AU2015203700A1 - Wind deflector assembly for a motor vehicle roof rack - Google Patents

Abstract

A wind deflector assembly (10) for attachment to a roof rack having two vertically spaced-apart bars, a first bar (11) and a second bar (12). The assembly includes a deflector plate (13) with two opposed surfaces, a wind-facing surface (14) and a sheltered surface (15). The assembly further includes one or more mounting brackets (16 and 17) operable to mount the deflector plate on the first and second bars of the roof rack in a mounting position in which the wind facing surface of the deflector plate is in front of the bars and the sheltered surface of the deflector plate is spaced a sufficient distance from the bars such that a rope, strap or other load tie down means may be received in a free space between the bars and the sheltered surface of the deflector plate. Figure 1 Figure 2

Description

WIND DEFLECTOR ASSEMBLY FOR A MOTOR VEHICLE ROOF RACK 2015203700 01 Μ 2015 [0001] The present invention relates to a wind deflector assembly suitable for a roof rack of a motor vehicle.

[0002] As used throughout this specification, the term "roof rack" is intended to refer to any framework suitable for carrying a load (such as luggage or equipment) on the roof of a motor vehicle and includes, but is not limited to, an open-top basket with at least two vertically spaced-apart bars that each extend partially or entirely around the perimeter of the basket.

BACKGROUND TO THE INVENTION

[0003] A roof rack has long been a popular feature on a motor vehicle because it allows a load to be transported on the roof of the vehicle without reducing the interior space of the vehicle for occupants or other objects.

[0004] Commercially available roof racks come in a variety of different configurations. However, despite the variation in design, it is common for a roof rack to comprise an open-top basket with two vertically spaced-apart bars, an upper bar and a lower bar, that each extend partially or entirely around the perimeter of the basket. Examples of such roof racks are disclosed in U.S. Patent Nos. D413,562, D422,553, D435,510 andD470,451.

[0005] The upper and lower bars of a roof rack provide anchorage points for fastening ropes, straps or other load tie-down means to prevent the load from shifting during transit. The bars may be vertically aligned so that the upper bar is located directly above the upper bar, for example, as shown in U.S. Patent Nos. D413,562, D435,510 and D470,451. Alternatively, the lower bar may be positioned forward of the upper bar, for example, as shown in U.S. Patent No. D422,553. There may also be reinforcement elements extending between the upper and lower bars, for example, as shown in U.S. Patent Nos. D413,562, D435,510 and D470,451. 1 [0006] Although roof racks are desired for their functionality, the noise made by wind buffeting the bars of the roof rack and any load contained therein during transit can be unpleasant and distracting to the driver and any other occupants of the motor vehicle. The fuel efficiency of a motor vehicle with a roof rack can also be reduced as a result of the increased aerodynamic drag on the vehicle from the roof rack. 2015203700 01 Μ 2015 [0007] As a consequence of the above, it is common for a wind deflector to be mounted to the front of the roof rack in a transverse direction to the direction of travel of the motor vehicle in order to deflect airflow above the roof rack and thereby reduce noise and drag.

[0008] Wind deflectors known in the art suffer from the disadvantage that there is insufficient space between the upper and lower bars of the roof rack and the wind deflector for ropes, straps or other load tie-down means to be fastened to the bars. As an example, reference is made to German Patent No. 2612954 in which a curved wind deflector is attached using screws to the front of a roof rack.

This reduces the locations available to secure the load to the roof rack and can compromise the security of the load.

[0009] It is an object of the present invention to provide a wind deflector assembly which will overcome the abovementioned disadvantage and/or provide the public with a useful choice.

SUMMARY OF THE INVENTION

[0010] According to a first broad aspect of the invention, there is provided a wind deflector assembly for attachment to a roof rack having two vertically spaced-apart bars, a first bar and a second bar, the assembly comprising a deflector plate with two opposed surfaces, a wind-facing surface and a sheltered surface, and one or more mounting brackets operable to mount the deflector plate on the first and second bars of the roof rack in a mounting position in 2 which the wind-facing surface of the deflector plate is in front of the bars and the sheltered surface of the deflector plate is spaced a sufficient distance from the bars such that a rope, strap or other load tie-down means may be received in a free space between the bars and the sheltered surface of the deflector plate. 2015203700 01 Μ 2015 [0011] The distance between the first or second bars of the roof rack and the sheltered surface of the deflector plate may be at least 30mm, preferably at least 40mm, and most preferably at least 45mm.

