingly, in these examples, a suitable actuator should
provide a downward force to the crossbar connector portion of the
crossbar clamps. Furthermore, it may be advantageous for a manual
actuator to be accessible from an outboard side of the coupler,
such that a user may operate the actuator easily when the coupler
is mounted on a vehicle. Such a crossbar clamp actuator is
described below, in which manipulation of a horizontal tightening
member is mechanically translated into a downward clamping
action.
[0086] In FIG. 8, a crossbar clamp 200 and a crossbar clamp
actuator 202 are depicted in an exploded view. Any suitable
crossbar clamp, such as the ones described above, may be used with
actuator 202. In this example, crossbar clamp 200 is substantially
identical to crossbar clamp 170, and includes a crossbar connector
204 and a crossbar seat 206. Crossbar connector 204 is a
collar-type connector having a sleeve portion 208 and a stem
portion 210. Crossbar seat 206 includes a pair of side walls 212
and 214 defining a seating surface 216 for an aero crossbar (not
pictured), a central channel 218, and an aperture 220. A rounded
lower surface of the crossbar seat includes positioning teeth 222
for positively locating the crossbar seat on the housing described
below.
[0087] Stem portion 210 of the crossbar connector includes a
threaded hole 224 passing vertically through the stem. Stem
portions of other crossbar clamps may include similar threaded
holes, which may or may not pass completely through the stem. These
threaded holes may be used to fasten a selected clamp to the
attachment bolt of the actuator (see below), which corresponds to
threaded member 90 of FIG. 3. Stem portion 210 may have a shaped
lower profile. In this example, the lower profile is stepped or
keyed to provide a mating surface for the wedge follower described
further below.
[0088] As shown in FIG. 8, actuator 202 (also called an actuator
assembly) includes a housing 226, a traveling wedge block 228 (also
called a slide wedge or wedge portion), a wedge follower 230 (also
called a slide follower), an attachment bolt 232 (also called a
second threaded member), a tightening screw 234 (also called a
first threaded member) for positioning the traveling wedge block,
and a security cover 236.
[0089] Housing 226 may include any suitable structure(s) configured
to provide a support surface 238 for crossbar seat 206, to define a
cavity 240 for housing wedge block 228 and wedge follower 230, and
to provide a stationary fulcrum or brace against which the mover of
the wedge block can apply force. In this example, the mover of the
wedge block is tightening screw 234. Accordingly, a head 242 of the
tightening screw abuts and turns against a substantially vertical
plate 244 (i.e., a wall) of housing 226, which provides a
stationary structural abutment. The tightening screw passes through
an hole 246 in the plate. Hole 246 may be elongated and/or arcuate,
facilitating side to side adjustment within the hole and/or minor
rotation/tilting of traveling wedge block 228. A washer may be
disposed between head 242 and plate 244. In other examples, the
mover of the traveling wedge block may include a cam mechanism, a
lever, and/or the like.
[0090] In this example, housing 226 is a unitary, box-like
structure having an open bottom (e.g., a five-sided box). Housing
226 includes features for attaching the housing to other components
or otherwise integrating the housing into a coupler, such as by
riveting, bolting, screwing, adhering, and/or the like, or any
combination of these. For example, housing 226 includes mounting
structures 248, 250, and 252. In some examples, housing 226
comprises separate components, attached to each other and/or to
other features of the host coupler. For example, rather than an
integral portion of the housing, plate 244 may comprise a separate
component bolted in position to the body of the coupler (e.g., see
FIG. 3).
[0091] Support surface 238, which comprises an upper portion of
housing 226, may have any suitable structures configured to mate
with and/or support crossbar seat 206 thereon, for example in a
selected orientation. In this example, support surface 238 includes
features that conform to corresponding features of the crossbar
seat. For example, raised edges 254 and 256 are configured to
positively locate and cradle the general shape of seat 206, and
teeth 258 and 260 are configured to mate with teeth 222 to hold the
crossbar seat in position. Support surface 238 further includes an
aperture 262. In this example, aperture 262 in the housing is
generally rectangular and corresponds positionally to aperture 220
of the crossbar seat. This positional correspondence allows, e.g.,
stem 210 of the crossbar connector to pass through the two aligned
apertures when the components are assembled.
