WO1999054168A1

WO1999054168A1 - Roof rack or load carrier

Info

Publication number: WO1999054168A1
Application number: PCT/NZ1999/000048
Authority: WO
Inventors: Peter Douglas Hubbard
Original assignee: Hubco Industries Limited
Priority date: 1998-04-22
Filing date: 1999-04-22
Publication date: 1999-10-28
Also published as: AU3631499A

Abstract

A vehicle roof bar has a moulded plastics sleeve (28) of aerofoil shape in cross section covering a steel C-shaped channel. The sleeve is held in a nose down attitude and has upper and lower rearward facing steps (30-31) at its nose so as to create rolling turbulence and thereby reduce wind noise. The aerofoil shape of the sleeve is maintained across the slot in the channel by a ridge (39) on a hollow compressible tubular infill member (38). The roof bar is clamped on to the vehicle roof with the aid of over-centre clamping arms which tension the clamps and are held in place (when is their down and secured position) by lockable covers.

Description

- 1 - ROOF RACK OR LOAD CARRIER

Field Of The Invention

The invention relates to a vehicle roof rack or load carrier with an aerodynamic shape crossbar which is mounted by feet at either end of the crossbar, the feet being fitted by clamps to door or window surrounds or gutter rims of a vehicle.

Background Of The Invention

Roof racks or load carriers for vehicles are very well known and are manufactured in a variety of configurations. Most roof racks suffer from inherent limitations, either in their manner of fitment or because in use they are not aerodynamic and create road noise caused by air flow over the rack.

Another problem with known roof racks is the fitment of load carrying members to the roof rack crossbar. Again a variety of methods have been used and most, if not all, result in a reduction in the aerodynamic characteristics of the crossbar.

Objects Of The Invention

An object of the invention is to provide a roof rack and load carrier for a vehicle which overcomes disadvantages of known load carriers.

Further objects and advantages of the invention will become apparent from the following descriptions which are given by way of example only. Summary Of The Invention

According to one aspect of the invention there is provided an aerodynamic shape of crossbar for a vehicle roof rack or load carrier, the crossbar having in cross-section a generally aerofoil shape with an upward and downward rearward facing step on its leading edge, the arrangement being such that in use the crossbar is mounted with a nose down attitude so that the steps create rolling turbulence with sufficient energy to delay separation and reduce noise across the top and bottom surfaces of the aerofoil.

The nose down attitude can be at an angle of between 4° and 1 1 ° to the horizontal and preferably the crossbar is mounted with a nose down attitude of about 7° .

The crossbar can be an assembly formed from a steel channel on which an aerofoil shaped sleeve is fitted, the sleeve having an internal recess substantially complementary in shape to the external shape of the steel channel, the interior of the channel having a compressible infill member engaged therein to maintain the aerodynamic shape of an upper surface of the crossbar.

According to a second aspect of the invention there is provided a roof rack or load bar assembly for a vehicle which incorporates an aerodynamic crossbar as hereinbefore described.

According to another aspect of the invention there is provided a compressible infill member for a crossbar of a vehicle roof rack or load carrier, the infill member being - 3 - hollow and extruded from a rubber or plastics material with an external shape generally complementary to the interior of a lipped channel section member of the crossbar, an upper edge of the infill member having a ridged section along the length thereof which extends through an open section of the lipped channel section member to thereby conform with an upper surface of an aerofoil sleeve fitted on the channel section.

The infill member can be, in section, the shape of a hollow inverted T in which the leg of the inverted T forms the ridged section .

According to yet another aspect of the invention there is provided an aerofoil sleeve for a crossbar of a vehicle roof rack or load carrier, the sleeve being extruded from a plastics or rigid rubber material, the sleeve being shaped to have on its leading edge an upward and downward rearward facing step and on its inner surface ribs which are situated to form locating means for a lipped channel shaped structural member of the crossbar on which the sleeve is mounted, at least one of the ribs abuts a lower surface of the structural member to, in use, orientate the sleeve in a nose down attitude, the sleeve having a slot formed in its upper surface through which a ridged section of an infill member extends to be flush with the upper surface of the sleeve to thereby maintain the aerodynamic shape of the crossbar.

