Roof rails for a motor vehicle, motor vehicle and method for manufacturing roof rails

Abstract

Roof rail (3) for a motor vehicle (1), comprising at least one gallery bar (5) and at least one fastening device (11) for end-side fastening of the gallery bar (5) to a roof (2) of the motor vehicle (1), wherein - the fastening device (11) comprises a fastening device (18) attached to the gallery rod (5) and attachable to the roof (2) and an adapter component (17) that at least partially accommodates the fastening device (18), wherein - the gallery rod (5) has a top surface (6) facing away from the fastening device (11) in cross-section, side walls (8) extending from the top surface (6) and a bottom wall (9) connected to the top surface (6) via the side walls (8), wherein - the bottom wall (9) lies flat against a support surface (28) of the adapter component (17), and wherein - the fastening device (18) has several first fastening recesses (22) extending through the support surface (28) and several second fastening recesses (23), wherein the first fastening recesses (22) are provided and designed for receiving first screw connectors (19) serving to fasten the fastening device (11) to the gallery rod (5) and the second fastening recesses (23) are designed and designed for receiving second screw connectors (20) serving to fasten the fastening device (11) to the roof (2), characterized in that - the adapter component (17) is designed as an injection-molded component and the fastening device (18) is overmolded in the adapter component (17), wherein - the adapter component (17) has first screw connector head receptacles (16) on its side facing away from the gallery rod (5) in longitudinal section, in which screw connector heads (27) of the first screw connectors (19) are arranged spaced apart from a bottom side of the adapter component (17).

Description

[0001] The invention relates to a roof rail for a motor vehicle, comprising at least one railing bar and at least one fastening device for fastening the railing bar to the end of a roof of the motor vehicle, wherein the fastening device comprises a fastening device fastened to the railing bar and attachable to the roof, and an adapter component that accommodates the fastening device at least in part, wherein the fastening device comprises a fastening device fastened to the railing bar and attachable to the roof, and an adapter component that accommodates the fastening device at least in part, wherein the railing bar has an upper side facing away from the fastening device (11) in section, side walls extending from the upper side, and a bottom wall connected to the upper side via the side walls, wherein the bottom wall lies flat against a support surface of the adapter component,and wherein the fastening device has a plurality of first fastening recesses and a plurality of second fastening recesses extending through the support surface, wherein the first fastening recesses are provided and configured to receive first screw connectors for fastening the fastening device to the rail, and the second fastening recesses are provided and configured to receive second screw connectors for fastening the fastening device to the roof. The invention further relates to a motor vehicle with a roof and roof rails attached to the roof, as well as to a method for producing roof rails.

[0002] The prior art includes, for example, the document WO 2013 / 107683 A1. This describes a roof rail for a motor vehicle, comprising at least one railing bar and at least one support element fastened to the railing bar for bridging a gap between the railing bar and the roof of the motor vehicle and for securing the roof rail to the roof of the motor vehicle, as well as at least one cover for the support element, wherein the railing bar, support element and cover are designed as separate components. It is provided that at least one end region of the railing bar is designed as a bent section, the front end of which forms a roof support end, that the support element is designed as an extruded component, and that the support element and cover are located at least partially in the region of the bent section.

[0003] Furthermore, the generic document DE 44 22 421 C1 discloses a roof rail for vehicles with a tubular bar extending at a distance from and essentially parallel to the roof surface along a lateral roof frame, wherein the bar is formed with a bend at each end region and has free ends which run plane-parallel to the roof surface, an insert element supported on the inner wall of the bar is introduced into each free bar end, to which insert element an adapter element is fastened by means of fastening elements penetrating the bar wall while clamping the bar wall, the adapter element is equipped with threaded bolts for fastening the roof rail to the vehicle roof and wherein the free bar end is encompassed by a cover cap which extends around the adapter element and essentially over the bend region of the bar.

[0004] In addition, the document JP 2005-145 124 A discloses a vehicle roof rail which has a rail body, supports by means of which the rail body can be attached to a roof, and a cover to which the supports can be attached. The cover is formed from a metal element with a predetermined shape.

[0005] The object of the invention is to propose a roof rail for a motor vehicle which has advantages over known roof rails, in particular can be fixed particularly reliably and permanently to the roof of the motor vehicle and is visually particularly pleasing.

[0006] This is achieved according to the invention with a roof rail for a motor vehicle having the features of claim 1. It is provided that the adapter component is designed as an injection-molded component and the fastening device is encapsulated in the adapter component, wherein the adapter component has first screw connector head receptacles on its side facing away from the gallery bar in longitudinal section, in which screw connector heads of the first screw connectors are arranged at a distance from an underside of the adapter component.

[0007] Advantageous embodiments with expedient further developments of the invention are specified in the dependent claims.

[0008] Roof rails are preferably an integral part of the vehicle, but can of course also be installed separately. Roof rails are used, for example, to attach a roof rack to the vehicle. The roof rack rests on the roof of the vehicle via the roof rails. However, roof rails can, of course, also be installed on the vehicle for purely aesthetic reasons.

[0009] The roof rail has at least one rail and at least one fastening device. The rail is understood to be a component of the roof rail which, after the roof rail has been mounted on the motor vehicle, preferably extends in the longitudinal direction of the motor vehicle or at least approximately in the longitudinal direction, i.e., is arranged parallel or approximately parallel to a longitudinal axis of the motor vehicle. The rail extends over a substantial portion of the roof's extent in the direction of the longitudinal axis, preferably over at least 70%, at least 80%, or at least 90%. However, other orientations and extensions of the rail are also fundamentally feasible.

