Roof rails for automobiles, automobile, and method for manufacturing roof rails
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Patents
- Current Assignee / Owner
- FYSAM AUTO DECORATIVE GMBH
- Filing Date
- 2022-01-14
- Publication Date
- 2026-08-04
Smart Images
Figure 0007900396000001 
Figure 0007900396000002 
Figure 0007900396000003
Abstract
Description
Technical Field
[0001] The present invention relates to a roof rail for a motor vehicle having at least one gallery bar and at least one fastening device for fastening at the end of the gallery bar to the roof of the motor vehicle, the fastening device having a fastening device that can be fastened to the gallery bar and to the roof, and an adapter part that at least partially houses the fastening device. The present invention also relates to a motor vehicle having a roof and a roof rail attached to the roof, and a method for manufacturing the roof rail.
Background Art
[0002] From the prior art, for example, the publication of International Publication No. 2013 / 107683 is known. This publication describes a roof rail for a motor vehicle having at least one gallery bar, at least one support element fastened to the gallery bar for bridging the gap formed between the gallery bar and the roof of the motor vehicle and for fixing the roof rail to the roof of the motor vehicle, and at least one cover for the support element, the gallery bar, the support element, and the cover being configured as independent parts. At least one end region of the gallery bar is formed as a curved section, the end face of which forms a roof contact end, the support element is formed as an extruded part, and it is provided that the support element and the cover are at least partially within the region of the curved section.
Summary of the Invention
[0003] The object of the present invention is to propose a roof rail for a motor vehicle that has advantages over known roof rails, and in particular can be fixed to the roof of a motor vehicle in a reliable and durable manner, and in particular has an aesthetically pleasing visual design.
[0004] This is achieved according to the present invention by a roof rail for a motor vehicle having the features of claim 1. The adapter part is configured as an injection-molded part, and it is provided that the fastening device is present in an overmolded form within the adapter part.
[0005] Advantageous configurations having further favorable embodiments of the present invention are shown in the dependent claims.
[0006] Roof rails are preferably part of the vehicle, but of course, they can also be separate from the vehicle. Roof rails are used, for example, to attach to a vehicle. In this case, the roof rails are supported on the roof of the vehicle via the roof rails. However, of course, roof rails can also be placed on a vehicle simply for aesthetic reasons.
[0007] The roof rail comprises at least one gallery bar and at least one fastener. The gallery bar is an element of the roof rail, which is understood to extend preferably in the longitudinal direction or at least substantially longitudinal direction of the vehicle after the roof rail has been mounted to the vehicle, i.e., it is positioned parallel or substantially parallel to the longitudinal axis of the vehicle. In this case, the gallery bar extends in the direction of the longitudinal axis over a substantial portion of the extension of the roof, preferably over at least 70%, at least 80%, or at least 90%. However, other orientations and extensions of the gallery bar are also feasible in principle. The gallery bar preferably has an upper side facing away from the fastener in cross-sectional view, a side wall extending from the upper side, and a bottom wall resting on the support surface of the fastener. The upper side and the bottom wall are connected to each other via the side wall.
[0008] For example, the gallery bar is configured to be supported on the roof of the vehicle, in particular, continuously or uninterrupted, over at least the majority of its longitudinal extension, after the roof rail has been installed on the vehicle. Preferably, the gallery bar is supported on the roof of the vehicle over its entire longitudinal range. However, the gallery bar may also be supported only partially on the roof of the vehicle, in particular, by one fastener or by multiple fasteners, or on only one side. The gallery bar may also be supported on the roof at its ends by fasteners, and spaced away from the roof only in specific areas between the fasteners. The roof rail presented herein can essentially be used for all of the aforementioned configurations of the gallery bar.
[0009] The gallery bars are preferably supported on the roof by a protective film, particularly made of plastic, especially elastomer and / or foam, which ensures that damage to the roof by the roof rails, or conversely, damage to the roof rails by the roof, and / or forms a waterproof connection between the roof rails and the roof of the vehicle, preventing moisture from entering the vehicle from the external environment through the roof rails or through the fastening of the roof rails to the roof. The protective film can be considered part of the roof for the purposes of this specification. Thus, when we say that the roof rails are supported on the roof, this can be done directly without the protective film, or preferably through the protective film. In the former case, the roof rails are placed directly on the roof, and in the latter case, they are placed on a protective film positioned on the roof.
[0010] The gallery bar is fastened, or may be fastened, at its ends to the roof of the vehicle using at least one fastener. “Fastened at its ends” means that the fastener engages with one end of the gallery bar, connecting the gallery bar to the roof of the vehicle. In other words, the fastener is located at or fastened to one end of the gallery bar. It should be understood that by fastening, the gallery bar is completely secured by the fastener, i.e., in the longitudinal, vertical, and transverse directions of the vehicle, so as to not create any play between the gallery bar and the roof, or to allow at most a small amount of play.
[0011] Particularly preferably, the gallery bar is fastened to the roof of the vehicle with multiple fasteners. Each fastener serves to fasten the end of the gallery bar to the roof, and the multiple fasteners act on the spaced ends of the gallery bar to secure the gallery bar to the roof. The areas of the gallery bar that lie between the areas of the gallery bar fastened by the fasteners are, for example, supported by the roof of the vehicle at least partially, preferably continuously or only partially, or continuously spaced from the roof. In any case, the gallery bar is supported by the roof at least at its ends via the fasteners, and in particular the gallery bar itself rests thereon on the roof of the vehicle or protective film.
