Abstract:
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.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority from U.S. provisional application Ser. No. 61/303,410, filed Feb. 11, 2010, the disclosure of which is incorporated herein by reference in its entirety. 
    
    
     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. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same become better understood by reference to the following detailed description when considered in light of the following drawings, wherein: 
         FIG. 1  shows a perspective view of the roof rack pad in an embodiment of the present invention mounted on a crossbar of a roof rack and having tie down straps thereon to secure an object thereto. 
         FIG. 2  shows a top plan view with an object fastening slot for receiving a tie down strap in an embodiment. 
         FIG. 3  shows a cross section of the pad in an embodiment. 
     
    
    
     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 pad  10  for a roof rack crossbar. As illustrated in  FIG. 1 , a perspective view of the roof rack pad  10  in an embodiment of the present invention mounted on a crossbar  12  of a roof rack  14  and having tie down straps  16  thereon to secure an object (not shown) thereto is shown. One or more object fastening slots  18  are provided for receiving the tie down strap  16 . An elongated hole  20  is provided through the length of the pad for receiving the crossbar  12 .  FIG. 2  is a top plan view showing the object fastening slot  18  for receiving a tie down strap  16  and the elongated crossbar-receiving hole  20 .  FIG. 3  shows a cross section of the pad  10  having an aerodynamic exterior shape having a leading edge  22 , a trailing edge  24 . The pad is comprised of a cushioning material  26 . It may also comprise an exterior skin  28 . The elongated crossbar-receiving hole  20  may be shaped to snuggly fit a variety of crossbar shapes. 
     The improved aerodynamic pad  10  shaft preferably comprises an elongated tube shape that has an exterior with a non-circular cross section having aerodynamic shape. In an embodiment the pad  10  comprises an elongated tube shape having an airfoil exterior cross section in a preferred embodiment, oriented with a leading edge  22  that is on the half of the pad  10  aligned with the direction of vehicle travel and a trailing edge  24  opposite thereto. In another embodiment a substantially airfoil-like elliptical or teardrop shape (or other suitable cross sectional shape) is used, wherein the elongated hole  20  is positioned radially closer to one part of the major axis making it the leading edge  22  and the object fastening slots  18  are located opposite on the trailing edge  24 . The aerodynamic shape of the pad  10  reduces drag and noise of the crossbars  12  by reducing turbulence. In one embodiment, the pad  10  has 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 edge  22  may 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 hole  20  disposed lengthwise through the pad  10  allows for mounting onto the crossbar  12 . The size and shape of the lengthwise hole  20  may be geometrically matched to a variety of crossbars for a snug fit and to prevent rotation about the crossbar  12 . 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 slots  18  are provided for receiving a tie down straps  16 . Straps  16  may be any of a known variety of strap, ropes, or the like. The slots  18  are located on the trailing edge  24  in any of a number of spaced relations as a matter of design choice to allow for receiving straps  16  to secure objects thereto. The slots  18  are placed at a radial depth  30  (with respect to the central axis  36  of the elongated hole  20 ) so as to prevent deformation/distortion of the trailing edge  24  airfoil shape. The radial depth  30  is preferably less than the trailing edge radius  32  and somewhat approaches the leading edge radius  34 . Preferably, the slots  18  are preferably of a T-shape so the straps  16  may 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 strap  16  would then be threaded through. In still a further embodiment, the straps  16  may be permanently affixed to the pad  10  at a location that is at a radial depth  30  so as to prevent deformation/distortion of the trailing edge  24 . 
     Preferably, the pad  10  also comprises (or is coated with) a material  26  that has a low coefficient of drag so that it will have a reduced tendency to be affected by air drag. The pad  10  is 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 pad  10  is made of a cellular material  26  such 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 material  26  is characterized in that the polyurethane foam has a self-skin layer  28  formed thereon (preferably on the exterior of the pad  10  and in certain embodiments along the walls of the elongated hole  20 ). With the formation of the self-skin layer  28 , 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 layer  28  or in addition to the skin layer. Manufacturing of the pad  10  may include a variety of firmness and skin thickness depending on the application. 
     Color may be added into the base cushioning material  26  or 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 pad  10  during manufacturing or integrated into the exterior of the pad. These inserts can provide reinforcement of the pad  10  to 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 slots  18  may 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 straps  16 . 
     Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise as specifically described herein.