DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0035] With reference to the figures where like elements have been given like numerical designations to facilitate the reader's understanding of the present invention, and particularly with reference to the embodiment of the pickup truck utility rack of the present invention illustrated in the figures, the preferred embodiments of the present invention are set forth below. The enclosed figures and drawings are merely illustrative of the preferred embodiments and represent several different ways of configuring the present invention. Although specific components, materials, configurations and uses of the present invention are illustrated and set forth in this disclosure, it should be understood that a number of variations to the components and to the configuration of those components described herein and in the accompanying figures can be made without changing the scope and function of the invention set forth herein.

[0036] As best shown in FIGS. 1 and 2 , the pickup truck utility rack of the present invention, identified generally as 10 and comprising generally a first rack assembly 12 and a second rack assembly 14 , is for use on pickup truck 16 . Pickup truck 16 has a cab portion 18 and a rear cargo area 20 located rearward of cab portion 18 . The rear cargo area 20 has a generally horizontal load bearing bed 22 that is bounded on its periphery by upstanding forward wall 24 , tailgate 26 and opposing sidewalls 28 and 30 . As is typical for pickup trucks 16 , each of sidewalls 28 and 30 has a bedrail 32 at the top thereof that comprises a generally planar upper edge 34 and an inwardly disposed lip 36 . The typical bedrail 32 may have one or more stake pockets 38 located thereon. First 12 and second 14 rack assemblies are positioned on bedrail 32 in spaced apart relationship, as shown in FIG. 1 , and configured to support ladders, pipe, lumber, canoes and other cargo (not shown) generally above rear cargo area 20 and cab 18 , as shown in FIG. 2 . As described in more detail below, first rack assembly 12 and second rack assembly 14 can be moved anywhere along bedrail 32 to change the spacing therebetween and between first rack assembly 12 and cab 18 and second rack assembly 14 and tailgate 26 (the rearward end of truck 16 ) where it is necessary and/or convenient for them to be located so as to support the desired cargo on truck 16 .

[0037] The utility rack 10 of the present invention has two different embodiments of first rack assembly 12 and second rack assembly 14 , one being suitable for use as the rack and the other for use as the rack and as a sawhorse that can be removed from pickup truck 16 and utilized on the ground or other desired surface in the known manner of using sawhorses. As shown in FIG. 1 , utility rack 10 can comprise a combination of the standard rack component (i.e., first rack assembly 12 ) and the sawhorse rack component (i.e., second rack assembly 14 ) or it can comprise two of the standard rack components (first rack assembly 12 ) or two of the sawhorse rack components (second rack assembly 14 ). As explained in more detail below, a utility rack 10 with at least one sawhorse component allows the user to use utility rack 10 to carry cargo and then take the sawhorse component off of pickup truck 16 and utilize it as a sawhorse. In either configuration, the primary, larger components are configured to be collapsible for easy installation, removal and storage.

[0038] In the preferred embodiment, best shown in FIGS. 1, 3 and 12 , first rack assembly 12 and second rack assembly 14 generally comprise an elongated main body member 40 , first support assembly 42 and second support assembly 44 . For both rack assemblies 12 and 14 , first support assembly 42 is located at first end 46 of main body member 40 and second support assembly 44 is located at the opposing second end 48 of main body member 40 to support first rack assembly 12 and second rack assembly 14 above rear cargo area 20 on pickup truck 16 . In the preferred embodiments of the present invention, as shown in the figures, first support assembly 42 and second support assembly 44 are attached to main body member 40 , also referred to as a spanner, and configured so as to transversely support main body member 40 in a substantially horizontal position above bed 22 of pickup truck 16 . In one configuration, as shown FIGS. 1 and 2 , main body member 40 transversely spans substantially the entire width of bed 22 .

[0039] Various materials and component connection mechanisms can be used for the components of utility rack 10 of the present invention. For instance, main body member 40 , first support assembly 42 and second support assembly 44 can be made out of metal, fiberglass, composites, certain plastics and various other materials and combinations of materials that have sufficient strength, rigidity, durability and corrosion resistance for utility rack 10 of the present invention. If desired, coated or covered materials can be used to provide the necessary corrosion resistance for use as an apparatus exposed to the outside elements. It is necessary that the material for main body member 40 be selected so as to be sufficiently strong to support the cargo desired to be transported on utility rack 10 with pickup truck 16 . In the preferred embodiment, the primary components are made out of metal, such as powder coated steel, stainless steel or aluminum.