[0010] For example, the roof rail is designed such that, after the roof rail has been mounted on the motor vehicle, it rests on the roof of the motor vehicle over at least a large part of its longitudinal extent, in particular continuously or uninterruptedly. Preferably, the roof rail is resting on the roof of the motor vehicle over its entire longitudinal extent. However, it can also be provided that the roof rail is only supported in certain areas on the roof of the motor vehicle, in particular only on one side by means of the fastening device or by means of several fastening devices. It is also possible for the roof rail to be supported on the ends by means of the fastening devices and to be spaced from the roof only in certain areas between the fastening devices. The roof rail presented here can basically be used for all of the aforementioned designs of the roof rail.

[0011] The railing bar is preferably supported on the roof via a protective film, in particular made of plastic, in particular an elastomer and / or a foam, which reliably prevents damage to the roof by the roof rails or, conversely, damage to the roof rails by the roof and / or creates a waterproof connection between the roof rails and the roof of the motor vehicle, thus preventing the penetration of moisture from the exterior of the motor vehicle via the roof rails or via an attachment of the roof rails to the roof. For the purposes of this description, the protective film can be regarded as a component of the roof. Therefore, if the roof rails are supported on the roof, this can be done directly without a protective film or, preferably, via the protective film.In the former case, the roof rails rest directly on the roof, in the latter case on the protective film arranged on the roof.

[0012] The gallery bar is fastened or can be fastened to the roof of the motor vehicle at its ends using at least one fastening device. End-side fastening means that the fastening device engages one end of the gallery bar and connects this to the roof of the motor vehicle. In other words, the fastening device is arranged at one end of the gallery bar or is fastened to it. And fastening means that the gallery bar is completely fixed by the fastening device, i.e. in the direction of a longitudinal axis, a vertical axis and a transverse axis of the motor vehicle, and allows or permits no play or at most very little play between the gallery bar and the roof.

[0013] Particularly preferably, the gallery bar is fastened to the roof of the motor vehicle using a plurality of fastening devices. Each of the fastening devices serves to fasten the gallery bar to the roof at the end, such that the plurality of fastening devices engage spaced-apart ends of the gallery bar and fix it with respect to the roof. A region of the gallery bar present between the regions of the gallery bar fastened using the fastening devices is supported, for example, at least in part, preferably continuously or only in part, on the roof of the motor vehicle or is continuously spaced from the roof. In any case, the gallery bar is supported on the roof at least at its end via the fastening devices; in particular, the gallery bar itself rests against the roof of the motor vehicle or the protective film there.

[0014] Particularly preferably, the roof rail has a plurality of gallery bars, which are arranged in particular at a distance from one another and parallel to one another on the roof of the motor vehicle. Each of these gallery bars is fastened to the roof of the motor vehicle at its end by means of at least one fastening device. Preferably, a plurality of fastening devices are used to fasten each of the gallery bars, in particular exactly two fastening devices. In this respect, the invention also relates to a roof rail for a motor vehicle, with at least one gallery bar and a plurality of fastening devices for fastening the respective end of the gallery bar to a roof of the motor vehicle, wherein each of the fastening devices has a fastening device fastened to the gallery bar and fastenable to the roof, and an adapter component that accommodates the fastening device at least in part.In this case, it is again provided that the respective adapter component is designed as an injection-molded component and the respective fastening device is encapsulated in the corresponding adapter component.

[0015] The adapter component is generally designed as an injection-molded component. This means that the adapter component is manufactured by injection molding. The fastening device is overmolded in the adapter component. This means that the fastening device is provided before the adapter component is manufactured and is overmolded with an injection-molding material during the manufacture of the adapter component, so that immediately after injection molding, the adapter component is present with the fastening device arranged therein. The fastening device is overmolded in the adapter component in such a way that it is held therein in a form-fitting manner. Particularly preferably, the fastening device is completely accommodated in the adapter component, so that the fastening device at least does not protrude beyond the adapter component. In this case, it can certainly be provided that the fastening device is visible from an external environment of the adapter component.Preferably, however, the fastening device is completely accommodated within the envelope of the adapter component or, at most, is flush with it. The envelope can also be referred to as the contour of the adapter component.

[0016] The adapter component and the fastening device are preferably made of different materials. For example, the fastening device is made of metal, whereas the adapter component is made of plastic and is therefore available as a plastic injection-molded component. For example, the fastening device is made of steel, preferably coated steel. For example, the steel is coated with zinc and / or nickel. In the case of zinc-coated steel, the steel can also be referred to as galvanized steel. The steel used is preferably a micro-alloyed steel, for example S355MC according to DIN EN 10149-2. This steel can also be referred to as 1.0976. The plastic used for the adapter component is, for example, acrylonitrile-styrene-acrylate copolymer (ASA), in particular acrylonitrile-styrene-acrylate copolymer according to TL52311.The surface of the adapter component is preferably provided, at least in some areas, with a surface structure, in particular a grain, for example a K 31 grain. The grain is preferably implemented only in a visible area of ​​the adapter component.

[0017] The fastening device can be implemented in different ways. For example, it is present as a continuous component, which is in particular a strip, in particular a metal strip, or an extruded component. The strip is preferably in the form of a sheet metal strip. The continuous component is particularly preferably curved or bent. Accordingly, it has at least one bend or curvature, particularly preferably several parallel bends or curvatures. Alternatively, the fastening device has several reinforcement elements arranged at a distance from one another.