[0092] As depicted in FIGS. 8 and 9, traveling wedge block 228 is a
generally rectangular block having a threaded hole 264 in an
outboard end. Threaded hole 264 is configured to accept tightening
screw 234, such that rotation of the tightening screw causes wedge
block 228 to move horizontally toward or away from plate 244 (i.e.,
in an outboard or inboard direction). Wedge block 228 includes one
or more ramped, downward-facing slide surfaces, in this example the
wedge block includes a pair of such surfaces 266 and 268. In this
example, slide surfaces 266 and 268 are generally parallel to each
other, and ramp downward toward the inboard end of the wedge block.
In some examples, the one or more slide surfaces may instead ramp
upward toward the inboard end.
[0093] Traveling wedge block 228 is open at the bottom, such that
the ramped slide surfaces are exposed. An elongate aperture 270
exists between slide surfaces 266 and 268. Aperture 270 generally
aligns with apertures 220 and 262. Maintenance of this alignment
during operation is facilitated by the elongated shape of aperture
270 in the wedge block's direction of travel.
[0094] Side surfaces of traveling wedge block 228 may include hooks
or protrusions 272, as shown in FIGS. 8 and 9. Hooks 272 facilitate
attachment of security cover 236 to wedge block 228, such that the
security cover moves with the wedge block when tightening screw 234
is rotated. Security cover 236 may be clipped or otherwise coupled
to the wedge block, for example by mating holes 274 of the security
cover with corresponding hooks 272.
[0095] With reference now to FIGS. 8 and 10-12, wedge follower 230
is a movable component having an upper interface 276 for mating
with stem 210 of crossbar connector 204. Wedge follower 230 further
includes a central aperture 278 passing vertically through the
wedge follower (and through which attachment screw 232 may pass),
and a pair of wedge-shaped side protrusions 280, 282.
[0096] Side protrusions 280 and 282 each have a ramped upper slide
surface 284, 286 configured to make frictional, flat-to-flat
contact with a respective one of slide surfaces 266 and 268 when
the wedge follower is placed into the open bottom of the traveling
wedge block. Upper slide surfaces 284 and 286 may be ramped planes,
such that the upper slide surfaces mate with correspondingly angled
and planar slide surfaces 266 and 268 of the sliding wedge block.
As indicated in FIG. 10, the ramped surface of each side protrusion
may define an angle A, which may be complementary to an angle B of
the correspondingly-ramped planes of surfaces 266 and 268. This
flat-to-flat contact facilitates a sliding motion and opposes
twisting of the wedge block and wedge follower components relative
to each other when in operation.
[0097] Accordingly, horizontal repositioning of wedge block 228,
e.g., in an outboard or first direction, will cause slide surfaces
266 and 268 to reposition horizontally on side protrusions 280, 282
of the wedge follower. When assembled, wedge follower 230 is
substantially blocked from moving in an outboard direction but free
to move in a direction orthogonal to the outboard direction (e.g.,
vertical). Because slide surfaces 266 and 268 are ramped,
horizontal repositioning of wedge block 228 will cause a wedging
action, such that the side protrusions and wedge follower 230 are
urged downward (i.e., orthogonal to the first direction of the
wedge block). The downward motion of wedge follower 230 may appear
vertical when viewed in a direction of vehicle travel, but may be
slightly off-vertical when viewed along the long axis of the
crossbar. This is because the traveling wedge block may be oriented
in a rotated position with respect to its long axis. Accordingly,
"vertical" travel of the wedge follower may actually be normal to
the plane generally defined by the width of the wedge block.
[0098] To transfer this forced downward motion to crossbar
connector 204, thereby causing a clamping action, attachment bolt
232 (also referred to as an attachment screw, a retention member, a
threaded member, a second threaded member) passes vertically
through aperture 278 of wedge follower 230 and fastens to crossbar
connector 204 via threaded hole 224 in stem 210. In some examples,
aperture 278 may be threaded. In some examples, aperture 278 may be
an unthreaded through-hole. Attachment screw 232 may be held in
position (when not attached to the crossbar connector) by a C-clip,
E-clip, or snap ring installed at the upper exit of aperture 278
(see FIG. 3). Various crossbar connector styles may be
interchangeably attached to the coupler and actuator assembly using
the same attachment bolt.
