Patent Description:
Modern vehicles include a portion upon an upper surface or roof of a vehicle, to attach a rail to in order to increase the usable space of the vehicle to transport items. Vehicle users typically utilize these rails to aid in transporting items such as, luggage or bicycles as non-limiting examples. Typically, these rails are attached to the vehicle via a connection member, often a bolt, incorporated within the roof of the vehicle. Roof rack covers encase the connection member when the rails are not mounted to the roof of the vehicle. These roof rack covers assist in improving the overall aesthetic of the vehicle, limit ingress of containments such as water and inhibiting the generation of rust around the connection member.

Current roof-rack designs incorporate an arm extruded from the body of the roof-rack cover frame. This arm is intended to provide a means for locating and securing the roof-rack cover to the vehicle in an x-direction. This arm presents a variety of manufacturing and assembly issues. As the roof-rack cover is assembled, the tolerance stack up within the roof-rack cover can result in misalignment when the roof-rack cover is assembled onto the roof-molding of a vehicle. This misalignment results in issues with the functionality of the roof-rack cover. In certain misalignment situations the cover is prevented from opening due to obstruction caused by an interaction with other vehicle components. As a result, this induces an increase in manufacturing cost. The roof-rack cover and other vehicle components often need to be discarded, replaced, or remodeled in order to accommodate the fit onto the roof-molding of a vehicle. Additionally, the arm increases the complexity of the component and induces an increased cost in the injection molding and assembly process. <CIT> describes a cover for molding according to the preamble of claim <NUM>, wherein the opening hole of the molding can be opened and closed without connecting and disconnecting parts due to a slide plate. <CIT> describes an opening/closing lid device for a vehicle in which the lid does not repeat the opening/closing movement.

Against this background, it is the object of the present invention to provide roof-rack cover securing feature that overcomes at least some of the stated problems above. This problem is solved according to the invention by a vehicle trim bar assembly having the features of claim <NUM>. Accordingly, a vehicle trim bar assembly according to claim <NUM> is provided.

Vehicle trim bar assembly are comparably narrow components, usually long in comparison to their width and height, made mostly of plastic and/or metal, which frequently have a primarily decorative function. Sometimes these vehicle trim bar assembly have a recess within the trim bar profile, usually rectangular, which can be closed by a flap or sliding mechanism. Due to the low rigidity of the trim bar profile, but also due to the very distinct sizes of these parts and due to material tolerances, it can happen that the flap or sliding mechanism can no longer be opened or closed when installed. The present invention is based on the knowledge that this potential malfunction is basically due to the direct coupling of the trim bar profile and flap or sliding mechanism. In the worst case, the flap or sliding mechanism may break if a user tries to close it forcibly.

The present invention is therefore based on the concept of decoupling the trim bar profile and flap or sliding mechanism from each other by providing a separate frame which is insertable within the recess of the trim bar profile. Here, the flap or sliding mechanism which forms a cover for covering an aperture defined by the recess is connected with or coupled with the frame so that the flap or sliding mechanism is no longer directly connected with or attached at the trim bar profile. By decoupling the flap or sliding mechanism of the cover part from the trim bar profile, jamming of these parts in case of opening or closing the cover, especially after a longer period of time and/or changing environmental conditions, is prevented or avoided as far as possible.

In addition, specially provided punch-outs on the trim bar profile are no longer required, which further simplifies the manufacturing process. Instead, it is sufficient to provide only a reference punching for defining an orientation. In the case of a vehicle trim part assembly, this saves at least four hydraulic tools or punching units for cutting out the contours. This way, a significant reduction in cycle times and manufacturing costs may be achieved.

The present invention also allows an easy, a self-fitting assembly of the vehicle trim bar assembly such that a standard vehicle trim bar assembly may be used for a large number of vehicle body shell structures and channel geometries, i.e. dimensions. Therefore, simplifying assembly in general and leaving less room for possible assembly faults is a further benefit.

Advantageous configurations and developments emerge from the further dependent claims and from the description with reference to the figures of the drawings.