[0018] The extrusion component is preferably in the form of an extruded part, i.e., it is manufactured using the extrusion process. This means that the extrusion component has a consistently uniform cross-section in one direction, namely in the extrusion direction in which the extrusion component is manufactured by extrusion. Preferably, the extrusion process is used to first produce a blank, which is then divided into several extrusion components, which are in particular identical, by cutting them in parallel planes. Configuring the extrusion component as an extrusion part enables particularly high strength while simultaneously reducing manufacturing costs.

[0019] If the fastening device is designed as an extruded component, it can only be adapted in one direction to the contours of the roof and the gallery bar. In this case, the adapter component serves to adapt the component to the roof or the gallery bar. For example, it is intended that identically designed fastening devices are used for a variety of roof rails, whereby these in particular have differently designed gallery bars. Each of the roof rails has an adapter component that adapts the respective fastening device to the different gallery bars. Accordingly, the fastening device can be produced in large quantities, resulting in a cost advantage.

[0020] The design of the adapter component as an injection-molded component ensures a high degree of flexibility in the design of the adapter component, so that the fastening device can be adapted extremely precisely to the gallery bar and / or the roof almost independently of the design of the fastening device. This results in a high level of strength in the connection between the gallery bar and the roof, namely due to the use of the fastening device, and a particularly pleasing visual impression of the roof rails. Due to its design as an injection-molded component, the adapter component is manufactured in one piece and from the same material. The adapter component therefore does not consist of several parts that are fastened together, for example by form-fitting and / or material-bonding. Rather, the adapter component is manufactured in one piece, i.e. as a single element.This also leads to cost-effective and efficient production.

[0021] In conventional roof rails, the fastening device alone serves to support and fasten the roof rail, whereas the adapter component - if present at all - merely serves to visually conceal the fastening device. According to the invention, however, the adapter component also has a load-bearing effect; in particular, the fastening device and consequently the roof rail are supported on the roof of the vehicle via the adapter component. For example, it is provided that the roof rail rests directly on the adapter component and / or the fastening device. Particularly preferably, the roof rail is arranged at a continuous distance from the fastening device, viewed in longitudinal section, and is supported on the adapter component. The roof rail is fastened to the fastening device using screw connectors.Additionally or alternatively, it is provided that the fastening device is supported directly or indirectly on the roof via the adapter component. A particularly preferred embodiment of the roof rail is one in which the fastening device rests directly on the roof in some areas and is supported indirectly on the roof via the adapter component in some areas.

[0022] It is therefore provided that the railing bar is fastened to the fastening device, wherein the fastening device in turn rests on the roof of the motor vehicle or is fastened to it after the roof rails have been mounted on the motor vehicle. It can be provided that the fastening device is supported exclusively directly on the roof of the motor vehicle, i.e. lies directly against this or the protective film. Preferably, however, the fastening device is supported at least partially on the roof via the adapter component. Particularly preferably, at least a large part of the fastening device is spaced from the roof by means of the adapter component, so that at most a small part of the fastening device is supported directly on the roof or the protective film, whereas the rest of the fastening device is supported exclusively on the roof or the protective film via the adapter component.This reliably prevents damage to the roof caused by the fastening device.

[0023] A further development of the invention provides that the fastening device has a plurality of first fastening recesses and a plurality of second fastening recesses, wherein the first fastening recesses are provided and configured to receive first screw connectors used to fasten the fastening device to the gallery rod, and the second fastening recesses are provided and configured to receive second screw connectors used to fasten the fastening device to the roof. The fastening device thus has a plurality of fastening recesses, namely a plurality of first fastening recesses and a plurality of second fastening recesses. The fastening recesses are configured as through-openings, thus each extending completely through the fastening device.

[0024] The first screw connectors, by means of which the fastening device is attached to the gallery rod, are arranged in the first fastening recesses. In contrast, the second screw connectors, by means of which the fastening device is or can be attached to the roof, are arranged in the second fastening recesses. The screw connectors, i.e., the first screw connectors and the second screw connectors, are preferably understood to be screws or bolts. Accordingly, each of the screw connectors has at least one screw connector head and one screw connector thread.

[0025] The fastening recesses, i.e., both the first fastening recesses and the second fastening recesses, are arranged at a distance from one another. Their longitudinal center axes preferably lie in a common imaginary plane. Additionally, their longitudinal center axes can run parallel to one another. However, it is preferably provided that the longitudinal center axes of at least some of the fastening recesses, particularly those located in the common imaginary plane, are angled relative to one another, i.e., they enclose an angle with one another that is greater than 0° and less than 180°.

[0026] A further development of the invention provides that each of the second fastening recesses is encompassed by an edge surface of the fastening device which is aligned with an underside of the adapter component or projects beyond it in the direction facing away from the gallery rod. The edge surface of the fastening device is to be understood as a surface of the fastening device which forms a continuous edge of the respective second fastening recess. The edge surface therefore completely and continuously encompasses the corresponding second fastening recess. The edge surface is therefore annular, in particular circular. The fastening device is particularly preferably supported via the edge surfaces on the roof of the motor vehicle or the protective film. Accordingly, it is aligned with the underside of the adapter component facing away from the gallery rod in longitudinal section or even projects beyond it.After the roof rails are mounted on the roof of the vehicle, at least the edge surfaces of the fastening device rest against the roof. Preferably, the underside of the adapter component also rests against the roof, at least in part. This design enables a particularly reliable and permanent connection of the roof rails to the vehicle.