[0040] Utility rack 10 of the present invention requires the use of at least two rack assemblies (i.e., as shown in FIG. 1 ) to support the cargo above bed 22 . As stated above, however, it is not necessary that the rack assemblies 12 and 14 be of the same configuration. In one embodiment of the utility rack 10 of present invention, shown in FIG. 1 , utility rack 10 has a first rack assembly 12 configured as a rack only and a second rack assembly 14 configured for use as a sawhorse. Alternatively, both types of rack assemblies can be used for either first 12 or second 14 rack assemblies. For purposes of discussion below, without intending to limit the utility rack 10 of the present invention 10 thereby, first rack assembly 12 is a rack-only component and second rack assembly 14 is a rack/sawhorse component.

[0041] Although first rack assembly 12 can be configured with a particular, fixed length of main body member 40 to fit a specific width bed 22 , the preferred embodiment of first rack assembly 12 of the present invention has main body member 40 configured to be longitudinally adjustable in length so that a single rack assembly 12 may be utilized on a variety of different sized pickup trucks 16 having different widths of bed 22 . In a preferred embodiment, best shown in FIGS. 3 and 4 , main body member 40 is comprised of two or more separate tubular substructures, such as first telescoping member 50 and second telescoping member 52 , that cooperate together in a telescoping manner to allow the user to lengthen or shorten the longitudinal length of main body member 40 to fit different sizes of bed 22 . First telescoping member 50 has first end 54 and second 56 and second telescoping member 52 has first end 58 and second end 60 , as shown in FIG. 4 . In the preferred configuration, second telescoping member 52 is a generally square tubular member that is sized and configured to have a smaller cross-section than first telescoping member 50 so that first end 58 is insertably received in second end 56 of first telescoping member 50 , which is also a generally square tubular member (although other shapes can be utilized). Different lengths of main body member 40 for different sized rear cargo areas 20 can be achieved by sliding second telescoping member 52 in and out of first telescoping member 50 so as to be received in first telescoping member 50 . As known in the art, a set screw 61 or other clamping member can be utilized to lock first telescoping member 50 to second telescoping member 52 so as to fix the length of main body member 40 . By preventing movement of first telescoping member 50 relative to second telescoping member 52 , use of set screw 61 reduces vibration of first rack assembly 12 .

[0042] First end 54 of first telescoping member 50 attaches to first support assembly 42 and second end 60 of second telescoping member 52 attaches to second support assembly 44 , as best shown in FIG. 3 . To allow for flexibility as to which support assembly 42 or 44 is used on which side of bed 22 , it is preferred that first end 54 of first telescoping member 50 have the same cross-sectional shape and size as second end 60 of second telescoping member 52 . This can be achieved by providing a reduced cross-section portion 62 at first end 54 of first telescoping member 50 . In the preferred embodiment, the cross-sectional shape and size of reduced cross-section portion 62 is substantially the same as second telescoping member 50 . Reduced cross-section portion 62 can be a separate component that is fixedly attached to first telescoping member 50 by welding or by the use of adhesives, bolts, screws, rivets or other connectors, or by other forms of joining two members of different cross-sectional sizes that are known in the art. Alternatively, first telescoping member 50 can be a single member that has reduced cross-section portion 62 cut or otherwise manufactured from that single member. The length of reduced cross-section portion 62 must be sufficient enough in order to maintain the alignment of the first telescoping member 50 in first support assembly 42 . When properly configured with the reduced cross-section portion 62 being substantially the same cross-sectional shape and size as second telescoping member 52 , first end 46 and second end 48 of main body member 40 can be interchangeable between first 42 and second 44 support assemblies.

[0043] As explained in more detail below, first end 46 and second end 48 of main body member 40 are each provided with a pair of holes to facilitate the function of first support assembly 42 and second support assembly 44 . In the preferred embodiment, best shown in FIG. 5 , the bottom side 63 of the ends 46 and 48 of main body member 40 has a generally square bottom hole 64 and the top side 65 of the ends 46 and 48 of main body member 40 has a generally circular top hole 66 . Bottom hole 64 is centered directly below top hole 66 and both holes 64 and 66 are shaped to correspond with other aspects of first support assembly 42 and second support assembly 44 . In the preferred embodiment, bottom hole 64 and top hole 66 are located on the reduce cross-section portion 62 at the first end 54 of first telescoping member 50 . When fully assembled, main body member 40 forms a complete transverse member that has vertically aligned holes 64 and 66 at its first 46 and second 48 ends.