[0012] Particularly preferably, the roof rail has a plurality of gallery bars, which are arranged on the roof of the vehicle particularly parallel to each other and spaced apart. Each of these gallery bars is fastened at its end to the roof of the vehicle by at least one fastener. Preferably, a plurality of fasteners, particularly exactly two, are used to fasten each gallery bar. In this regard, the present invention also relates to a roof rail for a vehicle having at least one gallery bar and a plurality of fasteners for fastening each end of the gallery bar to the roof of the vehicle, wherein each fastener has a fastening device that can be fastened to the gallery bar and to the roof, and an adapter part that at least partially houses the fastening device. In this case, it is again provided that each of the adapter parts is constructed as an injection-molded part, and each of the fastening devices exists in an overmolded form within the corresponding adapter part.
[0013] The adapter component is essentially constructed as an injection-molded part. That is, the adapter component is manufactured by injection molding. The fastener exists as an overmolded part within the adapter component. That is, the fastener is provided before the adapter component is manufactured and overmolded by the injection molding material during the manufacturing of the adapter component, so that an adapter component with the fastener positioned inside is obtained immediately after injection molding. The fastener exists as an overmolded part within the adapter component so that it is held in place by a shape connection within the adapter component. It is particularly preferable that the fastener is completely housed within the adapter component and does not protrude beyond the adapter component at all. In this case, it is quite conceivable that the fastener may be visible from the external environment of the adapter component. However, it is preferable that the fastener is completely housed within the envelope of the adapter component, or at most aligned with the envelope of the adapter component. The envelope is sometimes referred to as the contour of the adapter component.
[0014] Preferably, the adapter component and the fastening device are made of different materials. For example, the fastening device is made of metal, while the adapter component is made of plastic, and therefore an injection-molded plastic 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, it is also called galvanized steel. The steel used is preferably a microalloy steel, for example, S355MC in accordance with DIN EN 10149-2. This steel is also called 1.0976. The plastic used for the adapter component is, for example, an acrylonitrile-styrene-acrylic acid copolymer (ASA), particularly an acrylonitrile-styrene-acrylic acid copolymer in accordance with TL52311. The surface of the adapter component preferably has a textured surface structure, particularly a textured surface, for example, a K31 texture, in at least some areas. It is preferable that the texture is realized only in the visible areas of the adapter component.
[0015] Fastening devices can be implemented in various ways. For example, fastening devices exist as continuous parts, particularly strips, especially metal strips, or extruded parts. Strips are preferably in the form of thin metal strips. Continuous parts are particularly preferably curved or bent. Thus, fastening devices have at least one bent or curved section, and particularly preferably multiple bent or curved sections arranged in parallel. Alternatively, fastening devices have multiple reinforcing elements arranged at intervals from one another.
[0016] Extruded parts are preferably in the form of extruded molded parts, i.e., manufactured by extrusion molding. That is, extruded parts have a constant cross-section that is continuous in one direction, i.e., in the extrusion direction in which the extruded part is manufactured by extrusion molding. Preferably, a blank is first manufactured using an extrusion process, which is divided into a number of particularly identical extruded parts by separating them in planes arranged parallel to each other. By constructing extruded parts as extruded molded parts, particularly high strength and low manufacturing costs can be achieved simultaneously.
[0017] When fastening devices are constructed as extruded or extruded parts, they can only conform to the contours of the roof and gallery bars in one direction. In this case, adapter parts serve to adapt the parts to the roof or gallery bars. For example, suppose that fastening devices of the same configuration are used on multiple roof rails, which may have gallery bars of particularly different configurations. Each roof rail has adapter parts to adapt each fastening device to a different gallery bar. Therefore, fastening devices can be mass-produced, resulting in cost advantages.
[0018] By constructing the adapter component as an injection-molded part, a high degree of flexibility in the adapter component's configuration is ensured, and the fastener fits extremely precisely to the gallery bar and / or roof, largely independent of the fastening device's configuration. As a result, on the one hand, high strength is achieved in the connection between the gallery bar and the roof through the use of the fastening device, and on the other hand, a particularly aesthetically pleasing appearance of the roof rail is achieved. Because it is constructed as an injection-molded part, the adapter component is manufactured as a single, uniform piece of material. In this respect, the adapter component is not composed of multiple parts fastened together, for example, by shape connections and / or material connections. Rather, the adapter component is already manufactured as a single piece, i.e., as a single element. This also leads to cost-effective and efficient manufacturing.
[0019] In conventional roof rails, only the fastening device serves to support and fasten the gallery bar, while adapter components, if present, merely serve to visually conceal the fastening device. However, according to the present invention, the adapter components also have a supporting effect, and in particular the fastening device, and consequently the gallery bar, are supported on the roof of the vehicle via the adapter components. For example, the gallery bar is intended to be directly supported by the adapter components and / or the fastening device. Particularly preferably, the gallery bar is positioned at a continuous distance from the fastening device in a longitudinal section view and supported by the adapter components. The gallery bar is fastened to the fastening device by screw connectors. Additionally or alternatively, it is provided that the fastening device is supported only directly on the roof or only indirectly via the adapter components. A particularly preferred roof rail configuration is one in which the fastening device is directly mounted on the roof in some areas and only indirectly supported on the roof via the adapter components in some areas.
[0020] Therefore, the gallery bar is fastened to the fastening device, thereby intended to be supported or fastened to the roof of the vehicle after the roof rails have been installed on the vehicle. The fastening device may be provided to be supported only on the roof of the vehicle, i.e., to be placed directly on the roof or protective film. However, it is preferable that the fastening device is supported at least partially on the roof via an adapter component. Particularly preferable is that at least the majority of the fastening device is spaced away from the roof by an adapter component, so that a small portion of the fastening device is supported directly on the roof or protective film, while the rest of the fastening device is supported only on the roof or protective film via an adapter component. This ensures that the fastening device does not damage the roof.
