Extendable crossbars for vehicles

Abstract

The present invention relates to a roof rack system (100) for attachment to a vehicle having a plurality of mounting locations (146, 148). The roof rack system includes a crossbar assembly (102) including: an axis of motion (e.g., translational motion); an internal structure (116, 118); a first section (107); a second section (111); a third section (109); a first end support (104); and a second end support (104). The first section and the second section are configured to translate in opposite directions relative to the internal structure along the axis of motion. The internal structure is configured to cause the third section to be centered between the first section and the second section when the first section and the second section translate. The first end support and the second end support are coupled to respective outer portions of the first section and the second section. The first end support and the second end support are configured to be mounted to respective first and second mounting locations of the vehicle.

Description

Technical Field

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS:

[0002] This disclosure claims the benefit of U.S. Provisional Application No. 62 / 766,600, filed on November 13, 2018, which is hereby incorporated by reference in its entirety. Background Art

[0003] Typically, a cargo cross beam is a set length for a specific vehicle application. There may be many different use cases for a cross beam on a vehicle, which may require different mounting locations with different distances between them. It would be advantageous to have the cross beam easily adapt to different distances between mounting locations on a vehicle. Summary of the invention

[0004] In some embodiments, a roof rack cross beam assembly is provided. The roof rack cross beam assembly includes: a motion (e.g., translation) axis; an internal structure; a first section; and a second section. The first section is configured to translate relative to the internal structure along the motion axis. The first section may be movably coupled to the internal structure. The second section is configured to translate relative to the first section along the motion axis relative to the internal structure. The second section may be movably coupled to the internal structure. The internal structure is configured so that when the first section and the second section translate along the motion axis, for example, away from the transverse plane of the internal structure, a transverse plane (e.g., a transverse mid-plane) of the internal structure is centered between the first section and the second section. The transverse plane may be a plane perpendicular to the motion axis.

[0005] In some embodiments, the roof rack crossbar assembly includes a third section that can be rigidly attached to the inner structure.The third section can be arranged between the first section and the second section such that it is centered between the first section and the second section at a transverse plane of the inner structure.

[0006] In some embodiments, the internal structure includes at least one internal rod configured to provide structural rigidity to the cross-beam assembly. In some embodiments, the internal structure includes at least one movable coupling, such as a sliding mechanism, configured to allow the first section and the second section to translate relative to the at least one internal rod. In some embodiments, the at least one internal rod includes a hollow interior.

[0007] In some embodiments, at least one sliding mechanism includes a pulley-cable mechanism. The pulley-cable mechanism may include: a pulley rigidly attached to at least one internal rod, for example, toward the outer end of at least one internal rod; and a cable, the cable including a first cable end and a second cable end. In some embodiments, the first cable end is attached to the first section, for example, toward the inner end of the first section. In some embodiments, the second cable end is attached to the second section, for example, toward the outer end of the second section. In some embodiments, the cable is wound around the pulley, for example, so that the pulley engages the cable between the points where the cable is attached to the first section and the second section along the length of the cable. In some embodiments, the pulley is rigidly attached to at least one internal rod through an axle.

[0008] In some embodiments, the first section is positioned on a first side of the transverse plane of the cross-beam assembly, for example, on a first side of the third section. In some embodiments, the pulley-cable mechanism includes a first pulley rigidly attached to the at least one internal rod on a first side of the transverse plane of the cross-beam assembly. In some embodiments, the pulley-cable mechanism includes a second pulley rigidly attached to the at least one internal rod on a second side of the transverse mid-plane of the cross-beam assembly opposite the first side.

[0009] In some embodiments, the pulley-cable mechanism includes a first cable having a first cable end attached to a first segment (e.g., at a point toward an inner end of the first segment) and a second cable end attached to a second segment (e.g., at a point toward an outer end of the second segment), wherein the first cable is wrapped around a first pulley.

[0010] In some embodiments, the pulley-cable mechanism includes a second cable having a first cable end attached to the first segment (e.g., at a point toward the outboard end of the first segment) and a second cable end attached to the second segment (e.g., at a point toward the inboard end of the segments), wherein the second cable is wrapped around a second pulley.

[0011] In some embodiments, at least one sliding mechanism comprises a rack-and-pinion mechanism. The rack-and-pinion mechanism may comprise a first rack coupled to the first section, a second rack coupled to the second section, and a pinion coupled to the internal structure.

[0012] In some embodiments, the first segment and the second segment are configured to move toward and away from a transverse mid-plane of the cross-beam assembly to change a distance between an outboard end of the first segment and an outboard end of the second segment.

[0013] In some embodiments, the first section, the second section, and the third section (when assembled) each include a similar outer profile. The outer profile may include a T-shaped slot. The outer profile may include aerodynamic features.

[0014] In some embodiments, at least one of the first segment, the second segment, and the third segment is composed of a metal.

[0015] In some embodiments, the internal structure is coupled to the first section and the second section by an intermediate material. The intermediate material may include at least one of rubber and plastic.