[0012] The wind deflector assembly may include one or more pairs of mounting brackets, the or each pair consisting of one mounting bracket for attachment to the first bar of the roof rack and another mounting bracket for attachment to the second bar of the roof rack.

[0013] The or each mounting bracket may have an elongate body with two longitudinal ends, a plate abutment portion at one end of the body for abutment against the sheltered surface of the deflector plate and a generally U-shaped clevis portion at the other end of the body to receive the first or second bar of the roof rack.

[0014] The plate abutment portion may be inclined at a nonperpendicular angle to the body of the mounting bracket.

[0015] The plate abutment portion may be an elongate member with a longitudinal slot extending lengthwise therethrough.

[0016] The deflector plate may include one or more mounting holes extending between the wind-facing surface and the sheltered surface for use in attaching the deflector plate to the or each mounting bracket.

[0017] The deflector plate may include a curved support ledge adapted to engage with a correspondingly curved portion on at least one mounting brackets. 3 [0018] According to a second broad aspect of the invention, there is provided a roof rack comprising two vertically spaced-apart bars, a first bar and a second bar, the bars of the roof rack having a wind deflector mounted thereto, the wind deflector including a deflector plate with two opposed surfaces, a wind-facing surface and a sheltered surface, and one or more mounting brackets arranged to mount the deflector plate on the first and second bars of the roof rack in a mounting position in which the wind-facing surface of the deflector plate is in front of the bars and the sheltered surface of the deflector plate is spaced a sufficient distance from the bars such that a rope, strap or other load tie-down means may be received in a free space between the bars and the sheltered surface of the deflector plate. 2015203700 01 M2015 [0019] In one embodiment, the wind deflector is fixedly mounted to the first and second bars of the roof rack. In another embodiment, the wind deflector is releasably mounted to the first and second bars of the roof rack.

[0020] In one embodiment, the first and second bars extend around a portion of the perimeter of the roof rack. In another embodiment, the first and second bars extend around the entire perimeter of the roof rack.

BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Further aspects of the present invention will become apparent from the following description, which is given by way of example only, and with reference to the accompanying drawings in which: [0022] Figure 1 shows a cross-sectional side view of two circular bars of a roof rack with a wind deflecting apparatus according to a first embodiment of the invention mounted thereto; [0023] Figure 2 shows a perspective view of the deflector plate of the apparatus; 4 [0024] Figure 3 shows a plan view of the wind-deflecting surface of the deflector plate; 2015203700 01 Μ 2015 [0025] Figure 4 shows a plan view of the sheltered surface of the deflector plate; [0026] Figure 5 shows a side view of the upper mounting bracket of the apparatus; [0027] Figure 6 shows a plan view of a blank used to manufacture the upper mounting bracket; [0028] Figure 7 shows a side view of the lower mounting bracket of the apparatus; [0029] Figure 8 shows a plan view of a blank used to manufacture the lower mounting bracket; [0030] Figure 9 shows a cross-sectional side view of two circular bars of a roof rack with a wind deflecting apparatus according to a second embodiment of the invention mounted thereto; [0031] Figure 10 shows a perspective view of the deflector plate of the apparatus according to the second embodiment of the invention; [0032] Figure 11 shows a plan view of the wind-deflecting surface of the deflector plate of the apparatus according to the second embodiment of the invention; [0033] Figure 12 shows a side view of an upper mounting bracket of a wind deflecting apparatus according to a third embodiment of the invention for use with a bar having a rectangular cross-section; [0034] Figure 13 shows a plan view of a blank used to manufacture the upper mounting bracket shown in Figure 12; 5 [0035] Figure 14 shows a side view of a lower mounting bracket of the wind deflecting apparatus according to the third embodiment of the invention for use with a bar having a rectangular cross-section; and 2015203700 01 Μ 2015 [0036] Figure 15 shows a plan view of a blank used to manufacture the lower mounting bracket shown in Figure 14.

DETAILED DESCRIPTION OF THE INVENTION

[0037] The invention relates to a wind deflector assembly suitable for a roof rack of a motor vehicle. Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings.