[0044] First support assembly 42 and second support assembly 44 cooperate together to support main body member 40 above bed 22 of pickup truck 16 . In the preferred embodiment, first support assembly 42 and second support assembly 44 will be configured the same and, as a result, reference will be made only to first support assembly 42 . However, all such references shall apply equally to second support assembly 44 at second end 48 of main body member 40 , except that as necessary for second end 48 and right sidewall 30 . In the preferred embodiment of first support assembly 42 of utility rack 10 generally comprises a receiver member 68 , one or more leg members 70 , base 72 and clamp assembly 74 . In the preferred embodiment, receiver member 68 , leg members 70 and base 72 are square tubular members. Receiver member 68 has first end 76 attached to leg members 70 and clamp assembly 74 . Open second end 78 of receiver member 68 is sized and shaped to slidably receive first end 46 of main body member 40 . As described below, to facilitate operation of clamping assembly 74 of the preferred embodiment, first end 76 of receiver member 68 has bottom hole 80 on its bottom side 81 and top hole 82 on its top side 83 . When first end 46 of main body member 40 is inserted inside receiver member 68 , holes 64 and 66 at first end 46 of main body member 40 align with holes 80 and 82 of receiver member 68 to provide a straight path through both main body member 40 and receiver member 68 . As best shown in FIGS. 7 and 8 , in the preferred embodiment upper end 84 of leg members 70 attach at or about the middle of receiver member 68 . As known to those skilled in the art, leg member 70 can be welded, bolted, riveted or otherwise fixedly attached to receiver member 68 .

[0045] The lower end 86 of each leg member 70 connects to base member 72 . In the preferred embodiment, best shown in FIG. 8 , lower ends 86 of leg members 70 have a connecting element 88 that removably connects to base member 72 to allow base member 72 to flex or pivot as necessary when upper edge 34 of bedrail 32 is not horizontal relative to bed 22 so as to maintain a generally parallel planar relationship (i.e., parallel and abutting planes) between base member 72 and upper edge 34 of bedrail 32 . In the preferred embodiment, connecting element 88 is a snap button connector, which protrudes from a hole (not shown) at lower end 84 of leg members 70 , that is sized and configured to fit within opening 90 , best shown in FIG. 9 , at one end of base member 72 . Connecting element 88 on lower end 86 of leg members 70 pass through opening 90 into base member 72 and is held in place in base member 72 by the snap buttons which protrude from leg members 70 into base member 72 , which as described below mounts to bedrail 32 . Although leg members 72 are prevented from disengaging from base member 72 by connecting element 88 , base member 72 can pivot around the axis of the snap buttons to allow the angle of base member 72 to generally conform (i.e., planar relationship) with the angle of upper edge 34 of bedrail 32 . Base member 72 is prevented from sliding off bedrail 32 toward the outside of pickup truck 16 by the channel-shaped member 92 welded at or near the center of the inside surface of base member 72 . Channel member 92 contacts the inside edge of bedrail 32 . The angle formed by the receiver member 68 and leg members 70 of the first support assembly 42 is useful, for while receiver member 68 receives first end 46 of main body member 40 , and orients it so that it is generally horizontal to bed 22 , leg members 70 are not exactly perpendicular to the bed 22 . The plane formed by leg members 70 and base member 72 , although generally vertical, is canted several degrees (i.e., one to fifteen degrees or more) from the vertical, leaning toward the centerline of pickup truck 16 . Since there are support assemblies 42 and 44 on opposing sides of pickup truck 16 , the support assemblies 42 and 44 lean toward each other and the inside open ends of each short tube of receiver member 68 face each other, thereby providing much improved support and lateral stability for first rack assembly 12 and, overall, utility rack 10 .