[0016] In some embodiments, the cross-beam assembly includes a first locking mechanism configured to lock the first section to the internal structure. In some embodiments, the cross-beam assembly includes a second locking mechanism configured to lock the second section to the internal structure.

[0017] In some embodiments, a roof rack for attachment to a vehicle having a multiple mounting position system is provided.The roof rack system may include at least one of the cross beam assemblies.

[0018] In some embodiments, the roof rack system includes a first end support, such as a first support post, coupled to an outer portion of the first section. The first end support can be configured to be mounted to a first mounting location (e.g., a mounting location of a vehicle) and to support a cross beam, such as when the first end support is coupled to the first mounting location. In some embodiments, the roof rack system includes a second end support, such as a second support post, coupled to an outer portion of the second section. The second end support can be configured to be mounted to a second mounting location (e.g., a mounting location of a vehicle) and to support a cross beam, such as when the second end support is coupled to the mounting location.

[0019] In some embodiments, a roof rack system for attaching to a vehicle having a multiple mounting position system is provided. The roof rack system includes a crossbar assembly, which includes: an axis of motion, such as a translational motion; an internal structure; a first section; a second section; a third section; a first end support; and a second end support. The first section is configured to translate relative to the internal structure along the axis of motion. The second section is configured to translate relative to the first section along the axis of motion relative to the internal structure. The third section is rigidly attached to the internal structure and arranged between the first section and the second section. The internal structure is configured to cause the third section to be centered between the first section and the second section when the first section and the second section translate. The first end support is coupled to an outer portion of the first section. The first end support is configured to be mounted to a first mounting position (e.g., a mounting position of a vehicle). The second end support is coupled to an outer portion of the second section. The second end support is configured to be mounted to a second mounting position (e.g., a mounting position of a vehicle).

[0020] In some embodiments, a method for mounting a roof rack system on a vehicle is provided. The roof rack includes: an extendable cross-beam assembly; a first end mount coupled to a first end of the cross-beam assembly; and a second end mount coupled to a second end of the cross-beam assembly, wherein the second end is opposite the first end. The method includes attaching the first end mount to a first mounting location of the vehicle. The method includes changing a length of the extendable cross-beam by, for example, applying a force in a longitudinal direction of the cross-beam assembly. The method includes attaching the second end mount to a second mounting location of the vehicle.

[0021] In some embodiments, the extendable cross beam assembly includes a first section (e.g., a right section) and a second section (e.g., a left section). In some embodiments, the cross beam assembly further includes a third section (e.g., a center section). The cross beam extends along an axis, and the center section is centered along the axis, for example, longitudinally. In some embodiments, when the length of the extendable cross beam assembly changes, the center section remains centered, for example, with respect to a transverse plane of the cross beam assembly. In some embodiments, changing the length of the extendable cross beam assembly includes applying a force to at least one of the first section, the third section, and the second section, for example, in a longitudinal direction of the cross beam assembly. The center section may be a removable portion of the cross beam assembly. The center section may include a mounting feature configured to attach a cargo item to the cross beam assembly. The center section may be an integral part of the cross beam assembly.

[0022] In some embodiments, a roof rack cross beam assembly is provided. The roof rack cross beam assembly includes: a motion (e.g., translation) axis; an internal structure; a first section; and a second section. At least one of the first section and the second section is configured to translate relative to the internal structure along the motion axis. In some embodiments, the internal structure may be movably coupled to at least one of the first section and the second section. In some embodiments, the internal structure may be fixed relative to the first section by means of at least one detent feature of the internal structure, the at least one detent feature being configured to interact with at least one detent feature of the first section. In some embodiments, the internal structure may be fixed relative to the second section by means of at least one detent feature of the internal structure, the at least one detent feature being configured to interact with at least one detent feature of the second section. In some embodiments, the first section may include, for example, a series of detent features spaced apart along the motion axis. In some embodiments, the second section may include, for example, a series of detent features spaced apart along the motion axis. In some embodiments, the internal structure may include, for example, a series of detent features spaced apart along the motion axis. In some embodiments, the spacing of the pawl features may vary, for example, in the direction of the axis of motion. The spacing of the pawl features of the internal structure may be closer or farther apart than the spacing of the pawl features of at least one of the first section and the second section. The spacing of the pawl features of the first section may be closer or farther apart than the spacing of the pawl features of the second section. In some embodiments, the pawl features of at least one of the first section, the second section, and the internal structure may include an opening configured to receive a locking pin. In some embodiments, the internal structure may be rigidly connected to one of the first section and the second section and slidably connected to the other of the first section and the second section.

[0023] It should be understood that as used herein, the term roof rack or roof rack system is used to describe any type of rack or rack system, for example, a vehicle rack or vehicle rack system. The term roof rack or roof rack system is not limited to the roof of a vehicle, and may be applied to the roof, cargo bed, hood, load space, any other suitable exterior surface of a vehicle, any other suitable interior surface of a vehicle, or any combination thereof. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The present disclosure according to one or more various embodiments is described in detail with reference to the following drawings. The drawings are provided for illustrative purposes only and only show typical or exemplary embodiments. These drawings are provided to facilitate understanding of the concepts disclosed herein, and these drawings should not be considered as limitations on the breadth, scope or applicability of these concepts. It should be noted that for clarity and ease of description, these drawings are not necessarily drawn to scale.