According to yet another aspect of the invention there is provided an aerodynamic vehicle roof rack or load bar locating assembly including at each end of a crossbar, in association with foot pad mounts, an over centre clamping arm which tensions a clamp which holds the locating assembly and crossbar relative to a vehicle, the clamping arm cooperating via a connector with the clamp to tension the clamp in position when the clamping arm is in its down and locked position where it is held - 4 - in position by a top and bottom cover which can be locked over the locating assembly, the clamp being releasable after removal of the top cover by raising the clamping arm.

The connector can be adjustable in length and consist of a pin or the like and yoke, the yoke joining an end of the pin to an upper end of the locating assembly and the pin cooperating with an abutment formed in the clamp.

The upper end of the clamp can co-operate with a bridge of the locating assembly as the clamping arm is lowered to tighten and tension the locating assembly in position.

Further aspects of the invention will become apparent from the following descriptions which are given by way of example only.

Brief Description Of The Drawings

An example of the invention will now be described with reference to the accompanying drawings in which:

Figure 1 shows a perspective from the side of an example of mounting for a vehicle roof rack and load carrier assembly mounting with its top cover removed;

Figure 2 shows a cross-section through the assembly shown in Figure 1 with a clamp shown fitted therein;

Figure 3 shows a side view of the assembly shown in Figure 2 with the top cover removed; - 5 - Figure 4 shows diagrammatically from the front the over-centre action of a locking arm used for locating the assembly shown in Figures 1 to 3 to a vehicle roof;

Figure 5 shows a perspective view of the clamping arm and adjustment nut assembly with the parts thereof shown spaced apart; and Figure 6 shows a section through an aerodynamic crossbar for the vehicle roof rack and load carrier according to the invention.

Description Of Preferred Examples

Examples of the invention will now be described with reference to the accompanying drawings.

In the drawings the similar parts shown in each drawing are described by way of reference to the same numerals.

The vehicle roof rack consists of an aerodynamic shaped crossbar 1 mounted by a mounting assembly generally indicated by arrow 2 and shown in Figures 1 to 3.

A similar mounting assembly 2 is placed at each end of the aerodynamic crossbar 1 . The mounting assembly consists of a bottom cover member 3 cast moulded or fabricated from a suitable plastics or reinforced plastics material. The bottom cover member 3 and adjacently positioned top cover member 4 fit together to enclose members forming the adjustment and locating functions of the assembly 2. The balance of the mounting assembly 2 is an arcuate shaped, in front and rear elevation, member 5 which supports the end of a structural member 6 which forms - 6 - the base of the aerofoil shaped crossbar 1 . The member 5 is linked to the member 6 by bolts or other fitment means.

The lower end 7 of the member 5 supports relative thereto a swivelling foot 8 and associated footpad 9.

The bottom cover 3 co-operates with the top cover 4 which in Figure 1 is shown removed. The top cover can be fixed via a key locking mechanism to provide security.

The footpad 9 and foot 8 swivel about pin 10 which extends between holes in the lower end of the member 5. Footpad 9 is shaped to suit the shape of a vehicle surface to which it fits.

The member 5 supports relative thereto a bridge 1 1 which acts as an abutment for upper end 1 2 of clamp 1 3. The lower end 1 4 of clamp 1 3 is shaped to engage with a roof gutter or roof flange of the vehicle to which the roof rack is to be fitted. The top of the clamp 1 3 can slide up the bridge as the clamping arm is lowered thereby inducing a turning moment in the clamp. The bottom of the clamp 1 3 is restrained from movement in this position.

The clamp 1 3 is locked by an arcuate shaped mechanism shown in detail in Figures 2 to 5. The over-centre mechanism includes a locking arm 1 5 to which a yoke 1 6 is attached by pin 1 7. The clamping arm is riveted by rivets 1 8 to the upper end of the member 5. The relationship between the axis of pin 1 7 and rivets 1 8 create a over-centre mechanism when the free end 1 9 of the arm 1 5 is in its down position. In this position a bolt 20 mounted on the yoke 1 6 is under tension and lower end of - 7 - bolt 20 pulls on the clamp 1 3 so its upper end 1 2 rides against the bridge. The length of the bolt 20 is adjustable by adjustment nut 21 which bears against the shaped region 22 of the clamp 1 3.