[0099] When wedge follower 230 is coupled to crossbar connector 204
by attachment bolt 232, the shaped bottom of stem 210 nests in the
correspondingly shaped upper interface 276 of wedge follower 230.
For example, upper interface 276 may include castellations 288,
such that crossbar connector 204 is prevented from twisting
relative to wedge follower 230 by the castellated mating surfaces.
Attachment of a crossbar connector to the wedge follower is
complete when the stem is seated on the wedge follower and the
attachment bolt is fully tightened. In this illustrative actuator
system, attachment bolt 232 is only for securing crossbar connector
204 to the assembly, and bolt 232 is not used to directly actuate
the clamp.
[0100] Security cover 236 may include any suitable structure
configured to prevent access to attachment bolt 232. For example,
as shown in FIG. 8, security cover 236 may include a sheet of metal
or other tamper-resistant material that covers the head of bolt 232
to prevent unwanted tampering. In this example, the cover is
removably attachable to traveling wedge block 228 and shaped such
that repositioning of the wedge block in an outboard (i.e.,
clamp-tightening) direction causes the security cover to block
access to the bolt. Conversely, the bolt head may be uncovered when
the wedge block is repositioned in a clamp-loosening direction
(i.e., inboard).
[0101] Illustrative Clamp Actuation
[0102] Turning now to FIGS. 13 and 14, actuator 202 is assembled,
combined with clamp 130, and shown in a sectional side elevation
view. Line 13-13 of FIG. 9 indicates generally where the cross
section is taken with respect to traveling wedge block 228. FIG. 13
shows the actuator and clamp in a first, unclamped configuration,
and FIG. 14 shows the same actuator and clamp in a second, clamped
configuration.
[0103] As described above, actuator 202 may be combined with
various crossbar clamps and corresponding crossbars. In this
example, actuator 202 is combined with crossbar clamp 130 by
bolting stem 144 of crossbar connector 136 to wedge follower 230
(using attachment bolt 232). Crossbar clamp 130 and actuator 202
are incorporated into an exemplary coupler 300, which is shown in
engagement with T-slot crossbar 132.
[0104] In FIG. 13, crossbar 132 is seated on crossbar seat 134,
with guide flanges 154 and 156 inserted into the crossbar slot. The
crossbar is captured by flange 142 of crossbar connector 136, and
stem 144 extends downward through the crossbar slot. However,
flange 142 is in a raised position relative to lip 148 of the
crossbar. In other words, clamp 130 is in an unclamped position,
and flange 142 is not applying force to hold the crossbar against
the crossbar seat.
[0105] With continuing reference to FIG. 13, stem 144 extends from
flange 142 through the crossbar slot and through aperture 152 of
crossbar seat 134 to mate with the castellated support surface of
wedge follower 230. Wedge follower 230 is generally disposed within
traveling wedge block 228, with the upper slide surfaces of the
wedge follower's side protrusions in frictional contact with the
slide surfaces of the traveling wedge block. For example, upper
slide surface 284 is shown in contact with slide surface 266. It
should be understood that upper slide surface 286 is similarly in
contact with slide surface 268, but that this portion of the
assembly is obscured in FIGS. 13 and 14. In the unclamped
configuration shown in FIG. 13, traveling wedge block 228 is
horizontally spaced from plate 244 of housing 226, and held in
position by tightening screw 234.
[0106] Turning to FIG. 14, traveling wedge block 228 has been
horizontally repositioned in an outboard direction (i.e., to the
right in the drawing), by rotation of tightening screw 234, such
that the traveling wedge block is now closer to plate 244. Rotation
of screw 234 may be performed by any suitable method, such as using
a driver or other tool configured to mate with screw head 242. This
repositioning of wedge block 228 is generally indicated by an arrow
302.
[0107] As described above, wedge follower 230 is bolted to stem 144
of crossbar connector 136. Furthermore, the assembled wedge
follower and crossbar connector are blocked from moving
horizontally by the confines of the various apertures they pass
through (e.g., apertures 152, 262, 270). However, the wedge
follower/crossbar connector assembly does have some freedom to move
up and down.
