U.S. patent application number 14/564000 was filed with the patent office on 2015-08-06 for load carrier.
This patent application is currently assigned to HUBCO AUTOMOTIVE LIMITED. The applicant listed for this patent is HUBCO AUTOMOTIVE LIMITED. Invention is credited to Peter Douglas Hubbard, Bruce John Robertson.
Application Number | 20150217699 14/564000 |
Document ID | / |
Family ID | 44355629 |
Filed Date | 2015-08-06 |
United States Patent
Application |
20150217699 |
Kind Code |
A1 |
Hubbard; Peter Douglas ; et
al. |
August 6, 2015 |
LOAD CARRIER
Abstract
The invention relates to a roof box 1 for mounting to a vehicle
via roof racks 100. The roof box 1 includes a base section 3
mountable to a vehicle roof or roof rack 100 and a top section 2
that is movable relative to the base section 3 to allow the roof
box 1 to be opened and closed. The roof box 1 includes no external
protruding seam 4 with the seam 4 flush with the exterior of the
roof box 1. The roof box 1 also includes a curved seam 4, double
skinned top 2 and double acting action hinge 12 design that all
combine to provide improved aesthetics, lower weight, reduced
aerodynamic drag, better fuel efficiency and equivalent strength,
rigidity and loadings to the art.
Inventors: |
Hubbard; Peter Douglas;
(Christchurch, NZ) ; Robertson; Bruce John;
(Christchurch, NZ) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
HUBCO AUTOMOTIVE LIMITED |
Wellington |
|
NZ |
|
|
Assignee: |
HUBCO AUTOMOTIVE LIMITED
Wellington
NZ
|
Family ID: |
44355629 |
Appl. No.: |
14/564000 |
Filed: |
December 8, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
13577831 |
Nov 2, 2012 |
8905279 |
|
|
PCT/NZ2011/000018 |
Feb 8, 2011 |
|
|
|
14564000 |
|
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Current U.S.
Class: |
224/328 |
Current CPC
Class: |
B60R 9/055 20130101 |
International
Class: |
B60R 9/055 20060101
B60R009/055 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 8, 2010 |
NZ |
583170 |
Claims
1. A roof box for carrying cargo on top of a vehicle comprising a
base section including clamps for mounting the roof box on cross
bars on top of a vehicle, the base section having an outer surface
including a main outer surface region and a perimeter edge surface
region that bends inward from the main outer surface region to form
an inward offset, and a top section hinged to the base section and
configured for opening and closing the roof box, the top section
being fully double skinned.
2. A roof box for carrying cargo on top of a vehicle comprising a
base section including clamps for mounting the roof box on cross
bars on top of a vehicle, and a top section hinged to the base
section and configured for opening and closing the roof box, the
top section being fully double skinned and having a lip that
extends from a left side to a right side of the roof box via a
front end and a back end of the roof box, wherein the base section
has a rim that overlaps the lip of the top section to form an
exterior seam at a perimeter of the roof box when the roof box is
closed.
3. The roof box of claim 2, wherein top section includes an outer
skin and an inner skin, and wherein the outer skin and the inner
skin are fastened to one another at the lip of the top section.
4. The roof box of claim 3, wherein the outer skin and the inner
skin are substantially flush with one another at a bottom boundary
of the lip.
5. The roof box of claim 2, wherein the top section includes an
outer skin and an inner skin, and wherein the inner skin forms
multiple transverse ribs at which the inner skin is spaced from the
outer skin.
6. The roof box of claim 5, wherein a cavity is formed in the top
section between the outer skin and the inner skin, and wherein each
of the transverse ribs adjoins the cavity.
7. The roof box of claim 2, wherein the base section has an outer
surface including a main outer surface region and a perimeter edge
surface region that bends inward from the main outer surface region
to inwardly offset the rim of the base section.
8. The roof box of claim 2, wherein the exterior seam is flanked by
an exterior surface region of the top section and an exterior
surface region of the base section that are substantially flush
with one another.
9. A roof box for carrying cargo on top of a vehicle comprising a
base section including clamps for mounting the roof box on cross
bars on top of a vehicle, and a top section hinged to the base
section and configured for opening and closing the roof box, the
top section forming a lip and having an outer skin and an inner
skin that are fastened to one another at the lip, wherein the lip
of the top section extends along a left side, a right side, a front
end, and a back end of the roof box, and wherein the base section
forms a rim that overlaps the lip of the top section to form an
exterior seam at a perimeter of the roof box when the roof box is
closed.