[0025] Figures 1A to 1CSeveral views are shown of an exemplary roof rack system according to some embodiments of the present disclosure.

[0026] Figure 2 An exemplary beam is shown according to some embodiments of the present disclosure.

[0027] Figure 3 Shows Figure 2 A cross-sectional view of an exemplary beam.

[0028] Figure 4 Shows Figures 2 to 3 Top view of an exemplary beam with outer pieces removed.

[0029] Figure 5 Shows Figure 4 Side view of the center section of the crossbeam with the outer pieces removed.

[0030] Figure 6 Shows Figures 4 to 5 A perspective view of the center section of a crossbeam with the outer pieces removed.

[0031] Figure 7 Shows Figures 2 to 6 A cross-sectional view of a beam including the outer parts.

[0032] Figure 8 An exemplary crossbar is shown in an expanded state.

[0033] Fig. 9 An exemplary beam is shown in a retracted state.

[0034] Fig.10 An exemplary crossbar is shown in an expanded state with the outer piece removed.

[0035] Fig.11 An exemplary cross-beam is shown in a collapsed state with the outer piece removed.

[0036] Fig.12 Shown is a perspective view of the center section of the beam with the center outer piece in place.

[0037] Fig.13 Shown is a perspective view of a left side pulley with a left side cable having an eyelet configured to couple to an outer member.

[0038] Fig.14A and Fig. 14B A block diagram of an illustrative beam in a retracted state is shown according to some embodiments of the present disclosure.

[0039] Fig.15A and Fig. 15BA block diagram of an illustrative beam in an expanded state is shown according to some embodiments of the present disclosure.

[0040] FIG. 16A to FIG. 16C Three top views of a vehicle with mounting locations are shown, with and without a roof rack installed, according to some embodiments of the present disclosure.

[0041] Fig.17 A top perspective view of an illustrative roof rack in a retracted state is shown according to some embodiments of the present disclosure.

[0042] Fig.18 A top view of an illustrative roof rack is shown in a partially extended state according to some embodiments of the present disclosure.

[0043] Fig.19 A top perspective view of an illustrative roof rack in a fully extended state is shown according to some embodiments of the present disclosure.

[0044] Fig. 20 A perspective view of an illustrative roof rack in a retracted state is shown, according to some embodiments of the present disclosure.

[0045] Fig.21 A perspective view of an illustrative roof rack in a fully extended state is shown, according to some embodiments of the present disclosure.

[0046] Fig. 22 A top cross-sectional view of an illustrative roof bar in a retracted state is shown according to some embodiments of the present disclosure.

[0047] Fig.23 A top cross-sectional view of an illustrative roof bar is shown in a partially extended state, according to some embodiments of the present disclosure.

[0048] FIG. 24A to FIG. 24D Four top cross-sectional views of an illustrative roof rack in four respective states are shown, with all four views centered at the center of the roof rack, according to some embodiments of the present disclosure.

[0049] FIG. 25A to FIG. 25D Four top cross-sectional views of an exemplary roof rack in four respective states are shown, wherein all four views are directed toward the left-hand side of the roof rack, according to some embodiments of the present disclosure.

[0050] Fig.26 A top view of an exemplary internal structure of an exemplary roof rack according to some embodiments of the present disclosure is shown, including a left side pulley and a right side pulley, wherein the roof rack is in a retracted state.

[0051] Fig. 27A top cross-sectional view of an exemplary internal structure of a roof rack according to some embodiments of the present disclosure is shown, including a left pulley, a right pulley, a left cable, and a right cable, wherein the roof rack is in a retracted state.

[0052] Fig.28 A perspective view showing an exemplary internal structure of a roof rack according to some embodiments of the present disclosure, including left and right pulleys, wherein the roof rack is in a retracted state.

[0053] Fig.29 A perspective view of an exemplary internal structure of a roof rack according to some embodiments of the present disclosure is shown, including a left pulley, a right pulley, a left cable, and a right cable, wherein the roof rack is in a retracted state.

[0054] Fig.30 A perspective cutaway view of an exemplary left side outer piece and corresponding struts is shown, according to some embodiments of the present disclosure.

[0055] Fig.31 A perspective view of an exemplary left side outer piece and corresponding strut is shown according to some embodiments of the present disclosure.

[0056] Fig.32 A perspective cutaway view of an exemplary left side outer member and corresponding support post, including left and right side cables, is shown with the roof rack in a retracted state, according to some embodiments of the present disclosure.

[0057] Fig.33 A perspective cutaway view of an exemplary left side outer member and corresponding pillar, including left and right side cables, is shown with the roof rack in an extended state, according to some embodiments of the present disclosure.

