NL2022930B1 - Roof box system, motor vehicle with roof box system and method for roof box manufacturing and assembly - Google Patents
Roof box system, motor vehicle with roof box system and method for roof box manufacturing and assembly Download PDFInfo
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- NL2022930B1 NL2022930B1 NL2022930A NL2022930A NL2022930B1 NL 2022930 B1 NL2022930 B1 NL 2022930B1 NL 2022930 A NL2022930 A NL 2022930A NL 2022930 A NL2022930 A NL 2022930A NL 2022930 B1 NL2022930 B1 NL 2022930B1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R9/00—Supplementary fittings on vehicle exterior for carrying loads, e.g. luggage, sports gear or the like
- B60R9/04—Carriers associated with vehicle roof
- B60R9/055—Enclosure-type carriers, e.g. containers, boxes
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Abstract
The invention concerns a watertight and foldable roof box system, the system comprising a single watertight panel substantially rectangular in shape, a pattern of 5 folds is positioned in said panel and said folds are formed such that said panel can be folded from a substantially flat into a three dimensional shape comprising a useful interior space, characterized in that said single watertight panel substantially rectangular in shape is made from a material having a high bending stiffness and high yield strength and said pattern of folds is selected to provide after it has been 10 folded said interior space provided for arranging or storing of objects on the roof of a motor vehicle. The invention also concerns a method for manufacturing and for assembly of a roof box according to an embodiment of the invention.
Description
TECHNICAL FIELD The invention relates to a foldable and watertight roof box system, to a motor vehicle equipped with such a roof box system, to a method for manufacturing such a roof box system and to a method for assembly of the roof box system. The invention is situated in the domain of storage compartments, in particular storage compartments for luggage. The invention is important for the transportation, travel and leisure industry.
BACKGROUND Roof boxes are well-known in the art. Roof boxes are generally mounted on the roof of a motor vehicle, generally on a roof rack or on roof rails. Two types can roughly be distinguished: hard shell roof boxes with hinges and roof boxes made of fabrics mounted on a frame. Hard shell roof boxes have the disadvantage that they are voluminous and difficult to handle. Those boxes have a fixed volume which cannot be changed. Transport costs for B2B and B2C are considerable. The storage of hard shell roof boxes requires a significant amount of space. This is a disadvantage when no suitable garage or storage area is available. The use of hinges or brackets to connect individual rigid and non-flexible parts of a roof box, is disadvantageous as additional parts need to be mounted on or attached to the hard shell material. This increases the work needed to assemble the roof box, and increases costs. The hinges provide parts that are not watertight. As hinges are often made of metals, they are sensitive to oxidation and rust. Flexible type roof boxes made of fabrics have the disadvantage that they are sensitive to the wind conditions on the roof of a motor vehicle, particularly at high speeds. Fabric moving with the wind is noisy. Moreover, fabric wears and tears more easily than hard shell material. In addition, fabric is easier to open by thieves than hard shell material. Roof boxes are typically added to the roof of a motor vehicle, only temporarily. Most of the time they are unused, and stored somewhere. In addition, their function is limited to the storage of luggage for transportation.
US 2014/0132022 discloses a foldable roof box that requires a reduced amount of storage space due to a reduction in thickness. The systems proposed require the manipulation of a large bottom panel. The systems proposed use a large number of parts, in particular numerous individual panels and a large number of hinges. In WO 2013/06628 a transport box is described that combines hard shell parts with flexible material in-between. Supports arranged within the box, are used to change the volume of the box between a retracted position with a smaller volume and an expanded position with a larger volume. The supports are operated by pulling straps attached to the supports. This proposal has disadvantages of both hard shell boxes and fabric boxes. In addition, the supports occupy space inside the transport box which could otherwise be used as storage space for luggage. The pulling straps become difficult to operate when the box is almost in the retracted position.
Hard shell roof boxes are typically made by deep drawing of a thermoplastic panel material. Deep draw equipment is expensive. Other manufacturing methods, such as for instance described in US5,288,033 start by designing the ideal three dimensional shape and then obtain an unfolded structure from a single panel by cutting. The cutting not only provides the contours. In addition, folding lines are cut. Substantial material losses may occur. In addition, the cutting lines create leakage paths, from the exterior to the interior of the structure. The presence of sharp corners and edges is not beneficial to aerodynamic properties. Consequently, there is a need for further alternatives and improvements. The present invention aims to solve one or more of the above-mentioned problems. The object of the invention is to propose a roof box that is sturdier than a fabric type roof box, easier to transport and handle by the user than a hard shell type roof box, while at the same time maintaining as many as possible advantages of both types. It is another object of the invention to provide a compact system that is easy to assemble, easy to operate, has increased functionality, and can be manufactured at low cost.