10. The roof box of claim 9, wherein the inner skin forms multiple
transverse ribs at which the inner skin is spaced from the outer
skin.
11. The roof box of claim 10, wherein each transverse rib extends
from a position near the left side of the roof box to a position
near the right side of the roof box.
12. The roof box of claim 10, wherein a cavity is formed in the top
section between the outer skin and the inner skin, and wherein each
of the transverse ribs adjoins the cavity.
13. The roof box of claim 9, wherein the top section is fully
double skinned.
14. The roof box of claim 9, wherein the outer skin and the inner
skin are substantially flush with one another at a bottom boundary
of the lip.
15. The roof box of claim 9, wherein the base section has an outer
surface including a main outer surface region and a perimeter edge
surface region that bends inward from the main outer surface region
to inwardly offset the rim.
16. The roof box of claim 9, wherein the exterior seam is flanked
by an exterior surface region of the top section and an exterior
surface region of the base section that are substantially flush
with one another.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This is a continuation of U.S. patent application Ser. No.
13/577,831 filed Nov. 2, 2012 which application is a .sctn.371 U.S.
national phase filing from Application No. PCT/NZ2011/000018 filed
Feb. 8, 2011 which claims priority to New Zealand Application No.
NZ583170 filed Feb. 8, 2010. The complete disclosures of which are
hereby incorporated by reference for all purposes in their
entireties.
TECHNICAL FIELD
[0002] The invention relates to a load carrier. More specifically,
the invention relates to a vehicle roof box used to carry items on
the roof of a vehicle.
BACKGROUND ART
[0003] Roof boxes are well known and commercialised worldwide. Roof
boxes comprise a container mountable to a roof area of a vehicle
and are adapted to store luggage, cargo and/or other objects (e.g.
sporting equipment such as skis and snowboards). Typically, the
roof box is made up of a bottom part for mounting to the roof area
of a vehicle and a top part movable relative to the bottom part for
opening and closing the roof box. Roof boxes may be preferable to
an open roof rack accessory holder since they protect the items
stored inside from exposure to adverse weather and environmental
conditions as well as provide robust protection against theft and
vandalism.
[0004] There are a wide range of different styles, features and
prices available although roof boxes have become very standardised
in design. In particular, typical design features common to many
designs include central locking, double sided opening, quick fit
attachment from inside the roof box, the ability to fit a range of
roof racks and various styling shapes.
[0005] Noted drawbacks with existing designs included increased
fuel consumption due to greater aerodynamic drag, styling
constraints by existing manufacturing methods, the roof boxes are
difficult and slow to attach and remove, and the internal space is
reduced by the use of internal attachment mechanisms.
[0006] More specifically, all roof boxes known to the applicant
utilise an over lapping seam design i.e. the lid overlaps the base.
Whilst this is easy to manufacture and seals well, the styling and
aesthetics are not ideal and the design causes noticeable drag. The
drag also may result in increased noise when the vehicle is
driven.
[0007] It is an object of the present invention to address the
foregoing problems or at least to provide the public with a useful
choice.
[0008] It is acknowledged that the term `comprise` may, under
varying jurisdictions, be attributed with either an exclusive or an
inclusive meaning. For the purpose of this specification, and
unless otherwise noted, the term `comprise` shall have an inclusive
meaning--i.e. that it will be taken to mean an inclusion of not
only the listed components it directly references, but also other
non-specified components or elements. This rationale will also be
used when the term `comprised` or `comprising` is used in relation
to one or more steps in a method or process.
[0009] Further aspects and advantages of the present invention will
become apparent from the ensuing description that is given by way
of example only.
SUMMARY OF THE INVENTION
[0010] The invention broadly relates to a roof box with flush seams
that improves the styling of the box and improves the box
aerodynamics, reducing wind noise and fuel consumption compared to
existing roof box designs.
[0011] In a first embodiment there is provided a roof box including
a semi-rigid to rigid base section mountable to the roof of a
vehicle and a semi-rigid to rigid top section movable relative to
the base section for opening and closing the roof box wherein the
exterior of the seam between the base section and top section is
approximately flush when in a closed configuration.
[0012] In a second embodiment there is provided a roof box
including a semi-rigid to rigid base section mountable to the roof
of a vehicle and a semi-rigid to rigid top section movable relative
to the base section for opening and closing the roof box wherein
the roof box top section is lifted from the base section about at
least one hinge wherein the virtual hinge line is located outside
the roof box.