The clamping arm is retained in its down position by engagement of the top cover 4 which itself is located in position by a lock mechanism (not shown) which engages in bore 23 with a pin 24 extending to locate via a transverse member 25 which forms part of the lower end of the member 5.

The end 26 of the structural member 6 of the crossbar 1 is fitted relative to the mounting assembly by bolts 27.

The aerofoil shaped crossbar 1 shown in Figures 1 to 6, consists of a steel structural channel 6 with lips.

The channel member 6 is covered by an aerofoil shaped sleeve 28 injection moulded from plastics material or synthetic or natural rubber material. The shape of the sleeve 28 shown in Figures 1 to 5 differs from that shown in Figure 6. Figure 6 shows a preferred aerodynamic sleeve 28 in which a leading edge 29 is provided with upward 30 and downward 31 directed steps. The steps 30,31 create rolling turbulence over upper 32 and lower 33 surfaces of the aerofoil shaped sleeve 28.

The sleeve 28 has internal ribs 34 which form a space 35 the shape of which is generally complementary to that of the external surface of the channel 6. In the example shown in Figure 6 the ribs 34 do not extend between the upper and lower surface of the sleeve 28. The position of the channel 6 relative to the space 35 is stabilised by the provision of an elongate rib 36. The height of the rib 36 is - 8 - selected to provide a nose down attitude to the crossbar 1 . In Figure 6 the nose down attitude is 7° and experiments have shown that this configuration with the rearward facing steps 30,31 creates a sufficiently turbulent airflow with enough energy to delay separation and reduce noise across the aerofoil.

The aerofoil shape of the aerodynamic sleeve 28 is maintained across slot 37 (Figure 1 ) by the inclusion of an infill member 38. The infill member 38 is slidingiy engaged in the channel 6 and the shape is generally complementary to the shape of the interior of the channel. As can be seen in Figure 6 the infill member 38 in cross-section is generally the shape of a hollow inverted T and is manufactured from a flexible material. An upper elongate ridge 39 of the T closes the slot in the channel 6 to therefore reduce noise.

In practice in a commercial situation the roof rack can be sold as a fitting pack or with a new vehicle. In a fitting pack it would contain the following:

2 carry bars;

4 covers; and

2 keys.

For fitting, the bars are removed and identified as front and rear bars. (Bars can be labelled "front" and "rear" underneath).

The front car door is opened and the top body seals are pulled back to expose the roof flange.

The clamping arms are fitted on each leg and the bars are positioned on the vehicle. - 9 - Each clamp is positioned over the roof flange so that the cut-out in flange is visible through the hole in the clamp. If the clamp does not fit fully onto the flange, it is necessary to carefully remove body sealant under the flange using a sharp knife. Care must be taken not or allow the knife to scratch the metal as this may cause rust. Touch up using a matching body paint touch-up kit if necessary.

The clamp is held against the flange and the bars to the roof.

The door seals are refitted over the flanges and clamps.

The same steps are repeated for a rear bar.

The covers are then slid into the position and locked using the key provided.

Maximum permissible loads on the bars can apply such as up to 80kg. This load should be evenly distributed over the bars and kept as low as possible.

Loads can be secured to tiedowns supplied with the bars. To fit the tiedowns:

(a) Unlock and remove the covers on each leg.

(b) Push down end of infill member or strip and slide tiedown into the channel slot.

(c) Position tiedown as close as possible to load being carried.

(d) Secure your load using webbing or rope.

Care should be taken when carrying large flat loads e.g. surfboards. When possible these should be stacked on top of each other, not side by side. - 1 0 - Specialised accessories can be made available to carry specific equipment e.g. skis, bicycles.

Where in the accompanying drawings and description particular mechanical integers are referred to, it is to be appreciated that their mechanical equivalents can be included as if they were individually set forth herein.

Particular examples of the invention have been described and it is envisaged that modifications and improvements can take place without departing from the scope of the attached claims.

Claims

1 1 -CLAIMS

1 . An aerodynamic shape of crossbar for a vehicle roof rack or load carrier, the crossbar having in cross-section a generally aerofoil shape with an upward and downward rearward facing step on its leading edge, the arrangement being such that in use the crossbar is mounted with a nose down attitude so that the steps create rolling turbulence with sufficient energy to delay separation and reduce noise across the top and bottom surfaces of the aerofoil.