This object is achieved with a roof box system according to an embodiment of the invention. In particular, the invention provides a watertight and foldable roof box system, the system comprising a single watertight panel substantially rectangular in shape, said panel comprising a pattern of folds and wherein said folds are formed and positioned such that said panel can be folded from a substantially flat into a three dimensional shape comprising a useful interior space, characterized in that said single watertight panel of substantially rectangular shape is made from a material having a high bending stiffness and high yield strength, and said pattern of folds is selected to provide after it has been folded said interior space whereby said interior space is provided for arranging or storing of objects on a roof of a motor vehicle. A roof box system according to an embodiment of the invention has the advantage that it is compact, readily storable, easy to manipulate. The use of a single panel of substantially rectangular shape is beneficial to avoid material loss and to reduce manufacturing steps, such as the introduction of cutting lines. The pre-determined pattern of folds is advantageous as the work required to put different panels together is avoided. Furthermore, the folds are watertight. Hence, the use of a seal can be dispensed with. The fold pattern induces tensions in the (curved) shape, thereby increasing the stiffness of the structure. Aerodynamic performance is improved. In use, noise levels are reduced. In a second aspect, the invention provides a motor vehicle, characterized in that a roof box system according to an embodiment of the invention is attached to a roof of the motor vehicle.
A motor vehicle with attached to it a roof box system according to an embodiment of the invention, is advantageous because the roof box construction is easily constructible, with a minimum amount of parts, and can easily be taken up and down, without use of a complex mechanism. The construction is more rigid than a construction wherein a fabric is mounted on a frame. It is less sensitive to damage from wind exposure on the roof of a motor vehicle. Noise levels can be reduced. In a third aspect, the invention provides a method for manufacturing a roof box system according to an embodiment of the invention, comprising the steps of: - providing a single panel of substantially rectangular shape made from a material having a high bending stiffness and high yield strength,
- optionally attaching to a surface of said first material layer a flexible second material layer thereby obtaining a multi-layered panel substantially rectangular in shape, - wherein said first and/or second material layer have watertight properties, - introducing a pre-determined pattern of folds into said first material layer, preferably by compaction or by embossing, the folding pattern not being applied in the flexible second material layer; and wherein said pattern of folds is selected to provide, in use, a three dimensional shape comprising a useful interior space for arranging or storing of objects on the roof of a motor vehicle.
Construction of a roof box system according to the invention, has the advantage that at least the upper part, comprising a roof top segment and a side wall segment, and advantageously also the lower part, comprising a bottom segment, are made from a single panel. This reduces the amount of time otherwise needed to construct a roof box system by putting together individual panels. Making the roof box system watertight does not require the use of a seal. A step of making the roof box system watertight after it is construction, is avoided.
In a fourth aspect, the invention provides a method for assembling a roof box system according to an embodiment of the invention, comprising the steps of: - providing a roof box system according to an embodiment of the invention, - moving the edges of said substantially rectangular shaped panel towards the center of the panel, thereby activating the predetermined folding pattern and forming said useful interior space.
A roof box system according to an embodiment of the invention is easy to assemble. In the substantially flat state it takes up a minimum of space. In the unfolded state is occupies a maximum volume for storage of objects, such as luggage. There can be no mistakes in putting segments in, in a wrong way, as they remain attached by folds. A roof box system according to an embodiment of the invention can be put together with a minimum of manipulation effort.
In a final aspect, the invention provides uses for a roof box system according to an embodiment of the invention, as a foldable towbar cargo carrier or a foldable furniture.
Further preferred embodiments are elaborated in the dependent claims.
BRIEF DESCRIPTION OF THE DRAWINGS 5 Fig. 1 is a schematic representation of a prior art disclosure of a rectangular closed box, in folded (Fig. 1A) and unfolded (Fig. 1B) state. Fig. 2 is a schematic representation of an alternative prior art disclosure of a rectangular box in folded (Fig. 2A) and unfolded (Fig. 2B) state. Fig. 3 is a schematic representation of an alternative prior art disclosure of a box comprising a set of four panels prior to assembly (Fig. 3A) and in assembled (Fig. 3B) state.
Fig. 4 is a schematic representation of watertight and foldable roof box system according to an embodiment of the invention, in unfolded (Fig. 4A) and folded (Fig. 4B) state.
Fig. 5 is a schematic representation of an alternative watertight and foldable roof box system according to an embodiment of the invention, in unfolded state.
Fig. 6 is a schematic representation of another alternative watertight and foldable roof box system according to an embodiment of the invention, in unfolded state. Fig. 7 is a schematic representation of yet another alternative watertight and foldable roof box system according to an embodiment of the invention, in unfolded state. Fig. 8 is a schematic representation of an alternative watertight and foldable roof box system according to an embodiment of the invention. A rectangular panel is provided wherein the part on the left is for the provision of a bottom part and the part on the right is for the provision of a roof part of a roof box system.
Fig. 9A is a schematic representation of an alternative watertight and foldable roof box system according to an embodiment of the invention; wherein a substantially rectangular panel is provided with gusset folds in each corner of panel and two curve- shaped folds are provided on either side of the longitudinal axis of the panel. The pattern of folds has mirror-symmetry.
