Stowable Vehicle Cross Bar Assembly with Pivot End Supports
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Solution Overview
Problem
Existing vehicle article carrier systems face challenges such as increased wind resistance due to cross bars, difficulty in storing them when not in use, and requirements for specific mounting fasteners on vehicle roofs, which can be costly for manufacturers and inconvenient for users, especially those with limited hand strength who struggle with securing locking mechanisms.
Innovation Solution
A vehicle article carrier system with cross bars that can be configured to be secured to opposing door jams, featuring a tubular central portion and outer cross bar portions that telescope, along with locking levers and tap plates for secure attachment, and pivotally mounted end supports with latching levers and biasing elements to facilitate easy stowability and secure positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If cross bars are permanently installed on the vehicle roof, then article transport capability is maintained, but wind resistance increases and fuel economy deteriorates
Solution Approach 1:
The cross bar system transitions from a static permanently installed state to a dynamic removable state. The quick-release locking mechanism enables the cross bars to be easily detached and reattached, allowing the system to adapt between providing wind resistance reduction (when removed) and article transport capability (when installed), resolving the contradiction between aerodynamic efficiency and functional availability.
Solution Approach 2:
The cross bar system is divided into separable components: the cross bar itself, the support rails, and the quick-release locking mechanisms. This segmentation allows the cross bars to be independently removed from the support rails, enabling the vehicle to operate with reduced wind resistance while maintaining the infrastructure (support rails) for quick reinstallation when transport capability is needed.
2Object-affected harmful factors
If cross bars are removed from the vehicle, then wind resistance is reduced, but storage becomes problematic and cargo space is compromised
Solution Approach 1:
The cross bars are extracted from the permanent vehicle structure and designed as removable accessories. The quick-release locking mechanism enables rapid removal without tools, allowing cross bars to be taken out when not needed for transport, thereby eliminating wind resistance and preserving cargo space. The support rails remain installed as a permanent infrastructure that facilitates quick reinstallation when required.
3Reliability
If traditional locking mechanisms are used, then secure attachment is achieved, but significant rotational force is required that exceeds the capability of individuals with limited hand strength
Solution Approach 1:
The traditional threaded locking mechanism requiring high rotational torque is replaced with a cam-based quick-release system. The cam mechanism converts minimal lateral or rotational force into substantial clamping force through mechanical advantage, enabling secure attachment that can be operated by individuals with limited hand strength while maintaining reliable attachment security.
Solution Approach 2:
The quick-release locking mechanism acts as an intermediary between the user and the cross bar-support rail connection. It translates minimal user input force into the high clamping force required for secure attachment, serving as a force-multiplying intermediary that bridges the gap between limited human capability and the mechanical requirements of secure fastening.
4Strength
If mounting fasteners are positioned at specific roof locations, then structural attachment strength is ensured, but manufacturing cost increases due to roof redesign requirements
Solution Approach 1:
The support rails are designed with universal mounting capabilities that can accommodate various fastener positions and types. The rails incorporate features such as multiple mounting holes or adjustable positioning mechanisms, allowing them to be securely attached at different roof locations without requiring custom-designed rails for each position. This universality enables manufacturers to use existing roof structures while maintaining attachment strength.
Data Source
AI summary
A vehicle article carrier system is disclosed for use on an outer body roof surface of a vehicle to removably support articles above the outer body roof surface. The system makes use of a cross bar assembly having a central tubular portion and telescopically coupled outer cross bar portions. A locking lever may be used to lock at least one of the outer cross bar portions to prevent telescopic movement. A pair of end supports is used to latch to door jam areas of the vehicle. The end supports each have a construction such that both can be configured in a generally planar configuration to enable easy stowage of the cross bar assemblies, and each pivoted into an angled configuration which places the tubular cross bar portion above the vehicle outer body surface when the cross bar assembly is secured to the door jam areas.