Abstract
A roof rail including a rail profile including a sheet material. The sheet material includes a cover part and a mounting part. A flange wall includes an edge portion of the cover part and a proximal portion of the mounting part connected to the edge portion, wherein an inner surface of the proximal portion is arranged at an angle. A second flange wall includes a second edge portion of the cover part arranged opposite the edge portion and a second proximal portion of the mounting part connected to the second edge portion, wherein an inner surface of the second proximal portion is arranged at a second angle. The mounting part includes a distal portion, wherein the distal portion is attached to the proximal portion and the second proximal portion and arranged at a mounting distance of at least 1 mm above a plane including lowermost parts of the flange walls.
Claims
1. A roof rail for a roof of a vehicle, comprising: an elongated rail profile comprising a sheet material comprising a plurality of bends; wherein the sheet material comprises: a cover part for providing an outermost surface of the roof rail during use; and a mounting part for mounting the elongated rail profile to a vehicle, wherein the mounting part is positioned between sides of the cover part; wherein a first flange wall of the elongated rail profile comprises: a first edge portion of the cover part; and a first proximal portion of the mounting part connected to the first edge portion, wherein an inner surface of the first proximal portion is arranged at a first angle from an inner surface of the first edge portion of the cover part; wherein a second flange wall of the elongated rail profile comprises: a second edge portion of the cover part arranged opposite the first edge portion; and a second proximal portion of the mounting part connected to the second edge portion, wherein an inner surface of the second proximal portion is arranged at a second angle from an inner surface of the second side portion of the cover part; wherein the first flange wall is a folded flange wall, wherein the folded flange wall is provided by one or more of the plurality of bends in the sheet material arranged between the first proximal portion and the first edge portion; and wherein the mounting part further comprises a distal portion configured to provide a contact surface for mounting the elongated rail profile to a roof of the vehicle, wherein the distal portion is attached to the first proximal portion and the second proximal portion and arranged at a mounting distance of at least 1 mm above a first plane comprising lowermost parts of the first flange wall and the second flange wall.
2. A roof rail according to claim 1, wherein the first angle and/or the second angle is/are an acute angle.
3. The roof rail according to claim 1, wherein the distal portion comprises a first distal portion contiguous with the first proximal portion at a first end of the first distal portion.
4. The roof rail according to claim 1, wherein the distal portion further comprises a second distal portion contiguous with the second proximal portion at the first end of the second distal portion.
5. The roof rail according to claim 1, wherein the first proximal portion is contiguous with the first edge portion and/or wherein the second proximal portion is contiguous with the second edge portion.
6. The roof rail according to claim 1, wherein the elongated rail profile defines a fully enclosed interior space.
7. The roof rail according to claim 1, wherein the folded flange wall is an open folded flange comprising an intermediate portion, which at a first end thereof is connected to the first edge portion via a first intermediate bend and at a second end thereof is connected to the first proximal portion, via a second intermediate bend, such that an intermediate distance is provided between the first edge portion and the first proximal portion.
8. The roof rail according to claim 1, wherein the folded flange wall is a flush folded flange wall comprising the inner surface of the first proximal portion arranged substantially in parallel with the inner surface of the first edge portion.
9. The roof rail according to claim 1, wherein the mounting part comprises an additional bend arranged at an interface between the first proximal portion and the distal portion, and wherein the additional bend is provided at a third angle being an obtuse angle measured between the inner surface of the first proximal portion and an inner surface of the distal portion.
10. The roof rail according to claim 1, wherein the elongated roof rail further comprises a base profile comprising a second sheet material, and wherein the base profile is arranged to extend across a bottom opening extending between the distal portion of the mounting part and a second distal portion of the mounting part.
11. The roof rail according to claim 1, wherein the sheet material comprises a metal.
12. The roof rail according to claim 11, wherein the metal is stainless steel.
13. The roof rail according to claim 11, wherein the metal is a chromium-nickel stainless steel material.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0111] Aspects of the present disclosure will be described in the following with reference to the figures in which:
[0112] FIG. 1a shows a transverse cross-section of a roof rail according to a first embodiment of the invention,
[0113] FIG. 1b shows a transverse cross-section of a roof rail according to a second embodiment of the invention,
[0114] FIG. 1c shows a transverse cross-section of a roof rail according to a third embodiment of the invention,
[0115] FIG. 1d shows a transverse cross-section of a roof rail according to a fourth embodiment of the invention,
[0116] FIG. 1e shows a transverse cross-section of a roof rail according to a fifth embodiment of the invention,
[0117] FIG. 1f shows a transverse cross-section of a roof rail according to a sixth embodiment of the invention,
[0118] FIG. 1g shows the roof rail according to the first embodiment as seen in perspective,
[0119] FIG. 2a shows a transverse cross-section of a roof rail according to a seventh embodiment of the invention,
[0120] FIG. 2b shows a roof rail according to an eighth embodiment of the invention, seen in perspective,
[0121] FIG. 2c shows a roof rail according to a ninth embodiment of the invention, seen in perspective,
[0122] FIG. 3a shows a roof rail according to a tenth embodiment as seen in perspective,
[0123] FIG. 3b shows the roof rail according to the tenth embodiment as seen in perspective,
[0124] FIG. 4a shows a roof rail with fastening means according to an eleventh embodiment of the invention, as seen in perspective,
[0125] FIG. 4b shows a cross-sectional view of the roof rail according to the eleventh embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0126] In relation to the figures described below, where the present disclosure may be described with reference to various embodiments, without limiting the same, it is to be understood that the disclosed embodiments are merely illustrative of the present disclosure that may be embodied in various and alternative forms. The figures may not be to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for, e.g., teaching one skilled in the art to variously employ the present disclosure.