[0038] A first embodiment of the wind deflector assembly according to the invention is depicted in Figures 1 to 8. As shown in Figure 1, the wind deflector assembly (indicated generally by the reference numeral 10) is suitable for attachment to a roof rack having two vertically spaced-apart bars, a first or upper bar (11) and a second or lower bar (12). In the first embodiment, the upper (11) and lower (12) bars are of circular cross-section and are vertically aligned with each other such that the upper bar is located directly above the lower bar. The bars (11 and 12) may extend partially or entirely around the perimeter of the roof rack. Reinforcement elements (not shown), for example one or more uprights, may extend between the upper (11) and lower (12) bars.

[0039] The wind deflector assembly (10) includes a deflector plate (13) with two opposed surfaces, a wind-facing surface (14) and a sheltered surface (15). The assembly (10) further includes one or more pairs of mounting brackets (16 and 17) operable to mount the deflector plate (13) on the upper (11) and lower (12) bars of the roof rack in a mounting position, for example as shown in Figure 1, in which the wind-facing surface (14) of the deflector plate is in front of the bars and the sheltered surface (15) of the deflector plate is spaced a sufficient distance apart from the bars such that 6 a rope, strap or other load tie-down means (not shown) may be received in a free space between the bars and the sheltered surface of the deflector plate. 2015203700 01 Μ 2015 [0040] It is a significant advantage of the invention that there is a free space between the upper (11) and lower (12) bars of the roof rack and the sheltered surface (15) of the deflector plate (13) such that a rope, strap or the like can be tied around the bars without obstruction from the deflector plate. This space increases the available anchorage points on the bars to secure the load to the roof rack and thereby provides a more secure load. Additionally, the space can also be used to mount other objects, such as driving lights or spotlights, along the width of the roof rack. The space may be at least 30mm, preferably at least 40mm, and most preferably at least 45mm in distance.

[0041] Another significant advantage of the present invention is the ability to use the wind deflector assembly (10) with a variety of different makes and models of commercially available roof racks. In particular, as will be explained in detail below, the assembly can be mounted to roof racks having vertically spaced-apart upper (11) and lower (12) bars, in which: (a) there may be one or more reinforcement elements extending between the bars; (b) the bars may be vertically aligned so that the upper bar is located directly above the lower bar or alternatively the lower bar may be positioned forward of the upper bar; and (c) the cross-section of the bars may be circular or rectangular. The universal nature of the assembly (10) provides convenience and potential cost savings to the user.

[0042] A further significant advantage is that the mounting brackets (16 and 17) are attachable to the upper and lower bars (11 and 12) of the roof rack without the need to drill holes into the bars. Instead, each of the mounting brackets (16 and 17) has a generally U-shaped clevis portion (30 or 36) which is adapted to receive either the upper bar (11) or the lower bar (12) of the roof rack. This means of attachment is much less destructive to the roof rack 7 than drilling holes into the bars and does not risk introducing water into metal bars which can result in rust. 2015203700 01 Μ 2015 [0043] The individual components of the wind deflector assembly (10) will now be described in greater detail. The main components of the assembly (10) are the deflector plate (13) and the one or more pairs of mounting brackets (16 and 17). These components may be made of any suitable material, for example sheet metal, but are preferably made of stainless steel due to its long lifespan and resistance from degradation, including rust from salt water and deterioration from sulphur in geothermal areas.

[0044] The deflector plate (13) directs airflow above the roof rack on a moving motor vehicle. As shown in Figures 2 to 4, the deflector plate (13) consists of an elongate body with a wind-facing surface (14) and an opposed sheltered surface (15), two longitudinal edges (18 and 19), and two lateral edges (20 and 21) between the longitudinal edges. In the embodiments described herein, the deflector plate (13) consists of a single body. However, the deflector plate could comprise two or more connected bodies. The or each body of the deflector plate (13) may be any suitable shape, for example, generally rectangular as shown, and be made of any suitable material, for example, sheet metal and in particular stainless steel. The corners of the body may be bevelled, as shown, or else be curved so as to eliminate sharp points at the corners.

