Extensible cross-member for vehicle

Abstract

A roof rack system for attachment to a vehicle having a plurality of mounting locations, comprising: a cross-member assembly comprising: an internal structure; a first section configured to be translatable relative to the internal structure; a second section configured to translate opposite the first section relative to the internal structure; and a third section rigidly attached to the internal structure and disposed between the first section and the second section wherein the internal structure comprises: at least one internal rod configured to support the cross beam assembly; and at least one sliding mechanism configured to allow translation of the first section and the second section relative to the at least one inner rod, the roof rack system further including a first end mount coupled to an outer portion of the first section and configured to be mounted to a first mounting position; and a second end mount coupled to an outer portion of the section and configured to be mounted to a second mounting position.

Description

[0001] This application is a divisional application of a PCT international application that entered the Chinese national stage, with international application number PCT / US2019 / 060803 and filing date November 11, 2019 (national stage application number 201980067889.6). The above PCT international application claims the priority of US Provisional Application 62 / 766,600 filed on November 13, 2018. Technical Field

[0002] The present invention relates to a roof rack system for attachment to a vehicle having a plurality of mounting locations and a method for mounting the roof rack system on a vehicle. Background Art

[0003] Typically, cargo crossbars are of a set length for a particular vehicle application. There can be many different use cases for crossbars on a vehicle, which may require different mounting positions with different distances therebetween. It would be advantageous to enable the crossbars to easily accommodate different distances between the mounting positions of the vehicle.

[0004] US 4,354,625 discloses a universal roof carrier supported by a pair of spaced-apart full-length resilient mounting pads. The mounting pads are internally supported by spring rods to accommodate bending and produce a uniform pressure distribution along the length of the mounting pads. The cross-section of the mounting pads is triangular, thereby defining three elongated faces, each having a different profile and selectively adaptable to closely conform to the support roof line or corner. A pair of width-adjustable telescopic tubes / brackets are connected to the mounting pads by castings to accommodate different widths of the roof. Removable cam latches on each casting secure the straps of the gutter hooks, thereby locking the roof carrier to the roof. US 4,449,656 discloses a luggage carrier including a support bar and support legs connected to its ends. The support legs have fastening means for securing the luggage carrier to the vehicle. The support bar of the luggage rack consists of at least two concentrically positioned parts that are movable concentrically relative to each other, thereby allowing adjustment of the length of the support bar to adapt the luggage rack to the width of the vehicle. The support bar can be disassembled or pushed into a space-saving position of the luggage rack. The luggage rack includes a locking device for fixing the parts of the support bar in the desired relative positions. The fixing device consists of two complementary fixing devices, each connected to a different part of the support bar.

[0005] WO 99 / 19168 discloses a multi-functional rack for carrying articles on a vehicle, which includes an elongated carrying bar. The carrying bar includes a pair of outer carrying members, each outer carrying member being provided with a support foot adapted to rest on the vehicle, and an elongated inner carrying member adapted to be fixed to the outer carrying members at its opposite ends, thereby forming the multi-functional rack. Inner carrying members of different lengths can be used for vehicles of different widths. The inner carrying member can only be assembled to the two outer carrying members at a single position, and the spacing between the support feet cannot be adjusted.

[0006] WO 2013 / 115701 discloses a lowered roof rack which has support elements for supporting a vehicle load and has a lowering member and a rack mounting for lowering the loading surface. The lateral support elements can be connected to existing fastening means of the vehicle. The lowering member consists of an angular part which serves as a transition to the loading platform and extends downwards a certain distance towards the load surface and the roof. The ends of the support elements are adjustable, slidable and can be fixed to fastening points on the rack mounting to adapt to the width of the roof. Summary of the Invention

[0007] In some embodiments, a roof rack crossbar assembly is provided. The roof rack crossbar assembly includes: an internal structure; a first section; and a second section. The first section is configured to translate relative to the internal structure. The first section may be movably coupled to the internal structure. The second section is configured to translate towards the first section relative to the internal structure. The second section may be movably coupled to the internal structure. The internal structure is configured such that when the first section and the second section translate, for example, away from the lateral plane of the internal structure, the lateral plane (e.g., the lateral intermediate plane) of the internal structure is centered between the first section and the second section. The lateral plane may be a plane perpendicular to the first section and the second section.

[0008] In some embodiments, the roof rack crossbar assembly includes a third section that can be rigidly attached to the internal structure. The third section may be disposed between the first section and the second section such that it is centered at the lateral plane of the internal structure between the first section and the second section.

[0009] In some embodiments, the internal structure includes at least one internal rod configured to support the crossbar assembly. In some embodiments, the internal structure includes at least one movable coupling, such as a sliding mechanism, configured to automatically center the third section when the first section and the second section translate, such that the third section remains centered between the first section and the second section. In some embodiments, at least one internal rod includes a hollow interior.

