Motor vehicle roof longitudinal beams, motor vehicle and roof manufacturing methods

Abstract

The present invention relates to a roof longitudinal beam (3) for a motor vehicle (1), comprising at least one aisle (5) and at least one fastening device (11) for fastening the aisle (5) at its end to the roof (2) of the motor vehicle (1), wherein the fastening device (11) has a fastener (18) fastened to the aisle (5) and capable of being fastened to the roof (2) and an adapter component (17) at least partially accommodating the fastener (18). The present invention proposes that the adapter component (17) be constructed as an injection-molded component, and the fastener (18) be molded in the adapter component (17). The present invention also relates to a motor vehicle (1) having a roof (2) and a roof longitudinal beam (3) fastened to the roof (2) and a method for manufacturing the roof longitudinal beam (3).

Description

Technical Field

[0001] This invention relates to a roof longitudinal beam for a motor vehicle, comprising at least one bracket and at least one fastening device for fastening the bracket at its end to the roof of the motor vehicle. The fastening device includes a fastener fastened to the bracket and capable of being fastened to the roof, and an adapter component that at least partially accommodates the fastener. The invention also relates to a motor vehicle having a roof and a roof longitudinal beam fastened to the roof, and a method for manufacturing the roof. Background Technology

[0002] For prior art, please refer to patent document WO2013 / 107683A1. This document describes a roof longitudinal beam for a motor vehicle, comprising: at least one apron and at least one support member, the support member being fastened to the apron to bridge the gap formed between the apron and the roof of the motor vehicle and to fasten the roof longitudinal beam to the roof of the motor vehicle; and at least one cover for the support member, wherein the apron, support member, and cover member are constructed as separate components. It is proposed that at least one end region of the apron is constructed as a curved segment, the end of which forms a roof abutment end, the support member is constructed as an extrusion member, and the support member and cover member are at least partially located within the curved segment region. Summary of the Invention

[0003] The purpose of this invention is to propose a roof longitudinal beam for motor vehicles, which has advantages over known roof longitudinal beams, especially in that it can be reliably and permanently fixed to the roof of the motor vehicle, and its design is particularly pleasing to the eye.

[0004] To achieve the above objectives, the present invention provides a roof longitudinal beam for a motor vehicle. The present invention proposes that the adapter component is constructed as an injection-molded part, with the fastener molded into the adapter component.

[0005] Roof longitudinal beams are preferably an integral part of the motor vehicle, but they can also be separate from the motor vehicle. For example, roof longitudinal beams are used to secure roof racks to the motor vehicle. In this case, the roof rack is supported on the roof of the motor vehicle via the roof longitudinal beams. Roof longitudinal beams can also be installed on the motor vehicle purely for visual reasons.

[0006] The roof longitudinal beam has at least one corridor and at least one fastening device. As part of the roof longitudinal beam, after the roof longitudinal beam is assembled to the vehicle, the corridor preferably extends longitudinally along the vehicle or at least substantially longitudinally, i.e., parallel or substantially parallel to the longitudinal axis of the vehicle. In this case, the corridor extends over a large portion of the roof in the longitudinal direction, preferably over at least 70%, at least 80%, or at least 90%. However, other arrangements and extensions of the corridor are also possible in principle. Preferably, the corridor has an upper side facing away from the fastening device in cross-section, side walls starting from the upper side, and a bottom wall resting on a support surface of the fastening device. The upper side and the bottom wall are connected to each other via the side walls.

[0007] For example, the apron is designed such that, after the roof longitudinal beams are assembled to the vehicle, the apron supports the vehicle's roof at least over most of its longitudinal extension, particularly continuously or uninterruptedly. Preferably, the apron supports the vehicle's roof over its entire longitudinal extension. However, it is also possible that the apron is only partially supported on the vehicle's roof, particularly only at its ends by means of one or more fastening devices. Similarly, the apron can be supported on the roof at its ends by fastening devices, with only partial gaps between the fastening devices and the roof. The roof longitudinal beams proposed in this invention can, in principle, be used in all the above-described apron configurations.

[0008] The roof truss is preferably supported on the roof by a protective film, particularly made of plastic, especially elastomers and / or foam materials, which reliably prevents the roof longitudinal beams from damaging the roof or vice versa, and / or establishes a waterproof connection between the roof longitudinal beams and the roof of the vehicle, thereby preventing moisture from the external environment from seeping into the vehicle through the roof longitudinal beams or the attachment points between the roof longitudinal beams and the roof. Within the scope of this specification, the protective film can be considered as part of the roof. Therefore, when referring to the roof longitudinal beams being supported on the roof, it can be said that support is achieved directly without a protective film, or it can be said that support is preferably achieved through a protective film. In the former case, the roof longitudinal beams are directly located on the roof; in the latter case, the roof longitudinal beams are located on the protective film arranged on the roof.

[0009] The pergola is secured at one end to, or can be secured to, the roof of the motor vehicle by means of at least one fastening device. "Secure at one end" means that the fastening device engages with one end of the pergola and connects it to the roof of the motor vehicle. In other words, the fastening device is located at one end of the pergola or secured to one end of the pergola. "Secure" means that the pergola is completely fixed by the fastening device, that is, completely fixed in the longitudinal, vertical, and transverse directions of the motor vehicle, and there is no play or at most a slight play is allowed between the pergola and the roof.