[0127] A first group of figures containing FIGS. 1a-1f, 4a-4b, a second group of figures containing FIGS. 2a-2c and a third group of figures containing FIGS. 3a-3b generally shows three different types of roof rails 1 according to the invention. Common for all embodiments, and as seen for example in the transverse cross-sectional view FIG. 1a, is that the roof rail 1 includes a rail profile 2 made of a first sheet material 20, which is preferably formed by a roll forming method so as to provide a cover part 30 and a mounting part 40. The cover part is arranged to provide the outer visible surface of the roof rail 30b, which may be polished coated or otherwise made decorative. A bottom side of the rail profile 2b is arranged to be facing the vehicle when installed. The mounting part 40 is arranged to provide a strong connection between the roof of the vehicle and the roof rail 1.
[0128] Between the cover part 30 and the mounting part 40, e.g., at each side of the cover part 31, 32, the rail profile 2 includes a flange wall 71, 72 made by an edge portion 33, 34 and a neighboring proximal portion 41, 51, and providing a first angle α1 between inner surfaces of the neighboring first edge portion 33a and first proximal portion 41a and a second angle α2 between inner surfaces of the neighboring second edge portion 34a and second proximal portion 51a. In one or more examples, the first angle α1 and second angle α2 are preferably both sharp angles, e.g., between 0 degrees and 80 degrees, or such as between 0-50 degrees for the first angle α1 and between 0-85 degrees for the second angle α2, so that the proximal portion 41, 51 extents upwards and inwards into the interior space 4 covered by the cover part 30. In FIGS. 1a-c, 2a-c, 3a-b and 4a-b the first and second angle is approximately 0 degrees, such as between 0 and 10 degrees or between 0 and 5 degrees. An extent of the edge portion(s) and an extent of a proximal portion being proximal to the same first angle α1 and/or second angle α2 are preferably substantially planar.
[0129] The roof rail 1 further includes a distal portion 42, wherein the distal portion 42 is arranged to provide a contact surface as a mounting platform for fixing the rail profile 2 to the roof of the vehicle. The contact surface may include an inner surface of the distal portion 42a and/or outer surface of the distal portion 42b. Due to the first angle α1 and second angle α2, a mounting space 5 is provided and the distal portion 42 can be arranged with a minimum distance (H1) from the roof of the vehicle when installed, wherein the minimum distance (H1) is measured between a first plane P1 including the lowermost parts of the flange walls 75, 76 and an outer surface of the distal portion 42b, see e.g., FIG. 1a.
[0130] Additionally, by the flange wall 71, 72, the roof rail 1 is arranged so that upon fixing the rail profile 2 to the roof of the vehicle by applying a fixation force to the contact surface 42a, 42b towards the vehicle roof, the roof rail 2, e.g., in particularly in the cover part 30, may become pre-stressed increasing the strength of the roof rail 1.
[0131] The above-mentioned features described in relation to the example of FIG. 1a are common features, which are also present in the examples of FIGS. 1b-g 2a-2c, 3a-3b and 4a-4b. The elements described above in relation to FIG. 1a can generally be identified by the same or similar shape and/or relative location in the remaining figures. In the following each example will be described in more detail and the differing features between the different examples of the roof rail 1 according to the invention will become clear.
[0132] In FIGS. 1a-1f, the roof rail 1 encloses an interior space 4 by connecting longitudinal ends of the first sheet material, e.g., by a joint, e.g., welded connection 85, preferably at a bottom side of the rail profile 2b.
[0133] In FIG. 1a-1c, a first flange wall 71 is a first flush folded flange wall 73b made by a first edge portion of the cover part 33 and a first proximal portion of the mounting part 41, which have been arranged substantially in parallel and extending from a first lowermost part of the first flange wall 75. At a first side of the cover part 31, a first edge portion 33 is contiguous with a first proximal portion 41 at the first lowermost part of a first flange wall 75.
[0134] In FIG. 1a a first distal portion 42 is extending from the first proximal portion 41 at a first end of the first distal portion 43 towards the opposite second side of the cover part 32, where the first distal portion 42 is connected to a second proximal portion 51 at a second end of the first distal portion 44. The second proximal portion 51 is joined together with a second edge portion of the cover part 34, which joint provides a second flange wall 72 being a joined flange wall 74c. The second proximal portion 51 and the second edge portion 34 are arranged in abutting arrangement and preferably joined together. Preferably, an inner surface of the second edge portion 34a and an inner surface of the second proximal portion 51a are joined together by a glued or welded connection 85. Alternatively, the first flange wall 71 may be a joined flange wall, e.g., by welding or gluing, and the second flange wall 72 may be a flush folded flange wall.
