Universal expanding roof rack

Patent metadata

Field	Value
Publication number	US-12466326-B2
Application number	US-202217954400-A
Country	US
Kind code	B2
Filing date	Sep 28, 2022
Priority date	Oct 28, 2021
Publication date	Nov 11, 2025
Grant date	Nov 11, 2025

Abstract

A roof rack assembly for a vehicle that includes a structure that extends in a cross-car direction of the vehicle, the roof rack assembly has: a first rack portion comprising a first rail and an opposing second rail; and a second rack portion comprising a third rail and an opposing fourth rail. The first rail has a cutout, and the second rail has a cutout, and the cutout of the first rail is configured to align with the cutout of the second rail. The structure of the vehicle is configured to extend through the aligned cutouts of the first rail and the second rail when the roof rack assembly is installed on the vehicle.

First claim

The invention claimed is:

1 . A roof rack assembly for a vehicle, comprising:
a first rack portion comprising a first rail and an opposing second rail; a second rack portion comprising a third rail and an opposing fourth rail; wherein the first rail has a cutout, and the second rail has a cutout, and the cutout of the first rail is configured to align with the cutout of the second rail; wherein a structure associated with the vehicle is configured to extend through the aligned cutouts of the first rail and the second rail when the roof rack assembly is installed on the vehicle; and wherein the roof rack assembly comprises an inner cross bar and an outer cross bar, and the outer cross bar is configured to connect the roof rack assembly to the structure associated with the vehicle.

2 . The roof rack assembly according to claim 1 , wherein the first rail has a top flange and a bottom flange and the third rail has a top flange and a bottom flange, wherein a gap defined between the top flange and the bottom flange of the first rail is smaller than a gap defined the top flange and the bottom flange of third rail so that the first rail nests within the third rail when the cutout of the first rail is aligned with the cutout of the third rail.

3 . The roof rack assembly according to claim 1 , wherein the roof rack assembly comprises a mount and the outer cross bar comprises a lateral flange, the mount is configured to engage the lateral flange and the vehicle cross bar to connect the roof rack assembly to the vehicle.

4 . The roof rack assembly according to claim 3 , wherein the outer cross bar and the vehicle cross bar extend in the same direction and the outer cross bar is located on top of the vehicle cross bar.

5 . A roof rack assembly for a vehicle, comprising:
a first rack portion comprising a first rail and an opposing second rail; a second rack portion comprising a third rail and an opposing fourth rail; wherein the first rail has a cutout, and the second rail has a cutout, and the cutout of the first rail is configured to align with the cutout of the second rail; wherein a structure associated with the vehicle is configured to extend through the aligned cutouts of the first rail and the second rail when the roof rack assembly is installed on the vehicle; wherein the first rail has a top flange and a bottom flange and the third rail has a top flange and a bottom flange, wherein a gap defined between the top flange and the bottom flange of the first rail is smaller than a gap defined the top flange and the bottom flange of third rail so that the first rail nests within the third rail when the cutout of the first rail is aligned with the cutout of the third rail; and wherein the roof rack assembly comprises an inner cross bar and an outer cross bar, and the outer cross bar is configured to connect the roof rack assembly to the structure associated with the vehicle, the outer cross bar and the structure associated with the vehicle extend in the same direction and the outer cross bar is located on top of the structure associated with the vehicle.

6 . The roof rack assembly according to claim 5 , wherein the inner cross bar comprises a mounting flange for connecting the inner cross bar to the bottom flange of the first rail and/or the third rail, and wherein the structure associated with the vehicle is a vehicle cross bar.

7 . The roof rack assembly according to claim 5 , wherein the outer cross bar comprises a mounting flange for connecting the inner cross bar to the bottom flange of the first rail and/or the third rail.

8 . The roof rack assembly according to claim 7 , wherein the inner cross bar and the outer cross bar comprise one or more apertures for connecting one or more accessories to the roof rack assembly.

9 . The roof rack assembly according to claim 7 , wherein the roof rack assembly comprises a shim that is placed between an end of the inner cross bar or the outer cross bar, when the inner cross bar or the outer cross bar extends between the third cross bar and the fourth cross bar.

10 . A roof rack assembly for a vehicle, the vehicle comprising one or a plurality of vehicle cross bars that extend in a cross-car direction of the vehicle, the roof rack assembly comprising:
a first rack portion comprising a first rail and an opposing second rail, a second rack portion comprising a third rail and an opposing fourth rail, wherein the first rail has a cutout, and the second rail has a cutout, and the cutout of the first rail is configured to align with the cutout of the second rail after the first rail is nested together with the third rail; wherein third first rail has a cutout, and the fourth rail has a cutout, and the cutout of the third rail is configured to align with the cutout of the fourth rail after the second rail is nested together with the fourth rail; wherein a first of the vehicle cross bars is configured to extend through the aligned cutouts of the first rail and the second rail; and wherein a second of the vehicle cross bars is configured to extend through the aligned cutouts of the third rail and the fourth rail; and wherein the roof rack assembly further comprises an inner cross bar and an outer cross bar, and the outer cross bar is configured to connect the roof rack assembly to the structure associated with the vehicle.

11 . The roof rack assembly according to claim 10 , wherein the first rail, the second rail, the third rail, and/or the fourth rail has a U-shaped cross section.

12 . The roof rack assembly according to claim 10 , wherein the first rail is configured to nest within the third rail.

13 . The roof rack assembly according to claim 12 , wherein the second rail is configured to nest within the fourth rail.

14 . The roof rack assembly according to claim 13 , wherein the first rail is generally parallel to the second rail.

15 . The roof rack assembly according to claim 14 , wherein the third rail is generally parallel to the fourth rail.

16 . The roof rack assembly according to claim 14 , wherein the first rack portion comprises a connecting rail that extends between and connects the first rail and the second rail.

17 . The roof rack assembly according to claim 16 , wherein the second rack portion comprises a connecting rail that extends between and connects the third rail and the fourth rail.

18 . The roof rack assembly according to claim 9 , wherein both of the first rail and the third rail have a U-shaped cross section, and a cross section of the first rail is smaller than a cross section of the third rail so that the first rail nests within the third rail when the cutout of the first rail is aligned with the cutout of the third rail.

19 . The roof rack assembly according to claim 18 , wherein both of the second rail and the fourth rail have a U-shaped cross section, and a cross section of the second rail is smaller than a cross section of the fourth rail so that the second rail nests within the fourth rail when the cutout of the second rail is aligned with the cutout of the fourth rail.

Assignees

• Extang Corp

Inventors

• Warech Cameron

Classifications

• B60R9/045 Primary

  Carriers being adjustable or transformable, e.g. expansible, collapsible {(transformable into tents B60P3/36; into beds B60P3/38)} · CPC title