[0108] When wedge block 228 is repositioned as shown, ramped,
downward-facing slide surfaces 266 and 268 are also moved in the
outboard direction. This changes the effective vertical position of
slide surfaces 266 and 268 at their point of interaction with the
side protrusions, thereby applying a downward force on the side
protrusions. Side protrusions 266 and 268 may have any suitable
profile shape, and may comprise round pins or other shapes. In this
example, side protrusions 266 and 268 have ramped planar surfaces
that complement the ramped planar faces of surfaces 266 and 268. As
described above, this feature helps to prevent twisting and other
undesired moments. In some examples, this feature increases the
frictional contact area between the wedge block and wedge follower,
which may improve holding forces and prevent loosening of the
overall mechanism.
[0109] Application of the downward force on side protrusions 266
causes wedge follower 230 and therefore the crossbar connector 136
to move along a downward path, as indicated by an arrow 304 in FIG.
14. This downward movement brings flange 142 down onto lips 148 and
150, and secures (i.e., clamps) crossbar 132 against crossbar seat
134. Accordingly, actuator 202 translates the repositioning of
traveling wedge block 228 in a first direction (e.g., horizontal)
into the repositioning of crossbar connector 136 in a second
direction (e.g., substantially vertical), where the second
direction is substantially orthogonal to the first direction. Said
another way, actuator 202 translates rotational manipulation of a
horizontal member (i.e., tightening screw 234) into substantially
vertical tightening of a clamp portion (i.e., connector 136). It
should be understood that the terms horizontal and vertical are
used here in the context of the standard mounting position of the
coupler. Other mutually orthogonal or otherwise transverse
directions may be substituted without going beyond the scope of the
present disclosure.
[0110] Illustrative Crossbar-Coupler Combinations
[0111] As shown in FIG. 15, this section describes various suitable
combinations of an illustrative clamp actuator with different
crossbars, crossbar clamps, and coupler styles. The clamp actuator
described in this section is a schematic example of crossbar clamp
actuator 28, described above. Additionally, the crossbars and
crossbar clamps described in this section are examples of those
described above, and have features and functions substantially
identical to those already discussed. Accordingly, crossbars and
clamps are labeled with primed reference numbers corresponding to
the substantially identical versions above.
[0112] A clamp actuator 310 is shown schematically in FIG. 15, and
represents any example of clamp actuator 28 according to the
present teachings (e.g., clamp actuator 202). In this type of clamp
actuator, the substantially horizontal repositioning of a traveling
wedge block causes its ramped slide surface to urge a wedge
follower downward, thereby actuating (e.g., closing) the clamp.
[0113] As explained above, clamp actuator 310 is versatile in a
first respect, in that various different clamps can be attached to
the actuator. Generally speaking, a clamp that has a vertically
repositionable jaw or other element may be connected to the
attachment bolt of the clamp actuator. For example, a crossbar
connector (e.g., connector 106, 136, or 176) may be connected to
the attachment bolt, which protrudes in a generally vertical
direction from an accessible upper support surface of the coupler.
This is shown graphically in FIG. 15, where crossbar clamps 100',
130', and 170' are depicted as optionally attachable to actuator
310. Crossbars 102', 132', and 172' are shown with their
corresponding clamps.
[0114] Clamp actuator 310 is also versatile in a second respect, in
that clamp actuator 310 may be utilized or incorporated into
various couplers, such as couplers 312, 314, 316, 318 shown in FIG.
15. Although four such couplers are shown in FIG. 15 and described
below, it should be understood that inclusion of actuator 310 is
optional for any given coupler, and that more or fewer couplers may
be available for such inclusion. In general, when clamp actuator
310 is included in a coupler, the attachment bolt protrudes
generally vertically from an upper surface of the coupler, and the
tightening screw protrudes in an outboard direction from the
coupler. This orientation of components is illustrated, for
example, in FIG. 3.
[0115] As described above with respect to couplers 16, 60, 62, 64,
66, and 70, 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
crossbar interface 20 comprising a selected crossbar clamp and
actuator described above, as well as a vehicle interface 18 for
clamping or otherwise connecting the coupler to a vehicle
feature.
[0116] 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.
[0117] 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.
[0118] 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.
Seat 326 sits atop the vehicle roof, while clip 324 grabs onto the
vehicle gutter (or the like).
[0119] 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).
[0120] Illustrative Method
[0121] This section describes steps of an illustrative method for
attaching a crossbar to a vehicle; see FIG. 16. Aspects of
crossbars, couplers, and/or actuators described above may be
utilized in the method steps described below. Where appropriate,
reference may be made to previously described components and
systems that may be 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.
