The present invention relates to an improved roof bar and connection system for connecting accessories to the roof bar.

Roof bars are known. Roof bars are generally elongate and extend across a vehicle. The roof bars are attached to the vehicle at screw or bolt fixings or via rails attached to the vehicle. One known roof bar uses a T-track in the top surface of the roof bar for receiving the head of a bolt. Accessories are clamped to the roof bar using the bolt and T-track. The T- track is generally filled with a weatherproof strip.

It is known to design the roof bar for aerodynamic considerations such as to reduce drag and noise. However, improvements are always sought to further reduce these factors. Furthermore, ease of installing the accessories is also an important factor.

It is an aim of the present invention to attempt to overcome at least one of the above or other disadvantages. It is a further aim to provide a roof bar having improved performance characteristics. It is a further aim to provide a connection system providing an easy installation to the roof bar.

According to the present invention there is provided a roof bar, roof bar accessory and method of attaching a roof bar accessory to a roof bar as set forth in the appended claims. Other features of the invention will be apparent from the dependent claims, and the description which follows.

According to the exemplary embodiments, there is provided a roof bar having a generally tear-drop shaped cross-section, wherein a rear side of the bar is cut-off short of tapering to a point and such that the width of the bar is less at a mid-point of the cross section than at spaced positions on either side. Consequently, the roof bar has a depression on the rear facing surface. Advantageously, the depression can be used to improve the attachment of accessories. Typically the roof bar has a generally constant cross-section. Suitably, the roof bar is extruded. In the exemplary embodiment end caps are provided as is known in the art.

According to exemplary embodiments, accessories, including feet for attaching the roof bar to the vehicle, are connected to the roof bar. In the exemplary embodiments, the accessories are assembled using a saddle arranged to substantially envelope the outer periphery of the roof bar. A tension means is provided to apply a compressive force across two portions of the saddle so as to clamp the saddle to the roof bar. Advantageously, the saddle includes a protrusion that is received by the depression in the rear of the roof bar. Engagement of the protrusion and depression resist movement, for instance, rotation of the accessories about the bar, by keying together.

The tension means applies a compressive force between two portions of the saddle. The tension means may be provided by the natural resilience of the saddle, however, preferably, the tension means is a component spanning the two portions. Suitably, the tension component is a pin or other elongate structure operating in combination with another part that can be secured to the tension component at different extents to apply the compressive force. One of the parts could be integrally moulded to or with the saddle. In the exemplary embodiments, the tension component is shown as a nut and bolt. To improve the assembly of the tension component, the nut or bolt is captured integrally in the formation of the saddle.

The tension means may apply the compressive force transverse the front to back direction or parallel to it. In the embodiments where the tension means applies the compressive force transverse the front to back direction, the tension means is arranged across the front face of the roof bar. Here, the saddle wraps around the roof bar and the tension means acts to pull two portions of the saddle spaced in a top to bottom direction. In the embodiments where the tension means applies the compressive force parallel to the front to back direction, the tension means is arranged to extend in the front to back direction. Here, the saddle wraps around the roof bar and the tension means acts to pull two portions of the saddle spaced in a front to back direction.

In the exemplary embodiments, the saddle forms an open mouth. The open mouth accepts the roof bar. Here, the tension means is arranged to compress the open mouth around the roof bar. Suitably the saddle has a degree of flexibility to allow the open mouth to compress. Advantageously, by compressing the open mouth, the depression is brought into tighter contact with the roof bar improving the keying affect. In one exemplary embodiment, the saddle includes a hinge to open the mouth. The hinge allows the mouth to be opened widely. Thus the open mouth can fit easily around the roof bar. Furthermore, the hinge can be fitted from underneath. In the exemplary embodiments including the hinge, the tension mea ns acts to close the hinge, typically from a closed position wherein the accessory fits the roof bar closely to a tensioned position, wherein the saddle is tightened around the roof bar.

In some of the exemplary embodiments, the saddle is a single part with a main body of the accessory. Here the saddle may be integral with the main body or may be a separate part fixed securely to the main body. In an alternative embodiment, the saddle may be detachable from the main body. Here the saddle has an open mouth that fits around the roof bar and connects to the main body. The tension means is arranged within the main body and to close the open mouth. Consequently, the tension means acts to pull the saddle towards the main body.

In the exemplary embodiments, the accessories may be any known accessory that requires attaching to the roof bar, for instance, load stops, fixing feet, or pipe tubes. In one exemplary embodiment, the accessory is a rear roller system. Rear roller systems provide a transverse roller at the rear of a vehicle for use when loading and unloading elongate articles from the roof bar, for instance ladders. The rear roller system includes first and second arms that extend rearwardly from the roof bar. A roller is attached to the distal ends of the arms and extends between the arms in a width direction. The arms are attached to the roof bar by brackets. It will be appreciated that the brackets may include the depression of the previous embodiments. However, for systems that do not employ the improved roof bar described herein, the bracket may be a known bracket. That is the arms may be attached to the roof bar in any known manner. Advantageously, rather than the arms being a single piece as is known in the art, in the exemplary embodiment, each arm is formed from first and second arm pieces. Here the first and second arm pieces are telescopically arranged. Although multiple arm pieces may be telescopically arranged, the exemplary embodiments show first and second pieces that can be locked together to move the roller position relative to the roof bar. Advantageously, this allows the roller to be used on vertical lift boot doors. That is, because the roller needs to overhang the rear of the vehicle, the telescopic nature of the arms, allows the roller to be stowed in a position not overhanging the rear of the vehicle allowing the boot to be opened, whist being able to be deployed when needed.