[0021] According to a further embodiment of the present invention, the fastening device has a plurality of first fastening recesses and a plurality of second fastening recesses, the first fastening recesses provided and configured to accommodate a first screw connector that serves to fasten the fastener to a gallery bar, and the second fastening recesses provided and configured to accommodate a second screw connector that serves to fasten the fastener to a roof. The fastening device has a plurality of fastening recesses, i.e., a plurality of first fastening recesses and a plurality of second fastening recesses. The fastening recesses are configured as through holes, i.e., they each completely penetrate the fastening device.
[0022] The first screw connector fastens the fastening device to the gallery bar and is positioned in the first fastening recess. Meanwhile, the second screw connector is positioned in the second fastening recess and is positioned so that the fastening device can be fastened to the roof. The screw connectors, i.e., the first and second screw connectors, are preferably screws or bolts. Thus, each screw connector has at least one screw connector head and screw threads.
[0023] The fastening recesses, i.e., both the first and second fastening recesses, are spaced apart from each other. Preferably, their longitudinal axes lie in a common virtual plane. Additionally, these longitudinal axes may be parallel to each other. However, preferably, at least some of the longitudinal axes of the fastening recesses, particularly those in the common virtual plane, are at an angle to each other, i.e., within an angle greater than 0° and less than 180°.
[0024] According to a further embodiment of the present invention, each of the second fastening recesses is surrounded by an edge surface of a fastening device that is flush with the lower surface of the adapter component or protrudes beyond the lower surface of the adapter component in a direction opposite to the gallery bar. The edge surface of the fastening device should be understood as the surface of the fastening device that forms a continuous edge of each second fastening recess. Thus, the edge surface completely encloses the corresponding second fastening recess without interruption. In this respect, the edge surface is annular, and more particularly circular. Particularly preferably, the fastening device is supported by the roof or protective film of the automobile via the edge surface. Thus, the fastening device is flush with the lower surface of the adapter component in a longitudinal section opposite to the gallery bar, or even protrudes beyond the lower surface of the adapter component. Thus, after the roof rail is attached to the roof of the automobile, at least the edge surface of the fastening device is in contact with the roof. It is also preferable that the lower surface of the adapter component is at least partially in contact with the roof. Such a configuration allows for a particularly secure and permanent connection between the roof rail and the automobile.
[0025] According to a further embodiment of the present invention, the adapter component has a first screw connector head receptacle in which the head of the first screw connector is positioned at a distance from the lower surface of the adapter component. The first screw connector serves to attach the fastening device to the gallery bar. Preferably, the first screw connector engages with the threads of the screw connector directly on the gallery bar, or at least indirectly, via, for example, a screw sleeve. In either case, the screw connector head of the first screw connector is positioned on the side of the fastening device that is opposite to the gallery bar in a longitudinal cross-section. On this side, the adapter component has a first screw connector head receptacle. These are sized such that after the roof rail is attached to the vehicle, the first screw connector and in particular their screw connector heads are positioned at a distance from the roof. This prevents damage to the roof by the first screw connector, especially scratching of the roof.
[0026] According to a further embodiment of the invention, the first screw connector head receptacle is closed by the roof of the motor vehicle after the roof rail has been arranged on the motor vehicle. When the roof rail is arranged as intended, the first screw connector head receptacle has an opening on the side facing the roof that penetrates the lower surface of the adapter part. These openings are closed by the roof of the motor vehicle. This means in particular that the roof touches the adapter part such that the roof covers the opening or engages over the opening. Particularly preferably, the roof completely covers the opening. For example, the edge defining the opening formed by the adapter part touches the roof, especially continuously or without interruption.
[0027] Alternatively, the opening is arranged at a distance from the roof. However, in this case, the distance from the roof to the opening is relatively small. The distance corresponds at most to the diameter of the first screw connector, and particularly preferably is smaller. For example, the distance corresponds at most to the diameter of the first screw connector multiplied by a factor of 0.75, 0.5, or 0.25. In any case, the first screw connector head receptacle is dimensioned such that, particularly preferably, the first screw connector touches the roof before disengaging from the gallery bar. This is a particularly effective way to fix the roof rail so that it does not loosen unintentionally.
[0028] According to a further embodiment of the invention, the fastening device is configured as a continuous part or has a plurality of reinforcing elements that are accommodated spaced apart from one another within the adapter part and have fastening recesses. The configuration corresponding to the fastening device has already been described. In the case of a continuous part, the gallery bar is directly attached to the roof via the fastening device. That is, the fastening device is attached on the one hand to the gallery bar and on the other hand to the roof, and the force acting between the gallery bar and the roof is continuously transmitted via the fastening device.
[0029] On the one hand, when the fastening device has a reinforcing element, there is no continuous part. Rather, part of the reinforcing element is attached to the gallery bar, the other reinforcing element is attached to the roof, and they are accommodated at intervals within the adapter part. Therefore, the force acting between the gallery bar and the roof is not continuously transmitted via the fastening device, but at least partially via the adapter part. This is because the reinforcing element connected to the gallery bar on the one hand and the reinforcing element connected or connectable to the roof on the other hand are only connected or fastened to each other via the adapter part.
[0030] The fastening device configured as a continuous part features high strength, while the fastening device with a reinforcing element can be realized at a particularly low cost and is lightweight. The continuous part is particularly preferably an extruded part or a strip.