2. An aerodynamic shape of crossbar for a vehicle roof rack or load carrier as claimed in claim 1 wherein the nose down attitude is at an angle of between 4┬░ and 1 1 ┬░ to the horizontal.

3. An aerodynamic shape of crossbar for a vehicle roof rack or load carrier as claimed in claim 2 wherein the crossbar is mounted with a nose down attitude of about 7┬░ .

4. An aerodynamic shape of crossbar for a vehicle roof rack or load carrier as claimed in any one of the preceding claims wherein the crossbar is an assembly formed from a steel channel on which an aerofoil shaped sleeve is fitted, the sleeve having an internal recess substantially complementary in shape to the external shape of the steel channel, the interior of the channel having a compressible infill member engaged therein to maintain the aerodynamic shape of an upper surface of the crossbar. - 1 2 -

5. An aerodynamic shape of crossbar for a vehicle roof rack or load carrier as claimed in any one of the preceding claims substantially as hereinbefore described with reference to Figure 6 of the accompanying drawings.

6. An aerodynamic shape of crossbar for a vehicle roof rack or load carrier roof rack or load bar assembly for a vehicle which incorporates an aerodynamic crossbar as claimed in any one of the preceding claims.

7. A compressible infill member for a crossbar of a vehicle roof rack or load carrier, the infill member being hollow and extruded from a rubber or plastics material with an external shape generally complementary to the interior of a lipped channel section member of the crossbar, an upper edge of the infill member having a ridged section along the length thereof which extends through an open section of the lipped channel section member to thereby conform with an upper surface of an aerofoil sleeve fitted on the channel section.

8. A compressible infill member for a crossbar of a vehicle roof rack or load carrier as claimed in claim 7 wherein the infill member is, in section, the shape of a hollow inverted T in which the leg of the inverted T forms the ridged section.

9. A compressible infill member for a crossbar of a vehicle roof rack or load carrier as claimed in claim 8 and substantially as hereinbefore described with reference to Figure 6 of the accompanying drawings. - 1 3 -

10. An aerofoil sleeve for a crossbar of a vehicle roof rack or load carrier, the sleeve being extruded from a plastics or rigid rubber material, the sleeve being shaped to have on its leading edge an upward and downward rearward facing step and on its inner surface ribs which are situated to form locating means for a lipped channel shaped structural member of the crossbar on which the sleeve is mounted, at least one of the ribs abuts a lower surface of the structural member to, in use, orientate the sleeve in a nose down attitude, the sleeve having a slot formed in its upper surface through which a ridged section of an infill member extends to be flush with the upper surface of the sleeve to thereby maintain the aerodynamic shape of the crossbar.

1 1 . An aerofoil sleeve for a crossbar of a vehicle roof rack or load carrier as claimed in claim 10 and substantially as hereinbefore described with reference to Figure 6 of the accompanying drawings.

1 2. An aerodynamic vehicle roof rack or load bar locating assembly including at each end of a crossbar, in association with foot pad mounts, an over centre clamping arm which tensions a clamp which holds the locating assembly and crossbar relative to a vehicle, the clamping arm cooperating via a connector with the clamp to tension the clamp in position when the clamping arm is in its down and locked position where it is held in position by a top and bottom cover which can be locked over the locating assembly, the clamp being releasable after removal of the top cover by raising the clamping arm.

13. An aerodynamic vehicle roof rack or load bar locating assembly as claimed in claim 1 2 wherein the connector is adjustable in length and consist of a pin or the like and yoke, the yoke joining an end of the pin to an upper end of the - 1 4 - locating assembly and the pin cooperating with an abutment formed in the clamp.

4. An aerodynamic vehicle roof rack or load bar locating assembly as claimed in claim 1 3 wherein the upper end of the clamp co-operates with a bridge of the locating assembly as the clamping arm is lowered to tighten and tension the locating assembly in position.

5. An aerodynamic vehicle roof rack or load bar locating assembly as claimed in claim 1 2 and substantially as hereinbefore described with reference to the accompanying drawings.