[0013] In a third embodiment there is provided a roof box including
a semi-rigid to rigid base section mountable to the roof of a
vehicle and a semi-rigid to rigid top section movable relative to
the base section for opening and closing the roof box and further
including at least one double acting hinge linking the top and base
sections.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Further aspects of the present invention will become
apparent from the following description that is given by way of
example only and with reference to the accompanying drawings in
which:
[0015] FIG. 1 illustrates a perspective view from above of one
embodiment of the roof box in a closed configuration;
[0016] FIG. 2 illustrates a perspective view of the roof box in an
open configuration;
[0017] FIG. 3 illustrates an elevation view of the side of the roof
box;
[0018] FIG. 4 illustrates a cross section front elevation view of
the roof box along line AA shown in FIG. 3;
[0019] FIG. 5 illustrates a detail view of the joint between the
top and bottom section of the roof box being detail B shown in FIG.
4;
[0020] FIG. 6 illustrates a perspective view from above of the base
section of the roof box with the top section removed;
[0021] FIG. 7 illustrates a perspective view from below of the roof
box top section outer skin;
[0022] FIG. 8 illustrates a perspective view from below of the roof
box top section inner skin;
[0023] FIG. 9A illustrates a side elevation view of the assembled
roof box demonstrating the approximate position of a virtual hinge
line outside the box;
[0024] FIG. 9B illustrates a front view of the assembled roof box
demonstrating the approximate position of a virtual hinge line
outside the box;
[0025] FIG. 10 illustrates a detail side elevation of one
embodiment of seam illustrating the top and base sections of the
roof box as they approach each other on the side opposing the hinge
joint (point A as shown in FIG. 9);
[0026] FIG. 11 illustrates a detail side elevation of the top and
base sections of the roof box as they approach each other at points
B as shown in FIG. 9 along the virtual hinge line being distil ends
of the roof box;
[0027] FIG. 12 illustrates a detail side elevation of the top and
base sections of the roof box as they approach each other at point
C as shown in FIG. 9 along the virtual hinge line being the section
raised above the virtual hinge line;
[0028] FIG. 13 illustrates a perspective view of the roof box with
the top section opened revealing the hinges within the roof
box;
[0029] FIG. 14 illustrates a detail perspective view of a
simplified embodiment hinge being detail A shown in FIG. 13;
[0030] FIG. 15 illustrates a detail side elevation of the top and
base sections of the roof box in a closed configuration at the
hinge point using the simplified hinge of FIG. 14;
[0031] FIG. 16 illustrates a detail side elevation view of a hinge
with the hinge in a relaxed state;
[0032] FIG. 17 illustrates the hinge action when a pivoting force
is applied such as that which occurs when the roof box top section
is opened from the base section;
[0033] FIG. 18 illustrates the hinge action under a pivoting force
when moved to an extreme opening position; and
[0034] FIG. 19 illustrates the hinge action when a vertical force
is applied.
DETAILED DESCRIPTION
[0035] As noted above the invention broadly relates to a roof box
with flush seams that improves the styling of the box and improves
the box aerodynamics, reducing wind noise and fuel consumption
compared to existing roof box designs.
[0036] For the purposes of this specification, the term `roof box`
refers to structure with an enclosure typically fixed to the roof
of a vehicle such as a car used to convey luggage.
[0037] The term `semi-rigid to rigid` refers to the item having a
degree of hardness and in-flexibility in shape and configuration
that is not a totally deformable material such as a net or thin
sheet.
[0038] The term `flush` refers to the top section and base section
of the roof box when closed forming an approximately even or level
plane exterior surface about the joint between the two sections and
not having any pronounced off set at the joint.
[0039] The term `seam` or `join` or `joint` in the context of the
roof box described refers to the line about which the top section
and base section abut each other when the roof box is in a closed
configuration.
[0040] The term `virtual hinge line` refers to an imaginary axis
about which the hinge or hinges rotate.
[0041] In a first embodiment there is provided a roof box including
a semi-rigid to rigid base section mountable to the roof of a
vehicle and a semi-rigid to rigid top section movable relative to
the base section for opening and closing the roof box wherein the
exterior of the seam between the base section and top section is
approximately flush when in a closed configuration.
[0042] The seam between the top and base sections may vary in
height about a horizontal plane. In one embodiment, the front and
rear ends of the roof box when mounted to a vehicle have a seam at
a lower height relative to the seam height about the mid-section of
the roof box. It should be appreciated that a variety of
configurations may be possible and that the above configuration is
provided by way of example only.