[0031] According to a further embodiment of the present invention, the reinforcing element is configured as a bush each having at least one form-fitting collar overmolded at least partially onto the adapter part, and the bush having a second fastening recess additionally has an additional form-fitting collar arranged at a distance from the form-fitting collar, and the adapter part engages in a form-fitting manner between the form-fitting collar and the additional form-fitting collar. Thus, the reinforcing element is in the form of a bush in which a fastening recess is formed. Each bush has at least one form-fitting collar, which should be understood as a web-like projection extending from the base body of each bush. The form-fitting collar is, for example, a circumferential web, thus an annular web.
[0032] The shape-fitting collars are positioned on the adapter component to fasten each bush, i.e., engage with each bush by shape connection. At least these bushes, which have a second fastening recess formed therein, have an additional shape-fitting collar in addition to the shape-fitting collar. The shape-fitting collars and the additional shape-fitting collars are positioned spaced apart from each other, particularly parallel to each other. The additional shape-fitting collars can be configured according to an embodiment of the shape-fitting collar. The adapter component engages with the shape-fitting collars and the additional shape-fitting collars by shape connection to fasten the corresponding bushes by shape connection. It is particularly preferable that one of the shape-fitting collars, for example another shape-fitting collar, is flush with the underside of the adapter component. This forms fastening points for securely fastening the roof rail to the roof.
[0033] Preferably, bushes with a first fastening recess have a different configuration from bushes with a second fastening recess. In particular, bushes with a first fastening recess have only a shape-fitting collar and no additional shape-fitting collar. Preferably, the shape-fitting collar is formed at the center of each bush, or at least approximately at the center, in the longitudinal axis direction of each bush. On the other hand, in bushes with a second fastening recess, the shape-fitting collar and additional shape-fitting collar are preferably positioned off-center, and in each case, particularly towards the ends. That is, the shape-fitting collar and additional shape-fitting collar are positioned at both ends of each bush. This ensures secure fastening of the reinforcing element to both the gallery bar and the roof of the automobile.
[0034] According to a further embodiment of the present invention, the gallery bar has an upper side facing away from the fastener in cross-sectional view, a side wall extending from the upper side, and a bottom wall resting on the support surface of the fastener. In cross-sectional view, the gallery bar can be broadly divided into the upper side, the side wall, and the bottom wall. The upper side and the bottom wall are connected to each other via the side wall. In cross-sectional view, for example, the upper side, the side wall, and the bottom wall form at least a partially closed contour. The gallery bar is supported on the support surface of the fastener. The support surface is formed on the adapter component. The support surface preferably conforms to the shape and dimensions of the bottom wall of the gallery bar, and the bottom wall is in contact with the support surface so as to be flat.
[0035] According to a further embodiment of the present invention, the first fastening recess penetrates the support surface. In this respect, the opening of the first fastening recess on the side of the fastener or adapter component facing the gallery bar is defined by the support surface. In other words, the edge of the opening is formed by the support surface. This makes it possible to fasten the gallery bar compactly and visually inconspicuously by the fastening device.
[0036] According to a further embodiment of the present invention, the adapter component has at least one support wall that protrudes beyond the support surface and supports one of the side walls of the gallery bar or a side wall extension extending from one of the side walls of the gallery bar for lateral guidance of the gallery bar relative to the adapter component. To improve the lateral guidance of the gallery bar relative to the adapter component, a support wall is formed in the adapter component, which protrudes beyond the support surface, i.e., in the direction away from the roof of the automobile. One of the side walls of the gallery bar is supported, for example, by this support wall.
[0037] Alternatively, sidewall extensions extend from the sidewalls of the gallery bars and are supported by support walls. Sidewall extensions refer to extensions of the sidewalls that extend from each sidewall toward the roof of the vehicle. Preferably, the sidewall extensions are offset relative to the corresponding sidewalls, and in particular, offset parallel to them. The described roof rail configuration facilitates the alignment of the gallery bars during assembly and ensures secure attachment of the gallery bars to the roof.
[0038] According to a further embodiment of the present invention, the side wall and the side wall extension are connected via a bend in the gallery bar that extends beyond the support wall. As already mentioned above, the side wall and the side wall extension are preferably offset from each other, and in particular, are offset parallel to each other. This offset is achieved using a bend. The bend is understood to be a region of the gallery bar in which the width of the gallery bar decreases in the direction from the side wall to the side wall extension. In this respect, the bend achieves tapering of the gallery bar in a cross-sectional view in the direction of the roof.
[0039] According to a further embodiment of the present invention, the adapter component has a second screw connector head receptacle adjacent to the second fastening recess, on which the screw connector head of the second screw connector is positioned and which is fixed and held in a rotational position by shape fitting. The second screw connector serves to fasten the fastener to the roof of the automobile. The second screw connector is positioned in the second fastening recess of the fastening device. Typically, the fastener is first attached to the gallery bar, and then the assembly of the fastener and gallery bar is placed on the roof of the automobile. For this reason, it is necessary that the second screw connector is already positioned on the fastener in order to fasten the fastener to the roof quickly and reliably. Thus, it is intended that the second screw connector is inserted into the second fastening recess before the fastener and gallery bar are fastened to each other. Only then is the fastener fastened to the gallery bar, and then the assembly of the fastener and gallery bar is placed on the roof.
[0040] To prevent rotational movement of the second screw connector when fastening the roof rail to the roof, the adapter component is configured to fix and hold the screw connector head of the second screw connector in a rotational direction by shape fitting. For this purpose, the adapter component has a second screw connector head receptacle that matches the screw connector head of the second screw connector in shape and dimensions, i.e., retention of the second screw connector by shape connection is achieved at least on the adapter component. In particular, at least one of the second fastening recesses is positioned so that the gallery bar overlaps, in at least a certain area, after the fastener has been fastened to the gallery bar, especially the bottom wall of the gallery bar overlaps. Thus, at least one of the two screw connectors is held by the gallery bar on the adapter component so as not to come loose. The described roof rail configuration ensures easy and quick installation to the roof of the vehicle.
