Cargo carrier with aerodynamic illumination device

This application claims priority from U.S. Provisional Patent Application Ser. No. 61/240,121, filed Sep. 4, 2009 which is incorporated herein by reference. This application incorporates by reference the following: U.S. patent application Ser. Nos. 12/494,218, 11/606,638, 29/308,271 and U.S. Pat. No. 7,416,098.

The disclosed subject matter involves containers for carrying cargo on or in connection with a vehicle.

Cargo carriers, designed for clamping on a pair of crossbars mounted on top of a vehicle, continue to become more popular for increasing a vehicle's carrying capacity. External boxes provide a convenient compartment for carrying equipment or gear that may be desirably segregated from the main passenger compartment of the vehicle due to the shape or size of the cargo, or the fact that the cargo may be wet, dirty, etc. However, boxes present new challenges and problems to be addressed. For example, external boxes create extra drag creating noise and/or decreased efficiency (lower gas mileage). Boxes may make it difficult or impossible to safely drive in or under certain garages or parking structures due to their height above the vehicle. Boxes may also be difficult to access because of their location on top of a vehicle. It also may be difficult to view the interior of a cargo box due to its position or a lack of light. The box concepts described below may provide benefits and/or solutions to one or more of the problems mentioned above, among others.

A cargo box is configured for mounting on a pair of crossbars on top of a vehicle. A box includes a bottom portion equipped with clamps for mounting on a pair of crossbars. A lid is connected via hinge/latch assemblies, either on one or both, lateral sides of the bottom portion of the box.

A receptacle may be provided in the lid of a cargo box for receiving a photovoltaic light device. The receptacle is configured to receive and support the light device substantially below and/or flush with the outer surface of the lid.

FIG. 1 is a perspective view of a cargo box mounted on a pair of cross bars on top of a vehicle.

FIG. 2 is an end elevation view of the cargo box shown in FIG. 1 .

FIG. 3 is an upward perspective view of the interior of the lid of the box shown in FIGS. 1 and 2 .

FIG. 4 is a partial cross-sectional view through the lid shown in FIG. 3 illustrating inner components of a lid light.

FIG. 5 is a partial perspective view of the lid light shown in FIGS. 3 and 4 .

FIG. 1 shows the roof of vehicle 20 equipped with a pair of crossbars 24 a , 24 b . Crossbars 24 a , 24 b are mounted on vehicle 20 via towers 28 a - d . Cargo box 30 is mounted on crossbars 24 a , 24 b via clamps (not shown). Examples of clamps suitable for securing box 30 to crossbars 24 a , 24 b are disclosed in U.S. Pat. No. 6,918,521, which is hereby incorporated by reference.

Photovoltaic lid light device 34 is shown mounted in the lid of cargo box 30 . Lid light 34 may be mounted centrally, approximately equidistant from the front and the back of box 30 , and approximately equidistant from the lateral sides of box 30 . Alternatively, lid light 34 may be positioned in other locations, forward, backward, or side-to-side, in the lid of cargo box 30 . Further, although only one lid light is shown, multiple lid lights may be provided in the lid of cargo box 30 . Lid light device 34 , as shown in FIG. 1 , has an outer circular shape 38 . Rectangular photovoltaic panel 42 is also visible from the top view.

FIG. 2 shows an end view of cargo box 30 including bottom portion 34 and lid 38 . Cord 42 is provided for assisting with closing of lid 38 . Lid 38 is hinged along each lateral side of bottom portion 34 . An example of hinges, which alternatively function as latches, are shown in U.S. Pat. No. 7,503,470 which is hereby incorporated by reference. Other examples of hinge/latch devices which may be used to provide a dual-side opening box, as shown in FIG. 2 , are shown in U.S. Pat. No. 7,740,157 and U.S. patent application Ser. No. 12/494,218 each of which is hereby incorporated by reference. FIG. 2 shows lid 38 pivoted into an open position, providing access to the interior of cargo box 30 when loading or unloading the box. Lid 38 is also shown in dashed lines opened to the opposite side. The overall height profile of cargo box 30 is preferably shallow or short, for example, about 11.5-inches, compared to other cargo boxes, to provide maximum clearance and minimize the risk of collision with garages or other overhead structures.

FIG. 3 shows the interior of lid 38 . Lid 38 has opposing lateral sides 44 a , 44 b . Each of sides 44 a , 44 b has one or more hinge/latch components for providing dual-side opening capability. For example, as shown in FIG. 3 , side 44 a of lid 38 has hinge/latch components 50 a - c . Similarly, side 44 b of lid 38 has hinge/latch components 54 a - c.

Lid 38 also has circumferential rim 56 which fits over the upper edge portion of bottom portion 34 , as shown in FIG. 2 , for preventing rain from entering the closed box, and for providing overall form stiffness to lid 38 . Additionally, one or more stiffening structures may be secured to the interior surface of lid 38 . For example, as shown in FIG. 3 , three stiffening structures 58 a - c are mounted in a parallel configuration, substantially perpendicular to the long axis of lid 38 . Additional stiffening features may be employed, for example, as disclosed in U.S. patent application Ser. No. 11/606,638, which is hereby incorporated by reference. As shown in FIG. 3 , lid light 34 includes semi-spherical light compartment 62 , which descends from electronic compartment 66 . Electronic compartment 66 is circumsurrounded by circular edge portion 70 .