[0043] The top section may be hinged from the base section via
hinges located along at least one longitudinal side of the roof box
linking the top and base sections. In one embodiment, the roof box
may include opposing hinges located on opposite sides of the walls
of the roof box allowing the box to be opened from either side.
[0044] The hinge or hinges used may be designed to account for
variations in seam height relative to a horizontal plane so that,
when the top section of the box is hinged closed relative to the
base section, the top section seam aligns with the base section
seam at all points around the length of the seam. In one
embodiment, the hinge or hinges used have a virtual hinge line
outside the roof box. As may be appreciated, designing a hinge to
account for a varied horizontal and/or vertical profile seam
requires the hinge to be more than just a single pivot point hinge.
Hinges in the art for roof boxes have tended to only have one pivot
point and as a result, roof boxes have straight walls and the seam
is across a horizontal plane. To vary the seam in the case of the
single pivot hinge would result in the top section not aligning
with the base section.
[0045] In one preferred embodiment, the hinge may be double acting.
More specifically, the hinge action may comprise four pivot points
that allow for variation in vertical movement of the top section
seam relative to the hinge axis.
[0046] One particular embodiment of hinge found useful by the
inventors is a sash hinge. The sash hinge may include: a mounting
connected to the base section; two link arms connecting the
mounting to a connecting arm; and a connecting arm that
communicates movement between the link arms and top section.
[0047] In one embodiment, the connecting arm of the hinge or hinges
may be fastened to the top section of the roof box and the mounting
of the hinge or hinges may be releasably retained within one or
more housing brackets fastened to the base section of the roof box.
In this embodiment, the hinge may move in and out of the housing
when the roof box top section is opened. This configuration is
useful in applications where hinges are located on either side of
the roof box as the top section may be opened from either side.
More specifically, when one side is opened, the hinge or hinges at
the closed side of the roof box remain fixed in the housing bracket
or brackets while the hinge or hinges on the opposing opening side
remain fixed to the top section and the connecting arm(s), link
arms and mounting lift out of the housing bracket as the top
section is opened. When the top section is closed, the mountings of
the hinge or hinges return back into the housing bracket or
brackets. The top section of the roof box may then be opened from
the opposing side reversing the above mechanics.
[0048] The hinge or hinges described above may include at least one
interlock to reduce vertical movement of the roof box top section.
The interlock may be designed to engage when the hinge is forced in
a predominantly upward/vertical direction as opposed to a pivoting
action when used in a normal hinge operating mode. The vertical
motion causes two interlocking catches to be forced together as the
hinge linkages move thereby preventing any further upwards motion.
When the upward force is removed, the hinge relaxes to a resting
position where the catch interlocks no longer engage. The hinge may
be forced to a relaxed position via a bias means such as a spring.
When the hinge is used in a normal opening action the pivoting
track (rather than vertical track) of the hinge avoids the
interlock being engaged and the roof box top section is free to
open.
[0049] The seam between the base and top sections may include two
mating angled facing edges concealed behind a lip protruding from
the top section over a portion of the exterior of the base section
when the roof box is in a closed position. In an alternative
embodiment, the seam may include an angled shoulder recess
protruding inwards from the base section edge that receives the
edge of the top section.
[0050] A resilient and deformable seal may be located between the
top and base sections. In one embodiment, the seal may be affixed
to the top section on the top section mating angled face edge. The
seal may extend around the length of the roof box seam. The seal
may be a hollow seal such as a D-cross section seal. Alternatively,
the seal may be a flat seal. In a further alternative, the seal may
be fixed to the base section and have a protruding hinged flap that
abuts the top section when the top is closed against the base
section. In all cases, the seal may be manufactured from a
resilient deformable material so that when the roof box is closed,
the seal may be partially deformed thereby forming a barrier to
moisture entry between the mating angled facing edges.
[0051] The angle of the mating facings may be approximately
30.degree. to 60.degree. relative to a horizontal plane. In one
embodiment, the angle may be approximately 45.degree..
Alternatively, the angle of the base section shoulder may be
approximately 30.degree. to 60.degree. relative to a horizontal
plane. In one embodiment, the angle may be approximately
45.degree.. This angle has been found to be helpful by the
inventors. If no angle variation is used and the two surfaces
simply abut each other, the seal if used, provides the primary
barrier to the environment and over time may wear or in extreme
conditions fail. An angled mating surface provides an additional
design barrier to egress of the environment (e.g. dust, rain, snow)
into the roof box cavity. In addition, as noted above, a lip
protrudes from the base section seam into the box cavity area.