[0046] Clamp assembly 74 is configured to hold first support assembly 42 and main body member 40 together and hold first support assembly 42 to bedrail 32 of pickup truck 16 . In the preferred embodiment of the present invention, as best shown in FIG.10 , clamp assembly 74 comprises a generally square clamp tube 94 with a threaded shank member 96 at upper end 98 and hook member 100 at lower end 102 , a spacer 104 and nut tube 106 . Clamp tube 94 has a cross-sectional configuration that is slightly smaller than the square bottom 80 and top 82 holes in receiver member 68 and the square bottom hole 64 in main body member 40 and slightly larger than the round top hole 66 on main body member 40 , as set forth above, such that clamp tube 94 will pass through square bottom hole 80 in receiver member 68 and square bottom hole 64 in main body member 40 , but not through the round top hole 66 in main body member 40 . The use of square cross-section for clamp tube 94 and square holes 64 and 80 prevents rotation of clamp tube 94 , which helps prevent sliding of base member 72 and improves stability of first rack assembly 12 . Threaded shank member 96 is sized and configured to pass through round top hole 66 in main body member 40 and the square top hole 82 in receiver member 68 to protrude above receiver member 68 , as shown in FIGS. 2 and 6 . Clamp tube 94 aligns generally perpendicular to bed 22 so as to pass through channel-shaped member 92 attached to base member 72 . Hook member 100 , which as shown in FIG. 10 can comprise a generally “L” shaped bracket welded to lower end 102 of clamp tube 94 , is configured to go around and under lip 36 of bedrail 32 . The interior walls of channel-shaped member 92 enclose lower end 102 of clamp tube 94 to prevent it from moving laterally along base member 72 .

[0047] When first rack assembly 12 of utility rack 10 is mounted on bedrail 32 of pickup truck 16 , a portion of hook member 100 contacts the underside of bedrail 32 , which prevents clamp tube 94 from moving away from bedrail 32 toward the center of bed 22 . The length of clamp tube 94 is selected such that when hook member 100 is in contact with the underside of bedrail 32 , a small gap exists between the base of threaded shank 96 of clamp tube 94 and the round top hole 82 of receiver member 68 . Spacer 104 , which is configured like a washer or plate with a center-located hole, provides a stand-off between the lower end of nut tube 106 and top side 83 of receiver member 68 . The outside diameter of spacer 104 is smaller than the dimensions of the square top hole 82 in receiver member 68 , but larger than the diameter of the round top hole 66 on main body member 40 . When assembled, spacer 104 rests within the perimeter of the square top hole 82 on receiver member 68 and on top side 65 of main body member 40 at the round top hole 66 with threaded shank 96 passing through spacer 104 . Nut tube 106 , which comprises a short tubular member with a nut welded on to or threads tapped into the bottom end of the tubular member, is configured to threadably engage threaded shank 96 , as shown in FIG. 6 . When assembled, nut tube 106 is tightened down onto threaded shank 96 on clamp tube 94 to compress spacer 104 against top side 65 of main body member 40 so as to draw up clamp tube 94 until hook member 100 at lower end 102 of clamp tube 94 securely contacts the underside surface of bedrail 32 . Preferably, there is no contact between the lower edge of lip 36 and hook member 100 to prevent bending or otherwise damaging lip 36 . In addition to providing the clamping effect of first support assembly 42 , nut tube 106 of the preferred embodiment helps prevent cargo on first rack assembly 12 of utility rack 10 from sliding off the ends of main body member 40 .

[0048] When installed on bedrail 32 of pickup truck 16 , base member 72 of first 42 and second 44 support assemblies sits flush on top of upper edge 34 and is pivoted to reflect the possible non-horizontal configuration of the upper edge 34 of bedrail 32 . First 42 and second 44 support assemblies are generally configured in a triangle-shape that resists compression and the forward and backward sheer forces to support main body member 40 in a generally horizontal position above bed 22 for carrying cargo on utility rack 10 . Clamping assembly 74 ties main body member 40 and first support assembly 42 (or second support assembly 44 as the case may be) together to bedrail 32 . Installation and removal of first rack assembly 12 on or off pickup truck 16 is made relatively simple by the various interconnecting components that are configured so as to not require any drilling or other modification to pickup truck 16 . Because none of the various components is individually required to be very long, first rack assembly 12 can be easily stored when not in use on pickup truck 16 .