[0045] The body of the deflector plate (13) is flat except for a region along a longitudinal edge (19) which is curved so as to form a generally perpendicular support ledge (22) adjacent the sheltered surface (15). The support ledge (22) provides support to the lower mounting bracket (17) or, where there is more than one pair of mounting brackets, to the lower mounting bracket (17) in each pair of brackets. The support ledge (22) also causes some of the airflow to be deflected underneath the roof rack and thereby assists in providing stability to the roof rack when mounted on the roof of a motor vehicle. The curvature of the support ledge (22) corresponds to the curvature of a curved region (23) on the lower mounting - 8 - bracket (17) or, where applicable, to the curvature of a curved region (23) on each of the lower mounting brackets (17). 2015203700 01 Μ 2015 [0046] To assist with the attachment of the one or more pairs of mounting brackets (16 and 17) to the deflector plate (13), the body of the deflector plate is provided with one or more corresponding pairs of spaced-apart mounting holes (24 and 25). These holes extend through the body with openings in the wind-facing surface (14) and the sheltered surface (15) and are each sized and shaped to receive a shank of a fastening element (26 or 27), such as, a bolt or screw which may be secured with a nut such as a nyloc locking nut.

[0047] In the pair or each pair of mounting holes, one hole (24) is for use in attaching an upper mounting bracket (16) to the deflector plate (13) by means of a first fastening element (26), while the other hole (25) is for use in attaching a lower mounting bracket (17) to the deflector plate by means of a second fastening element (27). Figure 4 shows, by way of example only, the location of three pairs of mounting holes (24 and 25) relative to the locations of three pairs of mounting brackets shown in dashed outline.

[0048] The locations of the one or more pairs of mounting holes (24 and 25) in the body of the deflector plate (13) may differ depending upon the number and positions of any reinforcement elements between the upper bar (11) and the lower bar (12) of the roof rack. For example, in the embodiment of the deflector plate (13) shown in Figure 4, each of the three pairs of spaced-apart mounting holes (24 and 25) are offset from the centre line A—A at the longitudinal midpoint of the deflector plate. Accordingly, the deflector plate (13) of the first embodiment would be suitable for mounting to a roof rack having a reinforcement element, such as a central upright, located at a position between the upper and lower bars (11 and 12) corresponding to the centre line A—A on the deflector plate.

[0049] The upper (16) and lower (17) mounting brackets serve three main purposes. First, they connect the deflector plate (13) to the 9 roof rack. Secondly, they space the deflector plate (13) a distance from the roof rack to allow ropes, straps or the like to be tied around the bars (11 and 12) of the roof rack. Thirdly, they mount the deflector plate (13) at an incline to the roof rack so that airflow is directed above the roof rack. 2015203700 01 Μ 2015 [0050] As shown in Figure 5, the upper mounting bracket (16) has an elongate body (28) with two longitudinal ends, a plate abutment portion (29) at one end of the body for abutment against the sheltered surface (15) of the deflector plate (13) and a generally U-shaped clevis portion (30) with two spaced-apart arms at the other end of the body to receive the upper bar (11) of the roof rack between the arms. The upper bar (11) is coupled to the clevis portion (30) by means of a locking pin (31), such as a bolt, which extends through a hole in each arm of the clevis portion and may be secured by a fastener, for example, a nut such as a nyloc locking nut. Figure 6 shows a blank (32) which may be bent (along the dashed lines) and cut (along the solid lines) to form the upper mounting bracket (16) shown in Figure 5.

[0051] The plate abutment portion (29) of the upper mounting bracket (16) comprises an elongate member with a longitudinal slot (33) extending lengthwise therethrough. The slot (33) is multiple times larger than the corresponding mounting hole (24) in the deflector plate (13) so as to overlap the mounting hole when abutment occurs and thereby allow a degree of variation in the positioning of the upper mounting bracket (16) relative to the deflector plate prior to these two parts being held together by the fastening element (26). The ability to adjust the relative positions of the upper mounting bracket (16) and the deflector plate (13) is advantageous so as to avoid obstruction from any reinforcement elements positioned between the upper (11) and lower (12) bars of the roof rack.