FIG. 4 shows a cross-sectional view through lid light assembly 34 . The cross-sectional cut is taken in a direction parallel with the long axis of box 30 . Lid 38 has a recessed form configured to receive the lid light assembly so that, when the lid light is installed, it is substantially flush with the exterior surface of lid 38 . The lid receptacle (recessed form) has outer circular edge 80 . Edge 80 descends to a circular first step 84 . Graduated wall 88 descends from first step 84 . Graduated wall 88 has a generally rectangular shape, as shown in FIG. 5 . Graduated wall 88 merges into floor portion 92 . Circular aperture 94 is defined in floor portion 92 .

The lid receptacle receives cup assembly 100 which contains power, electronics, and lights for illuminating the interior of the box. Cup assembly 100 may be made of a transparent plastic material, for example, polycarbonate.

Cup assembly 100 includes cup portion 104 , which mainly contains lights and electronics, and is mated to top portion 108 which contains and supports a solar cell. Top portion 108 is circular and dimensioned to seat on first step 84 of the lid receptacle. Top portion 108 is sealed and bonded to first step 84 by an adhesive, for example, foam/double-stick tape running continuously around the circumference of the light assembly. Rectangular photovoltaic cell 42 is contained behind a transparent lens in top portion 108 . In a preferred embodiment, the photovoltaic cell is a standard cell commercially available from Sollight from Hood River, Oreg. Top portion 108 may be secured to cup portion 104 by screws (not shown). Gasket 112 is provided to seal top portion 108 to cup portion 104 . Cup assembly 100 has two main compartments, namely, generally rectangular electronic compartment 114 , and semi-spherical light compartment 116 . Electronic compartment 114 contains circuit board 120 and rechargeable battery 124 . Battery 124 is connected to, and rechargeable by, photovoltaic cell 42 . Other electronic components are included, but are not shown in FIG. 4 . For example, tilt sensors maybe provided for automatically switching the light on when lid 38 pivots to an open position, from either side of box 30 . Tilt sensors/switches may also automatically turn the light off when the lid pivots back to its closed position (horizontal). Further, the device may be programmed to automatically turn off the light after the box has remained open beyond a certain period of time.

Electronic compartment 114 also has post 125 for receiving a screw from the interior of the lid for securing light 34 in lid 38 . Other post and screw structures, preferably at least one more, may be provided for fastening the light to the lid along with the double-sided adhesive strip, previously described relative to the first step of the receptacle. Light compartment 116 includes convex frame structure 130 for anchoring an array of LED lights 136 . In a preferred embodiment as shown in FIGS. 4 and 5 , an array of LED lights 136 includes eight light elements in an array which alternates between a pair and a single light, for example, 2:1:2:1:2. The array may include a combination of spot and flood lights for providing optimal illumination over the longitudinal area inside a cargo box. For this purpose, a preferred array configuration has a substantially rectangular shape aligned with the rectangular shape of the box. A preferred light pattern array uses LED spotlights directed toward the ends of the box, and LED floodlights directed toward the middle portion of the box. For example, a preferred array uses a pair of spotlights, then one floodlight, then a pair of floodlights, then a single floodlight, then a pair of spotlights.

The light device may be programmed to conserve battery life by automatically switching off the light after a period of time, for example, 45-minutes. The tilt switch may be configured to work in any axis. For example, when the light is 15-degrees from horizontal in any direction, it turns on.

FIG. 5 shows a close-up perspective view of light 34 mounted in lid 38 . The receptacle in lid 38 includes outer edge 80 surrounding first step 84 . Graduated wall portion 88 is substantially rectangular, and descends from first step 84 . Floor portion 92 provides a ledge for seating the bottom side of electronics compartment 114 . Light compartment 116 descends through aperture 94 in floor portion 92 . Light array 136 is configured, as described above, for providing optimal lighting to the interior space of cargo box 30 .

In a preferred cargo box embodiment, the box weighs approximately 52 pounds. The box is approximately 92-inches long, 36-inches wide and 11.5-inches tall. A preferred box design has approximately 15 cubic feet of capacity, and may be made of ABS plastic or fiberglass.

The various structural members disclosed herein may be constructed from any suitable material, or combination of materials, such as metal, plastic, nylon, plastic, rubber, or any other materials with sufficient structural strength to withstand the loads incurred during use. Materials may be selected based on their durability, flexibility, weight, and/or aesthetic qualities.

It is believed that the following claims particularly point out certain combinations and subcombinations that are directed to one of the disclosed inventions and are novel and non-obvious. Inventions embodied in other combinations and subcombinations of features, functions, elements and/or properties may be claimed through amendment of the present claims or presentation of new claims in this or a related application. Such amended or new claims, whether they are directed to a different invention or directed to the same invention, whether different, broader, narrower or equal in scope to the original claims, are also regarded as included within the subject matter of the inventions of the present disclosure.