In a preferred embodiment, the at least one retaining member comprises at least one first retaining member wherein the at least one first retaining member is arranged and configured such to retain the frame to the trim bar profile inside the aperture at least crosswise or traverse to the longitudinal alignment of the trim bar assembly. The longitudinal alignment, which is also referred to as the X-direction, specifies the longitudinal alignment of the trim bar assembly. In the case of a roof trim assembly, for example, this longitudinal alignment is defined by the length of the vehicle. The crosswise or traverse direction is often referred to as Y-direction.

Preferably, in an inserted condition the first retaining member is located along a first boundary side of the aperture. Typically, the first boundary side is defined by the elongated side or edge of the aperture.

In a further preferred configuration, the at least one retaining member comprises at least one second retaining member wherein the at least one second retaining member is arranged and configured such to retain the frame to the trim bar profile inside the aperture at least along to the longitudinal alignment of the trim bar assembly.

Preferably, in an inserted condition the second retaining member is located along a second boundary side and/or a third boundary side of the aperture. In a further preferred embodiment, the second boundary side and the third boundary side are arranged opposite to each other with respect to the aperture, preferably at front edges or walls of the aperture.

According to a particular preferred configuration, the second boundary side and/or the third boundary side are arranged adjacent to the first boundary side with respect to the aperture. This way, it is possible to insert the frame inside the aperture of the trim bar profile such that it is fixed in either direction, which is as well in the X-direction and also in the y-direction. This makes it possible to safely position and align the frame within the aperture of the trim bar profile in a predefined way which makes the complete mounting steps easier.

In a preferred embodiment, the at least one retaining member is integrally molded within the frame.

According to another embodiment, a profile of the vehicle trim bar assembly may be manufactured as an extrusion part. According to another embodiment, the profile of the vehicle trim bar assembly may be manufactured as an extruded part. Alternatively or additionally, other manufacturing processes such as injection molding or the like may be applied. In exemplary embodiments, the profile of the vehicle trim bar assembly may be manufactured from a metal material, a metal alloy or a metallic material combination. For example, the profile of the vehicle trim bar assembly may be manufactured entirely from aluminum, in particular. Likewise, the profile of the vehicle trim bar assembly, in particular when completed, may be manufactured from a plastic material. In a preferred embodiment, the support web may also be extruded onto the extruded trim bar profile, or, combinedly, be manufactured in a single process step by means of a multi-component extrusion process. For example, the trim bar profile and/or the support web may be manufactured from a thermoplastic, e.g. PVC, or another suitable plastic material. For example, the trim bar profile may be manufactured by mono extrusion. The support web may be subsequently connected to it or extruded, for example. The trim bar profile may also be manufactured together with the support web by means of co-extrusion. In alternative embodiments, however, the trim bar profile may also be manufactured from a composite material such as a fiber-reinforced plastic or the like, for example a carbon-fiber-reinforced plastic.

According to a further embodiment, a profile of the trim bar profile of the vehicle trim bar assembly may be C-shaped. Each of the legs of the "C" shape may be adapted as a fixing leg, while the corresponding other leg functions as a support leg. A nearly C-shaped design of the trim bar profile is particularly simple to install. For this purpose, the vehicle trim bar may, for example, be slid in and/or inserted into the channel and fixed to the vehicle structure using the fixing leg, e.g. by means of fixing openings and/or mounting brackets, or the like, provided for this purpose. If the length of the support web has previously been adapted to the depth of the channel, e.g. by cutting to length, the vehicle trim bar is automatically sitting on the channel bottom, and covers the channel in an accurately fitting manner with the vehicle structure.

According to another embodiment, a profile of the trim bar profile of the vehicle trim bar assembly may be adapted with a trim bar core and a trim bar coating. The trim bar core may be, at least partially, embedded in the trim bar coating. In particular, the trim bar core may be completely embedded in the trim bar coating. In alternative embodiments, however, the trim bar core may also only be partially coated. For example, a trim bar profile which is open on one side may be provided, in which the trim bar core on one side of the trim bar profile remains open towards the outside. In a preferred exemplary embodiment, the trim bar profile may have an open trim bar core on a visible area facing away from the vehicle. In another preferred exemplary embodiment, the trim bar profile may have an open trim bar core on an inner surface facing the vehicle opposite from the visible area. The trim bar coating may function as the structural core of the trim bar profile providing stability and strength. The trim bar coating, on the other hand, may be manufactured from a material that is as light as possible and yet resistant to wear and tear. In addition, the trim bar coating itself may be coated with a varnish, paint, protective layer, etc. to ensure temperature resistance, fluid repellency, and durability. In alternative embodiments, however, the trim bar profile may also consist entirely or substantially entirely of one material, e.g. a metal material, e.g. aluminum or a plastic material.