Fig. 9B is a schematic representation of the panel of Fig. 9 with the addition of folds positioned perpendicularly to the longitudinal axis of the panel. The parallel folds are used for folding up the panel in a more compact and easier transportable shape. Fig. 10 is a schematic representation of an alternative watertight and foldable roof box system according to an embodiment of the invention; wherein a substantially rectangular panel is provided with gusset folds in each corner of panel and two curve- shaped folds are provided on either side of the longitudinal axis of the panel. In addition, the panel is provided with two additional folds, positioned in parallel to the longitudinal axis of the panel, that do not touch any other folds. The pattern of folds has mirror-symmetry. Fig. 11 A is a side view on a schematic representation of a three dimensional shape with useful interior space according to an embodiment of the invention, which can be used for arranging and storing of objects on the roof of a motor vehicle. Fig. 11 B is a schematic 3D-representation of the roof box system of Fig. 11A and corresponds to the foldable roof box system of Fig 9A. Fig. 12 is a schematic representation of a substantially rectangular panel for a roof part and a bottom part of a roof box system according to an embodiment of the invention. Fig. 13-16 are pictures of a motor vehicle with a roof box system mounted on the roof of the vehicle. The roof box system is according to an embodiment of the invention; the embodiment corresponds to Fig. 8 and Fig. 12. Fig. 13 provides a top view on the roof box system in opened position. Fig. 14 provides a side view on the roof box system in opened position. Fig. 15 provides a side view on the roof box system in closed position. Fig. 16 provides a motor vehicle with a roof box system in use as well as in unused condition, folded up in an easily transportable shape. Fig. 17 shows the footprint of several roof box systems. Fig. 18 is a schematic representation of an embodiment according to the invention, with a fold pattern with two gusset folds and one curve shaped fold. The drawings are only schematic and are non-limiting. In the drawings, the size of some of the elements may be exaggerated and not drawn on scale for illustrative purposes.
DETAILED DESCRIPTION OF THE INVENTION Unless otherwise specified, all terms used in the description of the invention, including technical and scientific terms, shall have the meaning as they are generally understood by the person skilled in the technical field the present invention relates to. Furthermore, definitions of the terms have been included for a better understanding of the description of the present invention. As used here, the following terms shall have the following meaning: "A", "an" and "the", as used here, refer to both the singular and the plural form unless clearly understood differently in the context. For example, “a compartment” refers to one or more than one compartment. "Approximately” as used here, that refers to a measurable value such as parameter, a quantity, an amount, a period and such, is meant to include variations of +/-20% or less, preferably +/-10% or less, more preferably +/-5% or less, still more preferably +/-1% or less, and even still more preferably +/-0.1% or less of the cited value, as far as such variations are appropriate for realizing the invention that is described. It will however be clear that the value to which the term “approximately” relates, will also be described specifically. The terms “include”, "including" and “included”, as used here, are synonym with “comprise”, “comprising” and “comprises” and are inclusive of open terms that indicate the presence of what follows e.g. a component, and that do not exclude the presence of additional, non-said components, characteristics, elements, members, steps, that are well-known from or described in the state of the art.
The citation of numeric intervals by means of end points includes all integers and fractions included within that interval, including these end points. In a first aspect, the invention provides a foldable and watertight roof box system for a motor vehicle, designed to form a useful interior space for arranging or storing objects. In particular, the invention provides a watertight and foldable roof box system, the system comprising a single watertight panel substantially rectangular in shape, said panel comprising a pattern of folds and wherein said folds are formed and positioned such that said panel can be folded from a substantially flat into a three dimensional shape comprising a useful interior space, characterized in that said single watertight panel of substantially rectangular shape is made from a material having a high bending stiffness and high yield strength, and said pattern of folds is selected to provide after it has been folded said interior space whereby said interior space is provided for arranging or storing of objects on a roof of a motor vehicle. A roof box system according to an embodiment of the invention has the advantage that it is compact, readily storable, easy to manipulate. The use of folds is advantageous as the work required to put different panels together is reduced. Furthermore, the folds are watertight. Hence, the use of a seal can be dispensed with. It is not required to make cuts for obtaining the roof box system in flat condition.
With the term “roof box” or “roof box system” as used herein, is meant a container mountable on the roof of a motor vehicle that, at least in the folded state, offers a useful interior space, for arranging or storing objects. The storage space created is typically used for the storage of luggage, e.g. suitcases or skis. The interior space is the storage space within the roof box that is enclosed by the walls of a roof box, which is at least an inverted container with at most one open end.
The roof box system according to an embodiment of the invention, is made out of a single watertight panel or the roof part and bottom part of the system are each respectively made out of a single panel. With the term “watertight” as used herein, is meant that the panel is sealed tightly enough so that water, as experienced by a roof box system in use, cannot enter. This particularly refers to the thinnest parts, i.e. the folds. Either a panel material is selected that is tightly enough so that water cannot enter, or a panel is made watertight by attachment of a watertight material layer to it.
Preferably the single watertight panel is also waterproof. In case a separate bottom panel is used, this panel is preferably also waterproof. With the term “waterproof” as used herein, is meant a panel that is not affected by water. Exposure to water, as experienced by a roof box system in use, cannot damage the panel.