[0052] As shown in Figure 7, the lower mounting bracket (17) has an elongate body (34) with two longitudinal ends, a plate abutment portion (35) at one end of the body for abutment against the sheltered surface (15) of the deflector plate (13) and a generally 10 U-shaped clevis portion (36) with two spaced-apart arms at the other end of the body to receive the lower bar (12) of the roof rack between the arms. The lower mounting bracket (17) also includes a curved region (23) for engagement with the correspondingly curved support ledge (22) of the deflector plate (13). The lower bar (12) is coupled to the clevis portion (36) by means of a locking pin (37), such as a bolt, which extends through a hole in each arm of the clevis portion and may be secured by a fastener, for example, a nut such as a nyloc locking nut. Figure 8 shows a blank (38) which may be bent (along the dashed lines) and cut (along the solid lines) to form the lower mounting bracket (17) shown in Figure 7. 2015203700 01 Μ 2015 [0053] The plate abutment portion (35) of the lower mounting bracket (17) comprises an elongate member with a longitudinal slot (39) extending lengthwise therethrough. The slot (39) is multiple times larger than the corresponding mounting hole (25) in the deflector plate (13) so as to overlap the mounting hole when abutment occurs and thereby allow a degree of variation in the positioning of the lower mounting bracket (17) relative to the deflector plate prior to these two parts being held together by the fastening element (27). The ability to adjust the relative positions of the lower mounting bracket (17) and the deflector plate (13) is advantageous so as to avoid obstruction from any reinforcement elements positioned between the upper (11) and lower (12) bars of the roof rack.

[0054] The body (34) of the lower mounting element (17) is substantially longer than the body (28) of the upper mounting element (16). In addition, the plate abutment portions (29 and 35) of the upper (16) and lower (17) mounting brackets are inclined at a non-perpendicular angle to the respective bodies (28 and 34). As a consequence, as shown in Figure 1, the deflector plate (13) is also inclined at a corresponding non-perpendicular angle to the bodies (28 and 34) of the upper (16) and lower (17) mounting brackets, so as to direct airflow above the roof rack.

[0055] Advantageously, as shown in Figures 5 and 7, the upper and lower mounting brackets (16 and 17) both have longitudinally 11 extending fins (40). When the assembly (10) is in use, these fins (40) act to disrupt the airflow and thereby reduce the noise made by the wind buffeting the assembly. 2015203700 01 M2015 [0056] The upper (16) and lower (17) mounting brackets may be made of any suitable material, for example, sheet metal and in particular stainless steel. The corners of the brackets may be bevelled, as shown, or else be curved so as to eliminate sharp points at the corners .

[0057] A second embodiment of the wind deflector assembly will now be described with reference to Figures 9 to 11. In the description of the second embodiment, portions corresponding to portions of the first embodiment are indicated by reference numerals made by the adding of a hundred to the corresponding reference numerals of the first embodiment. The second embodiment is substantially similar to the first embodiment. Accordingly, only the different portions will be referred to hereinafter.

[0058] In Figure 9 the second embodiment of the wind deflector assembly (indicated generally by the reference numeral 110) is shown, in use, mounted to an upper bar (111) and a lower bar (112) of a roof rack. Instead of the upper and lower bars being vertically aligned, the lower bar (112) is positioned forward of the upper bar (111) .

[0059] As shown in Figures 10 and 11, the deflector plate (113) of the second embodiment contains four pairs of spaced-apart mounting holes (124 and 125). As shown in Figure 11, each of these pairs of mounting holes (124 and 125) are offset from the centre line B—B at the longitudinal midpoint of the deflector plate (113) .

Accordingly, the deflector plate (113) of the second embodiment would be suitable for mounting to a roof rack having a reinforcement element, such as a central upright, located at a position between the upper and lower bars (111 and 112) corresponding to the centre line B—B on the deflector plate. 12 [0060] A third embodiment of the wind deflector assembly will now be described with reference to Figures 12 to 15. In the description of the third embodiment, portions corresponding to portions of the first embodiment are indicated by reference numerals made by the adding of two hundred to the corresponding reference numerals of the first embodiment. The third embodiment is substantially similar to the first embodiment. Accordingly, only the different portions will be referred to hereinafter. 2015203700 01 Μ 2015 [0061] As shown in Figures 12 and 14, in the third embodiment of the invention the upper bar (211) and the lower bar (212) both have a rectangular cross-section. The generally U-shaped clevis portion (230) of the upper mounting bracket (216) and the generally U-shaped clevis portion (236) of the lower mounting bracket (217) are both correspondingly shaped to receive the rectangular cross-section of the bars. Figure 13 shows a blank (232) which may be bent (along the dashed lines) and cut (along the solid lines) to form the upper mounting bracket (216) shown in Figure 12. Similarly, Figure 15 shows a blank (238) which may be bent (along the dashed lines) and cut (along the solid lines) to form the lower mounting bracket (217) shown in Figure 14.