[0010] Particularly preferably, the pergola is secured to the roof of the vehicle using multiple fastening devices. In this case, each fastening device is used to secure the pergola to the roof at its end, such that the multiple fastening devices act on the spaced ends of the pergola and fix it relative to the roof. The pergola areas secured by the fastening devices are, for example, at least partially, preferably continuously, or only partially supported on or continuously spaced from the roof of the vehicle. In any case, the pergola is supported on the roof at least at its ends by fastening devices, particularly the pergola itself abutting against the roof of the vehicle or against a protective film at this location.

[0011] Particularly preferably, the roof longitudinal beam has multiple corridors, which are arranged, in particular, in parallel and spaced apart from each other, on the roof of the motor vehicle. Each of these corridors is fastened to the roof of the motor vehicle at its end by at least one fastening device. Preferably, multiple fastening devices are used to fasten each corridor, particularly exactly two fastening devices. In this regard, the invention also relates to a roof longitudinal beam for a motor vehicle, comprising at least one corridor and multiple fastening devices for fastening the corridor to the roof of the motor vehicle at its end, wherein each fastening device has a fastener in the form of an extruded fastener and an adapter component that at least partially accommodates the fastener. The invention further proposes that each adapter component is constructed as an injection-molded component, and each fastener is molded into the corresponding adapter component.

[0012] The adapter component is essentially constructed as an injection-molded component, meaning that the adapter component is injection molded. The fastener is encapsulated within the adapter component, meaning that the fastener is provided before manufacturing the adapter component, encapsulated with injection molding material during the manufacturing process, thereby forming the adapter component with the fastener disposed therein immediately after injection molding. The fastener is injection molded into the adapter component such that it is held within the adapter component in a form-fit manner. Particularly preferably, the fastener is completely contained within the adapter component, such that the fastener does not protrude beyond the adapter component. In this case, the invention can certainly propose that the fastener be visible from the outside of the adapter component. However, preferably, the fastener is completely contained within or at most flush with the envelope of the adapter component. The envelope can also be referred to as the profile of the adapter component.

[0013] Preferably, the adapter component and the fastener are made of different materials. For example, the fastener is made of metal, while the adapter component is made of plastic and is correspondingly presented as a plastic injection molded component. For example, the fastener is made of steel, preferably plated steel. For example, the steel is plated with zinc and / or nickel. Zinc-plated steel is also referred to as galvanized steel. The steel is preferably a microalloyed steel, such as S355MC type steel conforming to DIN EN 10149-2. This steel is also referred to as 1.0976. For example, the plastic of the adapter component is an acrylonitrile / styrene / acrylate copolymer (ASA), particularly an acrylonitrile / styrene / acrylate copolymer conforming to TL52311. Preferably, the surface of the adapter component is at least partially provided with a surface structure, particularly a grained surface, such as a K31 grained surface. Preferably, the grained surface is only achieved in the visible area of ​​the adapter component.

[0014] Fasteners can be constructed in various ways. For example, fasteners may be presented as continuous components, particularly sheets (especially metal sheets) or extrusions. Sheets are preferably in the form of sheet metal. Continuous components are particularly preferably curved or bent. Accordingly, the continuous component has at least one curve or curvature, and particularly preferably has multiple parallel curves or curvatures. Alternatively, the fastener may have multiple reinforcing members arranged at intervals between each other.

[0015] The extruded part is preferably in the form of an extrusion part, i.e., produced in an extrusion process. This means that the extruded part has a continuous and constant cross-section in one direction (i.e., the extrusion direction in which the extruded part is produced by extrusion). Preferably, a billet is first manufactured by an extrusion process, and the billet is cut into multiple extruded parts in mutually parallel planes, and these extruded parts are particularly identical. The extruded part is designed to achieve extremely high strength while reducing production costs.

[0016] If the fastener is designed as an extrusion or stamping, it can only conform to the profile of the roof and pergola in one direction. In this case, an adapter component is used to fit the extrusion or stamping onto the roof or pergola. For example, for several roof longitudinal beams, especially pergolas with different designs, the same fastener design can be used. Each roof longitudinal beam has an adapter component that adapts the corresponding fastener to the different pergolas. Fasteners can be mass-produced accordingly, thus achieving a cost advantage.

[0017] The adapter component's injection-molded design ensures a high degree of design flexibility, allowing for a highly precise fit of the fastener to the pergola and / or roof, almost independently of the fastener design. This results in both increased connection strength between the pergola and roof due to the fastener and a remarkably pleasing visual appearance of the roof longitudinal beams. Because it is an injection-molded component, the adapter component is made from a single piece of material. Therefore, it is not composed of multiple parts attached to each other, for example, by form and / or material fitting. Rather, the adapter component is manufactured as a single piece, i.e., a single element. This also enables cost-effective and efficient production.

[0018] In conventional roof longitudinal beams, fasteners are used solely to support and secure the aisle, while adapter components (if present) are only used to visually conceal the fasteners. However, according to the present invention, the adapter components also have a load-bearing function, particularly since the fasteners and consequently the aisle are also supported on the roof of the vehicle via the adapter components. For example, the present invention proposes that the aisle directly abuts against the adapter components and / or the fasteners. Particularly preferably, viewed in longitudinal section, the aisle and fasteners are arranged continuously at intervals and supported on the adapter components. The aisle is fastened to the fasteners by means of bolts. Additionally or alternatively, the present invention proposes that the fasteners are supported on the roof directly or only indirectly via the adapter components. A particularly preferred design for the roof longitudinal beams is that the fasteners partially abut directly against the roof and partially indirectly supported on the roof via the adapter components.

