Nestable cargo box for a vehicle

Abstract

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

Description

CROSS-REFERENCES TO PRIORITY APPLICATIONS[0001]This application is based upon and claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application Ser. No. 61 / 390,103, filed Oct. 5, 2010; and U.S. Provisional Patent Application Ser. No. 61 / 454,403, filed Mar. 18, 2011. Each of these provisional patent applications is incorporated herein by reference in its entirety for all purposes.CROSS-REFERENCES TO OTHER MATERIALS[0002]This application incorporates herein by reference each of the following patent documents in its entirety for all purposes: U.S. Pat. No. 7,416,098; U.S. Pat. No. 7,503,470; U.S. Pat. No. 7,980,436; U.S. Patent Application Publication No. US 2007 / 0194185; U.S. Patent Application Publication No. US 2010 / 0084447 A1; and PCT Patent Application Publication No. WO 2011 / 094724 A1.INTRODUCTION[0003]Cargo boxes are vehicle top carriers that provide an enclosed storage space above the vehicle. As fuel becomes more expensive, vehicles have become smaller and ...

AI Technical Summary

Benefits of technology

[0003]Cargo boxes are vehicle top carriers that provide an enclosed storage space above the vehicle. As fuel becomes more expensive, vehicles have become smaller and interior cargo space has decreased, making the demand for reliable, easy-to-use top carriers even greater. Cargo boxes have become quite popular for carrying cargo and are often preferable over conventional open racks for a variety of reasons. For example, cargo boxes protect cargo from the elements, such as wind, rain, and snow, and are more secure from theft or vandalism.

[0004]However, cargo boxes are expensive to ship. The costs can mount when a cargo box needs to be shipped from a factory to a distribution center, from the distribution center to a retailer, and then on to a consumer. As a result, there are strong incentives to make cargo boxes less costly to ship. Efforts generally have focused on reducing weight. Constructing a cargo box with less or lighter material can reduce manufacturing and shipping costs, but may produce an inferior product that is less robust.

[0005]Cargo boxes typically have a base and a lid that are connected to each other by hinges, latches, and struts to form an enclosure that pivots open and fastens shut. The cargo box is often assembled completely at the factory: the hinges, latches, and struts are fully installed before the cargo box is packaged and shipped. This approach has obvious advantages because it provides a cargo box that is ready-to-use, simplifies construction by minimizing the number of parts, and ensures that hinge, latch, and strut components are positioned precisely and fastened permanently to the lid and the base (such as with rivets). Also, the more difficult aspects of assembly, such as mounting the struts inside the enclosure to both the lid and the base, are of no concern to the consumer. However, complete assembly of the cargo box in the factory produces a bulky product that is expensive to ship.

Problems solved by technology

However, cargo boxes are expensive to ship.

The costs can mount when a cargo box needs to be shipped from a factory to a distribution center, from the distribution center to a retailer, and then on to a consumer.

Constructing a cargo box with less or lighter material can reduce manufacturing and shipping costs, but may produce an inferior product that is less robust.

Also, the more difficult aspects of assembly, such as mounting the struts inside the enclosure to both the lid and the base, are of no concern to the consumer.

However, complete assembly of the cargo box in the factory produces a bulky product that is expensive to ship.

Images