[0062] While some preferred aspects of the invention have been described by way of example, it should be appreciated that modifications and/or improvements can occur without departing from the scope of the invention as claimed in this specification.

[0063] The terms comprise, comprises, comprising or comprised, if and when used herein, should be interpreted non-exclusively, that is, as conveying "consisting of or including". 13

Claims (15)

1. THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:

   1. A wind deflector assembly for attachment to a roof rack having two vertically spaced-apart bars, a first bar and a second bar, the assembly comprising a deflector plate with two opposed surfaces, a wind-facing surface and a sheltered surface, and one or more mounting brackets operable to mount the deflector plate on the first and second bars of the roof rack in a mounting position in which the wind-facing surface of the deflector plate is in front of the bars and the sheltered surface of the deflector plate is spaced a sufficient distance from the bars such that a rope, strap or other load tie-down means may be received in a free space between the bars and the sheltered surface of the deflector plate.
2. 2. The wind deflector assembly according to claim 1, wherein the distance between the first or second bars of the roof rack and the sheltered surface of the deflector plate is at least 30mm.
3. 3. The wind deflector assembly according to claim 1, wherein the distance between the first or second bars of the roof rack and the sheltered surface of the deflector plate is at least 40mm.
4. 4. The wind deflector assembly according to claim 1, wherein the distance between the first or second bars of the roof rack and the sheltered surface of the deflector plate is at least 45mm.
5. 5. The wind deflector assembly according to any one of claims 1 to 4, wherein the assembly includes one or more pairs of mounting brackets, the or each pair consisting of one mounting bracket for attachment to the first bar of the roof rack and another mounting bracket for attachment to the second bar of the roof rack.
6. 6. The wind deflector assembly according to any one of claims 1 to 5, wherein the or each mounting bracket has an elongate body with two longitudinal ends, a plate abutment portion at one end of the body for abutment against the sheltered surface of the deflector plate and a generally U-shaped clevis portion at the other end of the body to receive the first or second bar of the roof rack.
7. 7. The wind deflector assembly according to claim 6, wherein the plate abutment portion is inclined at a non-perpendicular angle to the body of the mounting bracket.
8. 8. The wind deflector assembly according to claim 6 or 7, wherein the plate abutment portion is an elongate member with a longitudinal slot extending lengthwise therethrough.
9. 9. The wind deflector assembly according to any one of claims 1 to 8, wherein the deflector plate includes one or more mounting holes extending between the wind-facing surface and the sheltered surface for use in attaching the deflector plate to the or each mounting bracket.
10. 10. The wind deflector assembly according to any one of claims 1 to 9, wherein the deflector plate includes a curved support ledge adapted to engage with a correspondingly curved portion on at least one mounting bracket.
11. 11. A roof rack comprising two vertically spaced-apart bars, a first bar and a second bar, the bars of the roof rack having a wind deflector mounted thereto, the wind deflector including a deflector plate with two opposed surfaces, a wind-facing surface and a sheltered surface, and one or more mounting brackets arranged to mount the deflector plate on the first and second bars of the roof rack in a mounting position in which the wind-facing surface of the deflector plate is in front of the bars and the sheltered surface of the deflector plate is spaced a sufficient distance from the bars such that a rope, strap or other load tie-down means may be received in a free space between the bars and the sheltered surface of the deflector plate.
12. 12. The roof rack according to claim 11, wherein the wind deflector is fixedly mounted to the first and second bars of the roof rack.
13. 13. The roof rack according to claim 11, wherein the wind deflector is releasably mounted to the first and second bars of the roof rack.
14. 14. The roof rack according to any one of claims 11 to 13, wherein the first and second bars extend around a portion of the perimeter of the roof rack.
15. 15. The roof rack according to any one of claims 11 to 13, wherein the first and second bars extend around the entire perimeter of the roof rack.