NZ561810A - Leg for a roof rack with a cover which forms an enclosure - Google Patents

Abstract

Disclosed is a leg for a roof rack. The leg includes a crossbar housing supported by a base. The crossbar housing has a profile shaped to hold a crossbar and the base includes means for attaching the leg to a vehicle. The leg is removably attachable to a leg cover which includes a single moulded piece with a body having an upper portion and a roof projecting from the upper portion. The roof includes a first surface and a second surface and side edges adapted to align with sides of the crossbar housing such that the leg cover and crossbar housing together form an enclosure.

Description

561810 SGl&f O m i iiiii i in 111 mi mil in *10056569681 * PATENTS FORM NO. 5 Our ref: BFR 227872NZPR NEW ZEALAND PATENTS ACT 1953 COMPLETE SPECIFICATION ROOF RACK AND VERSATILE LEG FOR A ROOF RACK We, Hubco Automotive Ltd a New Zealand Company of 46 Parkhouse Road, Sockburn, Christchurch, New Zealand 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 intellectual property office of n.z, 101274564_1. DOC:BFR:qwgtn SEP received 561810 ROOF RACK AND VERSATILE LEG FOR A ROOF RACK Field of the Invention The present invention relates to a vehicle roof rack or load carrier and a versatile leg for a roof rack.

Background of the Invention Roof racks are well known and are manufactured in a variety of configurations. Typically, roof racks include a crossbar with a leg at each end of the crossbar, the legs being used to support the crossbar and attach the crossbar to the roof of a vehicle. The legs are spaced apart from each other a selected distance. Generally, the distance between the legs is determined by the width of the vehicle 15 to which the roof rack is to be mounted. However, some loads require the crossbar of the roof rack to be longer than the distance between the legs of the roof rack. Therefore, roof racks were developed that allowed the crossbar to be longer than the distance between the legs of the roof rack when the rack is attached to a vehicle. That is, in such roof racks, the ends of the crossbar extend 20 beyond the legs of the roof rack. Such crossbars may be wider than the roof of the vehicle to which the roof rack is to be attached. Roof racks having a crossbar with ends extending beyond the legs of the roof racks are referred to in this specification as "through bar" roof racks.

To some people, through bar roof racks are not aesthetically pleasing. Furthermore, when a load is sufficiently small that the portions of crossbar extending beyond the legs are not utilised, those portions represent unnecessary drag to the vehicle and increase the amount of noise resulting from the roof rack. To help avoid these disadvantages, roof racks were developed that included legs, 30 which housed the ends of the crossbar, such that the ends of the crossbar were substantially flush with the respective leg of the roof rack supporting that end. Such roof racks are referred to in this specification as "flush bar" roof racks. The length of the crossbar in flush bar roof racks is less than the width of the roof of the vehicle to which the roof rack is to be attached. 2 561810 Legs are specifically manufactured for through bar roof racks and different legs are specifically manufactured for flush bar roof racks. Therefore, a manufacturer making both forms of roof rack needs to make different legs for the through bar 5 roof racks compared with the flush bar roof racks, thereby increasing manufacturing costs.

Furthermore, a retailer selling both types of roof racks has to stock both types of legs, thereby increasing stock levels.

It is an object of the present invention to go at least some way towards overcoming the above-mentioned disadvantages, or to at least provide the public with a useful choice.

Summary of the Invention The present invention provides a versatile leg for a roof rack. The leg can be used with either a through bar roof rack or a flush bar roof rack. Thus, the number of different types of component parts that a manufacturer of roof racks needs to 20 make is reduced. Furthermore, because a purchaser can buy the component parts to a roof rack individually, a retailer of roof racks needs only to stock one type of roof rack leg, thereby reducing stock levels.

In a first aspect, the invention provides a leg for a roof rack, wherein the leg has a 25 crossbar housing supported by a base, the crossbar housing having a profile shaped to hold a crossbar therein, and the base comprising a means for attaching the leg to a vehicle, wherein the leg is suitable for use with a crossbar in a through bar roof rack and for use with a crossbar in a flush bar roof rack.