[0027] A further development of the invention provides that the adapter component has first screw connector head receptacles, in which heads of the first screw connectors are arranged at a distance from the underside of the adapter component. The first screw connectors serve to fasten the fastening device to the roof rail. The first screw connectors preferably engage the roof rail with their screw connector thread directly or at least indirectly via, for example, a threaded sleeve or the like. In any case, the screw connector heads of the first screw connectors are located on the side of the fastening device facing away from the roof rail in longitudinal section. On this side, the adapter component has the first screw connector head receptacles. These are dimensioned such that the first screw connectors and in particular their screw connector heads are arranged at a distance from the roof after the roof rails have been mounted on the motor vehicle.This prevents damage to the roof caused by the first screw connectors, especially scratching of the roof.

[0028] A further development of the invention provides that the fastening device is designed as a continuous component or comprises several reinforcement elements spaced apart from one another in the adapter component and having the fastening recesses. A corresponding design of the fastening device has already been mentioned. In the case of the continuous component, the gallery rod is attached directly to the roof via the fastening device. This means that the fastening device is attached to the gallery rod on the one hand and to the roof on the other, so that forces acting between the gallery rod and the roof are transmitted continuously via the fastening device.

[0029] If, however, the fastening device includes reinforcement elements, this is not a continuous component. Rather, some of the reinforcement elements are attached to the gallery rod, while others are attached to the roof and accommodated in the adapter component at a distance from each other. The forces acting between the gallery rod and the roof are therefore not transmitted continuously via the fastening device, but at least partially via the adapter component, since the reinforcement elements connected to the gallery rod, on the one hand, and the reinforcement elements connected or connectable to the roof, on the other, are connected or attached to each other exclusively via the adapter component.

[0030] The fastening device designed as a continuous component is characterized by high strength, whereas the fastening device comprising the reinforcing elements is particularly cost-effective to implement and has a low weight. The continuous component is particularly preferably in the form of an extruded component or a strip.

[0031] A further development of the invention provides that the reinforcing elements are designed as bushings each having at least one form-fitting collar over which the adapter component is at least partially overmolded, wherein the bushings having the second fastening recesses each additionally have a further form-fitting collar spaced from the form-fitting collar, and the adapter component engages in a form-fitting manner between the form-fitting collar and the further form-fitting collar. The reinforcing elements are therefore present as bushings in which the fastening recesses are formed. Each of the bushings has at least one form-fitting collar, which is to be understood as a web-like projection extending from a base body of the respective bushing. The form-fitting collar is in the form of a circumferential web and thus as an annular web.

[0032] The form-fitting collar is arranged for fastening the respective bushing in the adapter component, i.e. it engages therein in a form-fitting manner. At least those bushings in which the second fastening recesses are formed have, in addition to the form-fitting collar, the further form-fitting collar. The form-fitting collar and the further form-fitting collar are arranged at a distance from one another, in particular spaced parallel. The further form-fitting collar can be designed in accordance with the explanations regarding the form-fitting collar. The adapter component engages in a form-fitting manner between the form-fitting collar and the further form-fitting collar in order to fasten the corresponding bushing in a form-fitting manner. It is particularly preferred here for one of the form-fitting collars, for example the further form-fitting collar, to be flush with the underside of the adapter component. This creates a fastening point for securely fastening the roof rails to the roof.

[0033] Preferably, the bushings in which the first fastening recesses are formed are designed differently than the bushings in which the second fastening recesses are present. In particular, the bushings having the first fastening recesses only have the form-fitting collar, but not the further form-fitting collar. Preferably, the form-fitting collar is formed centrally or at least approximately centrally in the direction of a longitudinal center axis of the respective bushing. On the bushings having the second fastening recesses, however, the form-fitting collar and the further form-fitting collar are preferably arranged off-center, in particular at each end. This means that the form-fitting collar and the further form-fitting collar are arranged at opposite ends of the respective bushing. This ensures reliable fastening of the reinforcing elements both to the gallery bar and to the roof of the motor vehicle.

[0034] A further development of the invention provides that the gallery rod has an upper side facing away from the fastening device in section, side walls extending from the upper side and a base wall resting on a support surface of the fastening device, wherein the adapter component has at least one support wall projecting beyond the support surface, against which one of the side walls of the gallery rod or a side wall extension extending from one of the side walls of the gallery rod bears for lateral guidance of the gallery rod with respect to the adapter component. Viewed in cross section, the gallery rod can be roughly divided into the upper side, the side walls and the base wall. The upper side and the base wall are connected to one another via the side walls. Viewed in cross section, for example, the upper side, the side walls and the base wall form a closed contour at least in some regions.

[0035] The railing bar rests on the support surface of the fastening device. The support surface is formed on the adapter component. The support surface is adapted in shape and dimensions to the base wall of the railing bar, ensuring that the base wall rests flat against the support surface. To improve the lateral guidance of the railing bar with respect to the adapter component, a support wall is formed on the adapter component. This support wall projects beyond the support surface, namely in the direction away from the roof of the vehicle. One of the side walls of the railing bar, for example, rests against this support wall.

[0036] Alternatively, the sidewall extension extends from the sidewall of the roof rail and rests against the supporting wall. A sidewall extension is understood to be an extension of the sidewall that extends from the respective sidewall toward the roof of the vehicle. Preferably, the sidewall extension is offset from the corresponding sidewall, in particular offset parallel to the corresponding sidewall. The described design of the roof rail facilitates the alignment of the roof rail during installation and ensures reliable attachment of the roof rail to the roof.