[0122] FIG. 16 is a flowchart illustrating steps performed in an
illustrative method, and may not recite the complete process or all
steps of the method. FIG. 16 depicts multiple steps of a method,
generally indicated at 400, which may be performed in conjunction
with crossbar clamping systems and devices according to aspects of
the present disclosure. Although various steps of method 400 are
described below and depicted in FIG. 16, the steps need not
necessarily all be performed, and in some cases may be performed in
a different order than the order shown.
[0123] Step 402 includes connecting a crossbar clamp (e.g., clamp
100, clamp 130, clamp 170) to a clamp actuator (e.g., actuator 202)
of a coupler assembly (e.g., coupler 312, coupler 314, coupler 318,
coupler 320). The clamp actuator includes a traveling wedge block
(e.g., wedge block 228) operatively connected to a movable wedge
follower (e.g., follower 230), such that a first portion (e.g.,
connector 204) of the crossbar clamp is attached to and movable
with the wedge follower. In some examples, step 402 may include
bolting the first portion of the crossbar clamp to the clamp
actuator (e.g., using bolt 232).
[0124] In some examples, the crossbar clamp may be selected from a
plurality of different crossbar clamps. For example, different
crossbar clamps may be suitable for different crossbar styles. For
example, crossbar clamp 100 for round crossbar 102, crossbar clamp
130 for slotted crossbar 132, and/or crossbar clamp 170 for aero
bar 172.
[0125] Step 404 includes capturing a crossbar (e.g., crossbar 102,
crossbar 132, crossbar 172) with the first portion of the crossbar
clamp. In some examples, capturing the crossbar with the first
portion of the crossbar clamp may include inserting the crossbar
into a sleeve portion of the crossbar clamp (see clamps 100 and
170). In some examples, capturing the crossbar with the first
portion of the crossbar clamp may include inserting a T-shaped
connector of the crossbar clamp into a T-slot of the crossbar (see
clamp 130 and bar 132).
[0126] Step 406 includes clamping the crossbar to the coupler
assembly by repositioning the traveling wedge block in a first
direction across the movable wedge follower, such that the movable
wedge follower is forced in a second direction, urging the first
portion of the crossbar clamp into a clamping position. The first
direction is substantially parallel to a long axis of the crossbar.
The second direction may be substantially orthogonal to the first
direction. The second direction may be substantially downward
(e.g., vertical), and the first direction may be horizontal. The
first direction may be an outboard direction.
[0127] In some examples, urging the first portion of the crossbar
clamp into the clamping position includes urging the first portion
toward a second portion (e.g., crossbar seat 206) of the crossbar
clamp.
[0128] In some examples, repositioning the traveling wedge block
includes manually operating a mover of the wedge block, wherein the
mover of the wedge block is accessible from a position outboard of
the coupler. In some examples, repositioning the traveling wedge
block includes manually rotating a threaded screw (e.g., screw 234)
inserted into the traveling wedge block.
[0129] Method 400 may further include clamping a vehicle interface
portion of the coupler assembly to a corresponding physical feature
of a vehicle. In some examples, the physical feature of the vehicle
is a rail mounted flush on a roof of the vehicle, and clamping the
vehicle interface portion to the rail includes clamping the rail
between opposed clips extending from the coupler. (See coupler
318). In some examples, the physical feature of the vehicle is a
raised rail on a roof of the vehicle, and clamping the vehicle
interface portion to the raised rail includes passing a strap of
the vehicle interface portion between the raised rail and the roof.
(See coupler 312).
[0130] Selected Aspects and Examples
[0131] This section describes additional aspects and features of
crossbar clamp actuators and 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.
[0132] A0. A rack for carrying cargo on top of a vehicle, the rack
comprising:
[0133] 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;
[0134] wherein each coupler includes: [0135] a crossbar clamp
having a crossbar seat and a crossbar connector movable relative to
the crossbar seat; and [0136] a crossbar clamp actuator comprising
[0137] a horizontally traveling wedge block having a ramped,
downward-facing first slide surface, and [0138] a wedge follower
coupled to and movable with the crossbar connector, the wedge
follower having a second slide surface in frictional contact with
the first slide surface of the traveling wedge block, such that
substantially horizontal repositioning of the traveling wedge block
causes the ramped first slide surface to urge the wedge follower
downward, moving the crossbar connector downward relative to the
crossbar seat.