The base of the leg may be adapted to be attached to a mounting system for attaching the leg to a roof rack mount on a vehicle. Alternatively, a suitable mounting system may be integral with the leg. 3 561810 Preferably, the leg is removably attachable to a leg cover, both the leg and leg cover comprising corresponding leg cover attachment means to attach the leg cover to the leg.

More preferably, the leg is attached to a leg cover comprising attachment means in the form of one or more lugs and/or one or more lug receiving apertures for engaging with corresponding lugs and/or lug receiving apertures provided on the leg.

The leg may be removably attached to a cover for a through bar roof rack. In a preferred form, the leg cover has an upper profile that substantially corresponds with at least a portion of the profile of a lower portion of the crossbar housing so as not to obstruct the fit of a crossbar when housed within the crossbar housing.

Alternatively, the leg may be removably attached to a leg cover for a flush bar roof rack. In this form, the leg cover comprises a body having an upper portion with a roof projecting therefrom, the roof comprising a first surface and a second surface and side edges adapted to align with sides of the crossbar housing such that the leg cover and crossbar housing together form an enclosure within which the end of 20 a crossbar can be housed.

A pair of rails may project from the second surface of the roof to define a receiving means between the rails and the roof and within which opposing lips of a crossbar can be inserted to attach the leg cover to the crossbar.

The through bar and the flush bar leg cover may each comprise one or more braces for supporting one or more tools to be housed within the cover.

The leg and leg cover may comprise a locking system for locking the cover to the 30 leg.

The leg optionally comprises a pair of leg supports, each support comprising opposing inner locating faces, and wherein the leg cover comprises at least one locating guide for abutting an inner face of a leg support. 4 561810 The crossbar housing of the leg is preferably shaped to hold a crossbar having an aerodynamic end profile.

In another aspect the invention relates to a roof rack comprising a leg according to the first aspect of the invention.

The term "roof rack" as used herein should be interpreted to include the similar 10 term "load carrier".

Similarly, the term "crossbar" is to be interpreted broadly to include a roof rail or any load carrying apparatus configured to be releaseably clamped or attached to a roof rack leg.

The term "relevant vehicle" means the vehicle to which a user intends to attach a roof rack.

The term "comprising" as used in this specification and claims should be 20 interpreted to mean "consisting at least in part of or "comprising". That is, when interpreting independent claims comprising that term, the features prefaced by that term in each claim all need to be present but other features can also be present. Variants, such as "comprised" and "comprises" are to be interpreted in the same manner.

Brief Description of the 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 30 accompanying drawings in which: Figure 1 is a perspective view of a roof rack leg according to one embodiment of the present invention; 561810 Figure 2 is a perspective view from above of a roof rack leg according to one embodiment of the present invention; Figure 3 is a perspective view of the inner face of a leg cover for a through bar roof 5 rack according to one embodiment of the present invention; Figure 4 is front view of the leg cover of figure 3; Figure 5 is a perspective view of a portion of a crossbar for a roof rack according 10 to one embodiment of the present invention; Figure 6 is a perspective view of an end cap for a crossbar for a through bar roof rack according to one embodiment of the present invention; Figure 7 is a perspective view of a portion of a through bar roof rack according to one embodiment of the present invention; Figure 8 is a perspective view from below of the inner face of a leg cover for a flush bar roof rack according to one embodiment of the present invention; Figure 9 is a perspective view of a portion of a flush bar roof rack according to one embodiment of the present invention.

Detailed Description of Preferred Embodiments Figure 1 shows a perspective view of a leg 10 for the left hand side of a roof rack (when viewed from the rear of the relevant vehicle and looking toward the front of the vehicle) according to one embodiment of the present invention. The leg 10 comprises two supports in the form of splayed arms 21a, 21b that form the base of 30 the roof rack.

The base of the leg comprises a mounting means by which the assembled roof rack, comprising leg, can be attached to a vehicle. The mounting means may be attached to, or integral with the base of the leg. 6 561810 Because many different types of mounting means or mounts can be used with the roof rack leg of the present invention, the figures show component parts according to the invention without a mount.