[0058] Fig.34 A perspective cutaway view of an illustrative roof rack according to some embodiments of the present disclosure is shown, wherein the roof rack is in a partially expanded state. DETAILED DESCRIPTION

[0059] The present disclosure relates to a roof rack system that includes an extendable cross beam, such as an extendable cross beam assembly. In some embodiments, the extendable cross beam can be mounted to a variety of mounting locations of a vehicle. For example, the extendable cross beam can be configured to be mounted at multiple pairs of mounting locations, each pair of mounting locations having a different distance between the mounting locations. In an illustrative example, the cross beam can be configured to achieve multiple lengths to match the distance between a particular pair of mounting locations.

[0060] A crossbar is a cargo accessory for a vehicle that expands the ability to mount gear and equipment. Additional accessories may be mounted to the crossbar for specific purposes, such as, for example, carrying bicycles, kayaks, skis, snowboards, cargo boxes, and cargo racks. In some cases, many of these accessories have similar attachment methods. For example, it may be important for the crossbar to maintain the same profile along its entire length (e.g., for mounting equipment / accessories in appropriate locations along the crossbar) or to maintain the same profile at specific areas along its entire length.

[0061] Figures 1A to 1C An exemplary vehicle roof rack system 100 is shown according to some embodiments of the present disclosure. The vehicle roof rack system 100 includes a crossbar 102 configured as a mounting device, wherein support members 104 (eg, posts) at either end of the crossbar 102 are configured to be mounted to a vehicle. Figure 1A A perspective view of the roof rack system 100 is shown. Figure 1B A perspective view of one end of the roof rack system 100 is shown, and Figure 1C A perspective view of the other end of the roof rack system 100 is shown. The post can be coupled to the crossbar in any suitable arrangement (e.g., rigidly coupled, coupled by a swivel joint, coupled by a sliding joint, a sliding interface, a fastening interface, or the post and corresponding outer piece can be integrated into a single component). The post includes an interface 106 for mounting to a vehicle (e.g., a plunger hole interface, a latch mechanism, a fastening interface, any other suitable interface, or any combination thereof).

[0062] Figures 2 to 13 Various views of an exemplary beam 102 are shown according to some embodiments of the present disclosure.

[0063] Figure 2 An exemplary cross-member 102 is shown according to some embodiments of the present disclosure. In some embodiments, the cross-member 102 includes a first section 107 (the first section includes a left side (LH) outer piece 108), a second section 111 (the second section includes a right side (RH) outer piece 110), and a third section 109 (the third section includes a center outer piece 112), all of which are formed to have the same outer profile (e.g., all have similar cross-sections). Figure 3 Shows Figure 2 A cross-sectional view of the beam 102 (eg, Figure 2 For example, the profile may include a standard T-shaped slot 114 (e.g., Figure 3 ), one or more aerodynamic features (e.g., a tapered surface, an inclined surface, or a curved surface), mounting features for additional accessories, any other suitable features, or any combination thereof. Beam 102 may be capable of achieving a minimum length (e.g., Figure 2 ), maximum length, and any length therebetween. For example, when the crossbar 102 is fully retracted to its shortest length, the three outer pieces can form one continuous outer profile. In another example, when the crossbar 102 is extended to its maximum length, the inner expansion feature bridges the gap between the outer pieces (i.e., the LH outer piece 108 and the RH outer piece 110) and holds the load therebetween.

[0064] Figure 4 Shows Figures 2 to 3 102, wherein the outer pieces 108, 110, 112 are removed to show the internal structure, for example, the inner expansion feature 116. The main structure of the inner expansion feature 116 includes one or more inner rods 118 arranged parallel to the outer profile (e.g., along the longitudinal axis of the beam 102). When the outer pieces 108, 110 are in any open position (e.g., fully extended or partially extended), the one or more inner rods 118 provide intermediate support. In some embodiments, the one or more inner rods 118 are configured so that accessories can be installed in the same manner as they are installed on the main beam sections (e.g., LH outer pieces 108, RH outer pieces 110, and center outer pieces 112). In some embodiments, the one or more inner rods 118 are rigidly attached to the center outer piece 112 and are therefore centered between the LH outer piece 108 and the RH outer piece 110. To illustrate, the LH outer 108 can slide along the inner rod 118, and the RH outer 110 can slide along the inner rod 118. The LH cable 120 is coupled to the LH outer 108 such that when the LH outer 108 moves outward, the end of the cable 122 coupled to the LH outer 108 also moves outward, e.g., by virtue of the other end of the cable 122 being anchored to another component. Similarly, the same is true for the RH outer 110 and the RH cable. Figure 4 The central region is shown disposed within the central outer piece 112 . Figure 5 Shows Figure 4 1 is a side view of a central section 126 (eg, including a central region) of the crossbar 102 with the outer pieces 108 , 110 , 112 removed. Figure 6 Shows Figures 4 to 5 1 is a perspective view of a central section 126 (eg, including a central region) of the crossbar 102 with the outer pieces 108 , 110 , 112 removed. Figure 7 Shows Figures 2 to 6 108, 110, 112. In some embodiments, the middle beam section (e.g., the center outer piece 112) is self-centered so that it remains centered about the transverse mid-plane of the beam 102, such as between the LH outer piece 108 and the RH outer piece 110.

