NZ520043A - Vehicle roof rack - Google Patents

Abstract

A vehicle roof rack includes a pair of foot assemblies (2) fixed to an elongate roof rack bar (1) and adapted to be secured to opposing sides of the roof of the vehicle. Telescoping members are received within the roof rack bar for telescoping movement with respect to both foot assemblies for extending the overall load-carrying length of the roof rack. The telescoping member extends from an aperture in the foot assembly and has an end section (5, 6) that, when the telescoping member is retracted, neatly closes the aperture and blends smoothly with the adjacent outer surface of the foot assembly.

Description

Invsilcctual Property V/illOO L'i ■ /:- « ^1" 520043 PATENTS FORM NO. 5 PATENTS ACT 1953 COMPLETE SPECIFICATION After Provisional No: 520043 Dated: 9 August 2002 James & Wells Ref: 41923/24 Telescoping Roof Rack We, Hubco Industries Limited of 43-47 Vickerys Road, Christchurch, New Zealand, a New Zealand company, hereby declare the invention for which we pray that a patent may be granted to us, and the method by which it is to be performed to be particularly described in and by the following statement: 1 Technical Field The present invention relates to an improved vehicle roof rack for carrying various articles. Background Art Vehicle roof racks provide additional storage space for a variety of articles, such as skis, 5 poles, snowboards, bicycles, and luggage. Typical roof racks comprise at least two parallel bars extending across the vehicle, these bars being immobile and rigidly secured to the roof of the vehicle.

The load capacity of previously known roof racks is limited by their overall load-carrying length when, for example, carrying a number of lighter items or with wide non self-supporting 10 loads. Long bars have been used, extending laterally (relative to the vehicle) beyond the roof mounts, and beyond the roofline, to provide for increased capacity and to make loading and unloading more convenient. However in addition to detracting from the aesthetics of the roof rack, these wide bars when not in use are a source of increased aerodynamic drag and noise. They also extend to present a hazard to users who may bump into them when 15 passing the side of the vehicle.

A known type of telescoping roof rack has two elongate bar sections, each having one foot assembly fixed thereto (for attachment to the vehicle's roof) with one of the bar sections being received within the other to allow for telescoping adjustment so that the roof rack can be adapted to different spans between the feet to suit different roof widths. However when 20 both feet are secured to the vehicle, this design does not provide a means for increasing the load-carrying length for increased capacity or improved convenience for loading and unloading. 2 Any publication cited in this specification is hereby incorporated by reference, however this does not constitute an admission that the document forms part of the common general knowledge in the art, in New Zealand or in any other country. The applicant reserves the right to challenge the pertinency of any publication cited herein, or to challenge the accuracy of any assertion made in a cited publication. As used herein, the word "comprises" means "includes, but is not limited to" and its derivatives have a corresponding meaning.

It is an object of the present invention to address the foregoing problems or at least to provide the public with a useful choice.

Further aspects and advantages of the present invention will become apparent from the ensuing description which is given by way of example only.

Disclosure of the Invention According to one aspect of the present invention there is provided a roof rack for a vehicle, including: an elongate roof rack bar; a pair of foot assemblies attachable to the roof rack bar, the foot assemblies being adapted to be detachably secured to opposing sides of a roof of the vehicle, each foot 20 assembly having an opening in which opposing ends of the roof rack bar are received; at least one telescoping member adapted for movement between a retracted position and an extended position in which it extends the length of the roof rack when both foot assemblies are secured to the vehicle, wherein each telescoping member includes an end section in which one end of a bar section is received, the bar section is slidably received within the roof rack bar and in the Intellectual Property Office of N.Z. -4 FEB 2005 retracted position the end section is slidably received within and closes an aperture in the respective foot assembly, the end section being shaped to blend substantially smoothly with an adjacent outer surface of the foot assembly for low drag and noise production (in the retracted position).

Preferably the telescoping member is received within the roof rack bar. The roof rack bar may be of any known type e.g. a single bar or having two telescoping sections, for example. Preferably each telescoping member is adapted for movement between a retracted position and a plurality of extended positions; and the roof rack further includes a latching mechanism 10 for fixing each telescoping member in the extended positions and in the retracted position. The latching mechanism may be any known mechanism for preventing relative sliding movement between to sliding members e.g. a fastener, clamp etc.