The supports or arms 21a, 21b of the leg 10 shown in figure 1 have opposing inner locating faces 29a, 29b. Between the supports or arms 21a, 21b is a bridge 27 to support a crossbar housing 23 located above the bridge. The surfaces of the crossbar housing are shaped to hold and support a crossbar for the roof rack. The 10 crossbar should fit snugly within the crossbar housing, although the fit should not be so tight as to prevent the crossbar from sliding longitudinally within the housing when force in the longitudinal direction is applied to the crossbar.

Although the embodiments illustrated in the drawings show the leg having a 15 bridge, it is not essential for the leg to have a bridge. It is envisaged that the central portion of the leg may extend to the bottom edge of the arms or supports 21a, 21b, such that the base of the leg has a continuous lower edge.

The crossbar housing shown in figure 1 is defined by a concave floor having two 20 open sides through which a crossbar can slide. The concave floor of the housing also comprises two closed sides, comprising opposing lips 24a, 24b that define an opening between them.

The leg is adapted such that the outer facing open end of the crossbar housing 23 25 (through which a crossbar can slide) is exposed and accessible from the outer facing side of the leg. The outer facing side of the leg and crossbar housing is that side that faces away from the opposing leg of the roof rack, when the roof rack is assembled. In effect, in one form of the invention, the crossbar housing is formed within the leg. The leg, therefore, has a profile or shape that allows a crossbar to 30 slide within the crossbar housing without being hindered by the leg.

In the embodiment shown in figure 1, the crossbar housing 23 is shaped to allow for a crossbar having an aerodynamic end profile (the profile of the crossbar when viewed from one end) to be slid into the housing 23. However, it is envisaged that 7 561810 the crossbar housing could, alternatively, be shaped to fit a crossbar having a different end profile.

The opposing lips 24a and 24b prevent the crossbar from pulling upward out of the 5 housing 23 when upward force is applied to the roof rack. The crossbar housing 23 houses and supports the crossbar and secures the crossbar to the leg 10.

The crossbar housing 23 may have a recessed area 28 for locating a crossbar extension adjustment mechanism therein (as shown in figure 2). The adjustment 10 mechanism may comprise a retractable latch for hooking into an aperture or recess in the crossbar, or any other suitable adjustment mechanism as would be readily apparnt to a person skilled in the art. The crossbar extension adjustment latch (not shown) allows the effective length of the crossbar between the legs to be extended, or retracted, and then locked in the desired extended or retracted 15 position.

Other features of the invention will now be described by generally describing how a roof rack that comprises a leg of the present invention is fitted together.

If the leg 10 of the roof rack is to be used with a through bar roof rack, a through bar leg cover 11 is fitted to the leg 10. A through bar leg cover is shown in figure 6.

Alternatively, if the leg 10 of the roof rack is to be used with a flush bar roof rack, a 25 flush bar leg cover 14 is fitted to the leg 10. A flush bar leg cover is shown in figures 8 and 9.

The through bar leg cover 11 and flush bar leg cover 14 may each have one or more braces 31 and 41 respectively. The braces 31, 41 are positioned to hold one 30 or more tools, such as a hex key and a spanner 51, within the leg cover. Figure 3 shows a spanner 51 being held to a through bar leg cover 11 by braces 31. Figure 8 shows a spanner 51 being held to a flush bar leg cover 14 by braces 41. 8 Received at IPONZ on 26 January 2010 The through bar leg cover 11 and flush bar leg cover 14 may additionally, or alternatively, have a locating means in the form of a guide 32, 48 protruding from the inner face of the cover 11, 14.

The guide 32, 48 is positioned on the inner face of the cover 11,14 such that the guide abuts with an inner face 29a, 29b of the leg 10 and, preferably also abuts the lower edge 26a, 26b of the bridge 27 when the leg cover is attached to the leg 10. The guide 32, 48 helps a user to locate the cover properly on the leg and also helps to prevent the cover from skewing relative to the leg.

Typically, the guide 32, 48 is substantially planar.

It is envisaged that two or more guides may be positioned on the inner face of the leg cover 11, 14 to locate the cover to the leg.

The inner faces of the leg covers 11 and 14 also comprise leg cover attachment means, such as a pair of lugs 34a, 34b and 44a, 44b, respectively, for engaging with corresponding lug receiving apertures 25a, 25b on the leg 10.