Suitably, a supporting foot may be arranged on the arms as is known in the art. Furthermore, the arms may be arranged to be positioned beneath, or above, the roof bar thereby allowing the arms to extend past the bracket.

Advantageously, the improved roof bar and roof bar accessory allows better connection between the roof-bar and roof-bar accessory.

For a better understanding of the invention, and to show how embodiments of the same may be carried into effect, reference will now be made, by way of example, to the accompanying diagrammatic drawings in which:

Figure 1 is a side view of a roof bar system according to an exemplary embodiment; Figure 2 is a side view of a roof bar system according to a second exemplary embodiment;

Figure 3 is a schematic view of a roof bar according to the exemplary embodiments;

Figure 4 is a schematic view of a roof bar accessory according to an exemplary embodiment;

Figure 5 is a schematic view of a roof bar system according to a further embodiment; and

Figure 6 is a schematic view of an attachment bracket of a further embodiment.

Referring to Figure 1 there is shown a roof bar system 100. The roof bar system comprises a roof bar 1 10 and an accessory 120 that is attached to the roof bar 1 10. The roof bar includes a depression 1 12 at a rear of the roof bar 1 10. Here the rear of the roof bar is relative to the orientation at which the roof bar is intended to be installed on a vehicle. A protrusion 122 on the roof bar accessory 120 is arranged to engage the depression and to key thereto in order to improve the connection of the roof bar accessory to the roof bar. The roof bar accessory includes a tension means 124, shown suitably as a nut and bolt. The tension means is arranged to act on the roof bar accessory to move two spaced parts of the roof bar accessory closer to each other in order to clamp the roof bar accessory to the roof bar.

In the exemplary embodiments, the roof bar accessory includes a saddle 130. The saddle 130 is shown as being the same part as a main body 140 of the roof bar accessory in Figures 1 and 2. Here, the saddle 130 has been fastened to the main body 140 by a bolt or other suitable fastening means. However, as shown in Figure 4, the saddle may be integral with the main body or the saddle may be a separate part to the main body, see figure 6. In the exemplary embodiments, the saddle carries the protrusion 122. The saddle encloses a substantial part of the roof bar. The part of the saddle enclosing the roof bar is shaped so as to substantially correspond to the size of the roof bar. The saddle is shaped so as to provide an open mouth for receiving the roof bar. The tensioning means 124 is arranged across the open mouth. The tensioning means acts on a first part on one side of the open mouth and another part on an opposite side of the mouth. In use, the tensioning means acts to urge the two parts towards each other. This force acts to clamp the saddle around the roof bar. In doing so, the saddle is caused to deform about the roof bar. Furthermore, the deformation acts to pull the protrusion into tighter engagement with the recess. The tensioning means is shown if Figure 1 a s a nut and bolt. It will be appreciated that one or both of the nut or bolt may be encapsulated in the saddle. If both are encapsulated, it will be appreciated that at least one of the nut or bolt needs to maintain an ability to rotate relative to the other. Although a nut and bolt arrangement is shown, other arrangements of the tensioning means are envisaged such as a ratchet, or over centre toggle. The tensioning means may be arranged substantially parallel to the front to back direction, see figure 1 , or substantially parallel to the vertical direction as shown in Figure 2. In Figure 2, a roof bar system 200 is shown. The roof bar system is substantially the same as that of Figure 1 except for the orientation of the tensioning means and mouth. That is, the roof bar system of Figure 2 includes a roof bar 210 having a recess 212 and a roof bar accessory 220 having a protrusion 222 that clamps to the roof bar. A tensioning means 224 acts to urge two sides of an open mouth 232 together to tension the roof bar accessory to the roof bar and to key the protrusion into tight engagement with the recess. The roof bar accessory has a saddle 230 attached to a main body 240 of the roof bar accessory.

Advantageously, engagement of the recess and protrusion acts to improve the clamping of the roof bar accessory to the roof bar.