[0049] In one configuration of utility rack 10 of the present invention, second rack assembly 14 is configured the same as first rack assembly 12 described above. In this manner, various cargo can be carried on utility rack 10 above rear cargo area 20 . In another preferred configuration, at least second rack assembly 14 is a sawhorse component (can be both rack assemblies 12 and 14 ) that can be removed from pickup truck 16 and placed on the ground to be used as a conventional sawhorse. When the user has completed his or her task, the sawhorse component is easily re-installed as second rack assembly 14 to complete utility rack 16 so as to carry any desired cargo.

[0050] In a preferred embodiment of the second rack assembly 14 of the utility rack 10 of the present invention, second rack assembly 14 is configured to be easily removed from pickup truck 16 and utilized as a sawhorse. In one configuration, main body member 40 is a wooden beam, such as a 2×4 or other sized wooden member, that spans between first support assembly 42 and second support assembly 44 to transverse bed 22 above rear cargo area 20 . In this configuration, main body member 40 of second rack assembly 14 is cut to the appropriate length to span bed 22 and should be sized to support the desired cargo loads to be carried by utility rack 10 . In an alternative configuration, main body member 40 is made of other (i.e., non-wood) materials and/or configured as described above with telescoping members 50 and 52 that can be fixedly positioned relative to each other. Many of the components for second rack assembly 14 are the same and function the same as those for first rack assembly 12 , including leg members 70 , base member 72 and the interaction of leg members 70 with base member 72 (i.e., the use of connecting element 88 on leg members 70 to interact with openings 90 in base member 72 to allow base member 72 to pivot so as to match up to the angle of upper edge 34 of bedrail 32 ). Instead of an open tubular receiver member 68 , as described above for first rack assembly 12 , receiver member 68 for second rack assembly 14 comprises at least one generally “L” shaped brackets 120 , as shown in FIGS. 11 and 14 . In the preferred embodiment, receiver member 68 is a pair of “L” shaped brackets 120 having a generally vertical portion 122 and a generally horizontal portion 124 . The vertical portion 122 of brackets 120 is fixedly attached at or near the upper end 84 of leg members 70 . Vertical portion 122 of brackets 120 can be welded or otherwise connected to leg members 70 and comprise one or more connecting holes 126 to connect brackets 120 to main body member 40 . In the preferred embodiment, with main body member 40 of second rack assembly 14 , being a wood beam, a plurality of connecting holes 126 and a like number of screws are utilized through connecting holes 126 to connect to main body member 40 . When assembled, first end 46 and second end 48 of main body member 40 rest on the horizontal portion 124 of brackets 120 on opposite sides of main body member 40 , as best shown in FIG.13 . If desired, a removable leg extension 127 can be attached to or at the top of leg members 70 , as shown in FIGS. 11, 13 and 14 , to prevent cargo from sliding off of second rack assembly 14 and removed when second rack assembly 14 is utilized off of pickup truck 16 as a sawhorse. In one configuration, leg extension 127 includes a snap-button connector that connects to the top of the tubular leg members 70 . Alternatively, leg members 70 can be made as a single piece that extends above main body member 40 .

[0051] To further support main body member 40 , interconnect first 42 and second 44 support assemblies with main body member 40 and assist in holding first 42 and second 44 support assemblies to bedrail 32 , the preferred embodiment of second rack assembly 14 includes brace member 128 , best shown in FIGS. 11, 13 and 15 . In the preferred embodiment, brace member 128 comprises a flat bar or other structural shape that has been bent at top 130 to conform with the bottom or side surfaces of main body member 40 and bent at bottom 132 to be generally horizontal to bed 22 , as best shown in FIG. 11 . The bent portion at top 130 has one or more holes 134 , as shown in FlG. 15 , to allow wood screws 135 , shown in FIG. 11 , to secure brace member 128 to the wooden main body member 40 . As known in the art, if main body member 40 is made out of material other than wood (i.e., metal), then another type of connecting mechanism is required. From main body member 40 , brace member 128 descends at an angle of approximately 20 to 40 degrees, or as necessary to provide the desired support.(i.e., 30 degrees in one embodiment), from the vertical to the horizontal bent portion at bottom 132 of brace 128 . In the preferred embodiment, the horizontal portion at bottom 132 of brace 128 contains two holes, first hole 136 and second hole 138 as shown in FIG. 12 , in the center along the long axis. A bolt 140 , welded to the top of base member 72 with the threaded portion thereof being upwardly directed, goes up through first hole 136 and a nut 142 is screwed onto the end of bolt 140 to hold brace 128 in position. Clamp assembly 74 of second rack assembly 14 comprises a short square tube 144 welded, one open end down and the other open end facing upward, to brace member 128 such that it is centered over second hole 138 . The purpose of tube 144 is to shield hook member 146 , such as the J-bolt nut shown in FIG. 11 , so as to prevent unauthorized tampering and to contain a very thick spacer (not shown) which helps align hook member 146 in the vertical position. The purpose of hook member 146 is to hold down first support assembly 42 or second support assembly 44 to bedrail 32 of pickup truck 16 . When in position, hook member 146 makes contact with the underside of bedrail 32 , with the long leg of hook member 146 passing around the outside edge of lip 36 , up through second hole 138 at bottom 132 of brace member 128 , through the thick spacer and into the threaded tube 142 .