According to another embodiment, the vehicle trim bar assembly is adapted as a roof trim bar configured for covering a roof channel of the structure or body of the vehicle.

In one preferred embodiment, the cover is pivotably coupled to the frame. In particular, the cover is pivotably coupled to the retaining members. Alternatively, the opening of the cover may also be executed by means of a sliding mechanism, a clip mechanism or the like.

In a configuration of the invention, the frame comprises a first guiding mechanism which is configured for defining and guiding an opening process and/or closing process, such as rotary movement, clapping movement, folding movement, sliding movement or the like.

According to a particular preferred configuration, at least one of the retaining members of the frame comprises a first sloped surface facing towards the aperture. The first sloped surface is preferably part of the first guiding mechanism and is arranged and configured such to enable an edge surface of the cover to move along the first sloped surface during an opening and/or closing process. As such, besides their function of retaining the frame within the aperture of the trim bar profile, the retaining members are assigned with an additional functionality of enabling a predefined opening and closing of the cover.

According to the invention the frame comprises a second guiding mechanism which is configured for guiding during an inserting process for inserting the frame inside an aperture of the trim bar profile. This enables an easy, self-adjusting insertion of the trim bar profile and avoids the chance of jamming the cover.

According to a preferred configuration, the at least one of the retaining members of the frame comprises a second sloped surface facing the far side of the aperture. The second sloped surface is part of the second guiding mechanism and is arranged and configured such to enable an edge surface of the trim bar profile to move along the sloped surface during an inserting process. As such, besides their function of retaining the frame within the aperture of the trim bar profile and/or defining an opening/closing process, the retaining members are assigned with still an additional functionality of enabling an inserting the frame inside the aperture of the trim bar profile.

According to a configuration of the invention, the at least one of the retaining members comprises a conical shaped portion that comprises as well the first and second guiding mechanism. Their first and second sloped surfaces are arranged on opposite sides of the conical shaped portion. Employing only one part which presents two different functionalities, i.e. guiding a defined inserting and additionally guiding an opening process of the cover, is efficient and cost reducing.

Preferably, at least one of the first or second guiding mechanism is rounded in their upper portion. The upper portion is that part of the guiding mechanism or retaining element which is facing to the upper surface of the trim bar assembly. This way, the inserting process and/or the opening and closing process are smoother and easier.

It should be noted that the features set out individually in the following description can be combined with each other in any technically advantageous manner and set out other forms of the present disclosure. The description further characterizes and specifies the present disclosure in particular in connection with the Figures.

<FIG> depicts an isometric view of a vehicle <NUM> with a trim bar profile <NUM>. In this variation the trim bar profile <NUM> defines the area wherein a roof-rack, not shown, is designed to be attached. In other variations the trim bar profile <NUM> may be on other areas of the vehicle <NUM> such as the hood, fender, door, bumper, or any other vehicle component. The trim bar profile <NUM> is further depicted in <FIG>. As shown in <FIG> the trim bar profile <NUM> comprises at least one cover assembly <NUM>. In this form there are four cover assemblies <NUM>, two on opposite sides of the vehicle <NUM>. Other variations may contain more or less cover assemblies <NUM> to align with design constraints. In this form, the cover assembly <NUM> assists in protecting the connection component for the attachment of a roof-rail (not shown) to the vehicle <NUM>.

<FIG> depicts a top view of the cover assembly <NUM>. As seen and previously mentioned, the cover assembly <NUM> cooperates with the molding component <NUM> to protect the connection component of the vehicle <NUM>, not shown. The cover assembly <NUM> comprises a cover <NUM>. The cover <NUM> is pivotably coupled to a frame <NUM>, as seen in <FIG>. The molding component <NUM> is located between the cover <NUM> and the frame <NUM>. Section A-A s shown in <FIG> and will be discussed in more details in <FIG>. <FIG> depicts a bottom view of the cover assembly <NUM>. The cover <NUM> comprises at least one cover pivot connection <NUM> that cooperates with at least one frame receiving element <NUM> located along a first boundary side <NUM>. In this form, the cover <NUM>, comprises two cover pivot connections <NUM>. For each cover pivot connection <NUM> there are two frame receiving elements <NUM>. In other variations there may be more or less cover pivot connections <NUM> and frame receiving elements <NUM> to align with design constraints.