With the term “substantially rectangular in shape” is meant, a rectangular shape or a rectangle with cut-off corners. T-shaped or cross-shaped panels, for example, are not rectangular in shape.
With the term “motor vehicle” as used herein, is meant a motorized vehicle or automotive vehicle, meaning a self-propelled vehicle, commonly wheeled, which is used for the transportation of people or cargo, wherein the motor vehicles appropriate for use in the present invention have a vehicle roof. Examples of suitable motor vehicles include passenger cars, trucks, convertibles, busses, (camper)vans, caravans.
The roof box system according to an embodiment of the invention, is made out of a single watertight panel. With the term “watertight” as used herein, is meant that the panel is sealed tightly enough so that water, as experienced by a roof box system in use, cannot enter. This particularly refers to the thinnest parts, i.e. the folds. Either a panel material is selected that is tightly enough so that water cannot enter, or a panel is made watertight by attachment of a watertight material layer to it.
Preferably the single watertight panel is also waterproof. With the term “waterproof” as used herein, is meant a panel that is not affected by water. Exposure to water, as experienced by a roof box system in use, cannot damage the panel.
In an embodiment of a roof box system of the invention, said single watertight panel comprises a thermoplastic material; preferably selected from a polypropylene, a polyethylene, a polyester, a cyclic olefin (co)polymer (COC), a polystyrene, a polycarbonate, a polyvinyl chloride (PVC), a fiber-reinforced plastic (FRP), a self- reinforced thermoplastic (SRP) or composite (SRC), or combinations thereof.
With the term “cyclic olefin copolymer” as used herein, is meant an amorphous polymer made by from cyclic monomers by polymerization methods. Examples of cyclic olefin monomers are 8,9,10-trinorborn-2-ene (norbornene) or 1,2,3,4,4a,5,8,8a-octahydro-1,4:5,8-dimethanonaphthalene (tetracyclododecene).
Cyclic copolymer materials are commercially available from Topas Advanced Polymer’'s under the tradename Topas, and from Mitsui Chemical under the tradename Apel. Cyclic polymer materials suing a single type of monomer, are commercially available from Japan Synthetic Rubber under the tradename Arton and from Zeon Chemical under the tradenames Zeonex and Zeonor. The use of COC material is advantageous as they are moisture insensitive. The material and its properties are described in a technical report by IUPAC, Chemical structure and physical properties of cyclic olefin copolymers, Shin et al., Pure and Applied Chemistry, 77; 801-814, 2005.
In a preferred embodiment the roof box is capable of withstanding fungal attack, decay by sunlight, and can be exposed to prolonged periods of rain. This may be obtained by including a fungicide and/or biocide and/or UV-additive in the composition of the panel, especially in the composition providing the outer surface of the panel.
With the term “fiber-reinforced plastic” or “fiber-reinforced polymer” as used herein, is meant a composite material that made of a polymer matrix reinforced with fibers.
The fibers may be fiberglass, carbon, or aramid. The polymer may be an epoxy, a vinyl ester, or a polyester. The skilled person, in view of the disclosure of the present invention, may find other suitable fiber-reinforced plastics. Use of “fiber-reinforced plastic” material is advantageous to prevent deformation of the roof box due to shifts of the luggage in the storage space. Use of this material maybe also advantageous to obtain resistance against cutting or carving. This material may serve as an anti- vandalism material. With the term “self-reinforced thermoplastic” as used herein, is meant a material that comprises uni-aligned, twisted (in bundles) or woven tapes, strings or yarns of preferably up to ten layers containing such molecularly oriented strands in conjunction with molecularly un-oriented thermoplastic or similar matrix material. By disposal in predetermined patters of subsequent layers or different layers unidirectional strength properties can be assured with the pre-tensioned strands extending inclined to each other in the same or in different layers of the material. Self-reinforced plastics have enhanced strength and stiffness compared to unreinforced plastics and they have improved recyclability and reduced weight compared to glass fiber-reinforced plastics. They also have outstanding impact energy absorption and the absence of abrasive fibers has advantages in terms of handling and tool wear. Self-reinforced plastics or composites are commercially available. A preferred self- reinforced plastic for use in the present invention is available from Propex under the tradename Curv. Curv material comprises highly oriented polypropylene tapes in a self-reinforced polypropylene matrix. The single watertight panel used in the present invention, preferably comprises highly oriented polypropylene tapes in a self- reinforced polypropylene matrix. The single panel can be one layer or may comprise multiple layers.
In another preferred embodiment, the roof panel is multi-layered and comprises at least a watertight and flexible outer material layer. The single watertight and flexible outer material layer is preferably attached to a second bendable material layer such that they form a whole. In order not to jeopardize the watertight properties, the folding pattern is not applied in the outer material layer.