Preferably the roof rack bar and foot assemblies together form a flattened arch-shaped 15 assembly with the elongate roof rack bar spanning the centre of the arch between opposing foot assemblies. The roof rack bar preferably extends only between the foot assemblies and does not extend beyond the foot assemblies. The foot assemblies are preferably fixed to opposing ends of the roof rack bar, but optionally there may be some provision for adjustment of the spacing between foot assemblies. For receiving each telescoping 20 member, an aperture is preferably formed in the respective foot assembly, the aperture extending substantially in the longitudinal direction of the roof rack bar. Each telescoping member preferably includes an end section that is received in and closes the aperture in the respective foot assembly when in the retracted position. The end section is preferably contoured, such that in the retracted position its outerface blends smoothly with the adjacent 25 outer surface of the foot assembly. In this manner in the retracted position each telescoping member is retained generally within the outline of the roof rack bar and foot assemblies, to present a substantially smoothly rounded surface to the air flow for low drag and noise Intellectual Property Office of NZ. -4 FEB 2005 production.

Preferably both the roof rack bar and each telescoping member have respective longitudinally extending openings in an upper face thereof, a central axis of the respective 5 openings being aligned, such that with the or each telescoping member in any extended position, the opening in each telescoping member is continuous with the opening in the roof rack bar. In the preferred embodiment the roof rack bar and telescoping members are channel sections, the mouth of each channel being formed between a pair of opposing flanges such that width of each mouth is narrower than the internal width of the respective 10 channel section. The opposing flanges on the roof rack bar preferably extend inwardly and are received in the mouth of the telescoping member channel.

Preferably the roof rack bar has an aerofoil profile, and each telescoping member has a corresponding aerofoil profile.

Preferably a soft tip is provided on the outermost end of each telescoping member to reduce potential impact damage when the telescoping member is extended.

Preferably each latching mechanism includes a spring-loaded detent for engagement with a 20 plurality of apertures in the telescoping member, the detent being releasable by a manually operated trigger. Each trigger is preferably located in the inside face of each foot, allowing it to be readily operated when extending or retracting the telescoping member. Alternatively, other latching mechanisms of a known type may be used.

In an alternative embodiment each latching mechanism is adapted such that it cannot operate to release the telescoping memberwithout a key or without some other impediment such as the need to remove the roof rack from a vehicle. This feature provides a higher Intellectual Property Office of N.Z. -4 FEB 2005 crciucn Intellectual Property Office of N.Z. -4 FEB 2005 RECEIVED degree of security, preventing unauthorized adjustment of the telescoping member. Preferably each latching mechanism comprises clamping means for clamping the telescoping member and roof rack bar together, the clamping means including a clamping arm positioned on the inside of the foot assembly. The clamping means preferably includes 5 a clamping arm and a spring-loaded clip for holding the clamping arm in an engaged position and a key is required either to directly release the clip or to remove an access panel so that the clip may be manually released.

According to another aspect of the present invention there is provided a roof rack 10 substantially as described above, further including: a fixture releasably attachable to either the roof rack bar channel or the telescoping member channel for securing a load to the roof rack, the fixture including: a body having a top flange and a necked section between the top flange and a lower face substantially opposing the top flange, the necked section being received in the 15 mouth of either the roof rack bar channel or the telescoping member channel for retaining the body therein, a block for abutting inner surfaces either side of the mouth of each channel, the block being slidably received within the body; a fastener connecting the block and the body for relative sliding movement, wherein to attach the fixture to the telescoping member channel the fastener is tensioned to clamp the channel internally, the block abutting inner surfaces either side of the mouth and the lower face of the body abutting a substantially opposing internal surface of the channel, and to attach the fixture to the roof rack bar channel the fastener is tensioned to clamp the channel between the inner surfaces and an external surface, the top flange abutting the external surface and the block abutting the inner surfaces on either side of the mouth. 6 Preferably the fixture is adapted such that when secured to the telescoping member, the fixture is able to slide within the roof rack bar. The fixture may be used directly for securing a load to the roof rack or alternatively it may further include a fitting (e.g. hook, eye) for receiving a rope, tie-down or the like. Likewise the fixture may include other fittings (e.g. for 5 holding skis, bicycles etc). Optionally such fittings may be secured to the fixture by the fastener.

This invention provides a roof rack with improved versatility, which is able to be readily adjusted for increased carrying capacity without compromising its performance. The roof 10 rack may be economically constructed and it may be extended beyond the roofline to make the rack easier to load and unload without damaging the vehicle. Advantageously, the fastening fixture may be fastened to either the roof rack bar or the telescoping section, and when fixed to the telescoping section, it permits the telescoping section to still be retracted within the roof rack bar.