[0135] In FIGS. 1b-1d, the rail profile 2 includes a first distal portion 42 extending from the first proximal portion 41 at a first end of the first distal portion 43 towards the second side of the cover part 32, and a second distal portion 52 is extending from the second proximal portion 51 at a first end of the second distal portion 53 towards the first side of the cover part 31. The first and second distal portions 42, 52 are joined at second ends 44, 54 thereof, preferably by a joint, e.g., welded connection 85. The extents of the distal portions may be substantially equal or different, and the connection may be provided in the middle of the bottom side of the rail profile 2b or closer to the first side of the cover part 31 or closer to the second side of the cover part 32. In FIGS. 1b-1c, the second proximal portion 51 provides a second flange wall 72 including a second flush folded flange wall 74b together with a second edge portion of the cover part 34 by being contiguously arranged with the second edge portion of the cover part 34. The second proximal portion 51 and the second edge portion 34 are arranged substantially in parallel and extending on opposite sides of a second lowermost part of the second flange wall 76.
[0136] In FIGS. 1a-1c, the first angle α1 between the inner surface of the first edge portion 33a and the inner surface of the first proximal portion 41a is between 0°-10°. Preferably, the second angle α2 between the inner surface of the second edge portion 34a and the inner surface of the second proximal portion 51a is also between 0°-10°. In one or more embodiments, the first angle α1 and second angle α2 may be substantially identical or different.
[0137] In one or more embodiments, the transverse cross-section of the elongated rail profile 2 includes a plurality of bends made in the first sheet material 20. The first angle α1 may be provided by a joined connection or by a first bend 61 provided between contiguously arranged first proximal portion 41 and first edge portion 33, and/or the second angle α2 may be provided by a joined connected or by second bend 62 between contiguously arranged second proximal portion 51 and second edge portion 34. An example of a rail profile 2 including both a first and second bend 61, 62 is for example shown in FIGS. 1b-1d, 2a-2c, and 3a. A line between inner and outer surfaces of the folded flange wall at the lowermost part of folded flange walls may define the interface between the neighboring edge portion and proximal portion.
[0138] The rail profiles may further includes a third bend 63 at an interface between a proximal portion 41, 51 and a distal portion 42, 52, see e.g., FIG. 1b-d. The bend may be provided at a third angle α3_1, α3_2, which is preferably an obtuse angle measured between inner surfaces of the proximal portion 41a, 51a and the adjacent distal portion 42a, 52a, see FIG. 1d, e.g., so that a dominant orientation of the distal portion(s) may optionally be substantially aligned along the roof of the vehicle, when installed thereon.
[0139] In FIG. 1c, a first distal portion 42 and a second distal portion 52 each include one or more further bends 60_1 . . . 60_8 collectively providing two inward protrusions along the collective extent of the distal portions. Alternatively, either the first distal portion 42 or the second distal portion 52 comprises the further bends 60_1 . . . 60_8 providing one or more inward protrusions along the connective extent of the distal portion(s) 42, 52.
[0140] FIG. 1c shows an example of how two protrusions may be made in the distal portion(s) 42, 52 of the roof rail 1. The first distal portion 42 is initially extending substantially horizontally from the third bend 63 connecting the first distal portion to the first proximal portion 41, towards the second side of the cover part 32. The one or more further bends include a first further bend 60_1 directing the first distal portion 42 inwards towards the interior space of the rail profile 4 and into an optional substantially vertical orientation, followed by a second further bend 60_2 of the one or more bends directing the first distal portion 42 towards the second side of the cover part 32 and into an optionally substantially horizontal orientation, followed by a third further bend 60_3 directing the first distal portion 42 downwards and into an optionally substantially vertical orientation, followed by a fourth further bend 60_4 directing the first distal portion 42 towards the second side of the cover part 32 and into an optionally substantially horizontal orientation, followed by an fifth further bend 60_5 directing the first distal portion 42 upwards towards the interior space 4 and into an optionally substantially vertical orientation, lastly followed by a sixth further bend 60_6 of the one or more bends directing the first distal portion 42 towards the second side of the cover part 32 and into an optionally substantially horizontal orientation. The second distal portion 52 is initially extending substantially horizontally from the second proximal portion 51 towards the first side of the cover part 31. The rail profile includes a further third bend 63 connecting the second distal portion 52 to the second proximal portion 51 and directing the second distal portion 52 inwards towards the interior space of the rail profile 4 and towards the opposite first side of the cover part 31, followed by a seventh further bend 60_7 directing the second distal portion 52 towards the top of the cover part 38 and into an majorly substantially vertical orientation and followed by an eight further bend 60_8 directing the second distal portion 52 towards the first side 31 and to the first distal portion 42. The connection may be made by a joint, e.g., glued or welded connection 85. The joint connection, e.g., welded connection 85 may be placed elsewhere along the mounting part, e.g., the one or more further bends 60_1 . . . 60_8 may be distributed differently between the first and second distal portions 42, 52 or they may all be provided in one distal portion 42, 52.