Again, this design feature has been found to be useful to provide
an additional barrier to moisture and avoids having a sharp edge on
the base section edge.
[0052] The top section and/or base section may be double skinned
having an outer top skin and an inner top skin fastened together,
and, if used, an outer base skin and an inner base skin fastened
together. In the double skin embodiment, the skin layers may be
shaped to provide angled facing edges at the seam between the top
and base sections. A shoulder in the inner skin may form the top
facing edge. In one embodiment, only the top section is double
skinned while the base section may include either no double skinned
sections or instead limited areas of double skinning.
[0053] In one embodiment, the top inner skin and top outer skin may
project from the top section in the shape of a lip that extends at
least partially over base section seam and wherein the two skins
are fastened together at this lip. Alternatively, the two skins may
project as a single slim profile edge. The two skins may be
fastened together via a non- mechanical fastener such as a bonding
glue. In an alternative embodiment, the base section may project
inwards and upwards relative to the base of the roof box thereby
forming a recessed edge on which the top section may be received.
In this embodiment, the recessed edge portion may further include
an internal shoulder to help provide a further barrier to egress of
materials from the exterior to the interior of the roof box and to
give the roof box base section an smooth surface at the seam
point.
[0054] Optionally, the entire top section may be removed altogether
from the base section and the base section used to convey goods
absent of the top section. An example of where this may be useful
is in the transport of unusual shaped items. The base section
interior still retains the item yet the item may protrude beyond
the height limitations of the roof box top section. Goods conveyed
in this manner may be retained within the base section via a cargo
net, straps or other retaining device.
[0055] In a second embodiment there is provided a roof box
including a semi-rigid to rigid base section mountable to the roof
of a vehicle and a semi-rigid to rigid top section movable relative
to the base section for opening and closing the roof box wherein
the roof box top section is lifted from the base section about at
least one hinge wherein the virtual hinge line is located outside
the roof box.
[0056] In a third embodiment there is provided a roof box including
a semi-rigid to rigid base section mountable to the roof of a
vehicle and a semi-rigid to rigid top section movable relative to
the base section for opening and closing the roof box and further
including at least one double acting hinge linking the top and base
sections.
[0057] Additional features described in reference to the first
embodiment may also apply to the above second and third embodiments
as described above.
[0058] Advantages of the above design should be apparent including
improved aesthetics by having a flush roof box exterior. This flush
finish is also advantageous is it reduces aerodynamic drag compared
to other external seam designs thereby improving fuel efficiency
due to the more aerodynamic profile able to be achieved along with
reduced wind noise.
[0059] A further advantage of the design, particularly relating to
the double skin configuration may be that it reduces the overall
weight of the roof box compared to a fully moulded top and base
section, whilst still retaining the desired load ratings and
rigidity necessary to be functional as a roof box. For example,
designed ratings are for the roof box to hold up to 75 kg in weight
and retain the box contents in a sudden loading event such as a
vehicle crash.
[0060] Yet another advantage of the design is that the seam needn't
be along a horizontal plane as in prior art designs. Instead the
seam may be of a varying level relative to a horizontal plane and
the design of the box including the seam shape, the seal, the lip
and the hinge design all make it possible to use a wide variety of
styling options. In particular, the hinge design was important to
achieve correct alignment between the base and top sections. A
hinge with a virtual hinge line outside the roof box that could
deal with variations in movement in a vertical and horizontal plane
meant that a snug alignment could be achieved. Hinges in the art
such as spring pistons, single pivot point hinges and so on cannot
account for variations along a hinge line in a vertical and
horizontal direction and hence limit roof box designs to a purely
horizontal plane seam and with straight walled sections at the
hinge points.
[0061] Finally, the roof box is useful in that it protects the
items stored inside from exposure to adverse weather and
environmental conditions as well as provides robust protection
against theft and vandalism.
WORKING EXAMPLE
[0062] The invention is now described with reference to a detailed
description of an embodiment of the roof box of the present
invention.
[0063] Referring to FIG. 1, the roof box, generally indicated by
arrow 1, when closed has a styled, aesthetically appealing shape.
The shape also minimises drag. The roof box 1 includes a top
section 2 and a base section 3 fitted to roof rack cross bars 100.
The box 1 has a seam 4 between the top 2 and base 3 sections. The
top 2 and base 3 sections are all that is seen when the box 1 is
closed, termed for the purposes of this specification as being a
`flush seam` 4. The seal interior and associated top 2 and bottom 3
section joints are not visible from the exterior of the roof box 1
when the box is in a closed configuration as shown in FIG. 1. FIG.
