WO2015085431A1

WO2015085431A1 - Automotive roof rail

Info

Publication number: WO2015085431A1
Application number: PCT/CA2014/051204
Authority: WO
Inventors: Kulbir Singh Dhillon; Marc-André OUELLET; Serge Moreau; Mike PROFYT
Original assignee: Salflex Polymers Ltd
Current assignee: Salflex Polymers Ltd
Priority date: 2013-12-12
Filing date: 2014-12-12
Publication date: 2015-06-18
Anticipated expiration: 2016-06-12

Abstract

An automotive roof rail system is provided comprising a roof rail and at least one bracket for use in attaching the roof rail to a roof structure. The bracket is configured with an arch structure that captures a similarly shaped footing provided on the roof rail when the bracket is fastened to the roof structure.

Description

AUTOMOTIVE ROOF RAIL

Field of the Invention

The present invention relates to the field of roof rails, and in particular, to a blow molded automotive roof rail system.

Background of the Invention

[0001] The automotive roof rail assembly is quickly becoming a sophisticated payload storage/transport system for modern vehicles, in particular for sport-oriented activities. The roof rack assembly is generally comprised of a pair of automotive roof rails, and in many configurations one or more transverse members interconnecting between them.

[0002] Historically, automotive roof rails have been of metallic construction, generally steel or aluminum. In more recent years, there has been a shift towards roof rails formed of thermoplastic materials. In large part, the move to thermoplastics has addressed long-standing issues relating to the metallic structures, including corrosion problems, and excessive weight.

[0003] Thermoplastic roof rails permit greater flexibility with respect to design parameters, enabling nicely tapered ends and generally enhanced overall aesthetics. But with this focus on form, the need for safe and secure function remains paramount, in particular given the expanded usage of exterior storage systems now available for use on automotive roof rail assemblies. Accordingly, automotive roof rail systems must be configured to handle significant payload requirements, necessitating attachment methodologies that compliment modem aesthetics while achieving the required performance characteristics.

Summary of the Invention

[0004] According to an aspect of an embodiment, provided is an automotive roof rail system comprising, a roof rail, and at least one bracket for use in attaching the roof rail to a roof structure, wherein the bracket is configured with an arch structure that captures a similarly shaped footing provided on the roof rail when the bracket is fastened to the roof structure.

Brief Description of the Drawings

[0005] The foregoing and other features and advantages of the invention will be apparent from the following description of the invention as illustrated in the accompanying drawings. The accompanying drawings, which are incorporated herein and form a part of the specification, further serve to explain the principles of the invention and to enable a person skilled in the pertinent art to make and use the invention. The drawings are not to scale.

[0006] Fig. 1 is an exploded perspective view of a roof rail system.

[0007] Fig. 2 is a perspective view of the roof rail system of Fig. 1 mounted on a vehicle.

[0008] Fig. 3a is a side view of the roof rail forming part of the roof rail system of Fig. 1.

[0009] Fig. 3b is a sectional view of the roof rail of Fig. 3a through line A-A.

[0010] Fig. 3c is a sectional view of the roof rail of Fig. 3a through line B-B.

[0011] Fig. 4a is a perspective view of the bracket forming part of the roof rail system of Fig.

1.

[0012] Fig. 4b is a partial perspective view of an attachment point of the roof rail system of Fig. 1, showing the relationship between the bracket and roof rail.

[0013] Fig. 4c is a partial sectional view of an attachment point of the roof rail system of Fig. 1, showing the relationship between the bracket and roof rail.

Detailed Description of Embodiments of the Present Invention

[0014] Specific embodiments of the present invention will now be described with reference to the Figures, wherein like reference numbers indicate identical or functionally similar elements. The following detailed description is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. A person skilled in the relevant art will recognize that other configurations and arrangements can be used without departing from the scope of the invention Although the description and drawings of the embodiments hereof exemplify the technology as applied to automotive roof rails, the invention may also be applied to other applications, such as marine and aviation applications. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, brief summary or the following detailed description.

[0015] In the following, a blow molded automotive roof rail is described. The roof rail is blow molded in one-piece, with or without intermediate cutout regions. The roof rail is generally attached to the vehicle at two attachment points, situated towards each terminal end of the roof rail. In some configurations, additional attachments points, for example at one or more points intermediate the terminal ends may be provided. At the terminal attachment points, the roof rail cooperates with a bracket to ensure secure attachment of the roof rail to the vehicle. The roof rail is suitable for use in tying or in some manner securing contents, for example sports equipment on the roof structure of the vehicle.

