Abstract:
A vehicle roof panel includes a roof portion and roof rack portion with an integrally embossed portion defined by longitudinally extending spaced apart side portions. A side rail is attached to each of the side portions. A cross member has connectors for selectively and slidably interconnecting to the side rail thereby retaining the cross member elevated above the planar surface of the roof panel.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    1. Field of Invention  
           [0002]    The present invention relates to an automotive roof panel. More particularly, the present invention relates to an automotive roof panel having an integrally formed roof rack portion. 2. Description of the Related Art  
           [0003]    Minivans and sport utility vehicles are commonly purchased from the factory with a luggage or sport rack mounted on the roof of the vehicle. Currently, the roof racks are separate components from the vehicle body and must be assembled either as a separate operation in the factory, or at the dealer, prior to delivery to the customer. An example of such a roof rack is illustrated in U.S. Pat. No. 5,924,614.  
           [0004]    Additionally, current roof racks are only available in black. No attempts have been made to color coordinate the roof rack with the color of the vehicle.  
           [0005]    The typical roof rack structure is a separate assembly that requires piercing the roof panel structure to attach the roof rack, thereby, allowing a possible ingress for water or other material.  
           [0006]    Therefore, it is desirable to produce a one piece roof panel for an automobile that has a roof rack portion molded into the roof panel.  
         SUMMARY OF THE INVENTION  
         [0007]    The disadvantages of the prior art may be overcome by providing a roof panel with an integrally molded roof rack.  
           [0008]    It is desirable to simplify the manufacturing steps required to produce an automobile roof panel with a roof rack, by negating the need to attach a separate roof rack assembly.  
           [0009]    According to one aspect of the invention, there is provided a vehicle roof panel assembly comprising a one piece panel having a generally planar surface and an embossed portion defined by longitudinally extending and generally parallel, spaced apart, side portions. At least one connector is coupled to each of the side portions and at least one cross member extends transversely between the side portions and is coupled to each of the connectors. The side portions and the connectors elevate and retain the cross member above the planar surface of the roof panel. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]    [0010]FIG. 1 is a partially broken perspective view of a roof panel assembly incorporating the aspects of the present invention; and  
         [0011]    [0011]FIG. 2 is a partially broken cross-sectional view of the side rails, connectors and cross member of the roof panel assembly. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0012]    Referring to FIG. 1 there is shown a roof panel assembly, generally denoted at  10 . The roof panel  10  is preferably formed of a solid body, one piece long-fiber reinforced thermoplastic, such as reinforced polypropylene or thermoset plastic. However, it is also possible to die stamp sheet metal in accordance with the present invention.  
         [0013]    The roof panel  10  includes a roof portion  12  and a roof rack portion  14 . The roof portion  12  includes a generally smooth planar area  16  with an appropriate curvature or contour, according to the vehicle design and specifications, which terminates at the front at a windshield opening  18 .  
         [0014]    The windshield opening  18  is provided with an appropriate flange structure  20  such that a glass windshield and seal can be mounted flush with the roof panel  10 . In the illustrated embodiment, the roof portion  12  includes a pillar portion  22  for integrating and connecting with the structural A-pillar of the vehicle.  
         [0015]    It is to be understood that the pillar portion  22  can be removed from the roof portion  12 , approximately along a line extended from the windshield opening  18 , providing a roof portion  12  that does not include a pillar portion  22 .  
         [0016]    The roof portion  12  is bounded on its outer peripheral sides by an attachment flange  24  that circumferentially surrounds the entire roof panel  10 , except for region adjacent to the windshield opening  18 . The attachment flange  24  is provided to allow an area to attach the roof panel  10  to the underlying roof structure as well as to provide a location for other body panels to intersect with the roof panel  10 .  
         [0017]    The roof rack portion  14  includes a raised or embossed portion  26  defining the periphery of the roof rack portion  14 . In the illustrated embodiment, the raised portion  26  has a front section  28  and two spaced apart, generally parallel and opposing side sections  30 ,  32  defining the roof rack portion  14 . It is to be understood that a fourth rear section, can be utilized should the roof rack portion  14  not be located at the rear most end of the roof panel  10 . The fourth rear section, if included, would complete the boundary of the roof rack portion  14 . Alternatively, the roof rack portion  14  could include only the two side sections  30 ,  32 .  
         [0018]    Each raised side portion  30 ,  32  projects upwardly from the planar surface  16  of the roof portion  12  and extending longitudinally between opposite first and second ends  34 ,  36 . Each raised side portion  30 ,  32  further includes an outside surface  38  and an inside surface  40 . The outside surface  38  has an appropriate radius of curvature to provide an aerodynamic transition to the roof portion  12  and the attachment flange  24 . An appropriate radius is based on the aesthetics of the roof rack design as well as other considerations, such as, the necessary height of the raised portion  26 , and the appropriate wind resistance qualities of the raised portion  26 .  