[0139] A1. The rack of A0, wherein the first slide surface of the
traveling wedge block is a substantially planar surface.
[0140] A2. The rack of A1, wherein the second slide surface of the
wedge follower is a substantially planar surface.
[0141] A3. The rack of A2, wherein the ramped first slide surface
defines a first ramp angle, and the second slide surface is ramped
at a second ramp angle complementary to the first ramp angle.
[0142] A4. The rack of any of paragraphs A0 through A3, wherein the
actuator further includes a threaded screw passing through a
housing of the actuator and inserted into an end of the traveling
wedge block, such that rotation of the threaded screw is configured
to cause the horizontal repositioning of the traveling wedge
block.
[0143] A5. The rack of any of paragraphs A0 through A4, wherein
each coupler further includes a vehicle interface configured to
releasably secure the coupler to a corresponding feature of the
vehicle.
[0144] A6. The rack of A5, wherein the vehicle interface includes a
strap that passes between a raised rail of the vehicle and the top
of the vehicle.
[0145] A7. The rack of A5, wherein the vehicle interface includes
at least one clip configured to grasp the feature of the
vehicle.
[0146] A8. The rack of A7, wherein the feature of the vehicle is a
flush rail.
[0147] A9. The rack of any of paragraphs A0 through A8, wherein the
crossbar connector includes a sleeve shaped to slide onto and
generally conform to an outer shape of the crossbar.
[0148] A10. The rack of any of paragraphs A0 through A9, wherein
the crossbar connector includes a flange configured to slide into a
slot of the crossbar, such that the flange spans a pair of opposing
lips of the slot.
[0149] A11. The rack of any of paragraphs A0 through A10, wherein
the traveling wedge block is horizontally repositionable parallel
to the long axis of the crossbar.
[0150] B0. A coupler for mounting a cargo rack to a vehicle, the
coupler comprising:
[0151] a coupler having a vehicle interface clamp configured to
releasably secure the coupler to a vehicle feature, and a crossbar
clamp actuator including a traveling wedge block having a ramped
first slide surface, and a movable wedge follower having a second
slide surface in frictional contact with the first slide surface of
the traveling wedge block; and
[0152] a crossbar clamp having a first clamping portion operatively
connected to and movable with the wedge follower and a second
clamping portion fixed relative to the coupler;
[0153] wherein repositioning of the traveling wedge block along a
first path causes the ramped first slide surface to urge the wedge
follower along a second path substantially orthogonal to the first
path, such that the first clamping portion moves closer to the
second clamping portion.
[0154] B1. The coupler of B0, wherein the first path is
horizontal.
[0155] B2. The coupler of B1, wherein the first path is in an
outboard direction when the coupler is mounted on a vehicle.
[0156] B3. The coupler of any of paragraphs B0 through B2, wherein
the vehicle feature includes a raised rail, and the vehicle
interface clamp includes a strap passable between the raised rail
and the vehicle.
[0157] B4. The coupler of any of paragraphs B0 through B3, wherein
the vehicle interface clamp includes at least one clip configured
to grasp the vehicle feature.
[0158] B5. The coupler of any of paragraphs B0 through B4, wherein
the ramped first slide surface defines a first angle, and the
second slide surface is ramped at a second angle complementary to
the first angle.
[0159] B6. The coupler of B5, wherein the second slide surface and
the first slide surface are planar.
[0160] B7. The coupler of any of paragraphs B0 through B6, wherein
the first clamping portion is bolted to the wedge follower.
[0161] B8. The coupler of any of paragraphs B0 through B7, wherein
the second clamping portion includes a seating surface configured
to support a crossbar.
[0162] B9. The coupler of any of paragraphs B0 through B8, the
crossbar clamp actuator further including a threaded screw passing
through a structural plate and into an end of the traveling wedge
block, such that rotation of the screw causes repositioning of the
traveling wedge block along the first path.