[0037] A further development of the invention provides that the side wall and the side wall extension are connected via a bend in the gallery rod that extends over the supporting wall. As already mentioned above, the side wall and the side wall extension are preferably offset from one another, in particular parallel. This offset is achieved by means of the bend. The bend is understood to be an area of ​​the gallery rod in which the width of the gallery rod decreases, starting from the side wall in the direction of the side wall extension. The bend thus achieves a tapering of the gallery rod in cross-section, viewed in the direction of the roof.

[0038] A further development of the invention provides that the adapter component has second screw connector head receptacles adjoining the second fastening recesses, in which screw connector heads of the second screw connectors are arranged and held in a form-fitting, rotationally fixed manner. The second screw connectors serve to fasten the fastening device to the roof of the motor vehicle. They are arranged in the second fastening recesses of the fastening device. Typically, the fastening device is first mounted on the roof bar and then the arrangement of fastening device and roof bar is placed on the roof of the motor vehicle. This makes it necessary for the second screw connectors to already be arranged on the fastening device in order to be able to fasten the fastening device quickly and reliably to the roof.Accordingly, it is intended that before the fastening device and the gallery rod are fastened together, the second screw connectors are inserted into the second fastening recesses. Only then is the fastening device attached to the gallery rod, and subsequently the assembly of fastening device and gallery rod is arranged on the roof.

[0039] In order to prevent any rotational movement of the second screw connectors during the fastening of the roof rails to the roof, the adapter component is designed such that it holds the screw connector heads of the second screw connectors in a form-fitting, rotationally fixed manner. For this purpose, the adapter component has the second screw connector head receptacles, which are adapted in shape and dimension to the screw connector heads of the second screw connectors, namely at least such that the form-fitting holding of the second screw connectors on the adapter component is realized. At least one of the second fastening recesses is in particular arranged such that, after the fastening device has been fastened to the railing bar, it is at least partially overlapped by the railing bar, in particular the bottom wall of the railing bar. Accordingly, at least one of the two screw connectors is held captively by the railing bar on the adapter component.The described design of the roof rails ensures simple and quick installation on the roof of the vehicle.

[0040] A further development of the invention provides that the adapter component has an extension which projects beyond the support surface and engages in a base region of the gallery rod which faces the roof, wherein the base region has a base surface facing the roof, which surrounds the extension in a U-shape and is aligned with the underside of the adapter component or projects beyond it in the direction facing the roof. The extension is an integral part of the adapter component. For example, the extension extends directly from the support surface. However, it can also be arranged at a distance from the support surface. In any case, it engages in the base region of the gallery rod in order to reliably fasten this as well, in particular to create a lateral guide for the base region.

[0041] In the base area, the roof rail rests against the roof after the roof rails are mounted on the vehicle, or at least has the shortest distance from the roof, viewed longitudinally, of the roof rail. The base area ends in the base surface, which is formed on the side of the roof rail facing the roof. The base surface can lie continuously and entirely in an imaginary plane. Preferably, however, the base surface is curved. In this case, it has a continuous, continuous profile.

[0042] After the roof rails are mounted on the vehicle, the base surface preferably rests continuously and completely against the roof. The base surface is U-shaped and encompasses the extension of the adapter component. Particularly preferably, the extension rests continuously against the base area. The base surface can protrude beyond the adapter component or its underside in the direction facing the roof. However, it is preferably flush with it. This ensures reliable attachment of the roof rails to the vehicle and, at the same time, creates an extremely pleasing visual impression.

[0043] The invention further relates to a motor vehicle with a roof and roof rails fastened to the roof, in particular roof rails according to the embodiments within the scope of this description, wherein the roof rails have at least one rail bar and at least one fastening device for fastening the rail bar to the end of a roof of the motor vehicle, wherein the fastening device has a fastening device fastened to the rail bar and to the roof and an adapter component that accommodates the fastening device at least in some areas. It is provided that the adapter component is designed as an injection-molded component, and the fastening device is encapsulated in the adapter component.

[0044] The advantages of such a design of the vehicle or roof rails have already been pointed out. Both the vehicle and the roof rails can be further developed according to the details in this description, so reference is made to these details in this regard.

[0045] The invention also relates to a method for producing a roof rail, in particular a roof rail according to the embodiments in the context of this description, wherein the roof rail has at least one gallery bar and at least one fastening device for fastening the gallery bar to the end of a roof of the motor vehicle, wherein the fastening device has a fastening device fastened to the gallery bar and fastenable to the roof and an adapter component that accommodates the fastening device at least in regions, wherein the gallery bar has an upper side facing away from the fastening device in section, side walls extending from the upper side and a bottom wall connected to the upper side via the side walls, wherein the bottom wall lies flat against a support surface of the adapter component, and wherein the fastening device has a plurality of,has first fastening recesses penetrating the support surface and a plurality of second fastening recesses, wherein the first fastening recesses are provided and designed to receive first screw connectors serving to fasten the fastening device to the gallery rod and the second fastening recesses are provided and designed to receive second screw connectors serving to fasten the fastening device to the roof.

[0046] It is provided that the adapter component is designed as an injection-molded component and the fastening device is overmolded with the adapter component so that it is overmolded in the adapter component, wherein the adapter component has first screw connector head receptacles on its side facing away from the gallery bar in longitudinal section, in which screw connector heads of the first screw connectors are arranged at a distance from a bottom side of the adapter component.

