Stamped roof rail for vehicle article carrier and method of making same

1. A vehicle article carrier system for securing articles above an outer body roof surface of a vehicle, wherein the outer body roof surface includes a pair of roof ditches formed therein that extend generally parallel to one another along a major longitudinal length of the vehicle, the vehicle article carrier system comprising:

a pair of support rails adapted to be secured to the outer body roof surface within respective ones of the roof ditches;

at least one cross bar configured to be secured to the support rails to extend generally perpendicularly between the support rails, the at least one cross adapted to support articles thereon above the outer body roof surface;

each one of said pair of support rails being formed from a stamping process and including:

a bottom wall;

a pair of sidewalls extending from the bottom wall;

an upper wall extending from the pair of sidewalls;

a cross bar mounting portion extending from at least one of the sidewalls and the upper wall, the cross bar mounting portion forming a structural component to which a portion of the cross bar may be attached to support the cross bar in an operative position;

at least the bottom wall and portions of the sidewalls being formed with a cross sectional shape in close accordance with a cross sectional shape of its respective said roof ditch to nest within its respective said roof ditch; and

a fastener for securing the bottom wall to its respective said roof ditch, and wherein the cross sectional shape of the support rail and its nested mounting within its respective said roof ditch serves to enhance a structural strength of the outer body roof surface.

2. The vehicle article carrier of claim 1 , wherein the support rail is formed from a single piece of metallic material.

3. The vehicle article carrier of claim 1 , further comprising a pair of decorative plastic covers, with each said decorative plastic cover adapted to be secured to a respective one of the support rails.

4. The vehicle article carrier of claim 3 , further comprising a plurality of fastening elements for securing each said decorative plastic cover to its respective said support rail.

5. The vehicle article carrier of claim 1 , wherein each said cross bar mounting portion includes at least one integrally formed gusset for enhancing structural strength thereof.

6. The vehicle article carrier of claim 1 , wherein each said cross bar mounting portion includes at least one hole adapted to receive an external fastening element for fastening one end of the cross bar thereto.

7. The vehicle article carrier of claim 1 , wherein portions of the upper wall of the support rail overlap one another.

8. The vehicle article carrier of claim 1 , wherein the upper wall includes a plurality of access holes for enabling access to at least one of said fastener or a securing element being used with said fastener to fasten the support rail to the outer body roof surface.

9. The vehicle article carrier of claim 1 , wherein said fastener is positioned in said bottom wall to generally align with a pillar of the vehicle, such that forces experienced by said support rail are able to be transferred through the fastener to the pillar of the vehicle.

10. The vehicle article carrier of claim 1 , wherein a plurality of spaced apart fasteners are disposed in said bottom wall and located such that at least a pair of the fasteners are generally aligned with a plurality of pillars of the vehicle such that forces experienced by said support rail are able to be transferred though the fasteners to the pillars of the vehicle.

11. A vehicle article carrier system for securing articles above an outer body roof surface of a vehicle, wherein the outer body roof surface includes a pair of roof ditches formed therein that extend generally parallel to one another along a major longitudinal length of the vehicle, the vehicle article carrier system comprising:

a pair of support rails adapted to be secured to the outer body roof surface within respective ones of the roof ditches;

at least one cross bar configured to be secured to the support rails to extend generally perpendicularly between the support rails, the at least one cross adapted to support articles thereon above the outer body roof surface;

each one of said pair of support rails being formed from a stamping process from a single piece of material and including:

a bottom wall having structure enabling it to be secured to said outer body roof surface;

a pair of sidewalls extending from the bottom wall;

an upper wall extending from the pair of sidewalls;

a cross bar mounting portion extending outwardly from at least one of the sidewalls and the upper wall, the cross bar mounting portion projecting above the upper wall and forming a structural component to which a portion of the cross bar may be attached to support the cross bar in an operative position;

at least the bottom wall and portions of the sidewalls being formed with a cross sectional shape in close accordance with a cross sectional shape of its respective said roof ditch to nest within its respective said roof ditch; and

wherein the cross sectional shape of the support rail and its nested mounting within its respective said roof ditch serves to enhance a structural strength of the outer body roof surface when the support rail is fixedly attached to its respective said roof ditch.

12. The vehicle article carrier of claim 11 , wherein the structure of the bottom wall includes a hole adapted to receive an external fastener, the external fastener fastening the support rail securely within its respective said roof ditch.

13. The vehicle article carrier of claim 11 , wherein said structure of the bottom wall includes a plurality of spaced apart holes adapted to receive a corresponding plurality of external fasteners.

14. The vehicle article carrier of claim 11 , wherein the structure of the bottom wall includes a plurality of holes, and wherein at least one of the holes is positioned to generally align with a placement of one of a plurality pillars of the vehicle, to thus enable a transfer of force generally through the one pillar by an external fastening element used to secure the support rail in said respective roof ditch.

15. The vehicle article carrier of claim 11 , wherein a plurality of the holes are located to align with a plurality of pillars of the vehicle.

16. A vehicle article carrier system for securing articles above an outer body roof surface of a vehicle, wherein the outer body roof surface includes a pair of roof ditches formed therein that extend generally parallel to one another along a major longitudinal length of the vehicle, the vehicle article carrier system comprising:

a pair of support rails adapted to be secured to the outer body roof surface within respective ones of the roof ditches;

at least one cross bar configured to be secured to the support rails to extend generally perpendicularly between the support rails, the at least one cross bar adapted to support articles thereon above the outer body roof surface;

each one of said pair of support rails being formed from a stamping process from a single piece of material and including:

a bottom wall having first structure enabling it to be secured to said outer body roof surface;

a pair of sidewalls extending from the bottom wall;

an upper wall extending from the pair of sidewalls, the upper wall having second structure enabling the at least one cross bar to be secured thereto and supported from the upper wall;

at least the bottom wall and portions of the sidewalls being formed with a cross sectional shape in close accordance with a cross sectional shape of its respective said roof ditch to nest within its respective said roof ditch; and

wherein the cross sectional shape of the support rail and its nested mounting within its respective said roof ditch serves to enhance a structural strength of the outer body roof surface when the support rail is fixedly attached to its respective said roof ditch.

17. The vehicle article carrier of claim 16 , wherein the second structure of the upper wall includes an opening adapted to engage with a portion of an external fastening element associated with the at least one cross bar.

18. The vehicle article carrier of claim 16 , wherein a seam is formed along the bottom wall of the support rail.

19. The vehicle article carrier of claim 16 , wherein the first structure includes a plurality of holes adapted to be used with external fastening elements to fasten the bottom wall within its respective said roof ditch.

20. The vehicle article carrier of claim 19 , wherein the plurality of holes is configured such that specific ones of said plurality of holes are located generally in line with a plurality of pillars of a body of the vehicle.