[0065] In some embodiments, a pulley-cable system 128 connects all three outer pieces 108 , 110 , 112 together. Figures 8 to 11 The retracted and expanded configurations of the cross-member 102 are shown with the outer members 108 , 110 , 112 in place and out of place. Figure 8 and Fig.10 The crossbar 102 is shown in an extended state, and Fig. 9 and Fig.11 The crossbar 102 is shown in a retracted state. For example, Figure 8 The crossbar 102 is shown extending with three outer members 108, 110, 112 spaced apart. Fig. 9 The cross beam 102 is shown retracted with all three outer pieces 108, 110, 112 together. Thus, the cross beam 102 can be extended or retracted to achieve a desired length (e.g., for installation at locations with different span distances). It should be understood that the pulley-cable system 128 is merely exemplary and any suitable mechanism may be used in accordance with the present disclosure. For example, a rack and pinion mechanism may be used.

[0066] refer to Figure 10 to Figure 11 , one end 130 of the RH cable 124 is attached to the RH outer member 110 (e.g., at the eyelet 132 shown), while the other end 134 is attached to the LH cross beam member (not shown). Between the two cable ends 130, 134, the RH cable 124 runs around an RH pulley 136 that is fixed (e.g., permanently attached) to the center cross beam section (e.g., the center-to-center distance of the RH pulley 136 and the LH pulley 138 is fixed). The RH cable 124 direction changes 180 degrees around the RH pulley 136 so that the section entering the RH pulley 136 is parallel, but in the opposite pulling direction from the section exiting the RH pulley 136. In terms of kinematics, the distance traveled by the free end 130 of the RH cable 124 (e.g., the end coupled to the RH outer 110 and capable of moving with the RH outer) relative to the fixed end 134 of the RH cable 124 (e.g., the end coupled to the LH outer 108) is twice the displacement of the RH pulley relative to the center section 126 (e.g., the transverse mid-plane of the center section). Regardless of the distance between the inboard ends of the outers 108, 110, the center outer 112 remains centered.

[0067] As shown, the RH cable 124 and the LH cable 122 are not visible to the user because they are guided through the hollow center of the inner rod 118 (e.g., a tube). Out of one respective end of the inner rod 118, each cable 122, 124 runs straight toward the end of one of the end outer pieces. The other end of each cable is wrapped around a respective pulley mounted to the end of the inner rod. Each cable 122, 124 is wrapped 180 degrees around a respective pulley 136, 138 and mounted to the inboard end of the other outer cross member.

[0068] In some embodiments, the LH outer piece 108, the RH outer piece 110, and the center outer piece 112 and the one or more inner rods 118 are constructed of metal. In some embodiments, the one or more inner rods 118 are isolated from the outer pieces 108, 110, 112 by an intermediate material. For example, the intermediate material may include nylon, rubber, or other suitable material formed as end caps for the one or more inner rods to prevent vibration, scratching, and wear.

[0069] To illustrate, starting from the fully retracted state, as the RH outer 110 moves outboard (i.e., away from the center outer 112), the eyelet end 130 of the RH cable 124 also moves outboard, while the other end of the RH cable 124 coupled to the LH outer 108 also moves outboard but in the opposite direction. As the LH outer moves outboard, similar movement occurs for the LH cable 122. Thus, the center outer 112 remains centered. For example, a user may apply force to any or all of the three outers 108, 110, 112, e.g., along the longitudinal axis of the crossbar 102, to retract or extend the length of the crossbar. The pulley system 128 helps ensure that the center outer 112 remains centered between the RH outer 110 and the LH outer 108.

[0070] Fig.12 A perspective view of the center section of the beam is shown with the center outer piece 112 in place. Fig.13 A perspective view of the LH pulley 138 is shown with the LH cable 122 wrapped 180 degrees, the LH cable having an eyelet 140 configured to couple to the LH outer 108. The RH cable 124 is wrapped 180 degrees. Fig.13 The LH pulley 138 (eg, LH pulley shaft) is rigidly coupled to the inner rod via a bracket 142, as shown.

[0071] 14-15 show block diagrams of exemplary beams 102 according to some embodiments of the present disclosure. For clarity, Fig.14A and Fig. 14B Two views are shown, where Fig.14A The view omits the LH cable 122, and Fig. 14B The view omits the RH cable 124. Fig.14A and Fig. 14B The crossbar 102 is shown in a fully retracted state. For clarity, Fig.15A and Fig. 15B Two views of the extended crossbar 102 are shown, wherein Fig.15A The view omits the LH cable 122, and Fig. 15B The view of omits the RH cable 124. Each of the ends 134, 144 of the RH and LH cables is fixed to the respective outer pieces 108, 110, and thus the cable ends 134, 144 move relative to the RH and LH pulleys 136, 138.

