Universal Load Carrier Mounting for Internal Bed Rail Systems

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Solution Overview

Problem

Existing load carriers for vehicles with bed structures struggle to securely attach to newer pickup trucks with internal bed rail systems due to varying rail configurations and the use of flexible materials, which complicates mounting and increases costs for manufacturers.

Innovation Solution

A universal mounting assembly with an intermediate adapter piece that customizes the mounting for different vehicle configurations, utilizing a combination of standard top and bottom mount pieces and a rail clamping assembly with adjustable components to ensure secure attachment across various truck bed designs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional sheet metal top rails are used, then structural rigidity is maintained, but manufacturing cost increases and adaptability to new vehicle designs decreases

Engineering Contradiction:

Improvestructural rigidityVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent changes the material parameter from rigid sheet metal to flexible plastic/composite materials for the top rail, while compensating for the loss of rigidity through the clamping assembly design that applies sufficient clamping force to secure the load carrier firmly

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite material construction where the top rail is made from plastic or composite materials rather than traditional sheet metal, combining cost-effectiveness with adequate structural performance through the integrated clamping mechanism

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If flexible plastic and composite materials are used for top rails, then manufacturing cost decreases, but structural rigidity is lost making mounting difficult

Engineering Contradiction:

Improvemanufacturing costVSAvoidstructural rigidity

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If universal mounting hardware is used, then load carrier manufacturer costs are reduced, but compatibility with varying rail configurations decreases

Engineering Contradiction:

Improvemounting hardware costVSAvoidcompatibility with rail configurations

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent designs a universal clamping assembly that can accommodate multiple rail configurations (traditional sheet metal top rails, internal bed rail systems, and various shapes) through a single standardized mounting hardware design, achieving both cost reduction and broad compatibility

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The mounting system is segmented into a standardized clamping assembly component that interfaces with different rail types through adaptive clamping mechanisms, allowing the same hardware to serve multiple vehicle configurations

Inventive Principle:

Principle #1Segmentation

4Ease of manufacture

If internal bed rail systems are implemented, then vehicle manufacturer costs decrease, but load carrier mounting complexity increases

Engineering Contradiction:

Improvevehicle manufacturing costVSAvoidmounting complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS7296837B2Load carrier arrangement for a vehicle bed comprising an internal bed rail system

Publication Date: 2007.11.20 THULE SWEDEN AB

AI summary

Load carrier mountable above a bed structure of a vehicle having an upper surface and an internal bed rail system is disclosed. The load carrier broadly includes an upright base support member, an internal rail clamping assembly, and a clamp adjustment assembly. The upright base support member rests upon the upper surface of the side wall of the bed structure and connects with the internal rail clamping assembly. The upright base support member has a first clamp surface for asserting a clamping force upon the upper surface of the side wall of the bed structure. The rail clamping assembly is releasably securable to the internal bed rail system and includes a second clamp surface for asserting a clamping force upon the internal bed rail system. The clamp adjustment assembly positionally adjusts the first clamping surface with respect to the second clamping surface between clamped and unclamped positions.