[0047] With regard to the advantages and possible advantageous further developments of the method and the roof rails, reference is again made to the details provided in this description.

[0048] The invention will be explained in more detail below with reference to the exemplary embodiments shown in the drawing. Fig. 1 a schematic representation of a motor vehicle with a roof rail attached to a roof of the motor vehicle, Fig. 2 a schematic longitudinal sectional view of a first embodiment of the roof railing, with a fastening device for attaching a gallery rod to the roof, Fig. 3 a schematic representation of the fastening device for the first embodiment of the roof rail, Fig. 4 a schematic longitudinal section of the roof rail in a second embodiment, and Fig. 5 a schematic representation of the fastening device for the second embodiment of the roof rail.

[0049] The Fig. 1 shows a schematic representation of a motor vehicle 1 having a roof 2 and roof rails 3. The roof rails 3 are attached to the roof 2. A protective film 4 is arranged between the roof 2 and the roof rails 3 in order to prevent mutual damage to the roof 2 and the roof rails 3. The protective film 4 can also be regarded as part of the roof 2, so that the roof 2 has the protective film 4 in certain areas, namely where the roof rails 3 rest on the roof 2 or touch it. The roof rails 3 have a roof bar 5. In principle, the roof rails 3 can have any number of roof bars 5. In this case, the multiple roof bars 5 preferably run parallel to one another. Only the roof bar 5 will be discussed below. If there are multiple roof bars 5, the explanations apply analogously to each of these roof bars 5.

[0050] The gallery bar 5 has, on its side facing away from the roof 2, an upper side 6 which is curved towards an end 7 of the gallery bar 5 in the direction of the roof 2. In particular, as shown, the entire gallery bar is curved in the direction of the roof 2. Side walls 8 extend from the upper side 6, only one of which is visible here. The side walls 8 run parallel to one another and preferably extend over a large part of the extent of the gallery bar 5. At the bottom, the gallery bar 5 is delimited at least in regions by a bottom wall 9 which is connected to the upper side 6 via the side walls 8. The bottom wall 9 preferably has a smaller extent in the longitudinal direction of the roof rail 3 than the upper side 6 and the side walls 8. As a result, a recess 10 (not visible here) is formed in the region of the end 7 of the gallery bar 5.

[0051] The gallery rod 5 is attached to the roof at its end by means of a fastening device 11. The fastening device 11 preferably also engages in the recess 10 for this purpose. For example, the end 7 of the gallery rod 5 has a foot region 12, in which a substantially U-shaped foot surface 13 is formed on the gallery rod 5. The gallery rod 5 is preferably supported directly on the roof 2 or the protective film 4 by means of the foot surface 13. For this purpose, the foot surface 13 is, for example, curved inward so that its shape is adapted to the roof 2. The foot surface 13 encompasses a region of the fastening device 11, namely an extension 14, to provide lateral guidance for the gallery rod 5, including at its end 7.Further lateral guidance of the gallery rod 5 relative to the fastening device 11 is achieved by means of a support wall 15, which is a component of the fastening device 11 and against which the side wall 8 or—as in the embodiment shown here—a side wall extension 16 rests flatly. The support wall is a component of an adapter component 17 of the fastening device 11.

[0052] In addition to the adapter component 17, the fastening device 11 has a fastening device 18, which is not visible here, however, since it is concealed by the adapter component 17. The adapter component 17 is in the form of an injection-molded component and accommodates the adapter component 17. The fastening device 18 is overmolded in the adapter component 17 and is thus held in a form-fitting manner. Preferably, the fastening device 18 is located entirely within an envelope or within a contour of the adapter component 17, i.e., it does not protrude beyond the adapter component 17.

[0053] The gallery rod 5 is finally fastened to the roof 2 by means of first screw connectors 19 and second screw connectors 20, only the latter being visible here. The first screw connectors 19 serve to fasten the fastening device 11, or more precisely the fastening device 18, to the gallery rod 5. By means of the second screw connectors 20, the fastening device 11, or more precisely the fastening device 18, is fastened to the roof 2. The first screw connectors 19 and the second screw connectors 20 engage the fastening device 11, or the fastening device 18, at a distance from one another. Preferably, the protective film 4 has recesses 21 for the second screw connectors 20.

[0054] The Fig. 2 shows a schematic longitudinal sectional view of a first embodiment of the roof rail 3. In the first embodiment, the fastening device 18, which can now be seen, is designed as a continuous component, in particular it is in the form of a bent sheet metal band or strip. This means that the fastening device 18 has a consistently constant material thickness and has significantly larger dimensions in a first direction than in a second direction perpendicular to this first direction. The first direction and the second direction are in turn perpendicular to a third direction in which the material thickness is present. For example, the dimensions in the first direction are larger than the dimensions in the second direction by a factor of at least 5, at least 7.5 or at least 10.

[0055] The fastening device 18 has first fastening recesses 22 and second fastening recesses 23. The first screw connectors 19 are arranged in the first fastening recesses 22 and the second screw connectors 20 are arranged in the second fastening recesses 23. Viewed in longitudinal section, the first fastening recesses 22 are arranged above the second fastening recesses 23, i.e. on the side of an imaginary longitudinal center plane of the fastening device 18 facing the gallery rod 5 or an imaginary plane intersecting the fastening device 18. In the exemplary embodiment shown here, one of the second fastening recesses 23 is located in a cranked region of the fastening device 18, in which the continuous component is cranked in the direction of the roof 2 or in the direction away from the gallery rod 5.