2 shows an open configuration where the internal details of the
seam 4 are visible along with any struts 200 that may be used. In
the embodiment illustrated, the seam 4 has a styled sloping shape
to match the roof box 1 shape with the seam 4 being at its highest
point around the central section of the box 1 and lowered regions
around the distil ends of the roof box 1 when fitted to a vehicle.
It should be appreciated that the seam 4 shape and/or profile may
be varied to suit a variety of roof box 1 designs without departing
from the scope of the invention.
[0064] FIG. 3 illustrates a side view of the closed roof box 1 and
section line AA, section AA detail view being shown in FIG. 4. As
shown in FIG. 4 the roof box 1 utilises double skinning in the top
section 2 to achieve the desired degree of rigidity required to
meet load requirements while the base section 3 includes ribbed
portions 3B to provide rigidity. The hinges 12 are shown in FIG. 4
as well, being two hinges 12 on either longitudinal side of the
roof box 1. As shown in detail view FIG. 5 of detail B from FIG. 4,
the top section 2 includes an outer skin 2A and an inner skin 2B.
The base section 3 may have strengthening sections such as double
skinning as well although the embodiment shown in FIG. 5 does not
include double skinning. The top section 2 at the seam 4 includes
the outer skin 2A and inner skin 2B. The inner skin 2B has a
shoulder forming a top section seam facing edge 3A. In the
embodiment shown, the top section 2 inner skin 2B and outer skin 2A
mate together to form an edge that abuts the recessed shoulder
portion 3A at the opposing base section edge. The base section 3
shoulder has a base section seam facing edge 3A. The seam 4 may
include a seal (shown in FIG. 5 as a flap seal 4X) between the
internal edges of the roof box 1 top section 2 and base section 3.
Seals may vary in cross section such as a hollow seal with a
D-shaped cross section, round cross section seals and more complex
shapes such as those with hinging joints or flaps. The seal if used
may be adhered to the top section interior or the base section
interior using, for example a chemical adhesive. The seal if used
may run along the entire length of the seam 4 between the top 2 and
base 3 sections. Variations may include use of a flat seal instead
of a hollow seal, the key design constraint being that the seal
impinges on both the top and base section seam edges sufficient to
form a barrier to prevent egress of dust, rain, dirt an the like
from the environment into the roof box 1. Finally, the shoulder of
the base section 3A is ideally inclined at an upwards angle
relative to the base section floor, in FIG. 5 shown as an
approximately 45.degree. angle to the floor of the roof box 1 base
section 3. An angled shoulder from the base section 3 may be useful
to ensure a snug closure, to provide an added degree of seal 4X
protection and to ensure that the flush seam 4 looks aesthetically
appealing from the exterior of the roof box 1. The angle also
ensures that the seal 4X is less critical as it is not open to the
environment but instead nested within the interior portion of seal
4.
[0065] FIG. 6 further illustrates one embodiment of the base
section 3 of the roof box 1 including internal details such as the
internal ribbed mouldings 3B that may be used to strengthen the
interior. The recessed shoulder 3A is also shown in more detail. Of
note is that there are few obstructions inside the box on which to
catch items stored in the box 1.
[0066] FIGS. 7 and 8 illustrate the top section 2 external skin 2A
(the outer skin) and internal skin 2B (the inner skin) in greater
detail. Inner skin 2B forms multiple transverse ribs 5A and 5B at
which inner skin 2B is spaced from outer skin 2A. A cavity 5C is
formed in top section 2 between outer skin 2A and inner skin 2B.
Each of transverse ribs 5A and 5B adjoins cavity 5C. The transverse
ribs each extend from a position near the left side of the roof box
to a position near the right side of the roof box.
[0067] A key design difficulty in achieving the flush seam 4
exterior of the current invention roof box 1 is ensuring that the
top 2 and base 3 sections seams align correctly when the roof box 1
is closed i.e. when the top section 2 is brought into contact with
the base section 3. The curved styling of the box 1 and seam 4
means that the top section 2 will approach the base section 3 seam
4 at differing angles dependent on the seam 4 locations relative to
a hinge point. Referring to FIG. 9, a side elevation view and front
view of the roof box 1 in a closed configuration is shown. A line
11 is drawn along the length of the roof box 1 in the side
elevation view FIG. 9A illustrating the approximate virtual hinge
line 11. The approximate corresponding virtual hinge point is shown
as a cross in the front view shown in FIG. 9B. As can be seen, the
seam 4 may vary in orientation above or below the virtual hinge
line 11 along the length of the roof box 1.