<FIG> and <FIG> depict an isometric view and a top view, respectively, of the cover assembly <NUM> with the cover <NUM> removed to illustrate the connection between the frame <NUM> and the molding component <NUM>. The frame <NUM> comprises at least one first retaining member <NUM> and/or at least one second retaining member <NUM>. The at least one first retaining member <NUM> and the at least one second retaining member <NUM> couple to the trim bar profile <NUM> along an inner boundary <NUM> of an aperture <NUM> within the trim bar profile <NUM>. The at least one of the first retaining member <NUM> locates and retains the trim bar profile <NUM> to the frame <NUM> in a y-direction. The at least one second retaining member <NUM> locates and retains the molding component <NUM> to the frame <NUM> in an x-direction. Both the first retaining member <NUM> and the second retaining member <NUM> also act as guides to align the frame <NUM> within the molding component <NUM>. In this form, the first and second retaining members <NUM>, <NUM> act as stoppers to retain the molding component <NUM> to the frame <NUM> in the y and x direction. In other variations, the first and/or second retaining members <NUM>, <NUM> may contain a clip or snap feature to secure the trim bar profile <NUM> to the frame <NUM>. In this form, there are two first retaining members <NUM> cooperating with the first boundary side <NUM> of the aperture <NUM>. In another variation, the retaining member <NUM> may be a single elongated retaining member. There are also two second retaining members <NUM>, in this form. One of the second retaining members <NUM> are located along a second boundary side <NUM> of the inner boundary <NUM> of the aperture <NUM>. Another of the second retaining members <NUM> are located along a third boundary side <NUM> of the inner boundary <NUM> of the aperture <NUM>. The second and third boundary side <NUM>, <NUM> are adjacent to the first boundary side <NUM>. In other forms, there may be more or less first retaining members <NUM> and/or second retaining members <NUM> in varying dimensions to align with design constraints.

<FIG> depicts an isometric view of the frame <NUM>. <FIG> shows the location of the first retaining members <NUM> and the second retaining members <NUM> within the frame <NUM>. In this form, the first and second retaining members <NUM>, <NUM> are integrally molded within the frame <NUM>. In other variations the first and second retaining members <NUM>, <NUM> may be disjointly coupled to the frame <NUM>. In this form, the second retaining member <NUM> has an L-shaped geometry. This enables the second retaining member <NUM> to efficiently retain the trim bar profile <NUM> to the frame <NUM>. In other variations, the second retaining member <NUM> may take on other geometries to align with design constraints.

<FIG> depicts a section view A-A, as seen if <FIG>, of the cover assembly <NUM>. The section view shows the relationship between the trim bar profile <NUM>, cover <NUM>, frame <NUM>, and the first retention member <NUM>. As seen in this form, the first retention member <NUM> has a trapezoidal shape to coincide with the geometry of the cover <NUM>. The geometry of the first retention member <NUM> cooperates with the geometry of the cover <NUM> to ensure efficient rotation of the cover <NUM> when it is opened and/or closed. In other variations, the first retention member <NUM> may take on other geometric forms that allows adequate clearance for the cover <NUM> to pivot while opening or closing. The trim bar profile <NUM> comprises a profile that includes a trim bar coating 102b. The trim bar coating 102b surrounds a trim bar core <NUM> which may be partially embedded in the trim bar coating 102b.

Hereinafter, the functionality of the elements of the cover assembly <NUM> are described with regard to the embodiments shown in <FIG> and <FIG>:
The cover <NUM> is pivotably coupled to the retaining members <NUM> of the frame <NUM>, wherein reference symbol <NUM> denotes the direction of the rotation of the pivotable cover <NUM>. The frame <NUM> is preferably removable and insertable in to the trim bar profile <NUM>. For this purpose, the frame <NUM> is inserted in a direction <NUM> into a recess of the trim bar profile <NUM>, which forms the aperture <NUM>.