[0141] FIG. 1d shows a roof rail 1 including a rail profile 2 including folded flange walls 73, 74 made by an edge portion 33, 34 and a neighboring proximal portion 41, 51, and providing a first angle α1 between inner surfaces of the neighboring first edge portion 33a and first proximal portion 41a and a second angle α2 between inner surfaces of the neighboring second edge portion 34a and second proximal portion 51a. The first angle α1 and second angle α2 are preferably both sharp angles provided at an first angle α1 between 30 and 45 degrees and a second angle α2 between 55-75 degrees, so that the proximal portion 41, 51 extents upwards and inwards into the space covered by the cover part 30. An extent of the edge portion(s) 33, 34 and an extent of a proximal portion 41, 51 being proximal to the same first angle α1 and/or second angle α2 are preferably substantially planar. In one or more further examples, one of the first or second angles α1, α2 may be provided at an angle above 30 degrees but below 75 degrees, while the other angle of the first and second angles α1, α2 may be provided at an angle below 30 degrees, such as between 0-10 degrees.
[0142] In FIG. 1e, the rail profile 2 includes a first flange wall 71 and a second flange wall 72, and each flange wall 71, 72 includes an intermediate portion 45, 46, of an intermediate distance D1 at each side of the cover 31, 32, which results in a first and second open folded flange 73a, 74a. A first intermediate portion 45 is connected at a first end thereof 45_e1 to the first cover portion 33 by first intermediate bend 61_1 in the sheet material 20 and is further connected at second end thereof 45_e2 to the first proximal portion 41 by a second intermediate bend 61_2 in the sheet material 20. A second intermediate portion 46 is connected at a first end thereof 46_e1 to the second cover portion 34 by first intermediate bend 62_1 in the sheet material 20 and is further connected at second end thereof 46_e2 to the second proximal portion 51 by a second intermediate bend 62_2 in the sheet material 20. A first distal portion 42 is extending from the first proximal portion 41 towards the second proximal portion 51 and a second distal portion 52 is extending from the second proximal portion 51 towards the first proximal portion 41 and are connected by a joint, e.g., welded connection 85.
[0143] In FIG. 1e, the first and second intermediate bend 61_1, 61_2, 62_1, 62_2 are preferably provided at first and second intermediate angles αI1_1, αI1_2, αI2_1, αI2_2, which when added together provides a result between 160-200°, e.g., at a sum (αI1_1+αI1_2 or αI2_1+αI2_2) substantially equal to 180° the proximal portion extending from the second intermediate bend 45_e2, 46_e2 is parallel to the edge portion extending from the first intermediate bend 45_1, 46_e2, e.g., as seen in FIG. 1e. In one or more examples, at a sum of the first and second intermediate angles of a flange wall 71, 72 of approximately 180°, the first and second angles between the proximal portion 41, 51 and the edge portion 33, 34 of the flange wall 71, 72 is consequently approximately 0°. The sum of intermediate angles (αI1_1+αI1_2 or αI2_1+αI2_2) at a first flange wall 71 may be different to the sum of intermediate angles (αI1_1+αI1_2 or αI2_1+αI2_2) at a second flange wall 72 or they may substantially correspond to each other.
[0144] The outer surface of the intermediate portions 45b, 46b are arranged to be directed towards the vehicle roof when the roof rail is installed while the inner surfaces of the intermediate portions 45a, 46a are directed towards the interior space 4 and may aid in enclosing the space 4. An intermediate upper space 4a provided between inner surfaces of the edge portion and the proximal portion of an open folded flange wall 73a, 74a may accommodate a fastening (not shown) and aid in securely fastening the rail profile 2 of the roof rail 1 to a vehicle and/or it may accommodate support elements (not shown) for supporting the sides of the cover part 31, 32.
[0145] The intermediate portions 45, 46 may be arranged extending in the first plane P1 comprising the lowermost parts of the flange walls 75, 76, as seen in FIG. 1e. E.g., substantially parallel with the vehicle roof portion, which the intermediate portions are to be facing upon installation.
[0146] In FIG. 1f, the roof rail 1 including a rail profile 2 only differs from the example shown in FIG. 1e in that the intermediate angles αI1_1, αI1_2, αI2_1, αI2_2 in the first sheet material 20 are of a slightly different value providing an extent of the intermediate portions 45, 46 being non-parallel with the first plane P1 including the lowermost parts 75, 76 of the open folded flange walls. The orientation of the intermediate portions 45, 46 creates lower intermediate space 4b, e.g., tapered space, provided in between the first plane P1 and the outer surface of the intermediate portion 45b, 46b, wherein the space is increasing in size from the edge portion 33, 34 towards the distal portion 42, 52. The lower intermediate space 4b may be utilized for fastening and/or sealing purposes.
[0147] FIG. 1g shows a roof rail 1 of FIG. 1a as seen in perspective, illustrating the longitudinal extent of the roof rail 1 with a first open end 1a and an oppositely arranged second open end of the roof rail 1b. The roof rail 1 is curved, so that the cover part 30 are to extend towards the roof and open ends 1a, 1b, and the bottom side of the rail profile 2b, are to be facing a roof of a vehicle upon installation of the rail profile 1. The roof rail 1 is further seen including a plurality of mounting apertures 95 for allowing fastening of the roof rail 1 to a roof of a vehicle. The mounting apertures 95 are provided in the mounting part of the rail profile 2. As can be seen in FIG. 1g, the roof rail 1 has a curved longitudinal centerline C1, extending through the center of transverse cross-sections thereof.