Brief Description of Drawings 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: Figure 1 is a side elevation of one end a first embodiment of the roof rack of the present invention; Figure 2 is pictorial view of the roof rack of Fig. 1; Figure 3 is a partially exploded view of the roof rack of Fig. 2; Figure 4 is a partially exploded view of the roof rack of Fig. 3; Figure 5 is a partially exploded view of the foot assembly of Fig. 4; Figure 6 is a detail of the trigger of Fig. 5 Figure 7 is a longitudinal sectional elevation of second embodiment of the roof rack of Intellectual Property Office of N.Z.

FEB 2005 Dcr>cn/rn the present invention; Figure 8 is pictorial view of a fastening fixture of the present invention; Figure 9 is a sectional view of the fastening fixture of Fig. 8 engaged with the roof rack bar; and Figure 10 is a sectional view of the fastening fixture of Fig. 8 engaged with the telescoping member.

Best Modes for Carrying out the Invention Referring to Figs. 1 and 2, a first embodiment of the present invention includes a roof rack 10 bar 1 which spans between a pair of foot assemblies 2 (only one of which is illustrated) to form a flattened arch-shaped roof rack. Telescoping members 3 are slidingly received within the bar 1, to form a telescopic extension at each end of the bar 1. Opposing ends of the roof rack bar 1 are received in openings in each foot assembly 2. Although in the embodiment shown the foot assemblies 2 are indirectly attachable to the roof by means of a roof-mounted 15 fixture (not shown), it will be understood the foot assemblies 2 may also be adapted for attachment directly to the roof, or by any known means.

The telescoping member 3 includes a bar section 4 and an end section 5. As best seen in Figs. 1 and 2 (which show the telescoping member 3 in the extended and retracted position 20 5 respectively), the end section 5 and resilient foam tip 6 are sized and contoured to fit into the foot assembly, to blend smoothly with the adjacent outer surface of the foot assembly 2 and present a smoothly contoured shape for reduced aerodynamic noise and drag. The end section 5 has a soft resilient foam tip 6 fixed at its outer extremity to protect the user when the telescoping member 3 is extended.

A trigger 7 for releasing a latch mechanism (described more fully with reference to Figs. 5 and 6) is provided on the concave inside of the half-arch shaped foot assembly 2 and is 8 Intellectual Property Office of N.Z.

FEB 2005 biased outwardly until depressed by a user. When the trigger 7 is depressed the telescoping member 3 is released and is readily manually moved into or out of the roof rack bar 1.

Referring to Fig. 3, an aperture 35 is formed in the foot assembly 2 for receiving the end 5 section 5 of the telescoping member 3. The aperture extends substantially in the longitudinal direction. Fig. 3 also illustrates the constant aerofoil shaped cross section of both the roof rack bar 1 and the telescoping bar section 4. Both the roof rack bar 1 and the telescoping bar section 4 are channels having longitudinally extending openings 8,9 in their respective upper surfaces. The opening 8 in the hollow roof rack bar 1 is bounded by a pair of 10 opposing flanges 10,11 which extend inwards. The opening 9 in the telescoping bar section 4 is the mouth of a channel section bounded by lips 12,13 which receives the flanges 10, 11. The fastening fixture 25 (described with reference to Figs. 8-10) may be inserted between the flanges 12,13 to fasten to the telescoping bar section 4 to provide means for securing the load at any point along the roof rack. Fig. 3 also illustrates a key 39 for 15 operating a locking mechanism (not shown) for fixing the roof rack to the vehicle.

As shown in Fig. 4, the latch mechanism of this first embodiment is of the spring-loaded detent type including a detent in the form of a pin 15 mounted in a central section of the foot assembly 2. The pin 15 is biased upward toward the lower face 17 of the bar section 4 by a 20 leaf spring 16 for engagement with one of a plurality of apertures (not shown) formed in the lower face 17 to thereby lock the bar section 4 in the retracted position or in one of several extended positions. The sliding bearing 21 is fixed to the end of the bar section 4 and is sized to engage with the inside of the roof rack bar 1. The opposing end of the bar section 4 is supported in a bearing 22 fixed in the foot assembly 2. Additional bearings 23 are fixed to 25 the upper walls of the roof rack bar 1 at position 24 (generally above the bearing 22 when assembled). The sliding bearing 21 abuts a rivet 14 fixed to the foot assembly 2 to prevent the bar section 4 from becoming disengaged from the roof rack bar 1 when extended Intellectual Property Office of N.Z.

FEB 2005 outwardly as shown in Fig. 1.

The pin 15 is fixed to the spring 16, as best seen in Figs. 5. The spring 16 is in the form of a strip of spring steel, or the like, having an aperture 18 atone end thereof by which it is riveted 5 to the foot assembly 2 in the manner of a cantilever beam. At the opposing end, adjacent to the pin 15, an offset 19 is formed in the strip. The offset 19 is received in a slot 20 in the trigger 7 for releasing the pin 15 to allow the telescoping section 3 to be moved. Fig. 6 illustrates the construction of the trigger 7 which is fixed for pivoting about axis XX and is biased to the released position by the spring 16.