The first retaining members <NUM> of the frame <NUM> comprises a first sloped surface 114a that functions as a first guiding mechanism <NUM> and a second sloped surface 114b that functions as second guiding mechanism <NUM>.

The first guiding mechanism <NUM> is configured for guiding an opening process and/or closing process. For this purpose, the first guiding mechanism <NUM> comprises a first sloped surface 114a. The first guiding mechanism <NUM> is configured and arranged such that the first sloped surface 114a is facing towards the aperture <NUM>. The first sloped surface 114a is arranged and configured such to enable an edge surface 106a of the cover <NUM> to move along the first sloped surface 114a during an opening and/or closing process.

The second guiding mechanism <NUM> is configured for guiding during an inserting process for inserting the frame <NUM> inside the aperture <NUM> of the trim bar profile <NUM>. For this purpose, the second guiding mechanism <NUM> comprises a second sloped surface 114b. The second guiding mechanism <NUM> is configured and arranged such that the second sloped surface 114b is facing the far side of the aperture <NUM>. The second sloped surface 114b is arranged and configured such to enable an edge surface 102a of the trim bar profile <NUM> to move along the second sloped surface 114b during an inserting process. The first and second guiding mechanisms <NUM> are rounded in their upper portion 114c such that their first and second surfaces 114a, 114b, respectively, have a curved surface in the upper portion. This enables the opening movement of the cover <NUM> in the direction <NUM> and the inserting movement of the frame <NUM> in the direction <NUM>.

In the embodiment shown in <FIG> and <FIG>, the first and second guiding mechanism <NUM> are part of the same portion of the retaining element <NUM> which has a conical shape. The first and second sloped surfaces 114a, 114b are arranged on opposite sides of the conical shaped portion of the retaining element <NUM>.

<FIG> depicts an exploded view of the cover assembly <NUM>. As seen, the cover <NUM> covers the aperture <NUM> in the trim bar profile <NUM>. Through the aperture <NUM>, the cover <NUM> is pivotably coupled to the frame <NUM> at the cover pivot connections <NUM> and the frame receiving elements <NUM>, seen in <FIG>. The trim bar profile <NUM> encases the trim bar core <NUM> which provides additional structural support to the trim bar profile <NUM>. The trim bar core <NUM> is a hard-material such as steel, aluminum, etc., to reinforce the trim bar profile <NUM>. A tolerance compensator <NUM> couples to the trim bar profile <NUM> to cover any gaps between the trim bar profile <NUM> and the vehicle <NUM> caused by tolerance misalignments. The tolerance compensator <NUM> is typically a soft-material substance to conform to gaps between components on the vehicle <NUM> provide a gap-free impression when the trim bar profile <NUM> is attached to the vehicle <NUM>. The trim bar profile <NUM> is coupled to the vehicle <NUM> via additional clips (not shown).

Claim 1:
A vehicle trim bar assembly (<NUM>) for a vehicle (<NUM>), comprising:
a trim bar profile (<NUM>), wherein the trim bar profile (<NUM>) comprises an inner boundary (<NUM>) that defines an aperture (<NUM>);
a frame (<NUM>) releasably coupled to the trim bar profile (<NUM>), the frame (<NUM>) comprising at least one retaining member (<NUM>, <NUM>), wherein the at least one retaining member (<NUM>, <NUM>) couples to the trim bar profile (<NUM>) within the inner boundary (<NUM>) of the aperture (<NUM>) to retain the frame (<NUM>) in an inserted condition to the trim bar profile (<NUM>); and a cover (<NUM>) coupled to the frame (<NUM>) and configured and arranged to cover the aperture (<NUM>) and to provide access to the aperture (<NUM>) upon demand,
characterized in that the frame (<NUM>) comprising a first and a second guiding mechanism (114a, 114b) which is configured for guiding an opening process and/or closing process,
wherein at least one of the retaining members (<NUM>) comprises a conical shaped portion that comprises as well the first and second guiding mechanism (114a, 114b) wherein their first and second sloped surfaces (114a, 114b) are arranged on opposite sides of the conical shaped portion and/or wherein at least one of the first or second guiding mechanism (114a, 114b) is rounded in their upper portion (114c).