[0019] Therefore, this invention proposes that the trellis be fastened to a fastener, and after the roof longitudinal beams are assembled to the vehicle, the fastener is supported on or fastened to the roof of the vehicle. This invention proposes that the fastener may be directly supported on the roof of the vehicle, i.e., directly against the roof or protective film. However, preferably, the fastener is at least partially supported on the roof via an adapter component. Particularly preferably, at least a majority of the fasteners are spaced from the roof by the adapter component, so that at most a small portion of the fasteners are directly supported on the roof or protective film, while the remaining fasteners are supported on the roof or protective film via the adapter component. This reliably prevents the fasteners from damaging the roof.

[0020] The improved embodiment of this invention proposes a fastener having multiple first fastening recesses and multiple second fastening recesses. The first fastening recesses are configured to receive a first threaded connector for fastening the fastener to a frame, and the second fastening recesses are configured to receive a second threaded connector for fastening the fastener to the vehicle roof. The fastener thus has multiple fastening recesses, namely multiple first fastening recesses and multiple second fastening recesses. These fastening recesses are designed as through holes, meaning they all completely penetrate the fastener.

[0021] A first threaded connector is arranged in the first fastening recess, by which the fastener is secured to the frame. A second threaded connector is arranged in the second fastening recess, by which the fastener is secured or can be secured to the roof. The threaded connectors (i.e., the first and second threaded connectors) are preferably screws or bolts. Accordingly, each threaded connector has at least one threaded connector head and a threaded connector thread.

[0022] The fastening notches (i.e., both the first and second fastening notches) are arranged at intervals. Preferably, the longitudinal central axes of the fastening notches lie within a common imaginary plane. Alternatively, the longitudinal central axes of the fastening notches may be parallel to each other. However, preferably, at least some of the longitudinal central axes of the fastening notches (particularly those within the common imaginary plane) are at an angle to each other, i.e., an angle greater than 0° and less than 180°.

[0023] The improved embodiment of the invention proposes that each second fastening recess is surrounded by a facet of the fastener, which aligns with or protrudes from the underside of the adapter component in a direction away from the vestibule. The facet of the fastener refers to the fastener surface forming a continuous edge of the corresponding second fastening recess. The facet completely and uninterruptedly encircles the corresponding second fastening recess. The facet is thus annular, particularly circular. Particularly preferably, the fastener is supported on the roof or protective film of the vehicle via the facet. Accordingly, in longitudinal section, the facet aligns with or even protrudes from the underside of the adapter component away from the vestibule. After the roof longitudinal beam is assembled to the roof of the vehicle, at least the facet of the fastener abuts against the roof. Preferably, the underside of the adapter component also at least partially abuts against the roof. This design allows the roof longitudinal beam to be reliably and permanently connected to the vehicle.

[0024] The improved embodiment of the invention proposes that the adapter component has a first screw head section receiving portion, wherein the head section of the first screw is spaced apart from the lower side of the adapter component. The first screw is used to fasten the fastener to the corridor. Preferably, the first screw is engaged to the corridor directly or at least indirectly through, for example, a threaded sleeve, by its screw thread. In any case, the screw head section of the first screw is located on the side of the fastener facing away from the corridor in the longitudinal section. The adapter component has a first screw head section receiving portion on this side, and their dimensions are designed such that, after the roof longitudinal beam is assembled to the vehicle, the first screw, especially its screw head section, is spaced apart from the roof. This prevents the first screw from damaging the roof, especially scratching the roof.

[0025] The improved embodiment of the invention proposes that, after the roof longitudinal beams are arranged behind the vehicle, the roof of the vehicle closes the first bolt head section receiving portion. When the roof longitudinal beams are arranged as intended, the first bolt head section receiving portion has openings on its roof-facing side that penetrate the underside of the adapter component. These openings are closed by the roof of the vehicle. This specifically means that the roof abuts against the adapter component in a manner that covers or overlaps the openings. In this case, the roof is particularly preferably continuously and completely overlapping the openings. For example, the edge of the defining opening formed by the adapter component abuts against the roof, particularly continuously or uninterruptedly.

[0026] Alternatively, the openings are spaced apart from the roof. In this case, the distance between the openings and the roof is relatively small. This distance preferably corresponds at most to the diameter of the first bolt, and is particularly smaller than the diameter of the first bolt. For example, this distance corresponds at most to the diameter of the first bolt multiplied by a factor of 0.75, 0.5, or 0.25. In any case, the dimensions of the receiving portion of the first bolt head are particularly preferably designed so that the first bolt contacts the roof before disengaging from the bracket. This provides particularly effective security for the roof longitudinal beams and prevents accidental loosening.

[0027] The improved embodiment of this invention proposes that the fastener be designed as a continuous component or having multiple reinforcing members, which are spaced apart and accommodated within the adapter component and have fastening recesses. The corresponding fastener design has already been described above. In the case of a continuous component, the pergola is directly fastened to the roof via the fastener. This means that the fastener is fastened to both the pergola and the roof, thereby continuously transmitting the force between the pergola and the roof through the fastener.

