Patent ID: 12252079

DESCRIPTION OF EMBODIMENTS

In the drawings, reference numeral10generally designates a vehicle roof rack10for supporting a load (not illustrated) relative to a roof12of a vehicle. The vehicle roof rack10includes an elongate member14configured to support the load, one or more mounting mechanisms16configured to mount the elongate member14to the roof12, and an assembly18for securing electrical wiring26(FIG.6) through the roof12and carrying the wiring26to the roof rack10. The assembly18includes: a body20(FIG.5) configured to be placed across a hole22(FIG.6) defined in the roof12, the body20defining a wiring aperture24extending through the body20; electrical wiring26(FIG.6) arranged through the wiring aperture24and fixed to the body20; a securing mechanism28for releasably securing the body20to the roof12; and a boot30configured to cover the body20, connect to the elongate member14, and carry the wiring26from the body20to the elongate member14.

FIG.1shows the roof rack10configured as a roof platform50and the elongate member14configured as a side rail52of the platform50. The platform50is mounted by the mounting mechanisms16to be operatively above an exterior surface13of the roof12. In other embodiments (not illustrated), the elongate member14is configured as a slat54of the platform50. The side rail52defines an internal cavity56(FIG.3B) and an entry aperture58(FIG.3B) in a sidewall60of the side rail52to allow access into the cavity56. The boot30includes a roof rack connector34connected to the side rail52to cover the entry aperture58. The arrangement of the assembly18and the side rail52in this way allows the wiring26to be routed from within the cabin (not shown) of the vehicle, through a hole (not visible) in the roof12, secured to the roof12by the assembly18, and conveyed, by the assembly18, to the side rail52.

An operatively front slat54is connected to, and carries, an electrically powered device, in the form of a light bar62. The light bar62is arranged to illuminate in front of the vehicle from an elevated position. In other embodiments (not illustrated), the device is in the form of a driving light, illuminated sign, or monitor/screen. The front slat54defines an internal cavity and an exit aperture (both not visible) in a sidewall of the slat54to allow access into the cavity. The cavity of the slat54is arranged to be in communication with the cavity of the side rail52. The light bar62is positioned adjacent the exit aperture. The arrangement of the slat54, the side rail52and the light bar62in this way allows the wiring26to be conveyed from the assembly18to the light bar62.

FIG.2shows the light bar62in isolation and the assembly18alternatively configured such that the roof rack connector34is substituted for a device connector38. The device connector38is releasably securable to a tubular portion36of the boot30and configured to mechanically couple with an electrical device, in this embodiment, being the light bar62. In some embodiments, the device connector38is configured to also electrically couple the wiring26with the device. This arrangement usefully allows the assembly18to convey the wiring26from the roof12directly to the device. For example, this may be practical where the device is roof-mounted, without a roof rack10, or access to electrical connectors of the device is inhibited by the roof rack10.

FIGS.3A and3Bshow the assembly18and side rail52in isolation. These figures show the internal cavity56defined by the side rail52and the entry aperture58arranged to allow access into the cavity56. In the illustrated embodiment, the roof rack connector34defines a resiliently deformable annular flange40dimensioned to be fitted around a periphery of the aperture58to engage the sidewall60. It will be appreciated that, in other embodiments, the roof rack connector34is alternatively configured to connect to the side rail52, such as having snap-fit tabs, defining a thread or bayonet fitting, and/or carrying mechanical fasteners. In yet other embodiments, alternatively or additionally, the connector34carries adhesive to allow bonding to the sidewall60.

FIG.3Billustrates the configuration of the roof rack connector34in detail. The connector34has a region42shaped to extend at a right angle to the flange40, such that when connected to the sidewall60, the region42extends perpendicularly to the aperture58and parallel to the sidewall60. This causes the tubular portion36, which is connected to the connector34, to partially extend parallel to the sidewall60. This can usefully arrange the tubular portion36alongside the side rail52to reduce drag during use, when the vehicle is being driven, and avoid the tubular portion36being snagged by cargo being loaded onto the roof platform50.

FIG.3Balso illustrates the side rail52in detail. The side rail52includes a tubular region64defining the cavity56, in this embodiment being an elongate hollow channel. The cavity56is configured to receive the wiring26and convey the wiring along the length of the side rail52. In this embodiment, the cavity56is enclosed to sealingly contain the wiring.

FIG.4illustrates a cover portion32of the boot30in detail. In the illustrated embodiment, the cover portion32defines an annular groove42dimensioned to receive a rim44(FIG.5) of the body20. A deformable skirt46extends from one side of the groove42, the skirt46arranged, in use, to be arranged against and conform to geometry of the vehicle to provide a primary seal. One or more drainage holes48are defined at the other side of the groove42and arrange to allow draining fluid from inside the boot30. The tubular portion36defines a corrugated structure to allow a limited degree of flexibility whilst maintaining a tubular form.

