Vehicle roof rack pads

An improved apparatus and system for vehicle roof rack pads that provide improved support, aerodynamics, and cushioning. The pad includes an aerodynamically shaped elongated tubular member, wherein a cross-section of the pad has an airfoil exterior shape with a leading edge and a trailing edge and has a lengthwise interior hole therein for receiving a crossbar and one or more slots along the trailing edge for receiving tie down straps, where the slots are placed at a radial depth so as to prevent deformation of the trailing edge and the exterior airfoil shape.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to vehicle roof rack pads, and specifically to an improved apparatus and system for vehicle roof rack pads that provide improved support, aerodynamics, and cushioning.

2. Discussion of the Background

Vehicle roof racks have been used for a number of years to increase the load carrying capability. Generally, these racks include a framework permanently or removeably attached to the roof having one or more crossbars for carrying objects such as sporting equipment (surfboards, skis, hang gliders), work equipment (ladders, poles, pipes), luggage, boxes, and the like.

In order to cushion the objects carried on the crossbars, mounting pads may be attached to the crossbars. Such pads generally comprise foam wrapped around the crossbars and secured with tape or the like, or cylindrical foam tubing having an elongated hole for receiving the crossbars, usually also further secured with tape or the like. Often closed-cell foam tubes that are designed as floating pool toys are used as padding for the crossbars.

Retaining means for securing the objects to the rack include rope, string, straps, or tension adjustable hook devices.

A number of patents exist that describe roof carriers and racks, such as U.S. Pat. Nos. 4,354,625; 5,067,644; 5,607,093; 5,769,291; 7,152,769 all incorporated herein by reference.

SUMMARY OF THE INVENTION

An embodiment of the invention comprises a pad for a crossbar of a vehicle roof rack, the pad comprising an aerodynamically shaped elongated tubular member, wherein a cross-section of the pad comprises an airfoil exterior shape having a leading edge and a trailing edge and has a lengthwise interior hole therein for receiving the crossbar and one or more slots along the trailing edge for receiving tie down straps wherein the slots are placed at a radial depth so as to prevent deformation of the trailing edge airfoil shape. The pad further comprises compressible material to provide cushioning. The pad further comprises an exterior skin for increased smoothness, aerodynamics, durability, and decreased water absorption.

Another embodiment of the invention comprises a crossbar and/or vehicle roof rack system comprising the pad described herein.

It is an object of the present invention to provide an improved apparatus and system for vehicle roof rack pads that provide improved support, aerodynamics, and cushioning.

A further object is to provide a pad that is quieter and has lower drag.

A still further object is to provide a pad that is durable and UV resistant.

Further objects and advantages of our invention will become apparent from a consideration of the drawings and the technical description.

All patents, patent applications, provisional applications, and publications referred to or cited herein, or from which a claim for benefit of priority has been made, are incorporated herein by reference in their entirety to the extent they are not inconsistent with the explicit teachings of this specification.

While the present invention will be described with reference to the details of the embodiments of the invention shown in the drawing, these details are not intended to limit the scope of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings, wherein like reference numeral designate identical or corresponding parts throughout the several views, embodiments of the invention are shown.

The present invention relates to an improved aerodynamic elongated pad10for a roof rack crossbar. As illustrated inFIG. 1, a perspective view of the roof rack pad10in an embodiment of the present invention mounted on a crossbar12of a roof rack14and having tie down straps16thereon to secure an object (not shown) thereto is shown. One or more object fastening slots18are provided for receiving the tie down strap16. An elongated hole20is provided through the length of the pad for receiving the crossbar12.FIG. 2is a top plan view showing the object fastening slot18for receiving a tie down strap16and the elongated crossbar-receiving hole20.FIG. 3shows a cross section of the pad10having an aerodynamic exterior shape having a leading edge22, a trailing edge24. The pad is comprised of a cushioning material26. It may also comprise an exterior skin28. The elongated crossbar-receiving hole20may be shaped to snuggly fit a variety of crossbar shapes.