[0028] On the other hand, if the fastener has reinforcements, then a continuous component is unnecessary. Specifically, some reinforcements are fastened to the pergola, while others are fastened to the roof and housed in adapter components spaced apart from each other. The forces between the pergola and the roof are not transmitted continuously through the fasteners, but at least partially through the adapter components, because the reinforcements connected to the pergola on one side and those connected to or potentially connected to the roof on the other side are connected or attached to each other only through the adapter components.

[0029] Fasteners designed as continuous components are characterized by high strength, while fasteners with reinforcing elements can significantly reduce costs and weight. Continuous components are particularly preferably in the form of extrusions or sheets.

[0030] The improved embodiment of this invention proposes that the reinforcing member be designed as a bushing, each bushing having at least one conformal clamp at least partially molded to the adapter component. Bushings including a second fastening recess each additionally have a conformal clamp spaced apart from the first conformal clamp. The adapter component is form-fitted between the conformal clamp and the additional conformal clamp. The reinforcing member is thus in the form of a bushing with a fastening recess. Each bushing has at least one conformal clamp, which is a tab-like protrusion extending from the base of the corresponding bushing. The conformal clamp may be, for example, a circumferential tab, or to some extent, an annular tab.

[0031] To secure the corresponding bushing, a conformal hoop is arranged in the adapter component, i.e., it engages with the adapter component in a form-fit manner. In addition to the conformal hoop, the bushing, which has at least a second fastening recess, also has an additional conformal hoop. The conformal hoop and the additional conformal hoop are arranged spaced apart from each other, particularly parallel to each other. The additional conformal hoop can be designed according to the description of the conformal hoop. The adapter component engages with the conformal hoop and the additional conformal hoop in a form-fit manner to secure the corresponding bushing in a form-fit manner. Particularly preferably, the invention proposes that one of the conformal hoops (e.g., the additional conformal hoop) is flush with the underside of the adapter component. This creates an attachment point for securely attaching the roof longitudinal beam to the roof.

[0032] Preferably, the bushing with the first fastening notch is designed differently from the bushing with the second fastening notch. Specifically, the bushing with the first fastening notch has only a conformal hoop, and no additional conformal hoops. Preferably, the conformal hoop is centered or at least approximately centered on the bushing in the longitudinal axis direction. On the other hand, the conformal hoop and additional conformal hoop are preferably eccentrically (particularly at the ends) arranged on the bushing with the second fastening notch. This means that the conformal hoop and additional conformal hoop are arranged at opposite ends of the respective bushings. This ensures that the reinforcement is reliably fastened to the vestibule and the roof of the vehicle.

[0033] The improved embodiment of the present invention proposes a pergola having, in cross-section, an upper side facing away from the fastening device, side walls starting from the upper side, and a bottom wall resting on the support surface of the fastening device. Viewed in cross-section, the pergola can be broadly divided into an upper side, side walls, and a bottom wall. The upper side and the bottom wall are connected to each other via the side walls. Viewed in cross-section, for example, the upper side, side walls, and bottom wall at least partially form a closed profile. The pergola is supported on the support surface of the fastening device. The support surface is constructed on the adapter component. The shape and size of the support surface are preferably adapted to the bottom wall of the pergola, such that the bottom wall rests flat on the support surface.

[0034] The improved embodiment of the invention proposes that the first fastening notch penetrates the support surface. In this respect, the opening of the first fastening notch, located on the side of the fastening device or adapter component facing the pergola, is defined by the support surface. In other words, the edge of the opening is formed by the support surface. This allows the pergola to be fastened in a compact and visually inconspicuous manner by the fastening device.

[0035] An improved embodiment of the invention proposes that the adapter component has at least one support wall protruding from the support surface, and a side wall of the pergola, or an extension of the side wall originating from the side wall of the pergola, is supported on this support wall to laterally guide the pergola relative to the adapter component. To improve the lateral guidance of the pergola relative to the adapter component, the adapter component is provided with a support wall that protrudes from the support surface, i.e., protrudes in a direction away from the roof of the vehicle. For example, one of the side walls of the pergola abuts against this support wall.

[0036] Alternatively, a sidewall extension extends from the sidewall of the vestibule and is supported on a supporting wall. The sidewall extension refers to a portion of the sidewall that extends from the corresponding sidewall toward the roof of the vehicle. The sidewall extension is preferably offset relative to the corresponding sidewall, particularly offset parallel to it. This roof longitudinal beam design facilitates alignment of the vestibule during assembly and ensures that the vestibule is reliably secured to the roof.

[0037] The improved embodiment of the invention proposes that the sidewalls and their extensions are connected via a curved portion of the pergola that overlaps the supporting wall. As described above, the sidewalls and their extensions are preferably offset from each other, particularly parallel offset. This offset is achieved by means of the curved portion. Here, the curved portion refers to the pergola region where the pergola width decreases from the sidewall towards the sidewall extension. The curved portion thus achieves the narrowing of the pergola towards the roof in cross-section.

