TECHNICAL FIELD

The present invention relates to an Improved load supporting structure for a vehicle, and a method of configuring or constructing and deploying a load supporting structure for a vehicle.

Reference In general throughout this; specification will be made to the present invention being used to implement roof rack or roof support p!atforms used in relation to road based vehicles. The use of this invention with other vehicles Is however also Is envisioned.

BACKGROUND TO THE INVENTION

In many instances it is of advantage for loads or equipment to be carried on the roof or exterior of a vehicle. For example, In the case of road vehicles, roof rack systems have been developed which allow large bulky cargo to be secured to the roof of the vehicle without damaging the vehicle's paint work. Roof platform based systems also allow a vehicle to carry significantly more cargo than would be possible if just the interior of the vehicle were utilised. Existing roof top cargo carrying systems are customised to particular applications or particular types of loads. For example, in recreational applications, it is common for a pair of transverse bars to be mounted on the roof of a vehicle to carry sporting equipment such as skis, bicycles, kayaks or aerodynamic carrying boxes. In trade or "off-road" applications, entire load supporting platforms can be mounted to the roof of the vehicle with a guard rail applied to the perimeter of the platform to assist in retaining loads thereon. In other commercial applications, a platform or transverse bars may be provided in addition to a long pipe or tube, which is commonly used to support, carry and protect lengths of conduit or other piping material.

With existing prior art cargo supporting systems, a user must choose the form or type of support which is customised to the primary application of interest to them. However, and particularly in the case of trade or commercial users, the vehicle involved generally serves a dual purpose or dual role - both transporting work related or commercial materials (commonly during weekdays) and transporting recreational equipment at other times (commonly on the weekends and during holiday periods).

Existing prior art load support systems are unable to cope with or adequately secure and support the wide range and different number of types of cargos which users may wish to carry on a vehicle at various times throughout the year. For example, a commercial roof platform with a surrounding guard rail cannot be used to transport large bulky articles such as kayaks or canoes. Conversely, a dual transverse bar based roof rack system cannot in turn support a number of cargo carrying containers, which could normally be placed on the surface of a platform based support. It would therefore be of advantage to have re-configurable load supporting structure or system for a vehicle, which could be rearranged or re-configured to support various different forms or types of load as required. In particular, it would be of advantage to have a re-configurable load supporting structure, which could be arranged to support and retain commercial or trade based cargos In one configurations, and then be re-configured or rearranged to support recreational based cargo at other times. SUMMARY OF THE INVENTION

According to a first aspect of the present invention there is provided a load supporting structure for a vehicle which includes, a support frame adapted to be connected to the vehicle, and a plurality of modular rail elements, wherein an engagement portion of each of the modular rail elements is configured to be removably engaged with portions of the support frame to form at least one guard rail.

According to a further aspect of the present invention there is a provided a load supporting structure for a vehicle which includes, a support frame connected to the vehicle, a plurality of modular rail elements, and a plurality of modular base elements, wherein a first portion of each modular base element Is configured to removably engage with at least one rail element and a second portion of each modular base element is configured to be removably engaged with portions of the support frame, thereby forming at least one guard rail on the support frame.

Preferably, the support frame includes a plurality of longitudinal slat members, each of which includes a channel therein adapted to engage with the engagement portions of the modular rail elements and the second portions of the modular base elements.

Preferably, the channel also includes at least one entry region, which is adapted to allow the engagement portion of the modular rail elements and the second portion of the modular base elements to be inserted into the channel. Preferably, the engagement portion of the modular rail elements and the second portion of the modular base elements is a projection that is adapted to be inserted into the channel and slldably secured therein, thereby allowing the modular rail elements and modular base elements to be slid down the length of the longitudinal slat to a desired position. Preferably, the projection is a bolt having a substantially T-shaped cross- section formed by laterally projecting arms extending at the head of the bolt.

In one preferred embodiment, the first portion of each modular base element is a projection that is adapted to be inserted and secured in a complimentary groove located in each of the modular rail elements and the second portion of each modular base element is a bolt having a substantially T-shaped cross-section formed by laterally projecting arms extending at the head of the bolt. More preferably, the projection of the first portion has a substantially T- shaped cross-section.

Preferably, an end portion of each of the plurality of modular rail elements includes a recess, which is adapted to frictionally engage with a corresponding projection of a corner element or end element. According to yet another aspect of the present Invention there Is provided a method of constructing a load supporting structure which includes the steps of securing a support frame to a vehicle; and removably engaging an engagement portion of one or more modular rail elements with portions of the support frame to form at least one guard rail. According to a further aspect of the present invention there is provided a method of constructing a load supporting structure which Includes the steps of: securing a support frame to a vehicle; and removably engaging a second portion of one or more modular base elements with portions of the support frame, and removably engaging a first portion of the one or more modular base elements with at least one modular rail element.

In this specification, unless the context clearly indicates otherwise, the term "comprising" has the non-exclusive meaning of the word, in the sense of "including at least" rather than the exclusive meaning in the sense of "consisting only of. The same applies with corresponding grammatical changes to other forms of the word such as "comprise", "comprises" and so on.