Preferably the multi-layer is a sandwich structure comprising a watertight and flexible outer layer, a middle layer of cell structured material and a watertight and flexible inner layer. With the term “outer layer” the layer is meant that faces away from the interior space provided by the roof box system. The “inner layer” is the layer that faces towards the interior space provided by the roof box system. In an embodiment of the present invention, a flexible layer has a thickness of between 0,01 mm and 2,0 mm; preferably between 0,1 and 1,6 mm; more preferably between 0,25 and 1,2 mm; most preferably between 0,3 mm and 0,8 mm.
In an embodiment of the present invention, said single panel has a total thickness of between 0,01 mm and 100 mm; preferably between 0,1 and 75 mm; more preferably between 0,2 and 60 mm; most preferably between 0,25 mm and 50 mm.
In case the single watertight panel is multi-layered, meaning the panel comprises at least two layers, the second layer preferably comprises a cell structured material. Cell structured materials have the advantage that they are strong and lightweight materials.
Preferably, a roof box system according to an embodiment of the invention, has provisions for the introduction of curvature in the roof box system contour. This is advantageous to obtain an aerodynamic shape for the roof box system. Such provisions may be gusset folds and/or curve shaped fold lines.
Preferably the selected pattern of folds, when in use, introduce curvature, thereby providing a watertight and foldable roof box system with curved panel segments. Preferably, a roof box system according to an embodiment of the invention, has gusset folds in some of the corner regions of said single watertight panel. In folded state, the gusset folds are overlapping. The overlaps are beneficial for keeping the whole 3D-structure into position. Support structures such as brackets or ties, are not required to maintain the 3D shape. The use of support structures may be cancelled. In a preferred embodiment, said pattern of folds only comprises gusset folds in each of the corner regions of said single watertight panel. By eliminating additional folding lines, stress is induced in the entire panel, which provides a curved instead of a flat surface. For this to work, it is required that the material used for the panel has a high bending stiffness. The stiffer the material is, the more the curvature of the shapes will extend over the complete shape of the box. The bending stiffness is defined by the thickness of the material and the Young's modulus of the outer layers of the panel. A person skilled in the art can select the appropriate bending stiffness, and can select the correct bending stiffness, and select the corresponding material with certain material properties and thickness of the panel. Typical dimensions for roof boxes are 110 x 80 x 40 cm (280 liters), 133 x 86 x 37 (320 liters), 190 x 63 x 39 cm (300 liters), 190 x 63 x 37 cm (330 liters), 175 x 82 x 45 (450 liters) expressed as length, width, height (volume) On the other hand, it is required that the material selected for the panel, has a high yield strength. The material requires a high elastic elongation before it becomes plastically deformed. If it becomes easily plastically deformed, the material will tend to create false folding lines at the areas where the stress is concentrated, eliminating the prolongation of stress throughout the whole surface. A roof box system according to a preferred embodiment of the invention has at one least curve shaped fold. This is an alternative method to create tension in the material in the 3D shape and induce cured surfaces thereby. Preferably when the structure is unfolded, the shape of the side of one pane is exactly the same shape of the side of the adjacent pane. Consequently, the two panes fit perfectly into each other when made into the flat shape. The curve shape is advantageous to help shape the roof box system. Use of curve shape folds reduces the number of edges, sharp corners. A segment of the panel delimited by a curve shaped fold can advantageously be used to gain access to the useful space inside the roof box system. The advantage of using techniques whereby stress is induced in the complete panel is threefold: - the 3D structure is created with a minimum of folds. Gusset folds have the advantage that the structure remains in place without the need for brackets. — Due to the deformation, the structure is stiffening. This is particularly interesting in roof boxes, because stiffer structures tend to have better aerodynamic behavior and make less noise. -The sheet material is transformed in a much more organic, futuristic shape with attractive design.
To help shape the roof box system structure, it is particularly useful to work with a multi-layered material with a honeycomb core structure. Honeycomb structures have a good isotropic behavior with respect to yields strength. In contrast thereto, channel panels, tend to easily show false folding lines if stress is distributed in the direction orthogonal to the direction of the panels.
Most preferably said cell structured material is a honeycomb cell structure material. In a preferred embodiment, said honeycomb material layer is sandwiched between two flexible material layers, each attached to an opposing surface of the honeycomb material layer. For both flexible material layers, it is advantageous to use polypropylene material for its good behavior in terms of stiffness and yield strength.
The manufacturing of a honeycomb cell structure material for a sandwich type construction may be performed as described in US7541085 or US5445861. it is an advantage of embodiments of the present invention that a material with a honeycomb structure provides firmness in several very distinct directions and not only substantially in one direction. A roof box system according to a preferred embodiment of the invention preferably has at least two folds that are curve shaped. The at least two curve shaped folds are preferably positioned such that the panel is segmented in a central roof top segment flanked by two side wall segments situated respectively left and right of the central roof top segment. More preferably, a roof box system according to an embodiment of the invention has exactly two curve shaped folds, wherein said two curve shaped folds are positioned on opposite sides of the longitudinal axis of the panel thereby segmenting the panel in a middle segment flanked by two mirror-image shaped wall segments situated respectively left and right of said middle segment. Most preferably, the above described pattern of folds comprises no additional folds. The curve shape is selected to provide a foldable region between the central roof top segment and a side wall segment. The at least two curve shaped folds are used to bring said panel from a substantially flat state in which the interior space has a minimum volume into an extended state in which the interior space has a maximum volume.