[0041] According to a further embodiment of the present invention, the adapter component has an extension that protrudes beyond the support surface and engages with the foot area of a gallery bar facing the roof, the foot area having a foot surface facing the roof, the foot surface engaging in a U-shape around the extension and being flush with the lower surface of the adapter component or protruding beyond the lower surface in the direction facing the roof. The extension is part of the adapter component. For example, the extension extends directly from the support surface. However, the extension may also be positioned at a distance from the support surface. In either case, the extension engages with the foot area of the gallery bar to securely fix the foot area of the roof rail, in particular to provide lateral guidance to the foot area.
[0042] In the foot region, the gallery bar is supported by the roof after the roof rails are attached to the vehicle, or the distance between the gallery bar and the roof is minimized when viewed longitudinally from the extension of the gallery bar. The foot region ends with a foot surface formed on the roof-facing side of the gallery bar. The foot region can be continuous and located entirely within a virtual plane. However, it is preferable that the foot surface is curved itself. In this case, the foot surface has a continuous path.
[0043] The foot surface is preferably in continuous and complete contact with the roof after the roof rail is attached to the vehicle. The foot area is U-shaped and surrounds the extension of the adapter component. Particularly preferably, the extension is in continuous contact with the foot area. The foot area can project in a direction toward the roof beyond the adapter component or its underside. However, it is preferable that the foot area is flush with the adapter component or its underside. On the one hand, this ensures secure fastening of the roof rail to the vehicle, and on the other hand, it ensures a very aesthetically pleasing appearance.
[0044] A particularly preferred embodiment of a roof rail for an automobile comprises at least one gallery bar and at least one fastener for fastening the end of the gallery bar to the roof of an automobile, the fastener comprising a fastening device that fastens to the gallery bar and can be fastened to the roof, and an adapter component that at least partially houses the fastening device. The gallery bar has an upper side facing away from the fastener in cross-sectional view, a side wall extending from the upper side, and a bottom wall connected to the upper side via the side wall. The adapter component is constructed as an injection-molded part, and the fastening device exists in an overmolded form within the adapter component. In this case, the bottom wall is supported flat on the support surface of the adapter component, and the fastening device is provided to have a plurality of first fastening recesses and a plurality of second fastening recesses passing through the support surface, the first fastening recesses provided and configured to house a first threaded connector that performs the function of fastening the fastener to the gallery bar, and the second fastening recesses provided and configured to house a second threaded connector that performs the function of fastening the fastener to the roof. The adapter component has a first screw connector head receptacle on the side facing away from the gallery bar in a longitudinal cross-section, with the screw connector head of the first screw connector positioned at a distance from the bottom surface of the adapter component.
[0045] The present invention further relates to an automobile having a roof and roof rails fastened to the roof, particularly roof rails according to embodiments within the scope of this specification, wherein the roof rails have at least one gallery bar and at least one fastener for fastening the ends of the gallery bar to the roof of the automobile, the fastener having a fastening device fastened to the gallery bar and the roof and an adapter part that at least partially houses the fastening device. The adapter part is provided to be constructed as an injection-molded part, and the fastening device is provided to be present in an overmolded form within the adapter part.
[0046] The advantages of such configurations of automobiles or roof rails have already been noted. Both automobiles and roof rails can be further configured according to the description herein, so please refer to that.
[0047] The present invention also relates to a roof rail, and more particularly to a method for manufacturing a roof rail as described herein, the roof rail having at least one gallery bar and at least one fastener for fastening the end of the gallery bar to the roof of a vehicle, the fastener having a fastening device that fastens to the gallery bar and can be fastened to the roof and an adapter part that at least partially houses the fastening device. The adapter part is constructed as an injection-molded part, and the fastening device is provided overmolded into the adapter part and overmolded within the adapter part.
[0048] Further details regarding the advantages of this method and roof rails, and possible advantageous further embodiments, refer to the description within the scope of this specification.
[0049] Features and combinations of features described herein, in particular those described in the following description of the drawings and / or shown in the drawings, can be used in any combination, or in any other combination, or in themselves, without departing from the scope of the invention. Accordingly, embodiments that are not expressly shown or described herein and / or in the drawings, but that arise from or can be derived from the described embodiments, should also be considered to be within the scope of the invention. [Brief explanation of the drawing]
[0050] Without any limitations on the present invention, the present invention will be described in more detail below with reference to the examples of embodiments shown in the drawings. Therefore, it is as follows. [Figure 1] This is a schematic diagram of a car with roof rails attached to the roof. [Figure 2] This is a schematic longitudinal cross-sectional view of a first embodiment of a roof rail having fasteners for attaching a gallery bar to the roof. [Figure 3] This is a schematic diagram of a fastener for a first embodiment of a roof rail. [Figure 4]This is a schematic longitudinal cross-sectional view of the roof rail in the second embodiment. [Figure 5] This is a schematic diagram of a fastener for a second embodiment of a roof rail. [Modes for carrying out the invention]
[0051] Figure 1 shows a schematic diagram of an automobile 1 having a roof 2 and roof rails 3. The roof rails 3 are attached to the roof 2. A protective film 4 is placed between the roof 2 and the roof rails 3 to prevent the roof 2 and the roof rails 3 from damaging each other. The protective film 4 can also be considered as part of the roof 2, and the roof 2 has the protective film 4 in the area, i.e., the area where the roof rails 3 are supported by or in contact with the roof 2. The roof rails 3 have gallery bars 5. In principle, the roof rails 3 can have any number of gallery bars 5. In this case, it is preferable that the multiple gallery bars 5 extend parallel to each other. Below, only the gallery bars 5 will be described. If there are multiple gallery bars 5, the same description can be applied to each of these gallery bars 5.