[0148] The roof rails 1 of FIGS. 2a-2c include a rail profile 2 and further include a base profile 3 made of a second sheet material 25, which may also be formed by a roll forming method or any other suitable method. The base profile 3 is of a width W3 being larger than the width of a bottom opening W2 provided in the bottom side of the rail profile 2b, as shown in FIG. 2a. The bottom opening 2b_o is provided by a spacing existing between a second end of a first distal portion 44 and a second end of a second distal portion 54, as indicated in FIG. 2a.
[0149] In the present examples, and as indicated in FIG. 2a, the first and second flange walls 71, 72 are flush folded flange walls 73b, 74b, where the edge portion 33, 34 is contiguous with the adjacent proximal portion 41, 51 in each folded flange wall 73b, 74b. Alternatively, one or both flange walls 71, 72 may be of a different type, e.g., joined or open folded flange wall.
[0150] As seen in FIG. 2a, third bends 63 are provided between the proximal portion 41, 51 and the adjacent distal portion 42, 52 of the mounting part 40, arranging the distal portion towards the opposing side of the cover part 31, 32, e.g., along a majorly horizontal orientation. Both the first and second distal portions 42, 52 include further bends, including a first further bend 60_1 changing the orientation of the distal portion 42, 52 from being directed towards the opposing side of the cover part to instead being directed towards the top of the cover part 38, e.g., along a majorly vertical direction. The further bends further includes a second further bend 60_2 following the first further bend 60_1, which directs the distal portion 42, 52 towards the opposing side of the cover part 31, 32, preferably along a majorly horizontal orientation. The further bends may thereby provide an advantageous contact surface for attachment and retaining fastening elements, e.g., even without a base profile 3, for mounting the rail profile 2.
[0151] The base profile 3 of FIGS. 2a-2c is preferably formed with one or more base profile bends configured to provide a base profile shape which corresponds to at least a part of the shape of the first and second distal portions 42, 52. FIG. 2a shows how the base profile 3 includes bends 160_1, 160_2, 160_3 at each side the longitudinal center thereof, which may be bent at angles so as to arrange the base profile in substantially flush arrangement with at least a part of the distal portions 42, 52, e.g., at the first and second further bends 60_1, 60_2. The base profile 3 includes a first side 3a arranged to be placed at the first distal portion 42 and a second side 3b arranged to be placed at the second distal portion 52. The initially flat and elongated sheet material 25 may at both the first and second side comprise three bends; a first base profile bend 160_1 extending along the longitudinal extent of the base profile and directing the sheet material 25 upwards in a transverse cross-section thereof, a second base profile bend 160_2 extending along the longitudinal extent of the base profile and directing the sheet material 25 sideways in a transverse cross-section thereof, a third base profile bend 160_3 extending along the longitudinal extent of the base profile and directing the sheet material 25 downwards in a transverse cross-section thereof, so as to create a cross-sectional shape as shown, e.g., in FIG. 2a. The specified upward, downward and sideway direction are relative to the base profile orientation as shown in FIG. 2a-2c, which orientation is expected to be the general orientation of the rail profile 1 when installed on a roof of a vehicle.
[0152] In FIGS. 2a-2c, the shape of the rail profile 2, to which the base profile 3 is to be connected, may be of a slightly tilted shape, i.e. with the first side of the cover part 31 tilted towards the second side 32 and the second side of the cover part 32 tilted away from the first side 31. The rail profile 2 may have other cross-sectional shapes, and may e.g., be symmetrical about a vertical plane extending through the center of the roof rail 1 or it may be tilted towards the opposite direction. With the tilted shape In FIG. 2a, there exist a larger gap between the second side of the cover part 32 and the second side of the base profile 3b, than between the first side of the cover part 31 and the first side of the base profile 3a. This gap may be utilized for placing a fastening, support elements or other components for a roof rail.
[0153] However, the base profile may also advantageously be shaped so as to add structural support to one or more sides of the cover part 31, 32, such as the second side of the cover part 32, e.g., as seen in FIGS. 2a and 2b, in a simple and easy manner without the need of adding additional elements to the inside of the rail profile 1. FIG. 2b and FIG. 2c shows a perspective view of a rail profile 1 of the invention, which has been cut through so that a cross-section thereof is shown. The roof rails 1 of FIGS. 2b and 2c include the features shown in embodiment of FIG. 2a but differs from the embodiments of FIG. 2a in that the base profile includes further bends. The base profiles 3 of FIGS. 2b and 2c further comprise further base profile bends 160_4, 160_5, 160_6 at one side of the base profile 3b; a fourth base profile bend 160_4 extending along the longitudinal extent of the base profile and directing the sheet material 25 sideways in a transverse cross-section thereof, a fifth base profile bend 160_5 extending along the longitudinal extent of the base profile and directing the sheet material 25 upwards in a transverse cross-section thereof, a sixth base profile bend 160_6 extending along the longitudinal extent of the base profile and directing the sheet material 25 slightly downwards, however mostly sideways towards the inner surface of the cover part 30a in a transverse cross-section thereof. In FIG. 2c the base profile extent between the fifth bend 160_5 and sixth bend 160_6 is longer than in FIG. 2b, in order to create support to the cover part 30 further towards the top of the rail profile 38. In FIGS. 2a-2c the first side of the cover part 31 may be supported by the collaborative presence of the first side of the base profile 3a and the first distal portion 42.