[0052] As a sawhorse, second rack assembly 14 can be removed from pickup truck 16 by disengaging the connection between hook member 146 and threaded tube 144 to unclamp first 42 and second 44 support assemblies from bedrail 32 . Hook member 146 is removed from second rack assembly 14 or moved up into threaded tube 144 so base member 72 can rest on the ground. Because second rack assembly 14 is removed as a unit, there is no need to reconfigure it for a sawhorse or as a second rack assembly 14 when taking it off or putting it on pickup truck 16 . When on pickup truck 16 , second rack assembly 14 , in conjunction with first rack assembly 12 , supports cargo above the rear cargo area 20 and, if desired, cab 18 . Second rack assembly 14 can be easily mounted or dismounted with only a few tools in a short period of time. Because base member 72 conforms to the angle of bedrail 32 and hook member 146 directly holds down brace member 128 and first 42 and second 44 support assemblies of second rack assembly 14 to bedrail 32 , utility rack 10 is particularly sturdy and safe and it resists vibration and sheer forces. As stated above, the triangle shape configuration of first 42 and second 44 support assemblies provide a more secure and safe utility rack 10 .

[0053] In use, the user of utility rack 10 of the present invention can decide whether to utilize first 12 and second 14 rack assemblies as sawhorse components or not. If desired, both first 12 and second 14 rack assemblies can be the rack assembly first described (non-sawhorse), both can be as second described (sawhorse) or one of each can be utilized in any position (sawhorse in forward or rearward position). First rack assembly 12 is installed on bedrail 32 of pickup truck 16 by clamping first support assembly 42 and second support assembly 44 to bedrails 32 on left 28 and right 30 sidewalls. If the first described embodiment is utilized, the first 46 and second 48 ends of main body member 40 are inserted into receiver member 58 and clamp assembly 74 is engaged by nut tube 106 to cause clamp tube 94 to draw hook member 100 upward to contact the underside of bedrail 32 and clamp first 42 and second 44 support assemblies in place on bedrail 32 . If an adjustable main body member 40 is utilized, the user adjusts main body member 40 to the width of bed 22 between sidewalls 28 and 30 . If the second described embodiment is utilized, hook member 146 is engaged with threaded tube 144 to clamp first 42 and second 44 support assemblies in place on bedrail 32 . Both rack assembly configurations 12 and 14 allow the user to quickly and easily remove utility rack 10 from pickup truck 16 . If desired, the embodiment described for second rack assembly 14 can be easily removed from pickup truck 16 and utilized as a sawhorse without the need for any modification or adjustment to second rack assembly 14 . Cargo can be held in place on utility rack with ropes, cables, straps and other tie-down devices. One or more tie-down loop members 148 , as best shown in FIGS. 3, 8 and 13 , can be provided on base member 72 or other places on support assemblies 42 and 44 for use as a tie-down hold to assist the user in securing the cargo on utility rack 10 .

[0054] While there are shown and described herein certain specific alternative forms of the invention, it will be readily apparent to those skilled in the art that the invention is not so limited, but is susceptible to various modifications and rearrangements in design and materials without departing from the spirit and scope of the invention. In particular, it should be noted that the present invention is subject to modification with regard to the dimensional relationships set forth herein and modifications in assembly, materials, size, shape and use.