[0052] The gallery bar 5 has an upper section 6 that curves toward the roof 2 on the side opposite to the roof 2, in the direction of one end 7 of the gallery bar 5. In particular, as shown, the entire gallery bar is curved toward the roof 2. Side walls 8 extend from the upper section 6, only one of which is visible here. The side walls 8 extend parallel to each other and preferably extend over most of the length of the gallery bar 5. The gallery bar 5 is bounded at its bottom by a bottom wall 9 in at least certain areas, the bottom wall 9 is connected to the upper section 6 via the side walls 8. The bottom wall 9 preferably has an extension in the longitudinal direction of the roof rail 3 that is shorter than the upper section 6 and the side walls 8. This forms a recess 10 in the area of the end 7 of the gallery bar 5, which is not visible here.
[0053] The ends of the gallery bar 5 are attached to the roof by fasteners 11. For this purpose, it is preferable that the fasteners 11 also engage with the recesses 10. The upper side 6 of the gallery bar 5 faces away from the fasteners 11 in a cross-sectional view, while the bottom wall 9 is positioned facing the fasteners 11 or towards the fasteners 11. In particular, the bottom wall 9 rests on a support surface 29 of the fasteners 11 (not shown here), and the gallery bar 5 is supported by it.
[0054] For example, the end 7 of the gallery bar 5 has a foot region 12 on the gallery bar 5, which is basically U-shaped, with a foot surface 13 formed thereon. Preferably, the gallery bar 5 is directly supported by the foot surface 13 by the roof 2 or protective film 4. For this purpose, the foot surface 13 is curved to conform to the shape of the roof 2, for example. To realize lateral guidance of the gallery bar 5 at its end 7 as well, the foot surface 13 engages around the area of the fastener 11, i.e., the extension 14. Additional lateral guidance of the gallery bar 5 relative to the fastener 11 is incidentally achieved by a support wall 15. The support wall 15 is an element of the fastener 11, with a side wall 8 or, as in the example of the embodiment shown herein, a side wall extension 16 in flat contact with it. The support wall is part of the adapter component 17 of the fastener 11.
[0055] In addition to the adapter component 17, the fastener 11 has a fastening device 18, which is hidden by the adapter component 17 and therefore not visible here. The adapter component 17 is in the form of an injection-molded part and houses the adapter component 17. In this case, the fastening device 18 is overmolded into the adapter component 17 and is therefore held therein by shape fitting. Preferably, the fastening device 18 is positioned entirely within the envelope or contour of the adapter component 17, i.e., it does not protrude beyond the adapter component 17.
[0056] Finally, the gallery bar 5 is fastened to the roof 2 by a first screw connector 19 and a second screw connector 20, where only the second screw connector 20 is visible. The first screw connector 19 serves to fasten the fastener 11, or more precisely, the fastening device 18, to the gallery bar 5. The second screw connector 20 fastens the fastener 11, or more precisely, the fastening device 18, to the roof 2. The first screw connector 19 and the second screw connector 20 engage with the fastener 11 and fastening device 18, respectively, spaced apart from each other. The protective film 4 preferably has a recess 21 for the second screw connector 20.
[0057] Figure 2 shows a schematic longitudinal section view of a first embodiment of the roof rail 3. In the first embodiment, the fastening device 18 visible therein is configured as a continuous component, specifically in the form of a bent thin sheet metal strip. It should be understood that the fastening device 18 has a constant material thickness throughout and has dimensions in a first direction that are significantly larger than those in a second direction perpendicular to this first direction. The first and second directions are, in turn, perpendicular to a third direction in which the material thickness exists. For example, the dimensions in the first direction are at least 5 times, at least 7.5 times, or at least 10 times larger than the dimensions in the second direction.
[0058] The fastening device 18 has a first fastening recess 22 and a second fastening recess 23. The first screw connector 19 is located in the first fastening recess 22, and the second screw connector 20 is located in the second fastening recess 23. In a longitudinal section view, the first fastening recess 22 is located above the second fastening recess 23, i.e., on the side facing the gallery bar 5 of the virtual longitudinal center plane of the fastening device 18 or a virtual plane intersecting the fastening device 18. In the example of the embodiment shown here, one of the second fastening recesses 23 is located in a bent region of the fastening device 18, in which a continuous component is bent in the direction of the roof 2 or away from the gallery bar 5.
[0059] Each of the second fastening recesses 23 is completely and uninterruptedly surrounded by the edge surface 24 of the fastening device 18. In this respect, each edge surface is annular. Preferably, each edge surface 24 is located completely and continuously within a virtual plane. Preferably, the edge surface 24 is aligned with the lower surface 25 of the adapter component 17, or even protrudes beyond the lower surface 25 in a direction opposite to the gallery bar 5. This means that the roof rail 3 is supported by the roof 2 at least via the edge surface 24, or that the edge surface 24 is in direct contact with the roof 2. Particularly preferably, the fastening device 18 is supported by the roof 2 only by the edge surface 24, and otherwise is spaced away from the roof 2, preferably the area located away from the edge surface 24 is housed within the adapter component 17 and does not protrude at least beyond its contour or envelope.