[0154] The roof rails 1 may further include mounting apertures 95, as seen in FIGS. 2b-2c. The roof rail 1 may be mounting on a roof of a vehicle by a fastenings, such as stud bolts, extending through mounting apertures 95, with a head of the stud bolt being retained by the distal portions 42, 52 of the mounting part 40 via the base profile 3. The roof rail 1 thereby can provide a pre-stressing of the rail profile 2 when be subjected to a fixation force towards the roof of the vehicle, e.g., by using the described fastening.
[0155] In FIGS. 2a-2c, the roof rail 1 encloses an interior space 4 by assembling the rail profile 2 with the base profile 3 at a bottom side of the rail profile 2b.
[0156] FIGS. 3a-3b shows an example of a third type of roof rail 1 according to the present disclosure. FIG. 3a shows a roof rail 1, which has been cut through so as to show a transverse cross-section thereof, and FIG. 3b shows the entire cut-out roof rail of FIG. 3a with the base profile 3 and the rail profile 2 separated. The roof rails 1 of FIGS. 3a-3b include a base profile 3 made of a second sheet material 25, which may be formed by a roll forming method or any other suitable method. The rail profile 2 is made of a first sheet material 20, which preferably also has been roll formed into the shown shape. The base profile 3 is of a width W3 being larger than the width of a bottom opening W2 provided in the rail profile 2, as shown in FIG. 3a. The bottom opening 2b_o is provided by the smallest spacing between the first and second distal portions 42, 52, e.g., a spacing existing between a second end of a first distal portion 44 and a second end of a second distal portion 54, as indicated in FIG. 3a.
[0157] In the present example of FIG. 3a, the first and second flange walls 71, 72 are flush folded flange walls 73b, 74b, where the edge portion 33, 34 is contiguous with the adjacent proximal portion 41, 51 in each folded flange wall 73b, 74b. Alternatively, one or both flange walls 71, 72 may be of a different type, e.g., joined or open folded flange wall.
[0158] In FIG. 3a, third bends 63 are provided between the proximal portion 41, 51 and the adjacent distal portion 42, 52, arranging the distal portion towards the opposing side of the cover part 31, 32 e.g., along a majorly horizontal orientation. Both the first and second distal portions 42, 52 include a further bend 60_1 in each distal portion 42, 52 changing the orientation of the distal portions 42, 52 from being directed towards the opposing side of the cover part to instead generally being directed away from of the cover part 38, e.g., along a majorly vertical direction. The distal portions 42, 52 extends a distance from the first further bend 60_1 but then terminates in a second end of the first distal portion 44 and a second end of the second distal portion 54. The extent of the second distal portion 52 between the third bend 63 and the further bend 60_1 thereof is longer than the extent of the first distal portion 42 between the third bend 63 and the first further bend 60_1 thereof, thereby placing a bottom opening 2b_o approximately centered about the center of the bottom of the rail profile 2b. The first further bend 60_1 and the third bend 63 may collectively provide a cavity and an advantageous contact surface for attachment and retaining fastening elements for mounting the rail profile 2.
[0159] The base profile 3 of FIGS. 3a-3b is preferably formed with one or more base profile bends. The bends may be configured to provide a base profile shape, which corresponds to at least a part of the shape of the first and second distal portions 42, 52 provided by the outer surfaces of the distal portions 42b, 52b, see FIG. 3a. FIG. 3a shows how the base profile 3 includes bends 160_1, 160_2 at a first side of the base profile 3a and bends 160_1, 160_2, 160_3 at a second side of the base profile 3b. The bends 160_1, 160_2 are provided so that the base profile 3 can be arranged in substantially flush arrangement with at least a part of the outer surfaces of the distal portions 42b, 52b, at least at the first further bend 60_1. The base profile 3 includes a first side 3a arranged to be placed at the first distal portion 42 and a second side 3b arranged to be placed at the second distal portion 52. The initially flat and elongated sheet material 25 may at both the first and second side includes two bends; a first base profile bend 160_1 extending along the longitudinal extent of the base profile and directing the sheet material 25 upwards in a transverse cross-section thereof and a second base profile bend 160_2 extending along the longitudinal extent of the base profile and directing the sheet material 25 sideways in a transverse cross-section thereof. The second side of the base profile 3b further includes a third base profile bend 160_3 extending along the longitudinal extent of the base profile and directing the sheet material 25 downwards in a transverse cross-section thereof, so as to create a cross-sectional shape as shown, e.g., in FIG. 3a. The specified upward, downward and sideway direction are relative to the base profile orientation as shown in FIG. 3a-3b, which orientation is expected to be the general orientation of the rail profile 1 when installed on a roof of a vehicle.
[0160] As seen in FIGS. 3a-3b, the roof rail 1 may further include mounting apertures 95. A seen in FIG. 3a, the roof rail 1 may be mounting on a roof of a vehicle by fastenings, such as stud bolts, extending through mounting apertures 95, with a head of the stud bolt being retained by the distal portions 42, 52, which are supported at an outer surface thereof 42b, 52b by the base profile 3. The base profile 3 may add stability to the rail profile, as the base profile is configured to maintain the width of the bottom opening of the rail profile 2b. It may further add structural strength and stability to the mounting part 40. The roof rail 1 can provide a pre-stressing of the rail profile 2 when be subjected to a fixation force towards the roof of the vehicle, e.g., by using the described fastening.