The improved aerodynamic pad10shaft preferably comprises an elongated tube shape that has an exterior with a non-circular cross section having aerodynamic shape. In an embodiment the pad10comprises an elongated tube shape having an airfoil exterior cross section in a preferred embodiment, oriented with a leading edge22that is on the half of the pad10aligned with the direction of vehicle travel and a trailing edge24opposite thereto. In another embodiment a substantially airfoil-like elliptical or teardrop shape (or other suitable cross sectional shape) is used, wherein the elongated hole20is positioned radially closer to one part of the major axis making it the leading edge22and the object fastening slots18are located opposite on the trailing edge24. The aerodynamic shape of the pad10reduces drag and noise of the crossbars12by reducing turbulence. In one embodiment, the pad10has a height of approximately 2.375-2.50 inches, a width from leading to trailing edge of approximately 4.90-5.0 inches, and a variety of lengths to fit partly or substantially all the length of the crossbar. The length may be cut to size.

Optionally, an aerodynamic “trip strip” (not shown) lengthwise along the leading edge22may be provided. The trip strip comprises a slightly raised ridge to provide for less drag and noise reduction as known in the art.

The elongated crossbar-receiving hole20disposed lengthwise through the pad10allows for mounting onto the crossbar12. The size and shape of the lengthwise hole20may be geometrically matched to a variety of crossbars for a snug fit and to prevent rotation about the crossbar12. Or one or more non-specific size/shapes may be provided (e.g., small, medium, large, square, rectangular, circular, etc.).

One or more object fastening slots18are provided for receiving a tie down straps16. Straps16may be any of a known variety of strap, ropes, or the like. The slots18are located on the trailing edge24in any of a number of spaced relations as a matter of design choice to allow for receiving straps16to secure objects thereto. The slots18are placed at a radial depth30(with respect to the central axis36of the elongated hole20) so as to prevent deformation/distortion of the trailing edge24airfoil shape. The radial depth30is preferably less than the trailing edge radius32and somewhat approaches the leading edge radius34. Preferably, the slots18are preferably of a T-shape so the straps16may be inserted through the lower portion of the “T” and secured in place at the top portion of the “T”. Other slot shapes which provide the same functionality are contemplated herein. For example, a slit comprising just the top portion of the T-shape may be utilized where the strap16would then be threaded through. In still a further embodiment, the straps16may be permanently affixed to the pad10at a location that is at a radial depth30so as to prevent deformation/distortion of the trailing edge24.

Preferably, the pad10also comprises (or is coated with) a material26that has a low coefficient of drag so that it will have a reduced tendency to be affected by air drag. The pad10is preferably compressible (and/or deformable) to provide cushioning in all directions, or at least cushioning along a top surface which receives the object thereon. In a preferred embodiment, the pad10is made of a cellular material26such as flexible polyurethane foam, or more specifically a urethane/polyurethane self-skinning material having a range of densities, resilience and colors. Features include light weight, open or closed cell, and abrasion resistance. The cushioning material26is characterized in that the polyurethane foam has a self-skin layer28formed thereon (preferably on the exterior of the pad10and in certain embodiments along the walls of the elongated hole20). With the formation of the self-skin layer28, smoothness increases, water absorption ratio decreases, drag decreases, and adhesion performance is improved. Polyurethane foams can be produced with a wide range of rigidity (from very soft to rigid) and a wide range of density, open-cell (and hence porous) or closed cell. In further embodiments, a cloth or vinyl covering may be used as the skin layer28or in addition to the skin layer. Manufacturing of the pad10may include a variety of firmness and skin thickness depending on the application.

Color may be added into the base cushioning material26or applied as a coating to the inside of the mold. Alphitic resin coatings or the like may be used to coat the inside of the mold. The two processes may be used in conjunction with each other or individually. Color additives and color coatings provide UV protection as well as color to the pad.

Inserts of various materials (such as metal or plastic) and shapes may be placed inside of the pad10during manufacturing or integrated into the exterior of the pad. These inserts can provide reinforcement of the pad10to help maintain its shape as well as carry a greater load. Moreover, inserts may be used to provide firm/rigid attachment points for mounting the pad to the crossbar or for attachment points for accessories, straps, or rope. For example, the object fastening slots18may be constructed of a more ridged material than the foam for durability, either under the self-skin layer or on the exterior surface. Attachment points, like buckles, female threads, recessed links, etc. can also be provided. Moreover, reinforcements can be placed at the point of permanently affixed attachment straps16.