RESILIENT INFILL

• US 20100308091A1
• Filed: 09/15/2008
• Published: 12/09/2010
• Est. Priority Date: 09/21/2007
• Status: Active Grant

• Current Assignee: Yakima Products Incorporated (Kemflo International Co., Ltd.)
• Original Assignee: Hubco Automotive Limited
• Inventors: Hubbard, Peter Douglas
• Granted Patent: US 8,544,707 B2
• Time in Patent Office: Days
• US Class Current: 224/316
• CPC Class Codes: B60R 9/04 Carriers associated with vehicle roof B60R9/08 takes precedence
• CPC Class Codes: B60R 9/05 Carriers characterised by wind deflecting means wind deflectors for open roofs B60J7/22

Abstract

The invention relates to a resilient infill for positioning in a channel in a crossbar of a roof rack or load carrier. The infill comprises a flexible upper portion and a base comprising a bottom. A pair of flexible, opposing side walls extend from the bottom and curve upwardly and outwardly to meet with outer edges of the flexible upper portion. The width of the upper portion is greater than the width of the bottom and the infill has a substantially hollow interior. The infill is compressible and makes minimal wind noise when positioned in the crossbar of a roof rack located on a moving vehicle.

Claims

1. A resilient infill and roof rack crossbar channel system, wherein the crossbar channel comprises a longitudinal opening defined by opposing lips having tapered inner surfaces, and the infill comprises:

a flexible upper portion; and

a base comprising a bottom and a pair of flexible, opposing side walls extending from the bottom and curving upwardly and outwardly to meet with outer edges of the flexible upper portion;

wherein the upper portion has a width greater than the width of the bottom and the upper portion comprises an upper surface, at least a portion of which is shaped to correspond with the tapered inner surfaces of the opposing lips of the crossbar channel;

and wherein the infill has a substantially hollow interior.

2. The resilient infill and roof rack crossbar channel system according to claim 1, wherein the curved outer walls have an apex that is higher than the outer edges of said upper portion.

3. The resilient infill and roof rack crossbar channel system according to claim 1, wherein the infill is made from an extrusion of either rubber or plastic.

4. A crossbar for a vehicle roof rack or load carrier, comprising a resilient infill and roof rack crossbar channel system, wherein the crossbar channel comprises a longitudinal opening defined by opposing lips having tapered inner surfaces, and the infill comprises:

a flexible upper portion; and

a base comprising a bottom and a pair of flexible, opposing side walls extending from the bottom and curving upwardly and outwardly to meet with outer edges of the flexible upper portion;

wherein the upper portion has a width greater than the width of the bottom and the upper portion comprises an upper surface, at least a portion of which is shaped to correspond with the tapered inner surfaces of the opposing lips of the crossbar channel;

and wherein the infill has a substantially hollow interior.

5. The crossbar according to claim 4, wherein the crossbar has an aerodynamic cross-sectional shape.

6. The crossbar according to claim 5, wherein the resilient infill is positioned within the channel, the upper surface of the infill corresponding with and contacting the tapered inner surfaces of the opposing lips.

7. The crossbar according to claim 6, wherein the upper surface of the upper portion includes an at least partially exposed substantially flat region and wherein the substantially flat region of the infill is substantially flush with the upper surface of the crossbar.

8. The crossbar according to claim 5, wherein the opposing lips each have a curved edge with a tight radius of curvature, and wherein the infill touches the lips at or near the curved edges of the lips such that the upper surface of the crossbar and upper surface of the resilient infill are substantially flush with each other.

9. A roof rack comprising a resilient infill and roof rack crossbar system, wherein the crossbar channel comprises a longitudinal opening defined by opposing lips having tapered inner surfaces, and the infill comprises:

a flexible upper portion; and

a base comprising a bottom and a pair of flexible, opposing side walls extending from the bottom and curving upwardly and outwardly to meet with outer edges of the flexible upper portion;

wherein the upper portion has a width greater than the width of the bottom and the upper portion comprises an upper surface, at least a portion of which is shaped to correspond with the tapered inner surfaces of the opposing lips of the crossbar channel;

and wherein the infill has a substantially hollow interior.