BRIEF DESCRIPTION OF THE DRAWINGS Preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:

FIGS 1 through 6 show a load supporting structure provided in accordance with a preferred embodiment of the invention with various configurations of guard rails defined;

FIG 7 shows the construction of a support frame platform provided In accordance with the embodiments of FIGS 1 through 6;

FIG 8 shows a modular rail element employed in the embodiment shown with respect to FIGS 1 through 7; FIGS 9A and 9B show various views of a modular base element employed in the embodiment shown with respect to FIGS 1 through 8;

FIGS 10A and 10B shows various views of a corner component employed in the embodiment shown with respect to FIGS 1 through 9; and

FIGS 11A through lie shows various views and arrangements of an end assembly used in the embodiment shown with respect to FIGS 1 through 10.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present invention is adapted to provide a load supporting structure for a vehicle. Such load supporting structures can be used to carry various types of cargo on the exterior of the vehicle and potentially provides a greatly increased load carrying capacity of the vehicle.

Reference throughout this specification will be made to the present invention being employed in conjunction with road vehicles and In specific embodiments being used in relation to 4WD, utility or off road vehicles.

However, those skilled In the art should appreciate that the present invention may be used with a range of vehicle ranging from vans, cars, motor homes or any number of a range of road based vehicles. Potentially, the invention could also be used with water vessels or rail carriages in other embodiments If required.

The present invention incorporates a support frame which defines a platform on which cargo or loads may be placed to be supported. This support frame is connected to the vehicle, usually through a permanent connection system associated with the roof top area of the vehicle. In a preferred embodiment, a support frame may be formed by an array of slats aligned both transversely and longitudinally to form the body of the platform. This array of slats can also be surrounded and enclosed by a perimeter housing. The use of a slat type structure in the construction of the support frame substantially reduces the overall weight of the resulting structure and can minimise manufacturing costs.

Reference throughout this specification will generally be made to the present invention incorporating a support frame formed by an array of longitudinally and transversely aligned slats, which form a base platform. However, those skilled in the art should appreciate that other configurations and arrangements of support frames may also be employed with the present Invention if required.

The present invention incorporates a plurality of modular rail elements. These rail elements can be arranged in various configurations, shapes or forms on the platform to provide one or more guard raiis. Each of these rail elements Is provided with a modular form to allow the component to be mass produced, thereby reducing manufacturing costs. The present invention is arranged and configured so that these modular rail elements can be removably engaged with the support frame or base platform - being either removably connected directly to the base platform or indirectly to the platform through a further element or component.

In a further preferred embodiment, a modular rail element may be formed by a substantially straight length of material with an upper rounded surface and a flat under side surface. However, those skilled in the art should appreciate that the various forms, shapes or arrangement of different types of rail elements may also be used in conjunction with the present invention.

The rail elements may form at least one guard rail which defines or provides a barrier to loads moving during transportation when the vehicle is in transit. For example, such guard rails may be erected along the perimeter of the platform to maximise the carrying area of the support structure or alternatively may define a localised perimeter In a restricted region or area of the platform.

In some embodiments, a single guard rail may be provided which extends around the entirety of the platform. In another embodiment, a single guard rail may be provided which extends only around a portion of the platform, thereby enclosing an area of the platform.

In other embodiments, a single guard rail may be provided to divide up the surface area of the platform or potentially to prevent loads from moving over one edge only of the platform. In yet other embodiments, a pair of guard rails may be provided on opposite sides of the platform, leaving two open unguarded ends to the platform for relatively large or long loads to extend over the edge of the platform.

Those skilled in the art should appreciate that the modular nature of these rail elements, and the removable connection system provided, allows for a high degree of flexibility in terms of the shapes, forms and arrangements of guard rails that can be deployed on the platform of the present invention. In one alternative embodiment, the rail elements may be formed or arranged so as to connect directly to the upper surface of a support frame or platform. In such embodiments, a rail element may be formed by a relatively large or tall component, which has a height equal to the distance that the resulting guard rail extends above the platform.

However, in a preferred embodiment, a rail element may be indirectly engaged with the support frame or platform through the provision of a modular base element A base element may provide an intervening component between the platform and rail element to elevate the rail element above the support frame platform. Such base elements may be arranged so as to removably connect or engage with the platform and also to removably engage or connect with one or more rail elements.

In a preferred embodiment, the removable connection arrangement between the under surface of a rail element and a base may be provided through a channel, which is defined in the under side of a rail element with a restricted entry throat provided for this channel. A complimentary projection may be formed in the upper surface of a base element with a projecting head and narrow neck being provided in this projection. The head of this projection can be threaded through and into the channel defined in the rail and then be secured by the restricted throat of the channel. These components can then be disconnected from one another by sliding the base element out along the channel in the rail element and off or past the end of the rail element.