[0163] C0. A method for attaching a crossbar to a vehicle, the
method comprising:
[0164] connecting a crossbar clamp to a clamp actuator of a coupler
assembly, the clamp actuator having a traveling wedge block
operatively connected to a movable wedge follower, such that a
first portion of the crossbar clamp is attached to and movable with
the wedge follower;
[0165] capturing a crossbar with the first portion of the crossbar
clamp; and
[0166] clamping the crossbar to the coupler assembly by
repositioning the traveling wedge block in a first direction across
the movable wedge follower, such that the movable wedge follower is
forced in a second direction, urging the first portion of the
crossbar clamp into a clamping position;
[0167] wherein the first direction is substantially parallel to a
long axis of the crossbar.
[0168] C1. The method of C0, wherein the second direction is
substantially orthogonal to the first direction.
[0169] C2. The method of any of paragraphs C0 through C1, wherein
urging the first portion of the crossbar clamp into the clamping
position includes urging the first portion toward a second portion
of the crossbar clamp.
[0170] C3. The method of any of paragraphs C0 through C2, wherein
capturing the crossbar with the first portion of the crossbar clamp
includes inserting the crossbar into a sleeve portion of the
crossbar clamp.
[0171] C4. The method of any of paragraphs C0 through C3, wherein
capturing the crossbar with the first portion of the crossbar clamp
includes inserting a T-shaped connector of the crossbar clamp into
a T-slot of the crossbar.
[0172] C5. The method of any of paragraphs C0 through C4, further
including clamping a vehicle interface portion of the coupler
assembly to a corresponding physical feature of a vehicle.
[0173] C6. The method of C5, wherein the physical feature of the
vehicle is a rail mounted flush on a roof of the vehicle, and
clamping the vehicle interface portion to the rail includes
clamping the rail between opposed clips extending from the
coupler.
[0174] C7. The method of C5, wherein the physical feature of the
vehicle is a raised rail on a roof of the vehicle, and clamping the
vehicle interface portion to the raised rail includes passing a
strap of the vehicle interface portion between the raised rail and
the roof.
[0175] C8. The method of any of paragraphs C0 through C7, further
including selecting the crossbar clamp from a plurality of
different crossbar clamps.
[0176] C9. The method of any of paragraphs C0 through C8, wherein
connecting the crossbar clamp to the clamp actuator includes
bolting the first portion of the crossbar clamp to the clamp
actuator.
[0177] C10. The method of any of paragraphs C0 through C9, wherein
repositioning the traveling wedge block includes manually operating
a mover of the wedge block, wherein the mover of the wedge block is
accessible from a position outboard of the coupler.
[0178] C11. The method of any of paragraphs C0 through C10, wherein
repositioning the traveling wedge block includes manually rotating
a threaded screw inserted into the traveling wedge block.
Advantages, Features, Benefits
[0179] The different embodiments and examples of the crossbar clamp
actuator and related systems and methods described herein provide
several advantages over known solutions for mounting crossbars on
vehicles. For example, illustrative embodiments and examples
described herein facilitate the use of interchangeable crossbar
clamps on the same coupler.
[0180] Additionally, and among other benefits, illustrative
embodiments and examples described herein provide increased
frictional holding power and resistance to loosening, because of
the flat-to-flat contact between the slide surfaces of the sliding
wedge block and the wedge follower.
[0181] Additionally, and among other benefits, illustrative
embodiments and examples described herein facilitate force
magnification when tightening the crossbar clamp using the crossbar
clamp actuator, because the complementary angles of the ramped
wedge and wedge follower surfaces may be selected such that the
downward force on the wedge follower is amplified relative to the
force of the tightening screw. For example, a shallow angle may
provide such force amplification, although a trade-off exists with
respect to the amount of horizontal space required to produce
sufficient downward movement of the wedge follower.
[0182] Additionally, and among other benefits, illustrative
embodiments and examples described herein may substantially align
the clamp tightening member (e.g., screw) parallel to a pitch axis
of the crossbar, and the pitch of the crossbar may be locked in
place simultaneously with clamping of the crossbar. This parallel
arrangement greatly reduces the displacement of the tightening
member as the crossbar is rocked on its pitch axis. The position of
the clamp tightening member also provide easy access from an
outboard position relative to the vehicle.
[0183] No other known system or device can perform all of these
functions. However, not all embodiments and examples described
herein provide the same advantages or the same degree of
advantage.
CONCLUSION
[0184] 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.
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