The lugs 34a, 34b and 44a, 44b, and the receiving apertures 25a, 25b are sized so that the lugs can mate with the lug receiving apertures to help position the cover 11,14 correctly on the leg 10 when the cover 11, 14 is attached to the leg.

It is envisaged that the lugs could, alternatively, be positioned on the leg and the lug receiving apertures could be positioned on the cover. It is also envisaged 25 that the leg and the leg cover could each comprise one or more lugs and one or more lug receiving apertures. Other leg cover attachments means could, alternatively, be used, as would be apparent to a person skilled in the art.

A lock barrel is positioned within a barrel housing 35, 45 in each type of leg cover 30 11, 14. When the cover 11 is attached to a leg 10, the end of the lock barrel opposes a lock aperture 22 in the leg 10. The lock extends through the barrel housing 35, 45 and through the lock aperture 22 located in the leg 10.

The catch of the lock is shaped to fit through the lock aperture 22 when the catch 35 is in the unlocked position. When the catch is in the locked position, it cannot 9 561810 retract or fit through the lock aperture 22. As such, each type of leg cover 11, 14, when fitted with a lock, can only be attached to a leg 10 when the lock is in the unlocked position.

The lock is used to secure the through bar leg cover to the leg. The lock prevents a user from detaching and dismantling the roof rack from the roof of a vehicle without the appropriate key.

Other engagement means or locking means may additionally or alternatively be 10 used to detachably attach the leg cover to the leg, such means being apparent to those skilled in the art.

The assembly of the leg 10 with components for a through bar roof rack will now be described.

As shown in figures 1 and 4, the upper portion of the through bar leg cover 11 is profiled to substantially align with at least a portion of the profile of the crossbar housing 23 of the leg 10 when the through bar leg cover 11 is attached to the leg 10. The alignment of the profiles of the crossbar housing 23 and the upper portion 20 of the leg cover 11 allows a crossbar to be slid through both the crossbar housing 23 and the leg cover 11 without interference.

In particular, the peripheral shape of the through bar leg cover substantially follows the outside edges of the supporting arms 21a, 21b or base of the leg 10, and the 25 bottom portion of the crossbar housing 23 so that the leg cover 11 and leg 10 substantially appear as one part and so that that crossbar 12 can be fitted within the crossbar housing 23 without its fit being obstructed by the through bar leg cover 11. The crossbar 12 may also be slid within the crossbar housing 23 without its movement being impeded by the leg cover 11. The bottom of the leg cover 30 preferably has a continuous bottom edge that extends substantially along the entire bottom of the base of the leg 10. Alternatively, the leg cover 11 may comprise a pair of supports and a bridge to substantially conform with a roof rack leg of similar shape. 561810 In use, the crossbar is typically slid into the crossbar housing 23 before the through bar leg cover is attached to the leg; although it is possible to attach the crossbar 12 to the leg 10 after the through bar leg cover 11 has been attached to the leg. The crossbar 12 is shown in figure 5.

The crossbar 12 comprises a first cavity 61, a second cavity 62, and a longitudinal channel 63 within which is positioned a resilient infill 53 (as shown in figure 7). Equipment brackets (also known as accessory clamps) for holding kayaks, or bicycles for example, can be inserted into the channel 63 and positioned between 10 the resilient infill 53 and the upper lips 64a, 64b of the crossbar 12, as described in New Zealand patent application no. 551764.

The resilient infill substantially fills the channel 63 so that the upper surface of the crossbar is substantially flush. It is important that the infill is substantially flush 15 with the upper surface of the crossbar because any cavity between the infill and the opposing lips of the crossbar will increase the wind noise resulting from the roof rack.

An end cap 13 is attached to each end of the crossbar 12. As shown in figure 6, 20 the end cap 13 comprises a support 74, from which projects a first plug 71 and a second plug 72. The first and second plugs 71, 72 each have a peripheral surface that substantially corresponds with the inner surfaces of the first and second cavities 61, 62 respectively, so that the plugs substantially fill the first and second cavities 61, 62 within the crossbar 12.

