SLOTTED CROSSBAR
A slotted crossbar may include an upper slot and a lower slot running continuously across the entire length of the crossbar. Internal channels associated with the upper and lower slots may be structurally independent, such that a floor of the upper channel is spaced from a ceiling of the lower channel. An illustrative slotted crossbar may be manufactured using an aluminum extrusion process.
1 . A crossbar for a vehicle rooftop cargo rack, the crossbar comprising:
an elongate metal body having a first end, a second end, and an aerodynamic outer profile defining an upper surface and a lower surface of the body;
a continuous first slot running lengthwise across the upper surface from the first end to the second end; and
a continuous second slot running lengthwise across the lower surface from the first end to the second end.
2 . The crossbar of claim 1 , wherein the first slot opens into a first continuous channel running lengthwise through the body of the crossbar, the first channel having a floor.
3 . The crossbar of claim 2 , wherein the second slot opens into a second continuous channel running lengthwise through the body of the crossbar, the second channel having a ceiling.
4 . The crossbar of claim 3 , wherein the floor of the first channel and the ceiling of the second channel are spaced from each other.
5 . The crossbar of claim 1 , further comprising a plurality of lengthwise internal cavities passing continuously through the body, the body including a pair of spaced-apart vertical webs spanning an internal height of the body, such that the plurality of lengthwise internal cavities includes a forward cavity, a central cavity, and an aft cavity.
6 . The crossbar of claim 1 , wherein the first slot is horizontally offset relative to the second slot. The crossbar of claim 1 , wherein the lower surface of the body is curved.
8 . The crossbar of claim 1 , wherein a first wall thickness of a top portion of the body is greater than a second wall thickness of a leading edge portion of the body.
9 . A rack for carrying cargo on top of a vehicle, the rack comprising:
a crossbar and a pair of couplers configured to mount the crossbar on top of a vehicle such that a long axis of the crossbar is substantially horizontal and perpendicular to a longitudinal axis of the vehicle;
the crossbar including an elongate metal body having a first end, a second end, and an aerodynamic outer profile defining an upper surface and a lower surface of the body;
a continuous first slot running lengthwise across the upper surface of the body of the crossbar from the first end to the second end, the first slot opening into a first channel; and
a continuous second slot running lengthwise across the lower surface of the body of the crossbar from the first end to the second end, the second slot opening into a second channel;
wherein the first channel and the second channel are structurally independent from each other.
10 . The rack of claim 9 , wherein each coupler of the pair of couplers is configured to be clamped to the second slot of the crossbar.
11 . The rack of claim 9 , the crossbar further comprising a plurality of lengthwise internal cavities passing continuously through the body of the crossbar, and a pair of spaced-apart vertical webs spanning an internal height of the crossbar, such that the plurality of lengthwise internal cavities includes a forward cavity, a central cavity, and an aft cavity.
12 . The rack of claim 9 , wherein the first slot is horizontally offset relative to the second slot.
13 . The rack of claim 9 , further comprising a first infill member disposed in the first slot, the first infill member including a deformable resilient tube.
14 . The rack of claim 9 , further comprising a second infill member covering the second slot, the second infill member being selectively removable from the second slot.
15 . A method of manufacturing a crossbar for a vehicle rooftop cargo rack, the method comprising:
extruding an aluminum bar having a first end, a second end, and an elongated profile defining an upper surface and a lower surface of the bar;
wherein the extruding step includes forming a plurality of lengthwise internal cavities passing continuously through the bar,
a continuous first slot running lengthwise across the upper surface of the bar from the first end to the second end, the first slot opening into a first channel, and
a continuous second slot running lengthwise across the lower surface of the bar from the first end to the second end, the second slot opening into a second channel that is structurally independent from the first channel.
16 . The method of claim 15 , wherein the first channel has a floor and the second channel has a ceiling, the floor and ceiling being generally parallel and spaced from each other.
17 . The method of claim 15 , wherein the extruding step further forms a pair of spaced-apart vertical webs spanning an internal height of the bar, such that the plurality of lengthwise internal cavities includes a forward cavity, a central cavity, and an aft cavity.
18 . The method of claim 15 , wherein the extruding step further forms a longitudinal ridge protruding from a leading edge portion of the bar, the ridge being disposed above a vertex of the leading edge portion.
19 . The method of claim 15 , wherein a first wall thickness of a top portion of the bar is greater than a second wall thickness of a leading edge portion of the bar.
20 . The crossbar of claim 15 , wherein the elongated profile of the bar is aerodynamic.