[0161] In FIGS. 2a-2c and 3a the first distal portion 42 may be contiguous with a first proximal portion 41 which may be contiguous with a first edge portion 33 which may be contiguous with the second edge portion 34, through the cover part 30, the second edge portion 34 may be contiguous with the second proximal portion 51, which may be contiguous with the second distal portion 52. I.e. the cover part 30 and the mounting part 40 may be made from one sheet material 20 and be devoid of joints such as glue or weld lines between the portions.
[0162] FIG. 4a shows a perspective view of a roof rail 1 assembled with fastening means 90. The roof rail includes a rail profile according to FIG. 1. The fastening 90 is arranged at suitable distance from each other and are extending through mounting apertures 95 of the roof rail 1.
[0163] FIG. 4b shows a cross-sectional view of a roof rail 1 according to FIG. 1a, which has been attached to a roof of a vehicle 101. The fastening 90 is arranged with a head portion 91 applying a fixation force towards the distal portion 42 of the roof rail 1, so that the distal portion 42 is clamped between the head portion 91 and the roof of the vehicle 101, e.g., via a mounting strip 80 and/or a counter portion of the fastening means 92, e.g., a threaded ring. The head portion 91 may further include an O-ring seal 91a circling the mounting aperture 95. The fastening 90 may further be fastened to the roof of the vehicle 101, e.g., by a threaded connection 93 and threaded ring 94. The roof rail may additionally be mounting with support elements, such as support brackets (not shown) inside the interior space 4 if needed, e.g., at the second side of the cover part 32.
[0164] The flange walls 71, 72 of the examples of FIGS. 1a-1f, 2a-2c, 3a-3b and 4a-4b all provide a mounting space 5 to be utilized for contacting and connecting the roof rail 1 to the roof of a vehicle, e.g., as seen in FIG. 4b. By providing this space 5 enclosed at each end by a flange wall 71, 72, the mounting space 5, and content thereof, may be hidden from the outside and it may appear as if the flange walls 71, 72 touches the roof of the vehicle when viewed from afar. The mounting space 5 may or may not include a lower intermediate space 4b, e.g., as seen in FIG. 1f. In FIG. 4b a mounting strip 80 with holes coinciding with mounting aperture 95 have been provided in the mounting space 5 and is hidden at each side thereof by the flange walls 71, 72. The lowermost parts of the flange walls 75, 76 are extending towards the vehicle roof 101, but are not touching the vehicle roof 101. A small gap exist between the lowermost parts 75, 76 and the vehicle roof.
[0165] The mounting strip 80 may be elongated, may include one or more filler elements and/or cushioning elements and/or dust protection elements and/or sealing elements and may be made of a rigid or flexible material, such as plastic or rubber. As seen in FIG. 1a, the roof rail 1 provides a mounting space 5 of a width W1, e.g., defined between flange walls 71, 72, which extends below the distal portion(s) 42, 52, allowing a mounting strip to support the mounting part 40 provided between flange walls 71, 72, preferably the entire width of the mounting part 40 transverse to the longitudinal extent of the roof rail. Further, due to the flange walls 71, 72 of the inventions, as described earlier, the mounting space 5 further is of a height H1 for accommodating the mounting strip 80.
[0166] The first sheet material 20 and/or the second sheet material 25, may be a stainless steel plate material, e.g., of a uniform sheet thickness T1 between 0.3 mm to 1.1 mm, such as between 0.4 mm and 0.9 mm, preferably between 0.5 mm and 0.8 mm prior to roll forming. Alternatively or additionally, one or both sheet material 20, 25 may be made of a thermoplastic composite material. The sheet thickness of the thermoplastic composite sheet material may be 3-4 mm. The sheet thickness T1 is measured between coinciding inner and outer surfaces of the sheet material 20, an example is shown in FIG. 1a.
[0167] The shape of the cover part between the first and second angle may be of any shape suitable for accommodating attachment of elements onto the roof rail, such as cross-bars, bicycle racks etc., and/or further may be aesthetic pleasing appearance and/or of aerodynamic advantage.
[0168] As seen in FIGS. 1a-1f, 2a-2c, 3b and 4b, the rail profile 2 includes a retainer protrusion provided by first retainer bend 67 and a second retainer bend 68 wherein the first retainer bend 67 is arranged between a first flange wall 71 and the second retainer bend 68. As seen in FIGS. 1d-1e, the retainer bend 67 provides a first retainer angle α_r1 and the second retainer bend 68 provides a second retainer angle α_r2, which collectively provide a retainer surface 37 suitable for engaging with attachment means used when attaching elements onto the roof rail 1, e.g., the first retainer angle α_r1 may provide a groove in the cover part 30 and/or a lip for engaging and retaining attachment means, e.g., including a clamp mechanism.
[0169] The first retainer angle α_r1 may be below 100 degrees, such as below 90 degrees or such as below 80 degrees, measured between the outer surfaces of the cover part 30b on each side of the first retainer angle α_r1. The second retainer angle α_r1 may be above 190 degrees, such as above 250 degrees, or such as above 270 degrees, measured between the outer surfaces of the cover part 30b on each side of the second retainer angle α_r2. The roof rail 1 may in embodiments include more than one retainer protrusion, e.g., a retainer protrusion may be provided on each side of the cover part 31, 32.