[0016] Turning now to Fig. 1, shown is an exploded perspective view of a roof rail system 10, the roof rail system 10 including a roof rail 20, a bracket 22 provided at each attachment point, suitable fasteners 24 for securing roof rail system 10 to a vehicle roof 26 (as seen in Fig. 2), a cover plate 28 for each attachment point, suitable hardware 30 to facilitate attachment of cover plate 28 to roof rail 20, and a gasket 32 (which may be optional) for placement between roof rail 20 and vehicle roof 26. Roof rail system 10 is generally provided in pairs, as shown in Fig. 2, and may cooperate to support contents (e.g. sports equipment) placed upon the vehicle roof. Roof rail system 10, and in particular where they are provided as pairs may further cooperate with one or more transverse members (not shown) to provide additional structure/support for carrying elongated loads (e.g. hard-case carriers).

[0017] Roof rail 20, shown in isolation in Fig. 3a, may be formed using a variety of processes, but is exemplified here as a blow molded structure. While a variety of designs may be achieved using a blow-molding manufacturing process, roof rail 20 is exemplified as an elongate structure having first and second cutout regions 34, 36. Blow-molding processes suitable for use in molding similar articles are known in the art. For roof rail 20 detailed in Fig. 3a, the blow mold process would broadly include the extrusion of a hollow parison, followed by the molding of the hollow parison in a mold tool having a suitably shaped cavity. Within the mold tool, the hollow parison is subjected to pressure, generally air pressure, to urge the parison against the cavity walls. After sufficient holding time, the mold tool is opened to discharge the molded product. If necessary, the molded product may receive additional post-mold processing, for example to remove flash. As is generally the case with blow molded articles, roof rail 20 is a hollow structure, as noted for example in the cross-sections shown in Figs. 3b and 3c, taken along lines A-A and B-B, respectively.

[0018] Turning now to Fig. 4a, illustrated is bracket 22 in isolation from roof rail system 10. Bracket 22 serves as a load bearing attachment point for securing roof rail 20 to the vehicle. As shown, bracket 22 includes two anchorage flats 38, 40 interconnected by a bridge structure 42. Bridge structure 42 defines an arch structure dimensioned to capture and lock in fixed position a similarly shaped footing 44 (see Figs. 4b and 4c) provided as an integral feature on roof rail 20. In particular, the arch structure is configured as a geometric arch to increase the contact surface between bracket 22 and footing 44. As shown, the geometric arch is defined by first and second wall sections 46, 48 and first and second ramped sections 50, 52 extending therebetween. Bridge structure 42 also provides on each of first and second ramped sections 50, 52 a ridge 54 to enhance stiffness of bridge structure 42.

[0019] When installed on the vehicle, for example as shown in Figs. 4b and 4c, bridge structure 42 is fitted over footing 44 of roof rail 20, and secured in position on the vehicle roof using suitable fasteners 24. In the example shown, fasteners 24 are represented as speed nuts configured to cooperate with threaded studs (not shown) extending upwardly from the vehicle roof structure. Alternatively, some embodiments may implement alternate fastening mechanisms, for example threaded bolts configured to mate with corresponding threaded bores provided on the vehicle.

[0020] With specific reference to Fig. 4c, it will be noted that bracket 22 is asymmetrical, with first ramp section 50 configured to be shorter than second ramp section 52. As a result, apex 56 is positionally displaced relative to plane of symmetry X. Where roof rail 20 is positioned such that point 58 is oriented towards the front of the vehicle, it will be noted that apex 56 is situated forwardly of plane of symmetry X, that is towards the front of the vehicle. As such, vertical loads are distributed towards the more forwardly located fastener 24. It will also be noted that while bracket 22 and footing 44 are similarly shaped, bracket 22 is dimensioned to provided gap Gl (between footing 44 and first wall 46) and gap G2 (between footing 44 and second wall 48), to reduce stress placed against walls 46, 48 under load, and to concentrate load stresses on the ramped portions of footing 44. Additionally, between footing 44 and first and second ramped sections 50, 52, there is provided gaps G3 and G4, respectively Gaps G3 and G4 serve to concentrate vertical loads towards the region of apex 56. Also present are notches Nl and N2 provided on footing 44, to reduce stresses imparted upon the corners of footing 44 by bracket 22. In the bracket shown (see Fig. 4a), also provided is an extension 60 having wall 62, support 64 and stiffening ridge 66. Where bracket 22 is located at a forward attachment point of roof rail 20 (as shown in Fig. 4b), extension 60 extends from the rear portion of bracket 22. Where bracket 22 is located at a rearward attachment point of roof rail 20 (as best seen in the exploded view of Fig 1), extension 60 extends from the front portion of bracket 22. In either arrangement, support 64 is configured to engage with roof rail 20, so as to absorb initial vertical force during use.