FIG.5illustrates the assembly18in isolation. It will be appreciated that the assembly18is installable and operable independently of the roof rack10, such as is shown inFIG.2. The assembly18includes: the body20which is configured to be placed against the exterior surface13of the roof12and across the hole22(FIG.6) defined in the roof12, the body defining the wiring aperture24extending through the body20; a seal37arranged at one side of the body20; a wiring insert21configured to fit within the wiring aperture24to arrange the wiring26through the aperture, the wiring insert21configured to be releasably secured to the body20to seal the wiring aperture24; at least two fasteners23carried by the body20to extend from the one side of the body20and past the seal37; and at least one receiving portion25configured to be arranged about the hole22and against an interior surface15of the roof12to allow receiving at least one of the fasteners23such that engaging the at least one fastener23with the at least one receiving portion25urges the body20and seal37against the roof12.

The assembly18includes an insert retention structure configured to releasably engage the body20to secure the insert21in the aperture24. In the illustrated embodiments, the retention structure is in the form of an insert retaining nut27configured to threadedly engage the body20to allow releasably securing the wiring insert21in the aperture24. This is achieved by engaging a threaded sleeve portion29of the body20. The inclusion of the nut27is useful as this allows releasably securing the wiring insert21to the body20without rotating the insert21, which could cause twisting of the wiring26. In other embodiments (not illustrated), the retention structure includes a plate securable with fasteners to the body20to trap the insert21in the aperture24. In yet other embodiments (not illustrated), the retention structure includes a cap having bayonet-fitting features configured to engage with bayonet-fitting features defined by, or connected to, the body20.

A slip ring35is arranged between the nut27and the insert21to enhance relative rotation. In other embodiments (not illustrated), the nut27is absent and, instead, the insert21is configured to be directly secured to the body20, such as by being threaded to engage an inner thread of the sleeve29, or by being deformed by the sleeve29to cause frictional engagement.

The wiring insert21defines a flange31arranged, in use, to abut an end of the sleeved portion29. The nut27is shaped to press against the flange31when mounted to the body20. This arrangement allows the flange31to be compressed against the sleeved portion29by tightening the nut27. In the illustrated embodiment, a seal33is arranged operatively below the flange31to allow sealing between the insert21and the body20. In other embodiments, the flange31and/or the insert21is resiliently deformable such that compressed the flange31with the nut27forms a seal.

In the illustrated embodiment, the seal37is in the form of a resiliently deformable pad carried by and extending across a base surface of the body20to allow pressing against, and sealing to, the roof12. In this embodiment, the seal37is separate to the body20. In other embodiments (not illustrated), the seal37is integrally formed, such as by over-moulding, with the body20, and may only define an annular ring.

In the illustrated embodiment, the fasteners23are threaded and in the form of bolts, and the receiving portion25includes two thread receiving U-nuts39to allow each fastener23to threadedly engage one of the U-nuts39. Each fastener23is associated with an O-ring seal41arranged to be compressed between the fastener23and the body20to form a seal. Each U-nut39is configured to be clipped to a rim of the hole22to allow receiving and engaging with one of the fasteners23. The enhances ease of assembling the assembly18to the roof12from the outside of the vehicle only. In other embodiments (not illustrated), the receiving portion25includes two or more nutserts, or a plate, having threaded openings to receive each fastener23. It will be appreciated that, in other embodiments (not illustrated), the fasteners23and receiving portion25are alternatively configured to allow engagement, such as the fasteners23comprising pop rivets and the receiving portion25comprising one or more plates or washers defining apertures dimensioned to receive the pop rivets.

FIG.6illustrates the assembly18installed to a roof12in detail. The wiring26is shown to include a bundle of a plurality of wires43. The wiring insert21is at least partially formed around the wires43to cause the wires43to be embedded in, and extend through, the insert21. In this embodiment, the insert21includes a cap45defining apertures47arranged to receive and retain the wires43to be spaced apart. The insert21also includes a core49which is formed against, and typically within, the cap45while the wires43are arranged through the apertures47to cause a portion of each wire43to be embedded in the core49. This means that the portion of each wire43is completely enclosed within, and fixed to, the core49which can prevent fluid flowing along the wire43and through the core49. This structure is typically achieved by over-moulding the core49against the cap45and the wires43. The arrangement of the apertures47usefully spaces the wires43apart to allow molten core material to flow between the wires43during the moulding process. This can reduce or eliminate voids or imperfections in the moulded core49and enhance the wires43being embedded in the core49to robustly seal against the wires43. It will be appreciated that other moulding or casting approaches may be appropriate. This approach advantageously means that each wire43is sealingly engaged with the insert21, which, in conjunction with the other components of the assembly18, substantially inhibits fluid penetrating into the hole22in the roof12. Also, providing the wires43on the outside of the roof12to be separate from each other and bonded to the insert21allows the wires43to be easily routed to supply power to different circuits or devices, avoiding requiring splicing a multi-wire cable which can increase risk of leaks, mechanical failure and/or costs.

