Crossbar Coupling Member for Tool-Free Locking and Compact Stowing
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Solution Overview
Problem
The challenge lies in coupling crossbar members and load carrier feet efficiently, particularly due to complex geometries resulting from aerodynamic and safety requirements, which makes stowing and transporting these components difficult, leading to increased fuel consumption and logistical issues such as equipping rental cars and integrating racks into car manufacturing processes.
Innovation Solution
A coupling member is designed to be fixable to crossbar members, comprising elongate coupling segments that can be inserted into the crossbar's interior spaces, providing a tool-free, positive locking connection without additional fixation means, and can be integrated with load carrier feet, allowing for easy assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If crossbar members are made with complex geometries to meet aerodynamic and safety requirements, then strength and aerodynamic performance are improved, but stowing and transporting become difficult
Solution Approach 1:
The coupling member is divided into multiple coupling segments (at least two elongate coupling segments) that can be independently inserted into interior spaces of the crossbar member. This segmentation allows the coupling system to adapt to complex crossbar geometries while maintaining ease of assembly and disassembly for stowing and transporting.
2Ease of operation
If crossbars are made divisible to allow space-saving stowing, then stowing becomes easier, but coupling segments become difficult to couple
Solution Approach 1:
The coupling segments are designed to be inserted into and nested within the interior spaces of the crossbar member. The coupling segments can be fully accommodated within the crossbar member, creating a compact nested structure that simplifies stowing while the internal geometry provides inherent alignment and coupling functionality.
Solution Approach 2:
The coupling segments are configured to self-align and self-lock within the crossbar member's interior spaces through their geometric compatibility. The engagement portions automatically engage with interior engaging portions, providing tool-free coupling without requiring complex alignment procedures or additional fixation means.
3Strength
If coupling members require additional fixation means, then connection strength is improved, but assembly complexity and time increase
Solution Approach 1:
The coupling segments are designed to automatically engage and lock with the crossbar member through their geometric compatibility. The engagement portions of the coupling segments mate with interior engaging portions of the crossbar member, creating a self-locking connection that requires no additional fixation means, tools, or complex assembly procedures.
Solution Approach 2:
The coupling segment acts as an intermediary element that transfers and distributes loads between the crossbar member and external forces. By being fully accommodated within the crossbar member's interior spaces, the coupling segment provides a distributed load path that maintains connection strength while enabling tool-free assembly.
Data Source
AI summary
Disclosed is a coupling member fixable to an end portion of a crossbar member. The coupling member includes at least two elongate coupling segments configured to be at least partially inserted in longitudinally extending interior spaces of the crossbar member wherein the interior spaces are separated by a common interior wall. Two adjacent coupling segments of the at least two elongate coupling segments are fixedly coupled to each other by means of a coupling portion. The coupling portion is configured to hold the elongate coupling segments at a predetermined distance with respect to each other to define a receiving space between the adjacent elongate coupling segments. The receiving space is configured for receiving a portion of the interior wall of the crossbar member.