In a preferred embodiment, a removable connection arrangement may be provided between a base element and the support frame platform through a channel or trough formed in a section of one of the transverse or longitudinal slats of the platform. An entry aperture or opening with an increased span to that of the channel may be provided at one or more points along the length of a slat to allow for the entry of a locking lug, which is defined on the under side of a base element. This arrangement of the platform and base elements allows the locking tugs of the base elements to be introduced into one of a number of channels formed in the slats of the platform and to slide down to the appropriate position on the platform, where the base element is to be deployed. A number of such channels may be provided over the surface area of the platform to provide flexibility in the arrangements of guard rails on the platform.

In a preferred embodiment, the load supporting structure provided may also include further components in addition to the modular rail elements, the support frame platform and the modular base elements discussed above. For example, in some embodiments the load supporting structure may also incorporate or Include a number of modular end caps, which extend from an open end or face of a rail element down towards and into contact directly with the support frame platform, These end cap elements may close off the end of a rail element and provide the resulting structure with an aerodynamic form or shape and an aesthetically pleasing appearance. In yet other embodiments, the load supporting structure may also incorporate corner sections that are arranged to indirectly connect two or more rail elements at an angle to one another. For example, in one embodiment, a corner element may be provided to connect two adjacent rail elements together substantially at a right angle to one another. Such corner elements can preferably be formed with similar profiles and dimensions to the rail elements, thereby improving the aerodynamic performance of the resulting structure and also its aesthetic qualities.

In some embodiments, the platform may also be arranged to removably connect other forms of accessories, which do not provide portions of a guard rail. For example, in some embodiments, the connection system employed to engage components of the guard rail with the platform may be used to engage or connect accessories, such as a bicycle carrier, canoe or kayak carriers, conduit retention tubes or any number of different customised elements directly to the upper surface of the support frame platform. Those skilled in the art should appreciate a wide number and range of different types of accessories may readily be engaged with the support platform using the connection facility it provides.

FIGS 1 through 6 show a load supporting structure provided in accordance with a preferred embodiment of the present invention with various configurations of guard rails or rails defined.

A local supporting structure 1 is Illustrated. This structure is composed of, or incorporates, a support frame platform 2 formed from and incorporating a range of transverse and longitudinally aligned slat elements 3.

FIGS l to 6 show various arrangements of guard rails 4 applied to and constructed on the platform 2. These guard rails 4 are arranged to either define or enclose the entire area of the platform (FIG 1), a sub-area of the platform (FIG 2), to close the various side edges of the platform (FIGS 3 and 5) or to sub-divide the area of the platform into different regions (FIGS 4 and 6). As can be appreciated by those skilled in the art, the guard rails of the ioad supporting structure can be re-configured or re-arranged on demand depending on the requirements of the loads to be carried.

The construction of the guard rails 4 is illustrated with respect to the components shown in FIGS 8 through 11. In particular, FIG 8 shows an end view of a rail element 5, which in use is supported by the modular base element 6 shown with respect to FIGS 9A and 9B. Also incorporated is a corner assembly 10, which is best illustrated with respect to FIGS 10A and 10B, and an end assembly 11 as best illustrated with respect to FIGS HA through to lie. These various components make up a guard rail and can be removably engaged both with one another and also with portions of the support frame platform 2. FIGS 8 and 9A, 9B illustrate the removeable connection arrangement employed between the rail element and base elements through a channel with a restricted throat 12 in the rail element and upper projection 13 formed on the base element. FIGS 10 and 11 show how projections 14 in the ends of a corner assembly 10 or end assembly 11 can slot into a complimentary cavity formed In the end of a rail extension to removably engage with these components.

FIG 7 shows a detailed view of the arrangement of the upper surface of the support frame platform 2, and in particular the arrangement of a set of channels 15 and entry apertures 17 provided in the longitudinal slats 3 of the platform. As can be seen from FIG 7, these channels 15 run the length of each longitudinal slat 3, thereby allowing a complimentary projection (not shown) on the under surface of each base element 6 to be inserted - initially Into the channel 15 through an entry aperture 16. Each base element 6 can then slide down the length of the slat 3 to the desired position on the platform 2.

The complementary projections located on the underside of each base element 6 (not shown) can be formed in a preferred embodiment by a T-bolt, which is a bolt with a substantially T-shaped cross-section formed by laterally projecting arms extending at the head of the bolt. This T-bolt may be threaded through an aperture 17 formed in the base element, as shown in FIG 9b with the T-end of the bolt engaging with the underside of the channel formed in the platform tray 2. As can been seen from the Figures provided, the preferred embodiment of the invention illustrated allow a wide range of different types of guard rail forms or configurations to be deployed on the platform. The support frame platform 2 can also receive and removably engage with various other forms of accessory systems (not shown), providing the resulting load supporting structure with a high degree of flexibility compared with existing customised or static prior art systems.

It will be apparent that obvious variations or modifications may be made which are in accordance with the spirit of the invention and which are intended to be part of the invention, and any such obvious variations or modifications are therefore within the scope of the Invention.