[0038] The improved embodiment of the present invention proposes that the adapter component has a second screw head section receiving portion adjacent to a second fastening recess, wherein the screw head section of the second screw is arranged and held in the second screw head section receiving portion in a form-fit manner to resist relative rotation. The second screws are used to fasten the fastening device to the roof of a motor vehicle, and they are arranged in the second fastening recess of the fastener. Typically, the fastening device is first assembled onto the roof rack, and then the fastening device and roof rack assembly is placed on the roof of the motor vehicle. This requires the second screws to be already arranged on the fastening device in order to quickly and reliably fasten the fastening device to the roof. The present invention correspondingly proposes that the second screws be inserted into the second fastening recess before the fastening device and the roof rack are fastened together. Then the fastening device is fastened to the roof rack, and subsequently the fastening device and roof rack assembly is placed on the roof.

[0039] To prevent the second bolted member from rotating during fastening to the roof longitudinal beam, the adapter component is designed to retain the bolt head of the second bolted member in a form-fit manner to resist relative rotation. For this purpose, the adapter component has a second bolt head receiving portion whose shape and size are adapted to the bolt head of the second bolted member, thus at least ensuring that the second bolted member is held in a form-fit manner on the adapter component. At least one second fastening recess is specifically arranged such that, after the fastening device is fastened to the aisle, the second fastening recess at least partially overlaps with the aisle, particularly the aisle's bottom wall. Accordingly, the aisle securely holds at least one of the two bolted members on the adapter component to prevent loss of detachment. The above-described roof longitudinal beam design ensures simple and quick assembly onto the roof of the motor vehicle.

[0040] The improved embodiment of the invention proposes that the adapter component has an extension protruding from the support surface, which engages with a foot area of ​​the pergola opposite the vehicle roof. This foot area has a foot surface facing the vehicle roof, which is U-shaped and interlocks with the extension, aligning with or protruding from the lower side of the adapter component in the direction facing the vehicle roof. The extension is an integral part of the adapter component. For example, the extension may begin directly from the support surface, but it may also be spaced apart from the support surface. In any case, the extension engages with the foot area of ​​the pergola to reliably secure it, particularly to achieve lateral guidance of the foot area.

[0041] In this footing area, after the roof longitudinal beams are assembled to the vehicle, the corridor abuts against the roof, or at least the distance between the corridor and the roof is shortest within the longitudinal extension of the corridor. The footing area terminates at a footing surface, which is formed on the side of the corridor facing the roof. The footing surface can be continuously and entirely within an imaginary plane. However, the footing surface is preferably curved, in which case it exhibits a continuous orientation.

[0042] Preferably, after the roof longitudinal beams are assembled to the vehicle, the foot face continuously and completely abuts the roof. The foot face has a U-shaped design and surrounds the extension of the adapter component. This extension particularly preferably abuts the foot area continuously. The foot face may protrude beyond the adapter component or its underside in the direction facing the roof, but preferably remains flush with it. This ensures both reliable fastening of the roof longitudinal beams to the vehicle and a particularly pleasing visual appearance.

[0043] A particularly preferred design for a roof longitudinal beam for a motor vehicle has at least one aisle and at least one fastening device for fastening the aisle at its end to the roof of the motor vehicle, wherein the fastening device has a fastener that is fastened to the aisle and can be fastened to the roof, and an adapter component that at least partially accommodates the fastener, wherein the aisle has an upper side facing away from the fastening device in cross-section, a side wall starting from the upper side, and a bottom wall connected to the upper side through the side wall, and the adapter component is constructed as an injection-molded component, and the fastener is encapsulated and molded in the adapter component. The present invention proposes that the bottom wall is placed flat on the support surface of the adapter component; the fastener has a plurality of first fastening recesses and a plurality of second fastening recesses penetrating the support surface, wherein the first fastening recesses are configured to receive a first screw connector for fastening the fastening device to the corridor, the second fastening recesses are configured to receive a second screw connector for fastening the fastening device to the roof, and the adapter component has a first screw connector head section receiving portion on the side of its longitudinal section facing away from the corridor, wherein the screw connector head section of the first screw connector is spaced apart from the lower side of the adapter component.

[0044] The present invention also relates to a motor vehicle comprising a roof and a roof longitudinal beam fastened to the roof, particularly a roof longitudinal beam as described within the scope of this specification, wherein the roof longitudinal beam has at least one aisle and at least one fastening device for fastening the aisle at its end to the roof of the motor vehicle, wherein the fastening device has a fastener fastened to the aisle and to the roof, and an adapter component that at least partially accommodates the fastener. The present invention proposes that the adapter component be constructed as an injection-molded component, and the fastener be molded into the adapter component.

[0045] The advantages of this motor vehicle or roof longitudinal beam design have been explained above. Both the motor vehicle and roof longitudinal beam described above can be modified within the scope of this specification; reference can be made to these embodiments.

[0046] The present invention also relates to a method for manufacturing a roof longitudinal beam, particularly a roof longitudinal beam as described within the scope of this specification, wherein the roof longitudinal beam has at least one bracket and at least one fastening device for fastening the bracket at its end to the roof of a motor vehicle, wherein the fastening device has a fastener fastened to the bracket and capable of being fastened to the roof, and an adapter component that at least partially accommodates the fastener. The present invention proposes that the adapter component be constructed as an injection-molded component, and that the fastener and the adapter component be molded together, such that the fastener is molded within the adapter component.

[0047] For further information on the methods and advantages of the roof longitudinal beams, as well as potential improvements, please refer to the statements within the scope of this specification.