[0060] The roof rail 3 is supported by adapter components 17 at the bottom wall 9, and is notably spaced apart from the fastening devices 18. The gallery bar 5 is supported on the roof 2 via the adapter components 17 and / or the fastening devices 18. In addition, optionally, the gallery bar 5 is supported directly on the roof 2 at the foot surface 13. Specifically, the adapter components 17 are intended to support the gallery bar 5 vertically, while the gallery bar 5 is secured to the roof 2, particularly longitudinally and laterally, by the fastening devices 18. Naturally, the fastening devices 18 also prevent the gallery bar 5 from moving vertically away from the roof 2, i.e., from shifting away from the roof 2. In general, the gallery bar 5 is firmly and securely fixed to the roof 2 by the interaction of the adapter components 17 and the fastening devices 18.
[0061] To prevent damage to the roof 2 by the first screw connector 19, the adapter component 17, i.e., the first screw connector head receptacle 26, is located on the side of the fastening device 18 that faces away from the gallery bar 5. The screw connector head 27 of the first screw connector 19 engages with the first screw connector head receptacle 26 so as to be spaced apart from the roof 2.
[0062] Figure 3 shows a schematic diagram of the fastener 11 of the first embodiment of the roof rail 3. Only the adapter component 17 and the first screw connector 19 and second screw connector 20 are visible. Here, the support surface 28 that supports the gallery bar 5 with its bottom wall 9 is visible. It can also be seen that the support wall 15 protrudes beyond the support surface 28 in the direction of the gallery bar 5. The extension 14 also protrudes beyond the support surface 28, i.e., in the longitudinal direction of the roof rail 3 or gallery bar 5.
[0063] In addition to the first screw connector head receptacle 26, the adapter component 17 has a second screw connector head receptacle 29 on which the screw connector head 30 of the second screw connector 20 is positioned. The second screw connector head receptacle 29 is shaped and dimensionally compatible with the screw connector head 30, and the screw connector head 30, and thus the second screw connector 20, are fixed to the adapter component 17 in a rotatable manner by a morphological mating. This makes it possible to easily and quickly attach the roof rail 3 to the roof 2 of the automobile 1.
[0064] Figure 4 shows a schematic longitudinal section view of the roof rail 3 in the second embodiment. In principle, the above description of the first embodiment will be used to explain only the differences. The difference is that the fastening device 18 is no longer configured as a continuous part, but has a plurality of reinforcing elements 31 that are spaced apart from each other and housed within the adapter part 17, each having fastening recesses 22 and 23. The reinforcing elements 31 are in the shape of bushes, each having at least one shape-fitting collar 32 overmolded onto the adapter part 17.
[0065] These reinforcing elements 31 that accommodate the first fastening recess 22 have only a single shaped fitting collar 32 positioned approximately or precisely at the center in the longitudinal axis direction of each. On the other hand, the reinforcing elements 31 in which the second fastening recess 23 is formed have an additional shaped fitting collar 33 formed at a distance from the shaped fitting collar 32. The adapter component 17 engages between the shaped fitting collar 32 and the additional shaped fitting collar 33 to secure each reinforcing element 31. The additional shaped fitting collar 33 is flush with the lower surface 25 of the adapter component 17, and it is particularly preferable that the additional shaped fitting collar 33 forms the aforementioned edge surface 24.
[0066] Figure 5 shows a schematic diagram of the fastener 11 of the second embodiment of the roof rail 3. Again, referring to the above description, only the differences from the first embodiment will be explained. The differences are basically due to the configuration of the second screw connector head receptacle 29. In the first embodiment, the adapter component 17 had a recess for forming the second screw connector head receptacle 29, whereas the second screw connector head receptacle 29 in the second representation is defined only by two webs that preferably extend parallel to each other. These two webs 34 serve to hold each second screw connector 20 in a shape connection so that it is fixed to the adapter component 17 in the rotational direction.
[0067] The described configuration of the automobile 1 or roof rail 3 allows for easy and quick attachment of the roof rail 2 to the roof 2 of the automobile. Furthermore, the fasteners 11 can be manufactured at low cost and ensure reliable load transfer from the gallery bar 5 to the roof 2. [Explanation of symbols]
[0068] 1. Automobile 2 Roof 3 Roof rails 4. Protective film 5 Gallery Bar 6. Upper side 7 End 8 side wall 9 Bottom wall 10 recesses 11 Fasteners 12 Foot area 13 Foot surface 14 Extension 15 Supporting wall 16 Side wall extension 17 Adapter parts 18 Fastening device 19. First threaded connector 20. Second screw connector 21 Recess 22 First fastening recess 23 Second fastening recess 24 Edge 25 Bottom side 26. First threaded connector head receptacle 27 Screw connector head 28 Support surface 29. Second threaded connector head receptacle 30 Screw connector heads 31 Reinforcement elements 32 Shape-matching collars 33 Shape-matching collar 34 Web
Claims
1. A roof rail (3) for an automobile (1), It has at least one gallery bar (5) and at least one fastener (11) for fastening the end of the gallery bar (5) to the roof (2) of the automobile (1), The fastener (11) is A fastening device (18) that can be fastened to the gallery bar (5) and to the roof (2), The fastening device (18) has an adapter component (17) that houses at least a portion of it, The adapter component (17) is constructed as an injection-molded part, and the fastening device (18) is present within the adapter component (17) in an overmolded form. The fastening device (18) has a plurality of first fastening recesses (22) and a plurality of second fastening recesses (23), the first fastening recesses (22) are provided and configured to accommodate a first screw connector (19) that performs the function of fastening the fastener (11) to the gallery bar (5), and the second fastening recesses (23) are provided and configured to accommodate a second screw connector (20) that performs the function of fastening the fastener (11) to the roof (2), Each of the second fastening recesses (23) is surrounded by an edge surface (24) of the fastening device (18) that is flush with the lower surface (25) of the adapter component (17), or by an edge surface (24) of the fastening device (18) that protrudes beyond the lower surface (25) of the adapter component (17) in a direction opposite to the gallery bar (5), in a roof rail.