The end cap 13 is attached to the crossbar by sliding the second plug 72 into the second cavity 62 of the crossbar 12, and by sliding the first plug 71 into the first cavity of the crossbar 12 until the support 74 of the end cap abuts the end of the crossbar 12.

The support 74 of the end cap 13 may comprise two parts: a body 75 and a hinged flap 76. The body 75 is attached to, or integral with, the first and second plugs 71 and 72 respectively. The hinged flap 76 is hinged from the body 75 so that the flap 76, when hinged away from the body 75, forms an opening through which it is 11 561810 possible to access the end of the crossbar 12 to which the end cap is attached. The hinged end cap allows for equipment brackets to be added to or removed from the roof rack without the need to remove the entire end cap.

The crossbar 12, together with end caps 13, legs 10, and through bar leg covers 11 comprise a through bar roof rack, part of which is shown in figure 7.

If the user wants to use the roof rack leg of the present invention with a flush bar roof rack, the leg is attached to component parts that are slightly different to the 10 parts of a through bar roof rack. The assembly of the leg 10 with component parts for a flush bar roof rack will now be described.

The same form of crossbar 12 can be used with a flush bar roof rack using the leg 10 of the present invention, except that the length of the crossbar for a flush bar 15 roof rack will typically be shorter than the length of a crossbar for a through bar roof rack.

To assemble a flush bar roof rack, the crossbar 12, comprising a resilient infill, is slid into the crossbar housing 23 of the leg 10, before the flush bar leg cover 14 is 20 attached to the leg. The crossbar housing 23 secures and supports the crossbar to the leg 10.

As shown in figure 8, the flush bar leg cover comprises a body 46 having an upper portion, and a roof 42. The roof 42 projects from the upper portion of the flush bar 25 leg cover 14 and comprises a first surface and a second surface. The second surface of the roof typically has the same profile as the upper surface of the crossbar.

In particular, the peripheral shape of the outboard face of the flush bar leg cover 30 substantially follows the outside edges of the supporting arms 21a, 21b or base of the leg 10, and the upper surface of the crossbar 12 and crossbar housing 23 to enclose the end of the crossbar 12. In effect, the upper portion of the leg cover substantially corresponds with the upper surface of a crossbar to be supported by the roof rack leg. The bottom of the flush bar leg cover 14 preferably has a 12 561810 continuous bottom edge that extends substantially along the entire bottom of the base of the leg 10. Alternatively, the leg cover 14 may comprise a pair of supports and a bridge to substantially correspond with a roof rack of similar shape.

The profile of the second surface of the roof allows for the second surface to slide against the upper surface of the crossbar. A snug fit is achieved between the upper surface of the crossbar and the second surface of the roof when the flush bar leg cover is attached to the crossbar.

A pair of locating rails 43a, 43b project from the second surface of the roof 42. The space between the rails 43a and 43b and the second surface of the roof 42 defines a receiving means for receiving the opposing lips 64a, 64b of a crossbar therein. By positioning the opposing lips within the receiving means, the roof of the leg cover is attached to the crossbar and does not lift from the top surface of 15 the crossbar as a vehicle bearing these components moves. The fit between the roof of the leg cover and the crossbar is a sung fit so that minimal air is trapped between the join of the components and, consequently, wind noise is reduced.

In the embodiment shown in figure 8, the roof 42 has side edges 47a, 47b that are 20 profiled to align with and slide against the lips 24a, 24b of the crossbar housing 23 in the leg 10 so that the leg cover and the crossbar housing form an enclosure within which an end of the crossbar can be held. In an alternative arrangement, the sides of the roof are adapted to align with an outside surface of the arms of the roof rack leg, again forming a substantially flush join between the roof and the leg 25 to minimise wind noise.

The flush bar leg cover 14 is attached to the crossbar 12 and leg 10 by sliding the roof 42 over the upper surface of one end of the crossbar 12 so that the lips 64a, 64b are positioned between the rails 43a, 43b and the second surface of the roof 30 42. By positioning the lips 64a, 64b within the rails 43a, 43b, the flush bar leg cover 14 is attached to the crossbar 12.