[0010] In some embodiments, at least one sliding mechanism includes a pulley-cable mechanism. The pulley-cable mechanism can include: a pulley rigidly attached to at least one internal rod, e.g., toward an outer end of the at least one internal rod; and a cable including a first cable end and a second cable end. In some embodiments, the first cable end is attached to a first section, e.g., toward an inner end of the first section. In some embodiments, the second cable end is attached to a second section, e.g., toward an outer end of the second section. In some embodiments, the cable is wound around the pulley, e.g., such 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 the at least one internal rod by an axle.

[0011] In some embodiments, the first section is positioned on a first side of a transverse plane of the crossbeam assembly, e.g., on a first side of a third section. In some embodiments, the pulley-cable mechanism includes a first pulley rigidly attached to the at least one internal rod on the first side of the transverse plane of the crossbeam 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 intermediate plane of the crossbeam assembly opposite the first side.

[0012] In some embodiments, the pulley-cable mechanism includes a first cable having a first cable end attached to the first section (e.g., at a point toward the inner end of the first section) and a second cable end attached to the second section (e.g., at a point toward the outer end of the second section), wherein the first cable is wound around the first pulley.

[0013] In some embodiments, the pulley-cable mechanism includes a second cable having a first cable end attached to the first section (e.g., at a point toward the outer end of the first section) and a second cable end attached to the second section (e.g., at a point toward the inner end of the section), wherein the second cable is wound around the second pulley.

[0014] In some embodiments, at least one sliding mechanism includes a rack-pinion mechanism. The rack-pinion mechanism can include a first rack coupled to the first section, a second rack coupled to the second section, and a pinion coupled to an internal structure.

[0015] In some embodiments, the first section and the second section are configured to move toward and away from a transverse intermediate plane of the crossbeam assembly to change a distance between an outer end of the first section and an outer end of the second section.

[0016] In some embodiments, the first section, the second section, and the third section (in the assembled case) each include a similar outer profile. The outer profile may include a T-shaped slot. The outer profile may include aerodynamic features.

[0017] In some embodiments, at least one of the first section, the second section, and the third section is composed of metal.

[0018] 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.

[0019] In some embodiments, the crossbeam assembly includes a first locking mechanism configured to lock the first section to the internal structure. In some embodiments, the crossbeam assembly includes a second locking mechanism configured to lock the second section to the internal structure.

[0020] In some embodiments, a roof rack for attachment to a vehicle having a multiple mounting location system is provided. The roof rack system may include at least one crossbeam assembly among the crossbeam assemblies.

[0021] In some embodiments, the roof rack includes a first end support, such as a first strut, coupled to an outer portion of the first section. The first end support may be configured to be mounted to a first mounting location (e.g., a mounting location of the vehicle) and to support the crossbeam, 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 strut, coupled to an outer portion of the second section. The second end support may be configured to be mounted to a second mounting location (e.g., a mounting location of the vehicle) and to support the crossbeam, such as when the second end support is coupled to the mounting location.

[0022] In some embodiments, a roof rack system for attachment to a vehicle having a multiple mounting location system is provided. The roof rack system includes a crossbeam assembly that includes: 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. The second section is configured to translate relative to the internal structure in a direction opposite to the first section. The third section is rigidly attached to the internal structure and is disposed 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 location (e.g., a mounting location of the 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 location (e.g., a mounting location of the vehicle).

[0023] In some embodiments, a method for installing a roof rack system on a vehicle is provided. The roof rack includes: an extendable crossbar assembly; a first end support coupled to a first end of the crossbar assembly; and a second end support coupled to a second end of the crossbar assembly, where the second end is opposite the first end. The method includes attaching the first end support to a first mounting location on the vehicle. The method includes changing the length of the extendable crossbar assembly by, for example, applying a force in the longitudinal direction of the crossbar assembly. The method includes attaching the second end support to a second mounting location on the vehicle.

[0024] In some embodiments, the extendable crossbar assembly includes a first section (e.g., a right side section) and a second section (e.g., a left side section). In some embodiments, the crossbar assembly further includes a third section (e.g., a center section). The crossbar extends along an axis, and the center section is centered, for example longitudinally, along the axis. In some embodiments, when the length of the extendable crossbar assembly is changed, the center section remains centered, for example, with respect to the transverse plane of the crossbar assembly. In some embodiments, changing the length of the extendable crossbar assembly includes applying a force to at least one of the first section, the third section, and the second section, for example, in the longitudinal direction of the crossbar assembly. The center section may be a removable portion of the crossbar assembly. The center section may include mounting features configured to attach cargo items to the crossbar assembly. The center section may be an integral part of the crossbar assembly.

[0025] In some embodiments, a roof rack crossbar assembly is provided. The roof rack crossbar assembly includes: a movement (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. 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 spaced-apart detent features. In some embodiments, the second section may include, for example, a series of spaced-apart detent features. In some embodiments, the internal structure may include, for example, a series of spaced-apart detent features. In some embodiments, the spacing of the detent features may vary, for example. The spacing of the detent features of the internal structure may be closer or farther from the spacing of the detent features of at least one of the first section and the second section. The spacing of the detent features of the first section may be closer or farther from the spacing of the detent features of the second section. In some embodiments, the detent features of at least one of the first section, the second section, and the internal structure may include openings configured to receive locking pins. 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.