[0072] In some embodiments, the roof rack system 100 includes one or more locking mechanisms configured to constrain the movement of cables, pulleys, outer pieces, or combinations thereof relative to an internal structure (e.g., an inner rod) when locked. For example, the locking mechanism may include a clamp on the cable that prevents the cable from moving by applying friction. In another example, the locking mechanism may include a set screw that prevents the pulley from rotating when tightened. In yet another example, the locking mechanism may include a clamp that applies friction between the inner rod and the LH outer piece or the RH outer piece when locked to prevent relative movement. In some embodiments, the internal structure may include a pawl position, or otherwise provide a discrete extension length. For example, the pulley shaft may be toothed, or the internal rod may include a ratchet mechanism so that the LH outer piece and the RH outer piece achieve a predetermined equilibrium position. In yet another example, the cable may include a belt that can withstand tension, a flexible rod, a wire, a toothed belt, any other suitable flexible component, or a combination thereof. Thus, the pulley may include a grooved pulley, a toothed pulley (e.g., a sprocket or gear), a multi-channel pulley or a cylindrical pulley, any other suitable rotating member, or any combination thereof. In some embodiments, the pulley may include a rotating element, such as a torsion spring, a damper, a ratchet mechanism, any other suitable rotating element, or any combination thereof. In some embodiments, the roof rack system may include one or more actuators (e.g., an electric motor, a linear actuator such as a solenoid), which are configured to apply a torque to the pulley, apply a force to the outer member relative to another outer member or an inner rod, or otherwise apply a force / torque to cause extension or retraction of the crossbar.

[0073] In some embodiments, the center outer piece 112 is centered (e.g., longitudinally centered) on the cross beam 112 and is configured to remain centered. For example, some mounting accessories may require the LH outer piece 108 or the RH outer piece 110 (e.g., its T-slot 114) and the center section 126 (e.g., its T-slot 114) to be attached to the roof rack system 110. In some embodiments, the LH outer piece 108 or the RH outer piece 110 may be relatively longer than the other. In some such embodiments, the RH outer piece 110 and the LH outer piece 108 may be moved an equal amount in respective directions relative to the center outer piece 112, but the center outer piece 112 is not centered along the cross beam 102, e.g., the center outer piece 112 is not centered about the transverse mid-plane of the cross beam 102. For example, the arrangement may be desirable to form a longer section of the T-slot 114 in one of the LH outer piece 108 or the RH outer piece 110, and a shorter section of the T-slot 114 in the other. Further, in some embodiments, the roof rack system 100 may be reversible in the lateral direction, such that the long and short pieces may be on either side of the center outer piece 112 (e.g., the roof rack 100 or crossbar 102 may be flipped from left to right). This arrangement may be useful for accommodating a range of accessory widths and shapes. The accessories may include, for example, a kayak, a storage container, a surfboard, a canoe, a ski, a snowboard, a bicycle or a bicycle rack, a cargo bed cover, any other suitable equipment, or any combination thereof.

[0074] FIG. 16A to FIG. 16C Three top views of a vehicle 145 with a mounting location 146 are shown, with and without a roof rack installed, according to some embodiments of the present disclosure. Fig.16A A vehicle 145 is shown without a roof rack installed, as well as pairs of mounting locations 146 (eg, mounting location pair 148 and mounting location pair 150 ). Fig. 16B The roof rack 100 is shown mounted on a vehicle at a mounting position pair 148 (e.g., in a cargo bed) in a fully retracted state. The span distance of the mounting position pair 148 (i.e., the distance between the two mounting positions of the pair) is less than the span distance of the mounting position pair 150. Fig. 16C A vehicle 145 is shown with the roof rack 100 mounted at a mounting position 150 (e.g., on top of a cargo bed) with the roof rack in an extended state. Thus, the roof rack 100 provides a system for mounting cargo on a vehicle at different positions. Further, a user can use the same crossbar 102 for multiple mounting arrangements. Still further, the roof rack 100 can be stored in its minimum configuration (e.g., fully collapsed), thereby minimizing the required packaging space.

[0075] Figures 17 to 33 Various views and states of an exemplary roof rack 100 are shown according to some embodiments of the present disclosure.

[0076] Fig.17 A top perspective view of an exemplary roof bar 100 is shown in a retracted state according to some embodiments of the present disclosure.

[0077] Fig.18 A top view of an exemplary roof bar 100 is shown in a partially extended state according to some embodiments of the present disclosure.

[0078] Fig.19 A top perspective view of an exemplary roof bar 100 is shown in a fully extended state according to some embodiments of the present disclosure.

[0079] Fig. 20 A perspective view of an exemplary roof bar 100 is shown in a retracted state according to some embodiments of the present disclosure.

[0080] Fig.21 A perspective view of an exemplary roof bar 100 is shown in a fully extended state according to some embodiments of the present disclosure.

[0081] Fig. 22 A top cross-sectional view of an exemplary roof bar 100 in a retracted state is shown according to some embodiments of the present disclosure. Fig. 22 The inner rod 118, the LH cable 122 and the RH cable 124 are shown.

[0082] Fig.23 A top cross-sectional view of an exemplary roof bar 100 is shown in a partially extended state according to some embodiments of the present disclosure. Fig.23 The inner rod 118, the LH cable 122 and the RH cable 124 are shown.