2. The roof rail according to claim 1, wherein the adapter component (17) has a first screw connector head receptacle (29) in which the head of the first screw connector (19) is positioned at a distance from the lower surface of the adapter component (17).
3. The roof rail according to claim 2, wherein the first screw connector head receptacle (29) is closed by the roof (2) of the automobile (1) after the roof rail (3) is positioned on the automobile (1).
4. The roof rail according to any one of claims 1 to 3, wherein the fastening device (18) is configured as a continuous part, or has a plurality of reinforcing elements (31) housed at intervals from each other within the adapter part (17) and having the fastening recesses (22, 23).
5. The roof rail according to claim 4, wherein the reinforcing element (31) is configured as a bush having at least one shape-fitting collar (32) overmolded at least partially onto the adapter part (17), and the bush having the second fastening recess (23) further has additional shape-fitting collars (33) spaced apart from the shape-fitting collars (32), and the adapter part (17) engages in a shape-fit between the shape-fitting collars (32) and the additional shape-fitting collars (33).
6. The roof rail according to any one of claims 1 to 5, wherein the gallery bar (5) has an upper side (6) facing away from the fastener (11) in a cross-sectional view, a side wall (8) extending from the upper side (6), and a bottom wall (9) resting on the support surface (28) of the fastener (11).
7. The roof rail according to claim 6, wherein the first fastening recess (22) penetrates the support surface (28).
8. The roof rail according to claim 6 or 7, wherein the adapter component (17) protrudes beyond the support surface (28) and has at least one support wall (15) that supports one of the side walls (8) of the gallery bar (5) or a side wall extension (16) extending from one of the side walls (8) of the gallery bar (5) for lateral guidance of the gallery bar (5) relative to the adapter component (17).
9. The roof rail according to claim 8, wherein the one side wall (8) and the side wall extension (16) are connected via a bent portion of the gallery bar (5) that extends beyond the support wall (15).
10. The roof rail according to any one of claims 1 to 9, wherein the adapter component (17) is adjacent to the second fastening recess (23) and has a second screw connector head receptacle (29) on which the screw connector head (30) of the second screw connector (20) is positioned and which is fixed and held in the rotational direction by shape fitting.
11. The roof rail according to any one of claims 6 to 9, wherein the adapter component (17) has an extension (14) that protrudes beyond the support surface (28) and engages with the foot area (12) of the gallery bar (5) facing the roof (2), the foot area (12) has a foot surface (13) facing the roof (2), the foot surface (13) engages in a U-shape around the extension (14) and is flush with the lower surface (25) of the adapter component (17), or protrudes beyond the lower surface (25) of the adapter component (17) in a direction facing the roof (2).
12. An automobile (1) having a roof (2) and a roof rail (3) fastened to the roof (2), particularly a roof rail (3) according to any one of claims 1 to 11, wherein the roof rail (3) has at least one gallery bar (5) and at least one fastener (11) for fastening the end of the gallery bar (5) to the roof (2) of the automobile (1), the fastener (11) having a fastening device (18) fastened to the gallery bar (5) and the roof (2), and an adapter part (17) that at least partially houses the fastening device (18), the adapter part (17) being constructed as an injection molded part, the fastening device (18) being overmolded within the adapter part (17), and the fastening device (18) being multiple An automobile having several first fastening recesses (22) and a plurality of second fastening recesses (23), wherein the first fastening recesses (22) are provided and configured to accommodate first screw connectors (19) that perform the function of fastening the fastener (11) to the gallery bar (5), and the second fastening recesses (23) are provided and configured to accommodate second screw connectors (20) that perform the function of fastening the fastener (11) to the roof (2), and each of the second fastening recesses (23) is surrounded by an edge surface (24) of the fastening device (18) that is flush with the lower surface (25) of the adapter part (17), or an edge surface (24) of the fastening device (18) that protrudes beyond the lower surface (25) of the adapter part (17) in a direction opposite to the gallery bar (5).
13. A method for manufacturing a roof rail (3), particularly a roof rail (3) according to any one of claims 1 to 6, wherein the roof rail (3) comprises at least one gallery bar (5) and at least one fastener (11) for fastening the end of the gallery bar (5) to the roof (2) of the automobile (1), the fastener (11) comprises a fastening device (18) that is fastened to the gallery bar (5) and can be fastened to the roof (2), and an adapter part (17) that at least partially houses the fastening device (18), the adapter part (17) being constructed as an injection molded part, the fastening device (18) being overmolded into the adapter part (17) and existing in an overmolded form within the adapter part (17), and the fastening device (18 The fastening device (18) has a plurality of first fastening recesses (22) and a plurality of second fastening recesses (23), wherein the first fastening recesses (22) are provided and configured to accommodate a first screw connector (19) that serves to fasten the fastener (11) to the gallery bar (5), and the second fastening recesses (23) are provided and configured to accommodate a second screw connector (20) that serves to fasten the fastener (11) to the roof (2), and each of the second fastening recesses (23) is surrounded by an edge surface (24) of the fastening device (18) that is flush with the lower surface (25) of the adapter component (17), or an edge surface (24) of the fastening device (18) that protrudes beyond the lower surface (25) of the adapter component (17) in a direction opposite to the gallery bar (5), the method.