Fig. 7 illustrates a second embodiment of the present invention that requires a key to release the telescoping member 1. The latching mechanism is of a clamping type, having a clamping arm 40 fixed by a pin 41 to the foot assembly 2. The clamping arm 40 tensions a fastener 42 received in a slots (not shown) in both the roof rack bar 1 and the telescoping 15 member 3, which is clamped between the head 43 and the roof rack bar 1. A clip 44 is biased to rotate counter clockwise (to the position shown) to hold the clamping arm 40 in its clamped position. To prevent unauthorized release of the telescoping member 3, a key (not shown) must be used to open the cover 45 to gain access to the clip 44. As illustrated, the clip 44 may be moved to its released position 44' when the cover 45 is removed, thus 20 permitting the clamping arm 40 to be pivoted to its respective released position 40'. The clamping arm 44, (like the trigger 7) is located on the inside of the foot assembly 2 and has an arcuate inner face 46 matching the inner face of the foot assembly 2. It will be understood that the key may directly release the clip 44 and be the same key used to for operating the mechanism (not shown) for locking the roof rack to the vehicle. This clamping 25 type latching mechanism clamps both the roof rack bar 1 and the telescoping member 3 to the foot assembly. In this manner the mechanism, in addition to providing for adjustably fixing the telescoping member 3, also provides for the feet to be adjustably fixed with respect Intellectual Property Office of N.2.

FEB 2005 to the roof rack bar 1 e.g for adjusting the span of the roof rack to suit different vehicles. In other respects, this second embodiment is like the first and includes, for example, the end section 5 and resilient foam tip 6 sized and contoured to fit into the foot assembly 2.

Referring to Figs. 8-10, a fastening fixture 25 for securing a load to the roof rack is received within the channel of the roof rack bar 1 and within the mouth of the telescoping member 3 and may be fastened to either channel member 1 or 3. The fastening fixture 25 includes a body section having a top flange 26 with a central aperture 27 formed therein. Fixed to opposing ends of the top flange 26 are end pieces 28 between which a block 29 is slidingly received, the block having a threaded opening (not shown) aligned with the central aperture 27. The end pieces 28 have a narrow necked section 32 to slidingly retain the fastening fixture 25 within the roof rack. As best seen in Fig. 8, the fastening fixture 25 may be fixed to the roof rack bar 1 using a threaded fastener 30 which engages with the block 29 to clamp the bar flanges 10,11 on either side of the mouth between the block 29 and the top flange 26. The block 29 is substantially U-shaped in transverse section having upstanding edges 36, the bases of which abut respective inner surfaces of the flanges 10,11 Alternatively, the fastening fixture 25 may also be fixed to the telescoping member 3 so as to permit the fastening fixture 25 to slide into the roof rack bar 1. To maintain the necessary clearance for a sliding fit between the top flange 26 and the roof rack bar 1, the fastening fixture 25 is clamped to the inside of the telescoping member 3, the lower face 35 of the body abutting the internal surface 31 and the block 29 contacting an opposing inner surface of the lips 12, 13 either side of the mouth as the fastener is tightened. The fastening fixture 25 is adapted to be inserted through the mouth of the telescoping member channel, between the lips 12 and 13. Firstly the block 29 is inserted between the lips 12 and 13. Diagonally opposing corners of the block 29 have chamfers 32 to reduce its diagonal dimension to less than the opening between the lips 12 and 13. This allows the block 29 to be inserted, then rotated to the position illustrated with its axis parallel to the longitudinal axis of the telescoping member 11 Intellectual Property Office of N.Z. -4 FEB 2005 3. Next the body section is dropped over the block and the two are connected by the fastener 30. The fastening fixture 25 may serve to attach fixtures tie-downs, or special-purpose fittings for holding ladders, skis, bicycles, etc.

In use, when fitting a bicycle for example, the telescoping section 3 on two adjacent roof rack bars may be extended beyond the roofline of the vehicle, allowing ready access to the fixtures for fastening the bicycle and avoiding possible damage to the vehicle. The bicycle may be fixed to the telescoping member 3 and once fastened, by releasing the trigger 7, the bicycle and telescoping member 3 can be slid inward to a transport position.

Aspects of the present invention have been described by way of example only and it should be appreciated that modifications and additions may be made thereto without departing from the scope thereof.