After positioning the lips 64a, 64b within the rails 43a, 43b, the cover 14 is then aligned with the leg so that the locating guide contacts a corresponding inner face 13 561810 of the leg. The cover is further slid towards the leg 10 until the lugs 44a, 44b mate with the lug receiving apertures 25a, 25b, on the leg 10.

The roof 42 and the crossbar housing 23 together form a cavity within which the 5 end of the crossbar is housed.

The assembled legs 10, crossbar 12, and flush bar covers 14 comprise a flush bar roof rack, a portion of which can be seen in figure 9.

As can be seen, the flush bar leg cover 14 completely surrounds the end of the crossbar 12 and the outboard face of the leg (the outboard face is the face projecting in the opposite direction to the corresponding roof rack leg). Thus, the leg 10 and the leg cover 14 for a flush bar roof rack comprise a tidy and aesthetically pleasing way to house and support a crossbar. This close-fitting 15 arrangement also reduces wind noise around the legs of the roof rack.

While the present invention has been illustrated by the description of the embodiments thereof, and while the embodiments have been described in considerable detail, it is not the intention of the applicant to restrict or in any way 20 limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. Therefore, the invention, in its broader aspects, is not limited to the specific details of the representative apparatus and method, and illustrative examples shown and described. Accordingly, departures may be made from such details without 25 departure from the scope of the applicant's general inventive concept. 14 Received at IPONZ on 23 February 2010

Claims (14)

WHAT WE CLAIM IS:

1. A leg for a roof rack, the leg comprising a crossbar housing supported by a base, the crossbar housing having a profile shaped to hold a crossbar therein, and the base comprising means for attaching the leg to a vehicle, and wherein the leg is removably attached to a leg cover comprising a single moulded piece with a body having an upper portion and a roof projecting therefrom, the roof comprising a first surface and a second surface and side edges adapted to align with sides of the crossbar housing such that the leg cover and crossbar housing together form an enclosure.

2. A leg for a roof rack according to claim 1, wherein a pair of rails project from the second surface of the roof to define a receiving means between the rails and the roof and within which opposing lips of a crossbar can be inserted to attach the leg cover to the crossbar.

3. A leg for a roof rack according to claim 1 or claim 2, wherein the leg cover comprises one or more braces for supporting one or more tools to be housed within the cover.

4. A leg for a roof rack according to any one of the above claims wherein the end of the crossbar is housed within the enclosure.

5. A leg for a roof rack according to any one of the above claims, wherein the base of the leg is adapted to be attached to a mounting system for attaching the leg to a roof rack mount on a vehicle.

6. A leg for a roof rack according to any one of the above claims, wherein the leg is removably attachable to a leg cover, both the leg and leg cover comprising corresponding leg cover attachment means to attach the leg cover to the leg.

7. A leg for a roof rack according to claim 6, wherein the leg is attached to a leg cover comprising attachment means in the form of one or more lugs and/or one or more lug receiving apertures for engaging with corresponding lugs and/or lug receiving apertures provided on the leg. 15 Received at IPONZ on 23 February 2010

8. A leg for a roof rack according to any preceding claim, wherein the leg is removably attached to a cover for a through bar roof rack.

9. A leg for a roof rack according to claim 8, wherein the leg cover has an upper profile that substantially corresponds with at least a portion of the profile of a lower portion of the crossbar housing so as not to obstruct the fit of a crossbar when housed within the crossbar housing.

10. A leg for a roof rack according to any one of the above claims, wherein the leg and leg cover comprise a locking system for locking the cover to the leg.

11. A leg for a roof rack according to any one of the above claims, wherein the leg comprises a pair of leg supports, each support comprising opposing inner locating faces, and wherein the leg cover comprises at least one locating guide for abutting an inner face of a leg support.

12. A leg for a roof rack according to any one of the preceding claims, wherein the crossbar housing is shaped to hold a crossbar having an aerodynamic end profile.

13. A roof rack comprising a leg according to any one of the above claims.

14. A leg for a roof rack comprising a base and a cover, wherein the cover is a single moulded piece with a body having an upper portion and a roof projecting therefrom substantially as herein described with reference to the Detailed Description and Figures 8 and 9. Hubco Automotive Limited By their Attorneys Create IP Per: 16