[0026] 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, e.g., a vehicle rack or vehicle rack system. The term roof rack or roof rack system is not limited to the roof and may apply to the roof, cargo bed, hood, load space, any other suitable outer surface of the vehicle, any other suitable inner surface of the vehicle, or any combination thereof. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The present disclosure is described in detail with reference to the following drawings. The drawings are provided for illustrative purposes only and show typical or exemplary embodiments. These drawings are provided to facilitate understanding of the concepts disclosed herein and should not be considered as limiting the breadth, scope, or applicability of these concepts. It should be noted that, for clarity and ease of illustration, the drawings are not necessarily drawn to scale.

[0028] Figures 1A to 1C Several views of an exemplary roof rack system in accordance with some embodiments of the present disclosure are shown.

[0029] Figure 2 Shows an exemplary crossbeam according to some embodiments of the present disclosure.

[0030] Figure 3 Shows Figure 2 A cross-sectional view of the exemplary crossbeam.

[0031] Figure 4 Shows Figures 2 to 3 A top view of the exemplary crossbeam with the outer member removed.

[0032] Figure 5 Shows Figure 4 A side view of the central section of the crossbeam with the outer member removed.

[0033] Figure 6 Shows Figures 4 to 5 A perspective view of the central section of the crossbeam with the outer member removed.

[0034] Figure 7 Shows Figures 2 to 6 A cross-sectional view of the crossbeam including the outer member.

[0035] Figure 8 Shows an exemplary crossbeam in an extended state.

[0036] Figure 9 Shows an exemplary crossbeam in a contracted state.

[0037] Figure 10 Shows an exemplary crossbeam in an extended state with the outer member removed.

[0038] Figure 11 Shows an exemplary crossbeam in a contracted state with the outer member removed.

[0039] Figure 12 Shows a perspective view of the central section of the crossbeam with the central outer member in place.

[0040] Figure 13 Shows a perspective view of a left pulley with a left cable having an eyelet configured to couple to an outer member.

[0041] Figure 14A And Figure 14B Shows a block diagram of an exemplary crossbeam in a contracted state according to some embodiments of the present disclosure.

[0042] Figure 15A And Figure 15B Shows a block diagram of an exemplary crossbeam in an extended state according to some embodiments of the present disclosure.

[0043] Figures 16A to 16C Shows three top views of a vehicle with an installation position according to some embodiments of the present disclosure, with a roof rack installed and without a roof rack installed.

[0044] Figure 17 Shows a top perspective view of an exemplary roof rack in a retracted state according to some embodiments of the present disclosure.

[0045] Figure 18 Shows a top top view of an exemplary roof rack in a partially extended state according to some embodiments of the present disclosure.

[0046] Figure 19 Shows a top perspective view of an exemplary roof rack in a fully extended state according to some embodiments of the present disclosure.

[0047] Figure 20 Shows a perspective view of an exemplary roof rack in a retracted state according to some embodiments of the present disclosure.

[0048] Figure 21 Shows a perspective view of an exemplary roof rack in a fully extended state according to some embodiments of the present disclosure.

[0049] Figure 22 Shows a top cross-sectional view of an exemplary roof rack in a retracted state according to some embodiments of the present disclosure.

[0050] Figure 23 Shows a top cross-sectional view of an exemplary roof rack in a partially extended state according to some embodiments of the present disclosure.

[0051] Figures 24A to 24D Shows four top cross-sectional views of an exemplary roof rack in four corresponding states according to some embodiments of the present disclosure, where all four views are centered at the center of the roof rack.

[0052] Figures 25A to 25D Shows four top cross-sectional views of an exemplary roof rack in four corresponding states according to some embodiments of the present disclosure, where all four views point to the left hand side of the roof rack.

[0053] Figure 26 Shows a top view of an exemplary internal structure of an exemplary roof rack according to some embodiments of the present disclosure, including a left pulley and a right pulley, where the roof rack is in a retracted state.

[0054] Figure 27 Shows a top cross-sectional view of an exemplary internal structure of a roof rack according to some embodiments of the present disclosure, including a left pulley, a right pulley, a left cable and a right cable, where the roof rack is in a retracted state.

[0055] Figure 28 A perspective view showing an exemplary internal structure of a roof rack according to some embodiments of the present disclosure, including a left pulley and a right pulley, wherein the roof rack is in a retracted state.

[0056] Figure 29 A perspective view showing an exemplary internal structure of a roof rack according to some embodiments of the present disclosure, including a left pulley, a right pulley, a left cable, and a right cable, wherein the roof rack is in a retracted state.

[0057] Figure 30 A perspective cross-sectional view showing an exemplary left outer member and a corresponding support column according to some embodiments of the present disclosure.

[0058] Figure 31 A perspective view showing an exemplary left outer member and a corresponding support column according to some embodiments of the present disclosure.