The use of these curve shaped folds provides tensioning to the roof. This contributes to the overall strength of the construction.
The curve shape used for a fold is preferably comprising a continuous portion of a circle, meaning an arc or bow. More preferably said at least two curves have an identical shape. Even more preferably said at least two curve shaped folds are positioned at equal distance from the longitudinal axis of the roof box system. Most preferably a curve shape fold runs between two corners of said single watertight panel, located on the same side of the longitudinal axis of the roof box system.
Preferably, a roof box system according to an embodiment of the invention, has provisions for weakening the bending stiffness of the panel material. Such provisions may comprise the introduction of local thinning of the panel thickness. Such thinning may be in the form of lines, which do not necessarily touch other folding lines or panel edges. Alternatively, such thinning is in the form of complete areas.
In case a sandwich material, with a foam core, honeycomb core or any other air- containing air material is used, such thinning may be obtained by heat pressing the selected areas.
In an alternative embodiment, reinforcement elements may be used. Such reinforcement elements may comprise bars, profiles, patches. At the edges, overfolding the sheet material may be done, locally creating a piece of sheet material of double thickness. The reinforcement elements may be permanently or removably attached to the panel. Preferably the reinforcement elements are removably attached. This is beneficial to be able to fold the panel into a more compact shape.
It is also advantageous in case a set of folding patterns is present in the panel, for a roof box system and for another function. The panel can then more easily be transformed from one three-dimensional object into another three-dimensional shape.
Preferably the reinforcement elements are used on the outer sides of the panel and resulting three-dimensional object. This ensures that, although the entire sheet may transform into a cured shape, parts of the contour will remain in a well-controlled, particularly in a straight, shape. Preferably, reinforcement means are used for obtaining a roof box system with a roof part comprising an open end of rectangular shape. This rectangular shaped footprint is advantageous for the space provision inside the roof box system.
Preferably, a roof box system according to an embodiment of the invention further comprises a bottom part. The bottom part may be a separate part. The bottom part may be made from a second watertight panel material that is different to the material used for the first panel. Preferably, a bottom part for the present invention, is an injection moulded bottom part. Injection molding has the advantage that it provides a large degree of freedom for shaping the bottom part. Most preferably the bottom part is shaped for housing of said single watertight panel in folded and unfolded state. Alternatively, the pattern of folds in the single panel, will provide a roof box system with a bottom part attached to a roof part. Preferably said bottom part has a substantially rectangular shape; more preferably said bottom part is shaped for housing of said single watertight panel in folded and unfolded state.
In order for the bottom sheet material to remain rigid and flat under the load of the objects that are stored in the roof box system, use may be made of reinforcement elements.
In a preferred embodiment, the roof box system further comprises a bottom part and roof part manufactured from one and the same panel. Preferably there is no fold line between the bottom part and the roof part. Alternatively, a fold can be applied transversal to the longitudinal axis of the panel. Having the upper section and bottom section made of the same panel and keeping them together, has the advantage that less attachment steps are required for the production of a roof box system.
In a preferred embodiment, the bottom section is provided with receiving means for receipt of the side wall segments and/or swivel bows for support of the central roof top segment and/or tensioning means for positioning of the side wall segments. Preferably the bottom segment comprises upstanding edges. This feature is advantages for preventing stored material to shift. The upstanding edges may be used to provide locking means for locking of side wall segment of the upper part of the roof box system. The bottom segment may additionally comprise features to increase the strength thereof, such as integration of reinforcing elements (bars, rods, ...). The reinforcing elements may be detachable. Alternatively, the strength is induced by creating an embossed permanent structure in the material.
In another preferred embodiment, said bottom segment has a substantially rectangular shape. In a more preferred embodiment, the bottom part is shaped for housing of the single watertight panel, in folded and unfolded state The number of wall segments in a roof box system of the invention is preferably kept as low as possible. The wall segments can for example comprise a cover segment, a rear wall segment and/or one or more side wall segments. Optionally also a bottom or floor segment is present. In addition, a front wall segment may be present. With the term “front” the side of the roof box system facing towards the driver side of the motor vehicle, is meant.
In a preferred embodiment, a front wall segment is present which is movable between a collapsed and expanded position. This is beneficial for the aerodynamic performance of the roof box system.
Preferably a side wall segment has a trapezoid shape with rounded corners. Selection of a trapezoid shape has the advantage that a roof box system can be shaped comprising a front and back wall segment of different heights. This may contribute to the aerodynamic properties of the roof box system.
In a preferred embodiment, at least one fold is a groove. Grooves may be obtained from clearing away or compressing material in a panel. For example, grooves may be made with a Computer Numerical Control (CNC) machine. CNC machining is the process through which computers control machine-based processes in manufacturing, in this case groove making. Alternatively, grooves may be made by compression. For instance, grooves may be made by compaction using a press or by embossing. This is beneficial for the automation and upscaling of manufacturing processes.