Intellectual Property Office of N.Z. -4 FEB 2005 RECEIVED

Claims (2)

WHAT WE CLAIM IS:

1. A roof rack for a vehicle, including:

an elongate roof rack bar;

a pair of foot assemblies attachable to the roof rack bar, the foot assemblies being adapted to be detachably secured to opposing sides of a roof of the vehicle, each foot assembly having an opening in which opposing ends of the roof rack bar are received;

at least one telescoping member adapted for movement between a retracted position and an extended position in which it extends the length of the roof rack when both foot assemblies are secured to the vehicle, wherein each telescoping member includes an end section in which one end of a bar section is received, the bar section is slidably received within the roof rack bar and in the retracted position the end section is slidably received within and closes an aperture in the respective foot assembly, the end section being shaped to blend substantially smoothly with an adjacent outer surface of the foot assembly for low drag and noise production (in the retracted position).

2. The roof rack claim 1 further including a soft tapered tip fixed to the outer extremity of the end section.

3. The roof rack claim 1 or claim 2 wherein the roof rack bar and foot assemblies together form a flattened arch-shaped assembly with the elongate roof rack bar spanning the

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centre of the arch between opposing half-arch-shaped foot assemblies.

4. The roof rack of any one of the preceding claims further including a latching mechanism for fixing each telescoping member in the extended positions and in the retracted position.

5. The roof rack of any one of the preceding claims wherein both the roof rack bar and each telescoping member have respective longitudinally extending openings in an upper face thereof, a central axis of the respective openings being aligned, such that with the or each telescoping member in any extended position, the opening in each telescoping member is continuous with the opening in the roof rack bar.

6. The roof rack of any one of the preceding claims wherein the roof rack bar and telescoping members are channel sections, the mouth of each channel being formed between a pair of opposing flanges such that width of each mouth is narrower than the internal width of the respective channel section.

7. The roof rack of claim 7 wherein the opposing flanges on the roof rack bar extend inwardly and are received in the mouth of the telescoping member channel.

8. The roof rack of any one of the preceding claims wherein the roof rack bar has an aerofoil profile, and each telescoping member has a corresponding aerofoil profile.

9. The roof rack of any one of the preceding claims wherein a soft tip is provided on the outermost end of each telescoping member to protect the user when the telescoping member is extended.

10. The roof rack of any one of the preceding claims wherein each latching mechanism includes a spring-loaded detent for engagement with a plurality of apertures in the telescoping member, the detent being releasable by a manually operated trigger.

11. The roof rack of any one of claims 5 to 11 wherein each latching mechanism is adapted such that it cannot operate to release the telescoping member without a key.

12. The roof rack of any one of claims 5 to 12 wherein each latching mechanism is adapted such that it cannot operate to release the telescoping member without the need to remove the roof rack from a vehicle.

13. The roof rack of claim 12 or claim 13 wherein each latching mechanism comprises clamping means for clamping the telescoping member and roof rack bar together, the clamping means including a clamping arm positioned on the inside of the foot assembly.

14. The roof rack of claim 14 wherein the clamping means clamps both the telescoping member and roof rack bar to the foot assembly.

15. The roof rack of any one of claims 14 or claim 15 wherein the clamping means includes a clamping arm and a spring-loaded clip for holding the clamping arm in an engaged position and a key is required either to directly release the clip or to remove an access panel so that the clip may be manually released.

16. The roof rack of any one of the preceding claims, further including a fixture releasably attachable to either the roof rack bar channel or the telescoping member channel for securing a load to the roof rack, the fixture including:

Int^fectual p"o^rty

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a. a body having a top flange and a necked section between the top flange and a lower face substantially opposing the top flange, the necked section being received in the mouth of either the roof rack bar channel or the telescoping member channel for retaining the body therein,

b. a block for abutting inner surfaces either side of the mouth of each channel, the block being slidably received within the body;

c. a fastener connecting the block and the body for relative sliding movement, wherein d. to attach the fixture to the telescoping member channel the fastener is tensioned to clamp the channel internally, the block abutting inner surfaces either side of the mouth and the lower face of the body abutting a substantially opposing internal surface of the channel, and e. to attach the fixture to the roof rack bar channel the fastener is tensioned to clamp the channel between the inner surfaces and an external surface, the top flange abutting the external surface and the block abutting the inner surfaces on either side of the mouth.

17. The roof rack of claim 17 wherein the fixture is adapted such that when secured to the telescoping member, the fixture is able to slide within the roof rack bar.

18. The roof rack of claim 17 wherein the fitting is secured to the fixture by the fastener.

20. A roof rack substantially as hereinbefore described with reference to the accompanying drawings.

END OF CLAIMS ^

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