[0059] Figure 32 A perspective cross-sectional view showing an exemplary left outer member and a corresponding support column according to some embodiments of the present disclosure, including a left cable and a right cable, wherein the roof rack is in a retracted state.

[0060] Figure 33 A perspective cross-sectional view showing an exemplary left outer member and a corresponding support column according to some embodiments of the present disclosure, including a left cable and a right cable, wherein the roof rack is in an extended state.

[0061] Figure 34 A perspective cross-sectional view showing an exemplary roof rack according to some embodiments of the present disclosure, wherein the roof rack is in a partially extended state. Detailed Description

[0062] The present disclosure relates to a roof rack system that includes an extendable crossbar, for example, an extendable crossbar assembly. In some embodiments, the extendable crossbar assembly can be mounted to various mounting positions of a vehicle. For example, the extendable crossbar assembly can be configured to be mounted at multiple pairs of mounting positions, each pair of mounting positions having a different distance between the mounting positions. In an exemplary example, the crossbar can be configured to achieve multiple lengths to match the distance between a specific pair of mounting positions.

[0063] The crossbar is a cargo accessory for a vehicle that extends the ability to mount gear and equipment. For specific purposes, such as, for example, carrying bicycles, kayaks, snowboards, snow skis, cargo boxes, and racks, additional accessories can be attached to the crossbar. In some cases, many such 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 place along the crossbar) or to maintain the same profile at specific regions along its entire length.

[0064] Figures 1A to 1C An exemplary roof rack system 100 in accordance with some embodiments of the present disclosure is shown. The roof rack system 100 includes a crossbar 102 that is configured to mount equipment, wherein support members 104 (e.g., struts) 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, while Figure 1C A perspective view of the other end of the roof rack system 100 is shown. The struts can be coupled to the crossbar in any suitable arrangement (e.g., rigidly coupled, coupled via a swivel joint, via a sliding joint, a sliding interface, a fastening interface, or the struts and corresponding outer members can be integrated as a single piece). The struts include an interface 106 for mounting to the vehicle (e.g., a plunger hole interface, a latch mechanism, a fastening interface, any other suitable interface, or any combination thereof).

[0065] Figures 2 to 13 Various views of an exemplary crossbar 102 in accordance with some embodiments of the present disclosure are shown.

[0066] Figure 2 An exemplary crossbar 102 in accordance with some embodiments of the present disclosure is shown. In some embodiments, the crossbar 102 includes a first section 107 (which includes a left-hand (LH) outer member 108), a second section 111 (which includes a right-hand (RH) outer member 110), and a third section 109 (which includes a center outer member 112), all of which sections are formed to have the same external profile (e.g., all having a similar cross-section). Figure 3 Shows Figure 2 A cross-sectional view of the crossbar 102 (e.g., taken at the "cross-section" label in Figure 2 . For example, the profile can include a standard T-slot 114 (e.g., shown in the cross-section in 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. The crossbar 102 may be capable of achieving a minimum length (e.g., asFigure 2 as shown), a maximum length, and any length therebetween. For example, when the crossbar 102 is fully retracted to its shortest length, the three outer members can form a continuous outer profile. In another example, when the crossbar 102 is extended to its maximum length, the internal extension feature bridges the gap between the outer members (i.e., the LH outer member 108 and the RH outer member 110) and maintains the load therebetween.

[0067] Figure 4 is shown Figures 2 to 3 A top view of an exemplary crossbar 102 is shown, where the outer members 108, 110, 112 are removed to show the internal structure, e.g., the internal extension feature 116. The main structure of the internal extension feature 116 includes one or more internal rods 118 arranged parallel to the outer profile (e.g., along the longitudinal axis of the crossbar 102). When the outer members 108, 110 are in any open position (e.g., fully extended or partially extended), the one or more internal rods 118 provide intermediate support. In some embodiments, the one or more internal rods 118 are configured such that fittings can be mounted in the same manner as they are mounted on the main crossbar sections (e.g., the LH outer member 108, the RH outer member 110, and the center outer member 112). In some embodiments, the one or more internal rods 118 are rigidly attached to the center outer member 112 and are thus centered between the LH outer member 108 and the RH outer member 110. For illustration, the LH outer member 108 can slide along the internal rod 118, and the RH outer member 110 can slide along the internal rod 118. The LH cable 120 is coupled to the LH outer member 108 such that when the LH outer member 108 moves outward, the end of the cable 122 coupled to the LH outer member 108 also moves outward, e.g., by virtue of the other end of the cable 122 being anchored to another component. Similarly for the RH outer member 110 and the RH cable. Figure 4 The central region shown is disposed within the center outer member 112. Figure 5 is shown Figure 4 A side view of the central section 126 (e.g., including the central region) of the crossbar 102 is shown, where the outer members 108, 110, 112 are removed. Figure 6 is shown Figures 4 to 5 A perspective view of the central section 126 (e.g., including the central region) of the crossbar 102 is shown, where the outer members 108, 110, 112 are removed. Figure 7 is shown Figures 2 to 6 A cross-sectional view of the crossbar 102 is shown, which includes the outer members 108, 110, 112. In some embodiments, the intermediate crossbar section (e.g., the center outer member 112) is self-centered such that it remains centered with respect to the lateral intermediate plane of the crossbar 102, e.g., centered between the LH outer member 108 and the RH outer member 110.