[0056] The second fastening recesses 23 are each completely and continuously encompassed by an edge surface 24 of the fastening device 18. The edge surfaces are therefore each annular. Preferably, the edge surfaces 24 each lie completely and continuously in an imaginary plane. Preferably, the edge surfaces 24 are aligned with an underside 25 of the adapter component 17 or even protrude beyond it in the direction facing away from the gallery rod 5. This means that the roof rail 3 is supported on the roof 2 at least via the edge surfaces 24 or that the edge surfaces 24 bear directly against the roof 2. Particularly preferably, the fastening device 18 bears against the roof 2 exclusively with its edge surfaces 24 and is otherwise spaced from the roof 2, preferably in that its regions lying away from the edge surfaces 24 are accommodated in the adapter component 17 and at least do not protrude beyond its contour or envelope.

[0057] It can be seen that the roof rail 3 rests with its base wall 9 against the adapter component 17 and is in particular spaced apart from the latter by the fastening device 18. The gallery bar 5 is supported on the roof 2 via the adapter component 17 and / or the fastening device 18. In addition, it optionally rests directly on the roof 2 with its base surface 13. In particular, it is provided that the adapter component 17 supports the gallery bar 5 in the vertical direction, whereas the gallery bar 5 is fixed by means of the fastening device 18, in particular in the longitudinal direction and in the transverse direction with respect to the roof 2. Of course, the fastening device 18 also prevents the gallery bar 5 from being removed from the roof 2 in the vertical direction, i.e., a displacement of the gallery bar 5 in the direction away from the roof 2.Overall, the gallery rod 5 is thus securely and reliably fixed to the roof 2 by the interaction of the adapter component 17 and the fastening device 18.

[0058] In order to prevent damage to the roof 2 by the first screw connectors 19, first screw connector head receptacles 26 are provided in the adapter component 17, namely on the side of the fastening device 18 facing away from the gallery rod 5. Screw connector heads 27 of the first screw connectors 19 engage in the first screw connector head receptacles 26, so that they are spaced apart from the roof 2.

[0059] The Fig. Figure 3 shows a schematic representation of the fastening device 11 for the first embodiment of the roof rail 3. Only the adapter component 17 as well as the first screw connectors 19 and the second screw connectors 20 are visible. A support surface 28 is now visible, against which the roof rail 5 rests with its base wall 9. It is also visible that the support wall 15 projects beyond the support surface 28 in the direction of the roof rail 5. Likewise, the extension 14 projects beyond the support surface 28, namely in the longitudinal direction of the roof rail 3 or the roof rail 5.

[0060] In addition to the first screw connector head receptacles 26, the adapter component 17 has second screw connector head receptacles 29, in which screw connector heads 30 of the second screw connectors 20 are arranged. The second screw connector head receptacles 29 are adapted in shape and dimension to the screw connector heads 30, so that the screw connector heads 30 and thus the second screw connectors 20 are positively and rotationally fixedly secured with respect to the adapter component 17. This enables simple and rapid attachment of the roof rail 3 to the roof 2 of the motor vehicle 1.

[0061] The Fig. 4 shows a schematic longitudinal section of the roof rail 3 in a second embodiment. Reference is generally made to the above statements regarding the first embodiment, and only the differences are discussed. These are that the fastening device 18 is no longer designed as a continuous component, but rather has a plurality of reinforcement elements 31 spaced apart from one another in the adapter component 17 and provided with the fastening recesses 22 and 23. The reinforcement elements 31 are provided as bushings, each of which has at least one form-fitting collar 32 overmolded with the adapter component 17.

[0062] Those of the reinforcing elements 31 which accommodate the first fastening recesses 22 have only a single form-fitting collar 32, which is arranged approximately centrally or exactly centrally in the direction of their respective longitudinal center axis. The reinforcing elements 31 in which the second fastening recesses 23 are formed, however, have a further form-fitting collar 33 which is spaced apart from the form-fitting collar 32. The adapter component 17 engages between the form-fitting collar 32 and the further form-fitting collar 33 to secure the respective reinforcing element 31. It is particularly preferably provided that the further form-fitting collar 33 is flush with the underside 25 of the adapter component 17, so that the further form-fitting collar 33 forms the edge surface 24 already mentioned above.

[0063] The Fig.5 shows a schematic representation of the fastening device 11 for the second embodiment of the roof rail 3. Reference is again made to the above explanations, and only the differences from the first embodiment are discussed. These are essentially based on the design of the second screw connector head receptacle 29. While in the first embodiment there was a recess in the adapter component 17 to form the second screw connector head receptacle 29, the second screw connector head receptacle 29 for the second embodiment is delimited only by two webs, which preferably run parallel to one another. These two webs 34 serve to hold the respective second screw connector 20 in a form-fitting manner, so that it is fixed in a rotationally fixed manner with respect to the adapter component 17.