[0021] Continuing with Figs. 4b and 4c, it will be noted that at each attachment point, bracket 22 is received in a recess 68 formed on roof rail 20, so as to remain largely hidden once covered by cover plate 28. Recess 68 is formed during the blow molding process, so as to maintain the largely sealed hollow interior on roof rail 20. As best seen in Fig. 4c, recess 68 is specifically dimensioned with openings 70, 72 to receive and permit direct attachment of flats 38, 40 of bracket 22 with vehicle roof 26 structure (and where gasket 32 is provided, with gasket 32 captured therebetween). The configuration of the wall structure defining recess 68 also serves to present footing 44 described previously.

[0022] As seen in Figs. 1 and 2, at each attachment point where bracket 22 secures roof rail 20 to the vehicle, bracket 22 is covered by cover plate 28. To secure cover plate 28 in position over recess 68 in which bracket 22 is received, suitable hardware 30 is provided. It will be appreciated that a range of fastening mechanisms may be implemented here. As shown for example in Fig. 4b, hardware 30 is presented as posts designed to engage and releaseably secure with cooperating features (i.e. tabs) provided on the rear side of cover plate 28. Other suitable fastening mechanisms may include, but are not limited to, the use of clips, tabs and grooves, or threaded fasteners.

[0023] While roof rail 20 has been exemplified as a blow-molded structure, it will be appreciated that other manufacturing techniques may be used, for example, but not limited to injection molding. Exemplary thermoplastic materials suitable for use include, but are not limited to, polypropylene, thermoplastic polyolefins (TPO), acrylonitrate-butadiene-styrene (ABS), polycarbonate (PC), polybutadiene terephthalate (PBT), polyethylene terephthalate (PET), nylon, polyvinyl chloride (PVC), polystyrene (PS), polyethylene (PPE), and blends of the above materials with other suitable materials (e.g. fillers including, but not limited to glass fibres, talk, etc.). Bracket 22 is generally a metallic structure (i.e. formed of a metal alloy), but other materials may be suitable (having either similar or different thickness and/or area of contact), including, but not limited to polymer and non-polymer based composites.

[0024] While roof rail system 10 has been exemplified as having two attachment points, namely at each terminal end of roof rail 20, in some applications additional attachment points may be implemented. For example, in some applications, it may be advantageous to incorporate an additional attachment point at one or more intermediate positions along roof rail 20. Specifically, having regard to Fig. 3, an additional attachment point may be incorporated at intermediate point I.

[0025] It should be noted that in the description, terms such as forward, front and derivations of these terms are intended to mean or refer to an orientation or location situated towards the front of the vehicle. Similarly, terms such as rearward, rear and derivations of these terms are intended to mean or refer to an orientation or location situated towards the back of the vehicle.

[0026] While various embodiments according to the present invention have been described above, it should be understood that they have been presented by way of illustration and example only, and not limitation. It will be apparent to persons skilled in the relevant art that various changes in form and detail can be made therein without departing from the scope of the invention. Thus, the breadth and scope of the present invention should not be limited by any of the above-descried exemplary embodiments, but should be defined only in accordance with the appended claims and their equivalents. It will also be understood that each feature of each embodiment discussed herein, and of each reference cited herein, can be used in combination with the features of any other combination. All patents and publications discussed herein are incorporated by reference herein in their entirety.

Claims

CLAIMED

1. An automotive roof rail system comprising,

a roof rail;

at least one bracket for use in attaching the roof rail to a roof structure;

wherein the bracket is configured with an arch structure that captures a similarly shaped footing provided on said roof rail when said bracket is fastened to said roof structure.

2. The automotive roof rail system according to claim 1, wherein said roof rail is blow molded.

3. The automotive roof rail system according to claim 1, wherein said system includes a pair of roof rails, said pair of roof rails cooperating with one or more transverse members to provide additional structure/support to said roof rail system.

4. The automotive roof rail system according to claim 1, wherein a gasket is provided for placement between said roof rail and said roof structure.

5. The automotive roof rail system according to claim 1, wherein said roof rail is configured with two attachment points defining anchorage footings, generally at each terminal end of said roof rail.

6. The automotive roof rail system according to claim 5, wherein said bracket includes a bridge structure interconnecting first and second anchorage flats, said bridge structure serving to capture and lock in position said footing of said attachment point, with first and second anchorage flats cooperating with suitable fasteners to secure said roof rail system to said roof structure.

7. The automotive roof rail system according to claim 6, wherein said bridge structure of said bracket is defined by a first ramp section and a second ramp section, wherein said first ramp section is shorter than said second ramp section.

8. The automotive roof rail system according to claim 7, wherein said bracket is positioned at each attachment point in such a manner so as to locate said first ramp section proximal to the terminal ends of said roof rail.

9. The automotive roof rail system according to claim 7, wherein said first and second ramp sections define an apex, said footing having positive contact with said apex of said bracket, and wherein a gap is provided between said footing and at least a portion of said ramped sections, distal from said apex.

10. The automotive roof rail system according to claim 7, wherein each of said first and second ramped sections is provided with a ridge to promote enhanced stiffness in said bridge structure.