FIG.7illustrates an alternative embodiment of the assembly180installed to the roof12, whereby common reference numerals to the assembly18described above indicate common features. The assembly180includes a wiring insert51configured to fit within the wiring aperture24to arrange the wiring26through the aperture24. The wiring insert51is configured to be releasably secured to the body20to seal the wiring aperture24. In the illustrated embodiment, the insert51includes an annular flange53arranged, in use, to abut the end of the sleeved portion29. This arrangement allows the flange51to be compressed by the insert retention structure, in this embodiment, being against the sleeved portion29of the body20by the nut27. It will be appreciated that in other embodiments, the flange53may be absent. For example, in such embodiments, the insert52may define one or more tapered regions to allow sealing against the body20.

The insert51defines a wiring conduit55which extends only partially through the insert51to terminate at a piercable end wall57. The end wall57is dimensioned to be sufficiently thin, in the region of 1-2 mm, to readily allow the wall57to be manually pierced and the wiring26to be arranged through the conduit55and, consequently, through the insert51. It will be appreciated that the insert51may define more than one conduit terminating at the piercable wall57to selectively allow multiple wires, or bundles of wires, to be arranged through the insert51.

In the illustrated embodiment, the conduit55defines a ribbed internal wall to allow gripping the wiring26arranged through the conduit55. In the illustrated embodiments, the ribbed wall defines an array of annular ribs59spaced longitudinally along the conduit55. The annular arrangement of the ribs59can inhibit fluid travelling past a wire retained in the conduit55. In other embodiments (not illustrated), the conduit55defines longitudinally extending ribs, or a combination of annular and longitudinal ribs, where at least the longitudinal ribs can provide strain relief to the wire(s) arranged adjacent the rib. It will be appreciated that in other embodiments, the ribs59may be absent.

FIG.8illustrates a further alternative embodiment of the assembly280installed to the roof12, whereby common reference numerals to the assembly18described above indicate common features. The assembly280includes: a first body70configured to be placed against the exterior surface13of the roof12and across the hole22defined in the roof12, the first body70defining a wiring aperture24extending through the body70; and a second body72formed around the bundle of wires43and within the wiring aperture24such that the wires43are embedded in, and extend through, the second body72. The second body72is typically configured such that a portion of each wire43is completely enclosed within, and fixed to, the body72which can prevent fluid flowing along the wire43and through the body72. This structure is typically achieved by over-moulding the second body72against the first body70and the wires43.

Installation of the assembly18,180involves: drilling the hole22in the roof12of the vehicle, and holes for the fasteners23; mounting the body20across the hole22such that the wiring aperture24is substantially aligned with the hole22and the seal37is placed against the roof22; securing the insert21in the aperture24so that the wiring26extends through the hole22and the insert21seals the aperture24; engaging the fasteners23with the receiving portions25, and tightening the fasteners23to urge the body20against the roof12.

When installed in this way, the assembly18,180fixes the wiring26through the hole22in the roof12of the vehicle, and seals against the roof12to inhibit fluid entering the hole, either directly or through the assembly18,180. This usefully reduces or prevents damage cause by fluid ingress into the vehicle. Furthermore, installation can be completed by accessing only the outside of the vehicle, reducing complexity and duration of the installation procedure. It will be appreciated that the assembly18,180is not limited to being mounted to the roof12and can alternatively be mounted to other surfaces of the vehicle if required, such as the bonnet, fender, or in the cargo bay.

Installation of the roof rack10involves: drilling the hole22in the roof of the vehicle22; securing the one or more mounting mechanisms16to the roof12: mounting the elongate member12to the one or more mounting mechanisms16; and mounting the assembly18to the roof12to secure the wiring26through the roof12and carrying the wiring26to the roof rack. Mounting the assembly18in this scenario involves: placing the body20across the hole22such that the wiring aperture24is substantially aligned with the hole22; arranging the wiring26through the aperture24and fixing the wiring26to the body20; operating the securing mechanism to secure the body20to the roof12; and mounting the boot30to the body20such that the cover portion32covers the body20, the roof rack connector34is connected to the roof rack10, and the wiring26is carried to the roof rack10. Where the roof rack10carries an electrically powered device, such as the light bar, the wiring26may be connected at one end to a power source, such as a battery, and the other end be routed from or through the roof rack10to be connected to the device to allow powering the device.

It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the above-described embodiments, without departing from the broad general scope of the present disclosure. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.