[0048] Without departing from the scope of this invention, the features and combinations thereof described in the foregoing description, and especially the features and combinations thereof described and / or shown in the following description and / or drawings, can be used not only in the various combinations given, but also in other combinations or alone. This invention should be considered to include embodiments not explicitly shown or described in the specification and / or drawings, but implied or deduced from the embodiments described herein. Attached Figure Description

[0049] The present invention will now be described in detail with reference to the embodiments shown in the accompanying drawings, but is not intended to limit the invention.

[0050] In the picture:

[0051] Figure 1 A schematic diagram of a motor vehicle is shown, showing the roof longitudinal beams fastened to the roof of the vehicle.

[0052] Figure 2 A longitudinal sectional view of a first embodiment of the roof longitudinal beam is shown, which has fastening devices for securing the corridor to the roof.

[0053] Figure 3 A schematic diagram of the fastening device for the first embodiment of the roof longitudinal beam is shown;

[0054] Figure 4 A longitudinal sectional view of the second embodiment of the roof longitudinal beam is shown;

[0055] Figure 5 A schematic diagram of the fastening device for the second embodiment of the roof longitudinal beam is shown. Detailed Implementation

[0056] Figure 1 A schematic diagram of a motor vehicle 1 having a roof 2 and roof longitudinal beams 3 is shown. The roof longitudinal beams 3 are fastened to the roof 2. A protective membrane 4 is arranged between the roof 2 and the roof longitudinal beams 3 to prevent mutual damage between them. The protective membrane 4 can also be considered as a portion of the roof 2, thus the roof 2 partially has the protective membrane 4, i.e., the portion of the roof longitudinal beams 3 supported by or in contact with the roof 2. The roof longitudinal beams 3 have corridors 5. In principle, the roof longitudinal beams 3 can have any number of corridors 5. In this case, the multiple corridors 5 are preferably parallel to each other. Only the corridors 5 are described below. If there are multiple corridors 5, these statements can be similarly applied to each of these corridors 5.

[0057] The pergola 5 has an upper side 6 on its side facing away from the roof 2, which curves in the direction of the end 7 of the pergola 5 toward the roof 2. Specifically, as shown, the entire pergola 5 curves in the direction of the roof 2. Side walls 8 extend from the upper side 6; only one side wall is visible in this figure. The side walls 8 are parallel to each other and preferably extend over most of the extension of the pergola 5. The lower part of the pergola 5 is defined at least partially 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 extension in the longitudinal direction of the roof beam 3 than the upper side 6 and the side walls 8. This forms a recess 10 (not shown in this figure) in the region of the end 7 of the pergola 5.

[0058] The pergola 5 is fastened to the roof 2 at its end by a fastening device 11. For this purpose, the fastening device 11 is preferably also engaged in the recess 10. Viewed in cross-section, the upper side 6 of the pergola 5 is located on the side of the pergola 5 facing away from the fastening device 11, while the bottom wall 9 faces the fastening device 11 or is arranged on the side of the pergola 5 facing the fastening device 11. Specifically, the bottom wall 9 rests on the support surface 29 (not shown in this figure) of the fastening device 11, such that the pergola 5 is supported thereon.

[0059] For example, the end 7 of the pergola 5 has a foot area 12, wherein a foot surface 13 is formed on the pergola 5, which is substantially U-shaped. Preferably, the pergola 5 is directly supported on the roof 2 or protective film 4 by the foot surface 13. For this purpose, the foot surface 13 is, for example, curved to fit the shape of the roof 2. The foot surface 13 loops around a certain area of ​​the fastening device 11, i.e., the extension 14, for lateral guidance of the pergola 5 at the end 7 of the pergola 5. In addition, the pergola 5 is further laterally guided relative to the fastening device 11 by a support wall 15, which is a component of the fastening device 11, and the side wall 8 or the side wall extension 16 (as in the embodiment shown in this figure) lies flat on the support wall 15. The support wall 15 is a component of the adapter part 17 of the fastening device 11.

[0060] In addition to the adapter component 17, the fastening device 11 also has a fastener 18, but in this figure, the fastener 18 is not visible because it is covered by the adapter component 17. The adapter component 17 is in the form of an injection-molded component and is housed within the adapter component 17. In this case, the fastener 18 is arranged in a form-fit manner within the adapter component 17 and is thus held therein by a form fit. Preferably, the fastener 18 is completely within the envelope or contour of the adapter component 17, that is, it does not extend beyond the adapter component 17.

[0061] Finally, the pergola 5 is fastened to the roof 2 by a first screw 19 and a second screw 20, only the second screw 20 is visible in this figure. The first screw 19 is used to fasten the fastening device 11, or more precisely, the fastener 18, to the pergola 5. Conversely, the fastening device 11, or more precisely, the fastener 18, is fastened to the roof 2 by the second screw 20. The first screw 19 and the second screw 20 act on the fastening device 11 or the fastener 18 at intervals from each other. The present invention proposes that the protective film 4 preferably has a notch 21 for the second screw 20.

[0062] Figure 2 A longitudinal sectional view of a first embodiment of the roof longitudinal beam 3 is shown. In the first embodiment, the visible fastener 18 is designed as a continuous component, specifically in the form of a curved sheet metal sheet or strip. This means that the fastener 18 has a consistently constant material thickness, and its dimension in a first direction is much larger than its dimension in a second direction perpendicular to the first direction. The first and second directions are in turn perpendicular to a third direction containing the material thickness. For example, the dimension in the first direction is at least 5 times, at least 7.5 times, or at least 10 times larger than the dimension in the second direction.