[0170] As seen in FIG. 1d, the rail profile 2 includes a plurality of bends; a first bend 61 at a first angle α1 between the first edge portion 33 and the first proximal portion 41, followed by a first retainer bend 67 at a first retainer angle α_r1 and a second retainer bend 68 at a second retainer angle α_r2 providing a retainer surface 37 between the retainer bends 67, 68, followed by a second bend 62 at a second angle α2 between the second edge portion 34 and the second proximal portion 51, when viewed along the rail profile 2 from left to right. Between the first angle α1 and the first retainer angle α_r1 a substantially planar extent of the cover part is provided, however alternatively, the extent may also be curved. Between the second retainer angle α_r2 and the second angle α2 the extent of the cover part is preferably gradually curved but may also include substantially planar portions.
[0171] The shown orientations in the examples are generally the expected orientation of the roof rail when installed on a roof of a vehicle. The bends mentioned herein, are generally elongated bends extending along the longitudinal extent of the roof rail. The roof rail may include further elongated crests/ridges, e.g., on the exterior surface not mentioned in the present disclosure.
REFERENCE LIST
[0172] 1 roof rail [0173] 1a first end of roof rail [0174] 1b second end of roof rail [0175] 2 rail profile [0176] 2a top side of rail profile [0177] 2b bottom side of rail profile [0178] 2b_o bottom opening [0179] 3 base profile [0180] 3a first side of the base profile [0181] 3b second side of the base profile [0182] 4 interior space [0183] 4a upper intermediate space [0184] 4b lower intermediate space [0185] 5 mounting space [0186] 20 first sheet material [0187] 25 second sheet material [0188] 30 cover part [0189] 30a inner surface of the cover part [0190] 30b outermost surface of the cover part [0191] 31 first side of the cover part [0192] 32 second side of the cover part [0193] 33 first edge portion [0194] 33a inner surface of the first edge portion [0195] 34 second edge portion [0196] 34a inner surface of the second edge portion [0197] 36 retainer protrusion [0198] 37 retainer surface [0199] 38 top of the cover part [0200] 40 mounting part [0201] 41 first proximal portion [0202] 41a inner surface of the first proximal portion [0203] 41b outer surface of the first proximal portion [0204] 42 first distal portion [0205] 42a inner surface of first distal portion [0206] 42b outer surface of first distal portion [0207] 43 first end of the first distal portion [0208] 44 second end of the first distal portion [0209] 45 first intermediate portion [0210] 45_e1 first end of first intermediate portion [0211] 45_e2 second end of first intermediate portion [0212] 45a inner surface of first intermediate portion [0213] 45b outer surface of first intermediate portion [0214] 46 second intermediate portion [0215] 46_e1 first end of second intermediate portion [0216] 46_e2 second end of second intermediate portion [0217] 46a inner surface of second intermediate portion [0218] 46b outer surface of second intermediate portion [0219] 51 second proximal portion [0220] 51a inner surface of the second proximal portion [0221] 52 second distal portion [0222] 52a inner surface of second distal portion [0223] 52b outer surface of second distal portion [0224] 53 first end of the second distal portion [0225] 54 second end of the second distal portion [0226] 55 dominant orientation of the distal portion(s) [0227] 60_1 . . . 60_8 mounting part bends [0228] 61 first bend [0229] 62 second bend [0230] 61_1 first intermediate bend of the first bend [0231] 61_2 second intermediate bend of the first bend [0232] 62_1 first intermediate bend of the second bend [0233] 62_2 second intermediate bend of the second bend [0234] 63 third bend [0235] 67 first retainer bend [0236] 68 second retainer bend [0237] 71 first flange wall [0238] 72 second flange wall [0239] 73 first folded flange wall [0240] 74 second folded flange wall [0241] 73a first open folded flange wall [0242] 73b first flush folded flange wall [0243] 74a second open folded flange wall [0244] 74b second flush folded flange wall [0245] 74c joined flange wall [0246] 75 lowermost part of first flange wall [0247] 76 lowermost part of second flange wall [0248] 80 mounting strip [0249] 81 filler part [0250] 85 welded connection [0251] 90 fastening [0252] 91 head portion [0253] 91a O-ring seal [0254] 92 counter portion [0255] 93 threaded connection [0256] 94 threaded ring [0257] 95 mounting aperture [0258] 101 roof of a vehicle [0259] 160_1 . . . 160_3 base profile bends [0260] α1 first angle [0261] α2 second angle [0262] α3_1 third angle between first proximal portion and first distal portion [0263] α3_2 third angle between second proximal portion and second distal portion [0264] α_r1 first retainer angle [0265] α_r2 second retainer angle [0266] αI_1 first intermediate angle [0267] αI_2 second intermediate angle [0268] H1 minimum mounting distance of mounting space [0269] W1 width of mounting space [0270] W2 width of bottom opening of rail profile [0271] W3 width of base profile [0272] D1 intermediate distance [0273] T1 thickness of first sheet material [0274] P1 first plane including the lowermost parts of the flange walls [0275] C1 longitudinal center axis