[0064] The described design of the motor vehicle 1 or the roof rail 3 enables simple and rapid installation of the roof rail 2 on the roof 2 of the motor vehicle. At the same time, the fastening device 11 can be manufactured cost-effectively and ensures reliable load transfer from the rail bar 5 to the roof 2. LIST OF REFERENCE SYMBOLS 1 motor vehicle 2 roof 3 roof rails 4 protective film 5 Gallery staff 6 Top 7 End 8 Side wall 9 Floor wall 10 Recess 11 Fastening device 12 foot area 13 Foot area 14 Extension 15 Retaining wall 16 Lateral wall process 17 Adapter component 18 Fastening device 19 1. Screw connectors 20 2. Screw connectors 21 recess 22 1. Mounting recess 23 2. Mounting recess 24 edge area 25 Bottom 26 1. Screw connector head holder 27 screw connector head 28 support surface 29 2. Screw connector head holder 30 screw connector head 31 reinforcement elements 32 Form-fitting collar 33 Form-fitting collar 34 jetty

Claims

[1] Roof rail (3) for a motor vehicle (1), with at least one gallery bar (5) and at least one fastening device (11) for fastening the end of the gallery bar (5) to a roof (2) of the motor vehicle (1), wherein - the fastening device (11) comprises a fastening device (18) fastened to the gallery rod (5) and fastenable to the roof (2) and an adapter component (17) receiving the fastening device (18) at least in regions, wherein - the gallery rod (5) has an upper side (6) facing away from the fastening device (11) in section, side walls (8) extending from the upper side (6) and a bottom wall (9) connected to the upper side (6) via the side walls (8), wherein - the bottom wall (9) lies flat against a support surface (28) of the adapter component (17), and wherein - the fastening device (18) has a plurality of first fastening recesses (22) and a plurality of second fastening recesses (23) passing through the support surface (28), wherein the first fastening recesses (22) are provided and designed to receive first screw connectors (19) serving to fasten the fastening device (11) to the gallery rod (5) and the second fastening recesses (23) are provided and designed to receive second screw connectors (20) serving to fasten the fastening device (11) to the roof (2), characterized by , that - the adapter component (17) is designed as an injection-molded component and the fastening device (18) is encapsulated in the adapter component (17), wherein - the adapter component (17) has, on its side facing away from the gallery rod (5) in longitudinal section, first screw connector head receptacles (16), in which screw connector heads (27) of the first screw connectors (19) are arranged at a distance from an underside of the adapter component (17). [2] Roof railing according to one of the preceding claims, characterized by that each of the second fastening recesses (23) is encompassed by an edge surface (24) of the fastening device (18) which is aligned with the underside (25) of the adapter component (17) or projects beyond it in the direction away from the gallery rod (5). [3] Roof railing according to one of the preceding claims, characterized by that the fastening device (18) is designed as a continuous component or has a plurality of reinforcing elements (31) which are accommodated at a distance from one another in the adapter component (17) and have the fastening recesses (22, 23). [4] Roof railing according to one of the preceding claims, characterized by in that the reinforcing elements (31) are designed as bushings each having at least one form-fitting collar (32) which is at least partially overmolded with the adapter component (17), wherein the bushings having the second fastening recesses (23) each additionally have a further form-fitting collar (33) spaced from the form-fitting collar (32), and the adapter component (17) engages in a form-fitting manner between the form-fitting collar (32) and the further form-fitting collar (33). [5] Roof railing according to one of the preceding claims, characterized by that the adapter component (17) has at least one support wall (15) projecting beyond the support surface (28), against which one of the side walls (8) of the gallery rod (5) or a side wall extension (16) extending from one of the side walls (8) of the gallery rod (5) bears for laterally guiding the gallery rod (5) with respect to the adapter component (17). [6] Roof railing according to one of the preceding claims, characterized by that the adapter component (17) has second screw connector head receptacles (29) adjoining the second fastening recesses (23), in which screw connector heads (30) of the second screw connectors (20) are arranged and held in a form-fitting, rotationally fixed manner. [7] Roof railing according to one of the preceding claims, characterized by in that the adapter component (17) has an extension (14) projecting beyond the support surface (28) and engaging in a foot region (12) of the gallery rod (5) facing the roof (2), the foot region (12) having a foot surface (13) facing the roof (2), which surrounds the extension (14) in a U-shape and is aligned with the underside (25) of the adapter component (17) or projects beyond it in the direction facing the roof (2). [8] Motor vehicle (1) with a roof (2) and a roof rail (3) fastened to the roof (2) according to one of the preceding claims. [9] Method for producing a roof rail (3), wherein the roof rail (3) has at least one gallery bar (5) and at least one fastening device (11) for fastening the gallery bar (5) to a roof (2) of the motor vehicle (1), wherein the fastening device (11) has a fastening device (18) fastened to the gallery bar (5) and fastenable to the roof (2) and an adapter component (17) receiving the fastening device (18) at least in regions, wherein - the gallery rod (5) has an upper side (6) facing away from the fastening device (11) in section, side walls (8) extending from the upper side (6) and a bottom wall (9) connected to the upper side (6) via the side walls (8), wherein - the bottom wall (9) lies flat against a support surface (28) of the adapter component (17), and wherein - the fastening device (18) has a plurality of first fastening recesses (22) and a plurality of second fastening recesses (23) passing through the support surface (28), wherein the first fastening recesses (22) are provided and designed to receive first screw connectors (19) serving to fasten the fastening device (11) to the gallery rod (5) and the second fastening recesses (23) are provided and designed to receive second screw connectors (20) serving to fasten the fastening device (11) to the roof (2), characterized by , that - the adapter component (17) is designed as an injection-molded component and the fastening device (18) is overmolded with the adapter component (17) so that it is overmolded in the adapter component (17), wherein - the adapter component (17) has, on its side facing away from the gallery rod (5) in longitudinal section, first screw connector head receptacles (16), in which screw connector heads (27) of the first screw connectors (19) are arranged at a distance from an underside of the adapter component (17).

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