[0068] Detail views illustrated in FIGS. 10 to 12 demonstrate the
different angles of approach needing to be designed for. Note that
FIGS. 10 to 12 illustrate a different approach to design of the
seam 4 between the top 2 and base 3 sections provided to illustrate
different ways that the seam 4 may be achieved. This view and the
previous seam 4 detail view should not be seen as limiting.
[0069] More specifically, FIG. 10 illustrates the angle of approach
between the top 2 and base 3 sections at points along the seam 4
opposing the hinge side. As demonstrated, the two sections 2,3
merge in a vertical orientation as would be expected given the
proximity of this portion of the seam 4 relative to the hinge
side.
[0070] By contrast, FIG. 11 illustrates the way the top 2 and base
3 sections approach each other at point B along the virtual hinge
line 11. Point B is on the hinge side of the roof box 1 and as
shown in FIGS. 9A and 9B, the seam 4 at point B is below the
virtual hinge line 11. The resulting approach angle between the two
sections 2,3 is approximately an off centre approach with the top
section 2 approaching the base section 3 at a variety of acute
angles including that shown in FIG. 11 being an approximately
45.degree. angle relative to a vertical axis.
[0071] Finally, FIG. 12 illustrates the way the top 2 and base 3
sections approach each other when the box 1 is closed at point C
along the virtual hinge line 11. Point C as shown in FIG. 9
corresponds to a point where the seam 4 rises above the virtual
hinge line 11. In this case, and as shown in FIG. 12, the top 2 and
base 3 sections approach each other in a horizontal direction. Note
that in FIGS. 10 to 12, the seal 8 is illustrated as having a
hollow D-shape cross-section but it should be appreciated that a
variety of other configuration may also be used without departing
from the scope of the invention.
[0072] As should be appreciated, designing a hinge system to cater
for an aerodynamic design of this nature including a seam 4 with a
varied profile results in considerable design difficulties as
illustrated in FIGS. 10 to 12.
[0073] FIG. 10 shows further aspects of top section 2. The top
section has a main portion 11A and lip 11B extending downward from
main portion 11A. Main portion 11A and lip 11B collectively form an
outer surface 11C of the top section.
[0074] FIG. 10 also shows further aspects of base section 3. The
base section has a main portion 11D and a rim 11E projecting upward
from main portion 11D. Base section 3 bends inward, toward an
interior of the roof box, at a junction 11F between main portion
11D and rim 11E. The base section has an outer surface 11G
including a main outer surface region 11H and a perimeter edge
surface region 11I extending from main outer surface region 11H.
Perimeter edge surface region 11I bends inward from main outer
surface region 11H to form an inward offset (i.e., with an offset
toward the interior of the roof box), and extends upward and inward
from main outer surface region 11H and junction 11F.
[0075] As illustrated in FIGS. 13 to 17, a hinge 12 is also central
to the roof box 1 design. Sash hinges 12 have a double acting
action. In the embodiment illustrated in FIG. 13, a total of four
sash hinges 12 are placed within the roof box 1 with two hinges 12
orientated on opposing sides of the roof box 1. The embodiment of
FIG. 13 is designed to open from either side hence there are two
sets of opposing hinges 12 in the roof box 1. The hinges 12 are
mounted within the base section 3 of the roof box 1. The hinges may
be received into receiving portions attached to the base section
that house the hinges 12.
[0076] A highly simplified hinge design is shown in FIGS. 14 and 15
to illustrate the action of the hinge 12 in more detail. As shown
in the detail view of FIG. 14, the hinge 12 includes a mounting
bracket 13, two link arms 14A and 14B and a connecting arm 15 that
links the top section 2 to the base section 3. The linkages between
the arms are mechanical fasteners. When the top section 2 is
opened, the hinge 12 pivots about the link arm 14A,14B pivot points
retaining the top section 2 in an orientation relative to the base
section 3 that ensures the top 2 and bottom 3 sections align about
the seam 4 when closed again. FIG. 15 further illustrates the hinge
12 assembly in a closed position. The seal 8 is compressed in the
closed position as shown in FIG. 15. The virtual hinge line 11 is
also shown in FIG. 15 being outside the roof box 1.