The groove needs to be made in the inner layer in case of a two-lavered structure, or in the middle layer in case of a sandwich structure. It is important that a groove does not cut through the first flexible and watertight layer, in order to maintain the watertight properties.
In a preferred embodiment of a roof box system according to the invention, said flexible outer layer has a melting temperature that is higher than the melting temperature of said stiff, bendable second layer. Preferably, the melting temperature of the first flexible layer and the second layer will differ by at least 20 °C, more preferably by at least 30°C, most preferably by least 40°C. Preferably, the temperature difference is at most 100 °C, preferably at most 75 °C, most preferably at most 60 °C, Due to the higher melting temperature of the first flexible layer, it is possible to melt the second layer by locally heating the first layer, Le, by directly heating the first layer and only heating the second laver indirectly, without the first layer itsalf melting. Thus, no direct contact between the heat source and the second layer is required, The composition with layers of different melting temperature can be advantageously used to make folds. It is an advantage of embodiments of the present Invention that the panel can be made foldable by the presence of the flexible layer In the panel.
In theory, both the first layer as the second layer can consist of multiple layers, such as, for example, glue layers, multiple layers of self-reinforced polypropylene embedded in normal polypropylene, etc. In addition, an equivalent of the second layer or another layer can be provided on both sides of the first layer.
In addition to the curved fold, the central roof top segment preferably further comprises a fold running parallel with the longitudinal axis of the roof box system and/or a fold that is perpendicular to the longitudinal axis of the roof box system. These folds can be advantageously used to obtain a compact folded structure for storage of the roof box system.
In a preferred embodiment, the roof box system further comprises a bottom segment shaped from the same panel as the central roof top segment. The panel can be bend thereby proving an upper section and a bottom section. Alternatively, a fold can be applied transversal to the longitudinal axis of the panel. Having the upper section and bottom section made of the same panel and keeping them together, has the advantage that less attachment steps are required for the production of a roof box system.
In a preferred embodiment, the bottom section is provided with receiving means for receipt of the side wall segments and/or swivel bows for support of the central roof top segment and/or tensioning means for positioning of the side wall segments.
Preferably the bottom segment comprises upstanding edges. This feature is advantages for preventing stored material to shift. The upstanding edges may be used to provide locking means for locking of side wall segment of the upper part of the roof box system. The bottom segment may additionally comprise features to increase the strength thereof, such as integration of reinforcing elements. Preferred reinforcing elements are bars or rods. The reinforcing elements may be detachable. Alternatively, the strength is induced by creating an embossed permanent structure in the material.
Receiving means may be provided in the form of ridges. Tensioning means may be provided by means of tensioning straps. In another preferred embodiment of the invention, the panel comprises several folds in the latitudinal and/or longitudinal direction of the panel such that the panel may be folded up into a more compact transportable shape, the length of the more compact shape is smaller than the width of the panel in the extended state. More preferably, the folds in the panel of the roof box system have been made such that the panel may be folded up in a single or double spiral shape.
In another preferred embodiment of the invention, the panel comprises several folds such that the panel may be folded up into a shape other than a roof box system. Said another shape, is for instance a table, a bath tub or a baby travel bed. This is advantageous for increasing the functionality of the single watertight panel.
In a second aspect, the invention provides a motor vehicle, characterized in that a roof box system system according to an embodiment of the invention is attached to a roof of the motor vehicle.
Preferably said attachment is realized by means of a roof rail, a roof rack or alternative attachment means. In a third aspect, the invention provides a method for manufacturing a roof box system according to an embodiment of the invention, comprising the steps of: - providing a single panel of substantially rectangular shape made from a material having a high bending stiffness and high yield strength,
- optionally attaching to a surface of said first material layer a flexible second material layer thereby obtaining a multi-layered panel substantially rectangular in shape,
- wherein said first and/or second material layer have watertight properties,
- introducing a pre-determined pattern of folds into said first material layer, preferably by compaction or by embossing, the folding pattern not being applied in the flexible second material layer; and wherein said pattern of folds is selected to provide, in use, a three dimensional shape comprising a useful interior space for arranging or storing of objects on the roof of a motor vehicle.
The single panel made of bendable material and the flexible and watertight material layer are permanently connected with each other so that they form a watertight roof top panel consisting of one whole.
The folds are applied in the second layer so that the panel can be folded into a previously intended shape.
A method for manufacturing a foldable and watertight roof box system according to an embodiment of the invention has the advantage that complex and capital- intensive equipment, such as injection molding devices or deep drawing equipment for the formation of storage space, is avoided.
An efficient production method is provided.
Different designs can be produced in a simple and efficient way without expensive or complex tools required for the production.
A solid and stable construction is obtained.
A separate step for making the roof box system watertight is no longer necessary.
It is an advantage of the present invention that the roof box system is easy to produce automatically, without requiring much manual labor.
