One-piece end support and method of forming thereof

A vehicle article carrier for supporting articles elevationally above an outer body surface of the vehicle, said vehicle article carrier comprising:

• a pair of one-piece side rails adapted to be disposed on said outer body surface parallel to one another so as to extend longitudinally along said outer body surface from front to rear of said vehicle;
• each said one-piece side rail comprising:
• a side rail portion having an inaccessible hollowed area and a pair of terminal end portions;
• and
• a pair of end supports integrally formed with said terminal end portions of said side rail portion to form a one-piece component;
• each said end support including:
• an aerodynamically shaped main body portion having an inaccessible hollowed portion;
• a bottom portion integrally formed with said main body portion;
• said hollowed area of said one-piece side rail and said hollowed portion of said main body portion being in communication with each other and said main body portion and said bottom portion forming a single, integrally formed end support adapted to be directly secured to said outer body vehicle surface.

A vehicle article carrier for supporting articles elevationally above an outer body surface of a vehicle, said vehicle article carrier comprising:

• a pair of one-piece side rails adapted to be secured fixedly to said outer body surface and positioned generally parallel to one another;
• each said one-piece side rail including a side rail portion having an inaccessible elongated hollow extending along substantially an entire length of said side rail portion, said side rail portion further including a pair of terminal end portions and;
• a pair of end supports integrally formed with said terminal end portions of said side rail portion such that no seams and connecting lines are visible where said end supports meet said terminal end portions of said side rail portion;
• each said end support including an inaccessible hollow area and being of a one-piece construction, said inaccessible hollow area being in communication with said hollow in said side rail portion.

A vehicle article carrier for supporting articles elevationally above an outer body surface of a vehicle, said vehicle article carrier comprising:

• a pair of one-piece side rails adapted to be disposed parallel to one another on said outer body surface;
• each said one-piece side rail including:
• an elongated side rail portion having an inaccessible elongated hollow area formed therewithin extending along substantially the entire length of said side rail portion, and a channel integrally formed with said side rail portion extending along at least a portion of a length of said side rail portion, said side rail portion further including a pair of terminal end portions at opposite ends thereof;
• a pair of one-piece end supports integrally formed with said terminal end portions of said side rail portion such that no seams and connecting lines are present where each said one-piece end support merges into its associated said terminal end portion of said side rail portion;
• each said one-piece end support further including an inaccessible hollow portion formed therein during manufacture of said side rail portion in communication with said hollow portion formed within said side rail portion.

For a vehicle article carrier adapted to support articles elevationally above an outer body surface of a vehicle, a one-piece, integrally formed side rail, said one-piece integrally formed side rail comprising:

• an elongated side rail portion having terminal end portions and an inaccessible hollow area formed along at least a portion of a length thereof;
• a pair of end supports each integrally formed with said terminal end portions of said side rail portion;
• each said end support including an inaccessible hollow area formed therewithin during manufacture which is in communication with said hollow area formed in said side rail portion;
• and
• each said end support having a gradually curving outer profile forming an aesthetically appealing and aerodynamically efficient structure.