[0083] FIG. 24A to FIG. 24D Four top cross-sectional views of an exemplary roof bar 100 in four respective states are shown, wherein all four views are centered at the center of the roof bar 100 , eg, centered about a transverse mid-plane of the cross-member assembly 102 , according to some embodiments of the present disclosure. Fig.24A The roof bar 100 is shown in a retracted state. Fig. 24B The roof bar 100 is shown in a first partially extended state. Fig.24C The roof bar 100 is shown in a second partially extended state. Fig.24D The roof bar 100 is shown in a fully extended state. FIG. 24A to FIG. 24D It is shown how each of the first and second segments 107, 109 translates along the longitudinal axis of the cross-beam assembly 102 while remaining centered about a transverse plane of the cross-beam assembly 102, which in this example is the transverse mid-plane to which the third segment is secured.

[0084] FIG. 25A to FIG. 25D Four top cross-sectional views of an exemplary roof bar 100 in four respective states are shown, wherein all four views are directed toward the LH side of the roof bar 100 , according to some embodiments of the present disclosure. Fig.25A The roof bar 100 is shown in a fully extended state. Fig.25B The roof bar 100 is shown in a first, partially retracted state. Fig.25C The roof bar 100 is shown in a second, partially retracted state. Fig.25D The roof bar 100 is shown in a fully retracted state. FIG. 25A to FIG. 25D It shows how the end 134 of the RH cable 124 is secured to the outboard end 152 of the first section 107, e.g., directly or indirectly, at a point on the LH strut 104, and how the end 154 of the LH cable 122 is secured to the inboard end 156 of the first section 107, e.g., directly or indirectly, at a point on the end plate 158.

[0085] Fig.26 A top view of an exemplary internal structure of an exemplary roof rack 100 is shown, including an LH pulley 138 and an RH pulley 136 , according to some embodiments of the present disclosure.

[0086] Fig. 27 A top cross-sectional view of an exemplary internal structure of a roof bar 100 is shown, showing the LH cable 122 and the RH cable 124 with the roof bar 100 in a retracted state, according to some embodiments of the present disclosure.

[0087] Fig.28 A perspective view is shown of an exemplary internal structure of a roof rack 100 according to some embodiments of the present disclosure.

[0088] Fig.29 A perspective view of an exemplary internal structure of a roof rack 100 having an LH cable 122 and an RH cable 124 is shown according to some embodiments of the present disclosure.

[0089] Fig.30 A perspective cutaway view of an exemplary LH outer piece 108 and corresponding strut 104 is shown, according to some embodiments of the present disclosure. Fig.30 Also shown is a bracket 160 configured to provide rigidity between the LH outer 108 and the strut 104. The ends of the RH cables may be secured to the bracket 160.

[0090] Fig.31 A perspective view of an exemplary LH outer piece 108 and corresponding strut 104 is shown, according to some embodiments of the present disclosure. Fig.31Also shown is a tensioner 161 configured to provide a feature for attaching a cable or other securing means for securing equipment to the roof rack 100. The bracket 160 prevents relative movement between the post 104 and the LH outer piece 108. Although not shown, a similar arrangement may be included for the RH outer piece 110 and corresponding post 104.

[0091] Fig.32 A perspective cutaway view of an exemplary LH outer piece 108 and corresponding strut 104 is shown, including LH cables 122 and RH cables 124 in a retracted state, according to some embodiments of the present disclosure. The RH cables 124 are attached to brackets 160. For example, a substantially vertical portion of the bracket 160 prevents the strut 104 from rotating relative to the cross beam 102 about an axis perpendicular to the plane of the vertical portion. In yet another example, a substantially horizontal portion of the bracket 160 maintains the vertical section in place and prevents rotation about the vertical axis altogether.

[0092] Fig.33 A perspective cutaway view of an exemplary LH outer piece 108 and corresponding strut 104 is shown, including the LH cable 122 and the RH cable 124 in an extended state, according to some embodiments of the present disclosure.

[0093] Fig.34 A perspective cutaway view of an exemplary roof rack 200 is shown. Similar to the roof rack 100, the roof rack 200 includes a first section 107 and a second section 109 that are configured to receive an inner rod 118. However, the roof rack 200 does not include a pulley cable mechanism. The inner rod 118 of the roof rack 200 slides freely through at least one of the first section 107 and the second section 109. In some embodiments, the roof rack 200 may include at least one bushing 163 (e.g., a sleeve bearing) that is configured to constrain eccentric movement of the inner rod 118 (e.g., movement of the inner rod 118 in a direction perpendicular to the axis of motion) while allowing the inner rod 118 to slide freely along the axis of motion. In some embodiments, the bushing 163 may be configured to constrain rotational movement of the inner rod 118, for example, rotation of the inner rod 118 around the axis of motion. It should be appreciated that, similar to the roof bar 200 , the roof bar 100 may include at least one bushing similar to the bushing 163 .