Figure 3 shows an exemplary roof bar 1 10. The roof bar is elongate having a substantially constant cross-section. Suitably the roof bar is extruded as a hollow structure to reduce weight. The walls of the roof bar are suitably substantially constant, however, extruding considerations and strength calculations determine the exact size of the walls. For instance, cross braces are shown in Figure 3 to provide the required strength. The roof bar 1 10 has an outer cross section shaped in consideration of noise and wind resistance. The cross section is generally tear-drop shaped. Here, the cross section has a front and back as configured to be arranged on a vehicle, where the front is generally the front facing the main direction of travel. The front face 1 14 of the roof bar is substantially arcuate. The front face extends between a lower face 1 16 and an upper face 1 15. The lower and upper faces are substantially parallel to a front to back direction. The upper and lower faces are shown having a plurality of parallel grooves, which may improve the grip between the saddle and roof bar. Trailing sections 1 17, 1 18 of the upper and lower faces are arranged to generally converge to a point. Thus a generally tear drop cross section is provided having good laminar flow. However, instead of tapering to a point, the trailing surfaces 1 17, 1 18 are cut short. Thus the cross-section has a rear face. In addition, the rear face forms the depression. That is a part of the rear face is arranged between the trailing faces. Consequently, when a protrusion is arranged in the depression, the protrusion must move backwards in order to clear an upper or lower corner formed between the rear surface and respective trailing edges. Figure 4 shows a roof bar accessory according to an exemplary embodiment. The roof bar accessory 320 is a load stop arranged on the roof bar to resist sideways movement of articles being carried on the roof bar. The roof bar accessory comprises an integral saddle and main part. The main part forms a generally elongate and upright attachment to the roof bar. The saddle 330 includes the protrusion 322 and forms an aperture that fits about a roof bar. The roof bar accessory is split in two and includes a hinge 334 that allows the roof bar accessory to open. The mouth is therefore formed between a split running through the main part 340. The hinge therefore allows the main pat to separate in two, opening up to receive the roof bar. A tensioning means is provided to act to squeeze the two parts together and thus acts to clamp the saddle to the roof bar, as is herein disclosed.

The hinge is formed in any suitable manner but is shown as a pinned hinge allowing the two parts to act as a clam shell opening and closing about the roof bar. The two parts may have guiding means to guide the closing, for instance ridges and sockets that fit together to prevent twisting or misalignment. A tensioning means 324 is provided. The tensioning means is encapsulated in the body of the roof bar accessory. The tensioning means is shown as a bolt having convenient wing grips that cooperates with an encapsulated bolt on the opposed part of the main body. Referring to Figure 5, a further exemplary roof bar accessory 400 is provided. The roof bar accessory 400 is a rear roller system, which provides a sideways extending roller at a rear of a vehicle to assist with the loading / unloading or articles form the roof bar. The rear roller system therefore comprises an accessory 420 comprising a pair of arms 451 , 452 extending rearwardly from a bracket affixing the arms to the roof bar. It will be appreciated that the bracket affixing the rear roller to the roof bar may be as herein described , for instance a saddle clamping to the roof bar with a keyed depression and protrusion. However, where the system is to affix to standard roof bars, other known fixing systems may be used.

The pair of arms 451 , 452 extend rearwardly and distal ends of which house a rear roller 454. The rear roller 454 extends widthways across the vehicle and is arranged to roll about a central axis as is known. For instance, the rear roller may rotate about stub axis on the arms or a sleeve of the rear roller may rotate relative to a fixed central core. Importantly, the pair of arms 451 , 452 are extendible. Suitably, they are shown as being telescopic. Here, a first part is extendible from the second part foxed to the roof bar. Consequently, the rear roller 454 may be stowed in a position and in use extended to protrude the rear of a vehicle or to accommodate different distances between roof bars and the rear of different vehicles.

The telescopic first and second sections are fixed in use relative to each other. Any suitable fixing method may be employed, for instance grub screws or pins that selectively engaging a plurality of holes. As shown in Figure 5, although the pair of arms may be attached in the same plane as the roof bar, the arms are shown in Figure 5 as being arranged under the roof bar. This increases the degree of movement and allows the rear roller to be stowed closer to the roof bar for the same extension compared to if the pair of arms were arranged in the same plane.

Figure 6 shows a further exemplary embodiment of a roof bar accessory 520. Here the saddle 530 is separate to the main body 540 of the roof bar accessory. Furthermore, the main body carries the protrusion 522. The saddle 530 includes a hinge 534 that allows the saddle to open around the roof bar. Again, the hinge is optional dependent on the material of the hinge and size of the corresponding mouth / bar and the hinge may be formed in any known way. Suitably, as shown the hinge 534 is a pinned clam shell allowing the two parts to rotate about the pin. When assembled to the roof bar, the saddle substantially encloses the roof bar, wrapping from the front to back. The main part 540 of the roof bar accessory includes the protrusion arranged to fit into the depression. Furthermore, the main part 540 includes apertures for receiving the saddle. The apertures are arranged either side of the protrusion. The saddle extends into the main part 540 where a tension means is provided to act on either side of the saddle's mouth and to tighten the saddle to the bar by bringing the two sides towards each other. The saddle also acts on the rear of the protrusion. Here tightening the saddle acts to push the protrusion into the depression. Referring to Figure 6, the tensioning means such as a bolt cooperating with a thread on one side of the saddle is inserted through hole 546