[0063] The fastener 18 has a first fastening recess 22 and a second fastening recess 23. A first threaded member 19 is disposed in the first fastening recess 22, and a second threaded member 20 is disposed in the second fastening recess 23. Viewed in longitudinal section, the first fastening recess 22 is disposed above the second fastening recess 23, i.e., on the side of the fastener 18 facing the imaginary longitudinal center plane or the imaginary plane intersecting with the fastener 18. In the embodiment shown in this figure, one of the second fastening recesses 23 is located in a bending region of the fastener 18, in which the connecting member bends in the direction of the roof 2 or in the direction away from the corridor 5.

[0064] The second fastening recesses 23 are all completely and uninterruptedly encircled by the facets 24 of the fastener 18. In this respect, the facets are all annular. Preferably, the facets 24 are all completely continuous within an imaginary plane. Preferably, the facets 24 are aligned with or even protrude from the lower side 25 of the adapter component 17 in the direction away from the truss 5. This means that the roof longitudinal beam 3 is supported on the roof 2 at least via the facets 24, or the facets 24 are in direct contact with the roof 2. Particularly preferably, the fastener 18 rests on the roof 2 only with its facets 24 and is otherwise spaced from the roof 2. Preferably, the area of ​​the fastener 18 away from the facets 24 is contained within the adapter component 17, at least not exceeding its outline or envelope.

[0065] As shown in the figure, the roof longitudinal beam 3 rests on the adapter component 17 with its bottom wall 9, particularly spaced from the fastener 18. The corridor 5 is supported on the roof 2 by the adapter component 17 and / or the fastener 18. Alternatively, the corridor 5 may contact the roof 2 directly with its bottom surface 13. In particular, the adapter component 17 supports the corridor 5 vertically, while the corridor 5 is secured relative to the roof 2, particularly in the longitudinal and transverse directions, by the fastener 18. The fastener 18 also prevents the corridor 5 from moving vertically away from the roof 2, i.e., from shifting in a direction away from the roof 2. Overall, through the interaction of the adapter component 17 and the fastener 18, the corridor 5 is securely and reliably fixed to the roof 2.

[0066] To prevent the first screw connector 19 from damaging the roof 2, a first screw connector head section receiving portion 26 is provided in the adapter component 17, that is, on the side of the fastener 18 facing away from the bracket 5. The screw connector head section 27 of the first screw connector 19 engages in the first screw connector head section receiving portion 26, thereby spacing them from the roof 2.

[0067] Figure 3 A schematic diagram of the fastening device 11 for a first embodiment of the roof longitudinal beam 3 is shown. Only the adapter component 17, the first screw connector 19, and the second screw connector 20 are visible in the figure. The support surface 28 is visible, on which the corridor 5 is supported by its bottom wall 9. It can also be seen that the support wall 15 protrudes from the support surface 28 in the direction of the corridor 5. Similarly, the extension 14 protrudes from the support surface 28, i.e., in the longitudinal direction of the roof longitudinal beam 3 or the corridor 5.

[0068] In addition to the first screw head section receiving portion 26, the adapter component 17 also has a second screw head section receiving portion 29, in which the screw head section 30 of the second screw 20 is arranged. The shape and size of the second screw head section receiving portion 29 are adapted to the screw head section 30, so that the screw head section 30, and thus the second screw 20, are fixed to the adapter component 17 in a form-fit manner without rotation. In this way, the roof longitudinal beam 3 can be quickly and easily fastened to the roof 2 of the vehicle 1.

[0069] Figure 4 A longitudinal sectional view of a second embodiment of the roof longitudinal beam 3 is shown. The description of the first embodiment is generally the same as above, with only the differences discussed. This is due to the fact that the fastener 18 is no longer designed as a continuous component, but instead has multiple reinforcements 31 spaced apart and housed within the adapter component 17, each having fastening recesses 22 and 23. The reinforcements 31 are in the form of bushings, each having at least one first conformal clamp 32, which is plastically molded to the adapter component 17.

[0070] The reinforcing member 31 receiving the first fastening notch 22 has only a single first conformal band 32, which is approximately or precisely centered in its corresponding longitudinal central axis direction. However, the reinforcing member 31 with the second fastening notch 23 has a second conformal band 33, which is configured to be spaced apart from the first conformal band 32. The adapter component 17 engages between the first conformal band 32 and the second conformal band 33 to secure the respective reinforcing member 31. Particularly preferably, the second conformal band 33 is flush with the lower side 25 of the adapter component 17, such that the second conformal band 33 forms the aforementioned facet 24.

[0071] Figure 5 A schematic diagram of the fastening device 11 for the second embodiment of the roof longitudinal beam 3 is shown. Referring again to the description of the first embodiment above, only the differences are discussed. This is mainly due to the design of the second screw head section receiving portion 29. Although there is a recess in the adapter component 17 in the first embodiment for forming the second screw head section receiving portion 29, in the second embodiment, the second screw head section receiving portion 29 is defined only by two preferably parallel tabs. These two tabs 34 are used to retain the corresponding second screw 20 in a form-fit manner, fixing it relative to the adapter component 17 against relative rotation.