[0068] In some embodiments, the pulley-cable system 128 connects all three outer members 108, 110, 112 together. Figures 8 to 11 The contracted configuration and the expanded configuration of the crossbeam 102 are shown, where the outer members 108, 110, 112 are in place and not in place. Figure 8 and Figure 10 shows the crossbeam 102 in the expanded state, while Figure 9 and Figure 11 shows the crossbeam 102 in the contracted state. For example, Figure 8 shows the crossbeam 102 extending with the three outer members 108, 110, 112 spaced apart, while Figure 9 shows the crossbeam 102 contracting with all three outer members 108, 110, 112 together. Thus, the crossbeam 102 can be extended or contracted 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 illustrative, and any suitable mechanism can be used in accordance with the present disclosure. For example, a rack and pinion mechanism can be used.

[0069] Referring Figures 10 to 11 , one end 130 of the RH cable 124 is attached to the RH outer member 110 (e.g., at the shown eyelet 132), while the other end 134 is attached to the LH crossbeam 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 central crossbeam section (e.g., the center-to-center distance between the RH pulley 136 and the LH pulley 138 is fixed). The direction of the RH cable 124 changes 180 degrees around the RH pulley 136 such that the section entering the RH pulley 136 is parallel, but in the opposite pulling direction to the section leaving the RH pulley 136. Kinematically, the travel distance of the free end 130 of the RH cable 124 (e.g., the end coupled to the RH outer member 110 and capable of moving with the RH outer member) relative to the fixed end 134 of the RH cable 124 (e.g., the end coupled to the LH outer member 108) is twice the displacement of the RH pulley relative to the central section 126 (e.g., the lateral midplane of the central section). The central outer member 112 remains centered regardless of the distance between the inner ends of the outer members 108, 110.

[0070] As shown, the RH cable 124 and the LH cable 122 are not visible to the user because they are routed through the hollow center of the inner rod 118 (e.g., a tube). Beyond a respective end of the inner rod 118, each cable 122, 124 extends straight towards the end of one of the end pieces. The other end of each cable is wound around a respective pulley mounted to the end of the inner rod. Each cable 122, 124 is wound 180 degrees around the respective pulleys 136, 138 and is attached to the inner end of the other outer crossbeam piece.

[0071] In some embodiments, the LH outer piece 108, the RH outer piece 110, the center outer piece 112, and one or more inner rods 118 are constructed of metal. In some embodiments, 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 materials that are formed as end caps for the one or more inner rods to prevent vibration, scratching, and wear.

[0072] For illustration, starting from the fully retracted state, when the RH outer piece 110 moves outward (i.e., away from the center outer piece 112), the eyelet end 130 of the RH cable 124 also moves outward, while the other end of the RH cable 124 that is coupled to the LH outer piece 108 also moves outward but in the opposite direction. A similar movement occurs for the LH cable 122 when the LH outer piece moves outward. Thus, the center outer piece 112 remains centered. For example, a user can apply a force to any one or all of the three outer pieces 108, 110, 112, e.g., along the longitudinal axis of the crossbeam 102, to contract or expand the length of the crossbeam. The pulley system 128 helps ensure that the center outer piece 112 remains centered between the RH outer piece 110 and the LH outer piece 108.

[0073] Figure 12 A perspective view of the center section of the crossbeam is shown, where the center outer piece 112 is in place. Figure 13 A perspective view of the LH pulley 138 is shown, where the LH cable 122 is wound 180 degrees and has an eyelet 140 configured to couple to the LH outer piece 108. The RH cable 124 is also visible in Figure 13 The LH pulley 138 (e.g., the LH pulley shaft) is rigidly coupled to the inner rod by a bracket 142, as shown.

[0074] Figures 14 through 15 show a block diagram of an exemplary crossbeam 102 according to some embodiments of the present disclosure. For clarity, Figure 14A and Figure 14B show two views, where Figure 14A the view of Figure 14B omits the LH cable 122, and the view ofFigure 14A and Figure 14B shows the crossbar 102 in a fully retracted state. For clarity, Figure 15A and Figure 15B shows two views of the extended crossbar 102, where Figure 15A the view of omits the LH cable 122, and Figure 15B the view of omits the RH cable 124. Each of the ends 134, 144 of the RH cable and the LH cable is fixed to the respective outer members 108, 110, and thus the cable ends 134, 144 move relative to the RH pulley 136 and the LH pulley 138.