[0077] Dual sided opening is achieved by the connecting arm 15 of
the hinge 12 or hinges 12 being fastened to the top section 2 of
the roof box 1 and the mounting 13 of the hinge or hinges 12 being
releasably retained within one or more housing brackets (not shown
in FIGS. 14 and 15) fastened to the base section 3 of the roof box
1. In this embodiment, the hinge 12 moves in and out of the housing
when the roof box 1 top section 2 is opened. This configuration is
useful in applications where hinges 12 are located on either side
of the roof box 1 as the top section 2 may be opened from either
side. More specifically, when one side is opened, the hinge 12 or
hinges 12 at the closed side of the roof box 1 remain fixed in the
housing bracket or brackets (not shown in FIGS. 14 and 15) while
the hinge or hinges 12 on the opposing opening side remain fixed to
the top section 2 and the connecting arm(s) 15, link arms 14A,14B
and mounting 13 lift out of the housing bracket as the top section
2 is opened. When the top section 2 is closed, the mounting(s) 13
of the hinge or hinges 12 return back into the housing bracket or
brackets. The top section 2 of the roof box 1 may then be opened
from the opposing side reversing the above mechanics.
[0078] The hinge may also include an interlock mechanism to prevent
vertical movement of the top section 2 of the roof box 1 from the
base section 3. FIGS. 16 to 19 illustrate one embodiment of a hinge
interlock system. FIG. 16 illustrates the hinge 12 in a relaxed
position. The hinge 12 includes a mounting bracket 50 that attaches
to the base section 3 e.g. via insertion into a receiving mount
(not shown), an arm 51 that attaches to the top section 2 (not
shown), link arms 52 and 53 and pins 52a, 52b, 53a and 53b.
[0079] When a pivoting force marked as F1 in FIG. 17 is applied to
the arm 51, a moment (marked as M in FIG. 17) is created around pin
52B in an anti-clockwise direction. This results in force F2
pushing pin 53B to the outer face of the slot in part 53. This
action pulls the two catch surfaces apart (shown in the detail
close up section) to avoid contact, allowing the hinge to operate
unrestricted moving to full extension as shown in FIG. 18.
[0080] FIG. 19 illustrates the action when a vertical force F1 is
applied. As force F1 is applied to the arm 51, a moment M is
created around pin 52B marked as M in FIG. 19 in a clockwise
direction. This results in force F2 pushing pin 53B to the inner
face of the slot in the link arm 53. This action pulls the two
catch surfaces (shown in the detail close up section) toward each
other that engage when the surfaces meet. The hinge 12 cannot
open.
[0081] The difference between the application of a pivoting force
and a vertical force is due to the movement of pin 53A in the slot
of part 53. When a pivoting force F1 is applied to the hinge 12,
the pin 53A is pressed against the outer face of the slot, holding
the catch surfaces apart. When a vertical force F1 is applied to
the hinge 12, the pin 53A is pressed against the inner face of the
slot, engaging the catches.
[0082] FIG. 15 shows the roof box in a closed configuration and
having a flush exterior seam. Lip 11B and outer surface 11C of top
section 2 overlap rim 11E and perimeter edge surface region 11I of
base section 3 to form the exterior seam. Also, lip 11B of top
section 2 points to junction 11F. Outer surface 11C of top section
2 and main outer surface region 11H of base section 3 each extend
to the same exterior seam and are substantially flush with one
another adjacent the exterior seam. The roof box has a general
exterior shape and transitions from outer surface 11C of the top
section to main outer surface region 11H of the base section
without protruding from the general exterior shape.
[0083] Optionally, the entire top section 2 may be removed
altogether from the base section 3 and the base section 3 only used
to convey goods. An example of where this may be useful is in the
transport of unusual shaped items. The base section 3 interior
still retains the item yet the item may protrude beyond the height
limitations of the roof box 1 top section 2.
[0084] Advantages of the invention roof box 1 should be apparent
including the removal of external seams by use of flush seams 4 and
the resulting improvement in aesthetics and drag resistance
resulting from the altered design. The flush seam 4 design also
includes design refinements to allow ensure a snug seal 8 results
along the seam 4 between the top 2 and base 3 sections of the roof
box 1, achieved in part due to use of a hinge 12 design not
currently used in roof boxes and modified from the art to suit the
roof box 1 application. Finally, as the roof box 1 of the present
invention includes use of double skinning, the box 1 can easily
withstand the loadings required under normal roof box 1 operation;
has a rigidity the same or better than existing art designs; and
does not have the weight that a single moulded equivalent box would
have.
[0085] Aspects of the present invention have been described by way
of example only and it should be appreciated that modifications and
additions may be made thereto without departing from the scope of
the claims herein.
* * * * *