[0094] In some embodiments, the inner rod 118 can be fixed relative to each of the first section 107 and the second section 109 by means of a detent feature 162 in the inner rod 118 that is configured to interact with a detent feature 164 on each of the first section 107 and the second section 109. For example, the detent feature 162 in the inner rod 118 and the detent feature 164 on each of the first section 107 and the second section 109 can include a series of openings configured to receive a locking pin. In this way, by aligning the desired detent feature 162 in the inner rod 118 with the detent feature 164 on each of the first section 107 and the second section 109, the length of the cross-beam assembly 102 can be adjusted. The detent feature 162 in the inner rod 118 can have a different spacing than the detent feature 164 on each of the first section 107 and the second section 109. For example, the spacing of the detent features 162 in the inner rod 118 may be closer or farther apart than the spacing of the detent features 164 on each of the first section 107 and the second section 109. In some embodiments, the inner rod 118 is rigidly connected to the first section 107 or the second section 109 and is slidably connected to the other section. In some embodiments, the roof bar 100 may include detent features 162, 164 similar to those shown on the roof bar 200. In some embodiments, the roof bar 100 and the roof bar 200 may be configured without the detent features 162, 164.

[0095] The foregoing is merely illustrative of the principles of the present disclosure, and various modifications may be made by those skilled in the art without departing from the scope of the present disclosure. The above embodiments are presented for purposes of illustration and not limitation. The present disclosure may also take many forms other than those explicitly described herein. Therefore, it should be emphasized that the present disclosure is not limited to the methods, systems, and devices explicitly disclosed, but is intended to include variations and modifications thereof, which are within the spirit of the following claims.

Claims

1. A roof rack system for attachment to a vehicle having multiple mounting locations, the roof rack system comprising: A crossbeam assembly, the crossbeam assembly comprising: Axis of motion; Internal structure; a first segment configured to translate along the axis relative to the internal structure, a second segment configured to translate relative to the first segment along the axis with respect to the internal structure, and a third segment rigidly attached to the internal structure and disposed between the first segment and the second segment, wherein the internal structure is configured to cause the third segment to be centered between the first segment and the second segment when the first segment and the second segment translate; a first end mount coupled to an outer portion of the first segment and configured to be mounted to a first mounting position; and a second end mount coupled to an outer portion of the second segment and configured to be mounted to a second mounting position, Characterized in that the internal structure comprises: at least one interior rod configured to provide structural rigidity to the cross-beam assembly; and at least one sliding mechanism configured to allow translation of the first segment and the second segment relative to the at least one internal rod, The first installation position and the second installation position constitute an installation position pair, and a plurality of installation position pairs are provided on the vehicle, and the installation position pairs have different span distances from each other. wherein the at least one sliding mechanism comprises a pulley-cable mechanism, wherein the first section is positioned on a first side of the third section, and wherein the pulley-cable mechanism comprises: a first pulley rigidly attached to the at least one inner rod on the first side of the third section; a second pulley rigidly attached to the at least one inner rod on a second side of the third section opposite the first side; a first cable attached to the first section and the second section, wherein the first cable is wrapped around the first pulley; A second cable is attached to the first section and the second section, wherein the second cable is wrapped around the second pulley.

2. The roof rack system of claim 1, wherein the at least one interior bar includes a hollow interior.

3. The roof rack system of claim 1, wherein the pulley-cable mechanism comprises: a pulley rigidly attached to the at least one internal rod; a cable comprising a first cable end and a second cable end, wherein: the first cable end is attached to the first section, The second cable end is attached to the second section, and the cable is wrapped around the pulley.

4. The roof rack system of claim 3, wherein the pulley is rigidly attached to the at least one inner rod by an axle. 5 . The roof rack system of claim 1 , wherein the first section, the second section, and the third section each include a similar outer profile.

6. The roof rack system of claim 5, wherein the outer profile comprises a T-shaped slot.

7. The roof rack system of claim 5, wherein the outer contour includes aerodynamic features.

8. The roof rack system of claim 1, wherein the first section, the second section, and the third section are composed of metal.

9. The roof rack system of claim 1, wherein the inner structure is coupled to both the first section and the second section via an intermediate material.

10. The roof rack system of claim 9, wherein the intermediate material comprises at least one of rubber and plastic.

11. The vehicle roof rack system of claim 1 , further comprising a first locking mechanism configured to lock the first section to the inner structure. 12 . The roof rack system of claim 11 , further comprising a second locking mechanism configured to lock the second section to the inner structure.

13. A method for installing a roof rack system according to any one of claims 1 to 12 on a vehicle, the method comprising: attaching a first end mount to a first mounting location of the vehicle; changing the length of the extendable beam by applying a force; A second end mount is attached to the vehicle at a second mounting location.

14. The method according to claim 13, wherein: The extendable cross beam includes a right section, a center section and a left section; The crossbeam extends along an axis; The central section is centered along the axis; and The central section remains centered as the length of the extendable beam changes. 15 . The method of claim 14 , wherein changing the length of the extendable beam comprises applying a force to at least one of the right segment, the center segment, and the left segment.

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