[0075] In some embodiments, the roof rack system 100 includes one or more locking mechanisms configured to constrain the movement of the cables, pulleys, outer members, or combinations thereof relative to an internal structure (e.g., an internal rod) when locked. For example, the locking mechanism can include a clamp on the cable that prevents the cable from moving by applying friction. In another example, the locking mechanism can include a set screw that prevents the pulley from rotating when tightened. In yet another example, the locking mechanism can include a clamp that applies friction between the internal rod and the LH outer member or the RH outer member when locked to prevent relative movement. In some embodiments, the internal structure can include detent positions or otherwise provide discretized extended lengths. For example, the pulley shaft can be toothed, or the internal rod can include a ratchet mechanism such that the LH outer member and the RH outer member achieve a predetermined equilibrium position. In yet another example, the cable can include a belt, a flexible rod, a wire, a toothed belt, any other suitable flexible component, or a combination thereof that can withstand tension. Accordingly, the pulley can include a grooved pulley, a toothed pulley (e.g., a sprocket or a gear), a multi-channel pulley, or a cylindrical pulley, any other suitable rotating member, or any combination thereof. In some embodiments, the pulley can include rotating elements such as torsion springs, dampers, ratchet mechanisms, any other suitable rotating elements, or any combination thereof. In some embodiments, the roof rack system can include one or more actuators (e.g., an electric motor, a linear actuator such as a solenoid) configured to apply torque to the pulley, apply a force to an outer member relative to another outer member or an internal rod, or otherwise apply a force / torque to cause extension or retraction of the crossbar.

[0076] In some embodiments, the center outer member 112 is centered (e.g., longitudinally centered) on the crossbar 112 and is configured to remain centered. For example, some mounting attachments may need to be attached to the LH outer member 108 or the RH outer member 110 (e.g., its T-slot 114) and the center section 126 (e.g., its T-slot 114) of the roof rack system 110. In some embodiments, the LH outer member 108 or the RH outer member 110 may be relatively longer than the other. In some such embodiments, the RH outer member 110 and the LH outer member 108 may move an equal amount in respective directions relative to the center outer member 112, but the center outer member 112 is not centered along the crossbar 102, e.g., the center outer member 112 is not centered about the lateral midplane of the crossbar 102. For example, this arrangement may be desirable to form a longer section of the T-slot 114 in one of the LH outer member 108 or the RH outer member 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 members may be on either side of the center outer member 112 (e.g., the roof rack 100 or the crossbar 102 may be flipped from left to right). This arrangement may be useful for accommodating a range of attachment widths and shapes. Attachments may include, for example, kayaks, storage containers, surfboards, canoes, skis, snowboards, bicycles or bike racks, cargo bed covers, any other suitable equipment, or any combination thereof.

[0077] Figures 16A to 16C Three top views of a vehicle 145 with mounting locations 146, with and without a roof rack mounted, are shown, in accordance with some embodiments of the present disclosure. Figure 16A A vehicle 145 without a roof rack mounted is shown, along with pairs of mounting locations 146 (e.g., mounting location pair 148 and mounting location pair 150). Figure 16B A vehicle with the roof rack 100 mounted at mounting location pair 148 (e.g., in the cargo bed) is shown, with the roof rack in a fully retracted state. The span distance of mounting location pair 148 (i.e., the distance between the two mounting locations of the pair) is less than the span distance of mounting location pair 150. Figure 16C A vehicle 145 with the roof rack 100 mounted at mounting location pair 150 (e.g., on top of the cargo bed) is shown, with the roof rack in an extended state. Thus, the roof rack 100 provides a system for mounting cargo on a vehicle at different locations. Further, a user may use the same crossbar 102 for multiple mounting arrangements. Still further, the roof rack 100 may be stored in its minimum configuration (e.g., fully retracted), thereby minimizing the packaging space required.

[0078] Figures 17 to 33 Various views and states of an exemplary roof rack 100 are shown, in accordance with some embodiments of the present disclosure.

[0079] Figure 17 Shows a top perspective view of an exemplary roof rack 100 in a retracted state according to some embodiments of the present disclosure.

[0080] Figure 18 Shows a top plan view of an exemplary roof rack 100 in a partially extended state according to some embodiments of the present disclosure.

[0081] Figure 19 Shows a top perspective view of an exemplary roof rack 100 in a fully extended state according to some embodiments of the present disclosure.

[0082] Figure 20 Shows a perspective view of an exemplary roof rack 100 in a retracted state according to some embodiments of the present disclosure.

[0083] Figure 21 Shows a perspective view of an exemplary roof rack 100 in a fully extended state according to some embodiments of the present disclosure.

[0084] Figure 22 Shows a top cross-sectional view of an exemplary roof rack 100 in a retracted state. The Figure 22 shows the inner rod 118, the LH cable 122, and the RH cable 124.

[0085] Figure 23 Shows a top cross-sectional view of an exemplary roof rack 100 in a partially extended state. The Figure 23 shows the inner rod 118, the LH cable 122, and the RH cable 124.