[0072] Through the design of the above-mentioned vehicle 1 or roof longitudinal beam 3, the corridor 2 can be quickly and conveniently fastened to the roof 2 of the vehicle. At the same time, the fastening device 11 can reduce production costs and ensure reliable load transfer from the corridor 5 to the roof 2.

[0073] List of reference numerals

[0074] 1 Motor vehicles

[0075] 2. Roof

[0076] 3. Roof longitudinal beams

[0077] 4. Protective film

[0078] 5. Pergola

[0079] 6 upper side

[0080] 7. Tail end

[0081] 8. Sidewalls

[0082] 9 bottom wall

[0083] 10 concavity

[0084] 11 Fastening device

[0085] 12. Foot area

[0086] 13. Bottom surface

[0087] 14 Extension

[0088] 15 Supporting wall

[0089] 16 Sidewall extension

[0090] 17 Adapter Components

[0091] 18 Fasteners

[0092] 19 First screw connector

[0093] 20 Second screw connector

[0094] 21 gaps

[0095] 22 First fastening notch

[0096] 23 Second fastening notch

[0097] 24 facets

[0098] 25 Lower side

[0099] 26 First screw connector head section receiving part

[0100] 27. Screw connector head section

[0101] 28 Support surface

[0102] 29 Second screw connector head section receiving part

[0103] 30 Screw connector head section

[0104] 31 Reinforcing Components

[0105] 32 First conformal hoop

[0106] 33 Second conformal hoop

[0107] 34 stitched pieces

Claims

1. Roof rail (3) for a motor vehicle (1), comprising at least one gallery (5) and at least one fastening device (11) for fastening the gallery (5) at the end to a roof (2) of the motor vehicle (1), wherein The fastening device (11) has a fastener (18) fastened to the roof rack (5) and fastenable to the roof (2) and an adapter part (17) which at least partially accommodates the fastener (18), wherein the adapter part (17) is configured as an injection-molded part and the fastener (18) is overmolded in the adapter part (17), characterized in that the fastener (18) has a plurality of first fastening recesses (22) and a plurality of second fastening recesses (23), wherein the first fastening recesses (22) are configured to accommodate first screw connections (19) for fastening the fastening device (11) to the roof rack (5) and the second fastening recesses (23) are configured to accommodate second screw connections (20) for fastening the fastening device (11) to the roof (2); each of the second fastening recesses (23) is surrounded by a facet (24) of the fastener (18), which is aligned with a lower side (25) of the adapter part (17) or projects beyond the lower side (25) in a direction facing away from the roof rack (5).

2. Roof rail according to claim 1, characterized in that The adapter part (17) has a first screw connection head segment accommodation (26), wherein a head segment of the first screw connection (19) is arranged spaced apart from a lower side of the adapter part (17).

3. Roof rail according to claim 2, characterized in that The roof longitudinal beam (3) is arranged behind the motor vehicle (1), and a roof (2) of the motor vehicle (1) closes the first screw connection head segment accommodation (26).

4. Roof rail according to any one of claims 1-3, characterized in that, The fastener (18) is designed as a one-piece part or has a plurality of reinforcing elements (31) which are accommodated spaced apart from one another in the adapter part (17) and include the first fastening recesses (22) and the second fastening recesses (23).

5. Roof rail according to claim 4, characterized in that The reinforcing elements (31) are designed as bushings, each having at least one first form-fitting collar (32) which is at least partially overmolded with the adapter part (17), wherein the bushings which contain the second fastening recesses (23) each additionally have a second form-fitting collar (33) which is spaced apart from the first form-fitting collar (32), the adapter part (17) being joined in a form-fitting manner between the first form-fitting collar (32) and the second form-fitting collar (33).

6. Roof rail according to any one of claims 1-3, characterized in that The roof rack (5) has an upper side (6) which faces away from the fastening device (11) in cross section, a side wall (8) starting from the upper side (6), and a bottom wall (9) which rests on a bearing surface (28) of the fastening device (11).

7. Roof rail according to claim 6, characterized in that The first fastening recesses (22) extend through the bearing surface (28).

8. The roof rail of claim 6, wherein, The adapter part (17) has at least one support wall (15) which projects beyond the bearing surface (28), one side wall (8) of the roof rack (5) or a side wall extension (16) starting from a side wall (8) of the roof rack (5) being supported on the support wall (15) in order to laterally guide the roof rack (5) relative to the adapter part (17).

9. Roof rail according to claim 8, characterized in that The one side wall (8) and the side wall extension (16) are connected by a curved portion of the roof rack (5) which overlaps the support wall (15).

10. Roof rail according to any of claims 1-3, characterized in that The adapter part (17) has a second screw head segment accommodation (29) adjoining the second fastening recess (23), in which a screw head segment (30) of the second screw (20) is arranged and held in a form-fitting manner against relative rotation.

11. The roof rail of claim 6, wherein, The adapter part (17) has an extension (14) projecting from the support surface (28), which engages into a foot region (12) of the roof bow (5) opposite the roof (2), wherein the foot region (12) has a foot surface (13) facing the roof (2), which U-shapedly encloses the extension (14) and is aligned with or projects beyond a lower side (25) of the adapter part (17) in the direction facing the roof (2).

12. Motor vehicle (1) comprising a roof (2) and a roof rail (3) according to any one of the preceding claims, which is fastened to the roof (2).

13. Method for producing a roof rail (3) according to any one of claims 1 to 11.

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