         [0019]    The inside surface  40  provides a transition to the roof rack portion  14 . The interior surface  40  of the two side portions  30 ,  32  have integrally formed pockets  42 ,  44  created or recessed therein for receiving and securing a side rail  46  to each of the side portions  30 ,  32 . The pockets  42 ,  44  define an elongated channel having a generally U-shaped cross-section and extending between the first and second ends  34 ,  36  of the side portions  30 ,  32 .  
         [0020]    Referring to FIGS. 1 and 2, the side rail  46  is preferably formed of metal to withstand the wear and forces placed upon it during use. Each side rail  46  extends longitudinally between opposing first and second ends  48 ,  50  and has a generally C-shaped cross section with a channel  52  formed therein for receiving a connector  54 . The side rails  46  further include a plurality of spaced apart notches, or slots,  56  formed in either the top or bottom edge of the channel  52  defining an adjustment boundary  58  therebetween to positively locate and secure connector  54  to the side rail  46 . The side rails  46  can be molded into the pockets  42 ,  44  during the molding operations or the side rails  46  may be attached or bonded inside the pockets  42 ,  44  after the roof panel  10  has been formed.  
         [0021]    A connector  54  is designed to slidably engage each of the respective side rails  46  via the channel  52  to allow for slidable movement of the connector  54  between the first and second ends  48 ,  50  of the side rails  46 . The connector  54  includes a rail engagement portion  58  having a generally T-shaped cross section for corresponding mating engagement within the C-shaped channel  52  to facilitate the sliding engagement of the connector  54  with the side rail  46 . Further, the rail engagement portion  58  includes a spring bias locking tab  60  for engaging one of the notches  56  in the side rail  46 , to positively lock the connector  54  in place along the longitudinal length of the side rail  46 .  
         [0022]    The connector  54  further includes an arcuate shaped extension neck portion  62  extending outwardly from the rail engagement portion  58  and terminating at a distal cross bar engagement portion  64 . The engagement portion  64  is generally rectangular in cross section and stepped down from the neck portion  62  forming a male end fitting. The neck portion  62  and the engagement portion  64  are designed to allow attachment of an elongated cross bar  66  that transversely extends across the roof rack portion  14  and between the side rails  46  in the opposing side sections  30 ,  32 . The cross bar  66  extends between opposite distal ends and includes a generally hollow rectangular or oval cross sectional shape. The engagement portion  64  is received in ends of the cross bar  66  in a telescoping male/female type arrangement. The cross bar  66  may be fixedly attached to the connectors  54  by any type of fastener  68 , such as a screw, as depicted in the drawing, or may be attached using other conventional means, including rivets, lock pins, or the like.  
         [0023]    The cross bar  66  is preferably made of metal and has a slot  70  formed in the center of the top surface thereof extending the length of the cross bar  66 . The slot  70  allows for the attachment of accessories to the roof rack, such as a bicycle rack, ski rack or other similar devices. The roof panel  10 , and specifically, the roof rack portion  14  may include one or more cross bars  66  slidably coupled between the side sections  30 ,  32  via the connectors  54  in a parallel arrangement.  
         [0024]    The roof rack portion  14  further includes a generally planar central portion  72  that is within the interior periphery defined by the raised portion  26 . The central portion  72  has a plurality of spaced apart and generally parallel raised skid channels  74  formed therein to provide a skid plate or raised area such that items placed in the roof rack portion  14  will not rub on the central portion  72 . The raised skid channels  74  also serve to strengthen the roof rack portion  14  and provide heightened rigidity to support the forces exerted upon it when carrying an item.  
         [0025]    The roof rack portion  14  also includes a brake light platform  76  on which a central or third brake light (CHMSL) that is required on most vehicles can be mounted. It is to be understood that the roof rack portion  14  can be formed without the brake light platform  76 .  
         [0026]    In use, the cross bars  66  are slidably adjustable along the side rails  46  by depressing or releasing the locking tabs  60  and moving the opposing connectors  54  to desired corresponding locations on the opposing side rails  46  defined by the notches  56 . The locking tabs  60  are then released to engage with a corresponding notch  56  to lock the connectors  54  in place along the side rails  46 . In this manner, the spacing of the cross bars  66  can be customized to accommodate a multitude of orientations for various uses.  
         [0027]    While the invention has been illustrated in detail in the drawings and in the foregoing description, the same is to be considered as illustrative and not restrictive in nature. It is understood that only the preferred embodiments have been shown and described fully and that all changes and modifications that come within the spirit of the invention are desired to be protected.  
         [0028]    Thus, it is to be appreciated from the preceding disclosures that there has been described a roof panel having an integrally formed roof rack portion.