[0086] Figures 24A to 24D Shows four top cross-sectional views of an exemplary roof rack 100 in four corresponding states, where all four views are centered at the center of the roof rack 100, e.g., centered about the transverse intermediate plane of the crossbeam assembly 102. Figure 24A Shows the roof rack 100 in a retracted state. Figure 24B Shows the roof rack 100 in a first partially extended state. Figure 24C Shows the roof rack 100 in a second partially extended state. Figure 24D Shows the roof rack 100 in a fully extended state. Figures 24A to 24D Shows how each of the first section 107 and the second section 109 translates along the longitudinal axis of the crossbeam assembly 102 while remaining centered with respect to the transverse plane of the crossbeam assembly 102, which is the transverse intermediate plane in this example, and the third section is fixed to this transverse intermediate plane.

[0087] Figures 25A to 25D Four top cross-sectional views of an exemplary roof rack 100 in four respective states in accordance with some embodiments of the present disclosure are shown, where all four views are directed towards the LH side of the roof rack 100. Figure 25A The roof rack 100 in a fully extended state is shown. Figure 25B The roof rack 100 in a first partially retracted state is shown. Figure 25C The roof rack 100 in a second partially retracted state is shown. Figure 25D The roof rack 100 in a fully retracted state is shown. Figures 25A to 25D Shows how the end 134 of the RH cable 124 is fixed, directly or indirectly, for example, at a point on the LH strut 104 to the outer end 152 of the first section 107, and how the end 154 of the LH cable 122 is fixed, directly or indirectly, for example, at a point on the end plate 158 to the inner end 156 of the first section 107.

[0088] Figure 26 A top view of an exemplary internal structure of an exemplary roof rack 100 in accordance with some embodiments of the present disclosure is shown, including the LH pulley 138 and the RH pulley 136.

[0089] Figure 27 A top cross-sectional view of an exemplary internal structure of a roof rack 100 in accordance with some embodiments of the present disclosure is shown, which shows the LH cable 122 and the RH cable 124 in the case where the roof rack 100 is in a retracted state.

[0090] Figure 28 A perspective view of an exemplary internal structure of a roof rack 100 in accordance with some embodiments of the present disclosure is shown.

[0091] Figure 29 A perspective view of an exemplary internal structure of a roof rack 100 in accordance with some embodiments of the present disclosure is shown, which exemplary internal structure has the LH cable 122 and the RH cable 124.

[0092] Figure 30 A perspective cross-sectional view of an exemplary LH outer member 108 and a corresponding strut 104 in accordance with some embodiments of the present disclosure is shown. Figure 30 Also shown is a bracket 160 configured to provide stiffness between the LH outer member 108 and the strut 104. The end of the RH cable may be fixed to the bracket 160.

[0093] Figure 31 A perspective view of an exemplary LH outer member 108 and a corresponding strut 104 in accordance with some embodiments of the present disclosure is shown. Figure 31Also shown is a tensioner 161 configured to provide a feature for attaching a cable or other fixture for securing the device to the roof rack 100. The bracket 160 prevents relative movement between the strut 104 and the LH outer member 108. Although not shown, a similar arrangement may be included for the RH outer member 110 and corresponding strut 104.

[0094] Figure 32 A perspective cross-sectional view of an exemplary LH outer member 108 and corresponding strut 104 in accordance with some embodiments of the present disclosure is shown, including the LH cable 122 and the RH cable 124 in a retracted state. The RH cable 124 is attached to the bracket 160. For example, a substantially vertical portion of the bracket 160 prevents the strut 104 from rotating relative to the crossbar 102 about an axis perpendicular to the plane of the vertical portion. In another example, a substantially horizontal portion of the bracket 160 maintains the vertical section in place and together prevents rotation about the vertical axis.

[0095] Figure 33 A perspective cross-sectional view of an exemplary LH outer member 108 and corresponding strut 104 in accordance with some embodiments of the present disclosure is shown, including the LH cable 122 and the RH cable 124 in an extended state.

[0096] Figure 34 A perspective cross-sectional 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 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 freely slides 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., sleeve bearing) configured to constrain off-axis movement of the inner rod 118 (e.g., movement of the inner rod 118 in a direction perpendicular to the first and second sections) while allowing the inner rod 118 to slide freely. In some embodiments, the bushing 163 may be configured to constrain rotational movement of the inner rod 118. It should be understood that, similar to the roof rack 200, the roof rack 100 may include at least one bushing similar to the bushing 163.

[0097] In some embodiments, the inner rod 118 may be fixed relative to each of the first section 107 and the second section 109 by means of a pawl feature 162 in the inner rod 118, the pawl feature being configured to interact with a pawl feature 164 on each of the first section 107 and the second section 109. For example, the pawl feature 162 in the inner rod 118 and the pawl feature 164 on each of the first section 107 and the second section 109 may include a series of openings configured to receive locking pins. In this way, by aligning the desired pawl feature 162 in the inner rod 118 with the pawl feature 164 on each of the first section 107 and the second section 109, the length of the crossbar assembly 102 can be adjusted. The pawl feature 162 in the inner rod 118 may have a different spacing from the pawl feature 164 on each of the first section 107 and the second section 109. For example, the spacing of the pawl feature 162 in the inner rod 118 may be closer to or farther from the spacing of the pawl feature 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 rack 100 may include pawl features 162, 164 similar to those shown on the roof rack 200. In some embodiments, the roof rack 100 and the roof rack 200 may be provided without pawl features 162, 164.

[0098] The foregoing is only illustrative of the principles of the present disclosure, and those skilled in the art may make various modifications 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. Accordingly, 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 within the scope of the following claims.

Claims

1. A roof rack system (100, 200) for attachment to a vehicle having a plurality of mounting locations, the roof rack system comprising: Crossbeam assembly (102), the crossbeam assembly comprising: Internal structure; A first section (107) configured to be translatable relative to the internal structure; A second section (111) configured to be translatable relative to the internal structure and towards the first section; and A third section (109) rigidly attached to the internal structure and disposed between the first section and the second section, wherein the internal structure includes: At least one internal rod (118) configured to support the crossbeam assembly (102); and At least one sliding mechanism configured to allow the first section (107) and the second section (111) to translate relative to the at least one internal rod, wherein the sliding mechanism is configured to automatically center the third section (109) when the first section and the second section translate, so that the third section remains centered between the first section and the second section; A first end support (104) coupled to an outer portion of the first section and configured to be mounted to a first mounting position; and A second end support (104) coupled to an outer portion of the second section and configured to be mounted to a second mounting position.

2. The roof rack system (100, 200) according to claim 1, wherein the at least one inner rod (118) comprises a hollow interior.

3. The roof rack system (100) according to claim 1, wherein the at least one sliding mechanism comprises a pulley-cable mechanism (128).

4. The roof rack system (100) according to claim 3, wherein the pulley-cable mechanism (128) comprises: Pulleys (136, 138) rigidly attached to the at least one internal rod (118); Cables (122, 124), the cables including first cable ends (130, 144) and second cable ends (134, 154), wherein: The first cable end is attached to the first section (107), The second cable end is attached to the second section (111), and The cable is wound around the pulleys (136, 138).

5. The roof rack system (100) according to claim 4, wherein the pulleys (136, 138) are rigidly attached to the at least one inner rod (118) by an axle.

6. The roof rack system (100) according to claim 3, wherein the first section (107) is located on a first side of the third section (109), and wherein the pulley-cable mechanism (128) comprises: A first pulley (136) rigidly attached to the at least one internal rod (118) on the first side of the third section; A second pulley (138) rigidly attached to the at least one internal rod (118) on a second side of the third section opposite the first side; A first cable (122) attached to the first section and the second section, wherein the first cable is wound around the first pulley (136); A second cable (124) attached to the first section and the second section, wherein the second cable is wound around the second pulley (138).

7. The roof rack system (200) according to claim 1, wherein the at least one sliding mechanism comprises a rack and pinion mechanism, wherein a first rack is coupled to the first section (107), a second rack is coupled to the second section (111), and the pinion is coupled to the internal structure.

8. The roof rack system (100, 200) according to claim 1, wherein the first section (107), the second section (111) and the third section (109) each comprise a similar outer profile.

9. The roof rack system (100, 200) according to claim 8, wherein the outer profile comprises aerodynamic features.

10. The roof rack system (100, 200) according to claim 1, wherein the internal structure is coupled to both the first section (107) and the second section (111) by an intermediate material, and wherein the intermediate material comprises at least one of rubber and plastic.

11. The roof rack system (100, 200) according to claim 1, the roof rack system further comprising a first locking mechanism configured to lock the first section (107) to the internal structure; and the roof rack system further optionally comprises a second locking mechanism configured to lock the second section (111) to the internal structure.

12. A method for installing a roof rack system on a vehicle, the roof rack comprising: Crossbeam assembly (102), the crossbeam assembly comprising: Internal structure; A first section (107) configured to be translatable relative to the internal structure; A second section (111) configured to be translatable relative to the internal structure and towards the first section; and A third section (109) rigidly attached to the internal structure and disposed between the first section and the second section, wherein the internal structure includes: At least one inner rod (118), the inner rod being configured to support the crossbeam assembly (102); and At least one sliding mechanism, the sliding mechanism being configured to allow the first section (107) and the second section (111) to translate relative to the at least one inner rod, wherein the sliding mechanism is configured to automatically center the third section (109) when the first section and the second section translate, such that the third section remains centered between the first section and the second section; A first end support (104), the first end support being coupled to an outer portion of the first section and being configured to be mounted to a first mounting location; and A second end support (104), the second end support being coupled to an outer portion of the section and being configured to be mounted to a second mounting location, The method includes the steps of: Attaching the first end support (104) to the first mounting location of the vehicle; Changing the length of the crossbeam assembly (102) by applying a force; and Attaching the second end support (104) to the second mounting location of the vehicle.

13. The method according to claim 12, wherein: The crossbeam assembly (102) includes a first section (107), a second section (111) and a third section (109); The crossbeam assembly extends along an axis; The third section (109) is centered along the axis; and When the length of the crossbeam assembly changes, the third section (109) remains centered.

14. The method according to claim 13, wherein changing the length of the crossbeam assembly includes applying a force to at least one of the first section (107), the second section (111), and the third section (109).

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