In a preferred embodiment of a method according to the invention, a flexible and watertight material layer is selected having a melting point that is higher than the melting point of the stiff and bendable material layer.
Due to the higher melting temperature of the first flexible layer, it is possible to melt the second layer by locally heating the first layer, i.e. by directly heating the first layer and only heating the second layer indirectly, without the first layer itself melting.
Thus, no direct contact between the heat source and the second layer is required.
The fact that the first layer has a higher melting temperature than the second layer also allows for faster pressing cycles in a press. The higher melting temperature can be used to avoid the material from attaching itself to the press. Consequently, shorter cooling cycles and heating cycles can be used.
In embodiments of the present invention, the first flexible layer and the second layer can already be connected to each other before the application of the folds, for example, via lamination or gluing. It is an advantage of such an embodiment that the first layer holds the second layer in place and keeps it in shape, so that no material runs off during the production process of the folds. This allows the second layer to be warmed up to or above the melting temperature, without it being damaged.
It is an advantage of some embodiments that the creation of folds can be done by heating locally and making a groove in the locally heated material that forms the folding line. In some embodiments, this can be done by providing one or more hot air blowers on a CNC machine, combined with an element for forming a groove, for example, a blunt rolling blade. The hot air is then applied shortly before the rolling blade passes, so that the second layer is melted and the first layer has been made softer and moister. By applying pressure with the element, a groove is formed, whereby the layer can easily be folded at that place.
More preferably, a curve shaped fold is made by locally heating said flexible outer layer to a temperature situated between the melting temperature of the flexible outer layer and the melting temperature of the layer to be scored, followed by scoring said indirectly heated second layer thereby providing a curve shaped fold line.
Furthermore, in particular embodiments, in addition to fold lines, other forms be created, wherein a selected shape can be pressed in the locally melted portion. This allaws other patterns to be generated in the second layer.
The cross section of a fold can be an angle a. It is an advantage of embodiments of the present invention that the degree of foldability of the panel segments around the fold can be adjusted by adjusting the size of the angle. By, for example, making a folding line with an angle o of between 75° - 185°, the panel around the folding line can be folded such that the plane along the one side of the folding line forms an angle of between 75° - 165° with the plane along the other side of the folding line.
The technique for making folds can advantageously be used for the application of complex fold patterns, e.g. comprising a double arched shape. It can be used to provide the upper segment of the roof box segment with an arch shape. Preferably said arch shape will, when viewing in longitudinal direction towards the front of the motor vehicle, become narrower going from the back to the front of the motor vehicle where the driver seat is located. The technigue for making folds can advantageously be used for the application of fold with varying widths. For instance, the width of an arched fold can be made broader than the width of a straight-lined fold. This improves the ability of the segments to pivot at the folds. In a fourth aspect, the invention provides a method for assembling a roof box system according to an embodiment of the invention, comprising the steps of: - providing a roof box system according to an embodiment of the invention, - moving the edges of said substantially rectangular shaped panel towards the center of the panel, thereby activating the predetermined folding pattern and forming said useful interior space. A method of assembly according to an embodiment of the invention is time saving and with little complexity. The method of assembly and disassembly is efficient. In a preferred embodiment, the method also comprises the steps of - selecting a roof box system wherein two curve shaped folds are positioned on opposite sides of the longitudinal axis of the panel thereby segmenting the panel in a middle segment flanked by two mirror-image shaped wall segments situated respectively left and right of said middle segment, - gripping said side wall segments and bending said side wall segments towards said longitudinal axis, thereby acting upon the middle segment and bending said middle segment, preferably arching said middle segment, thereby providing a three dimensional shape with improved contours. This method is advantageous as no additional means are required to move between a flat and extended state.
Preferably, a method according to an embodiment of the invention also comprises the steps of:
- moving one of said side wall segments from a closed to an open position, thereby providing access to said useful interior space, - arranging or storing objects in said useful interior space. More preferably, a method according to an embodiment of the invention also comprises the steps of: - providing, preferably injection moulding, a separate bottom part made from a second watertight panel material; wherein said bottom part comprises wall segments, - bending said wall segments towards the center of the second watertight panel thereby forming a substantially rectangular panel surrounded by upstanding walls and one open end, - storing said single watertight panel in substantially flat and folded state between said walls.
In a preferred embodiment, said at least one side wall segments are moved from a position with an angle « of 180° between said at least one side wall segment and the central segment to a position with an angle « situated between 90° and 135° between the central segment and each of the side wall segments. More preferably the angle « is situated between 95°- 130°. Even more preferably the angle « is situated between 100 °C - 125 °, most preferably between 115 © and 120 °. Angles larger than 90 °C, are advantageous for providing increased storage space. Shapes that different from a rectangular box contribute to providing a more aerodynamic shape, reduced fuel consumption.
Preferably the roof box system is mounted so that the watertight material layer is situated on the outside. More preferably a watertight material layer is also situated on the inside. The latter is beneficial for protection of the roof box system from liquids stored inside the interior space, e.g. for use as a children’s bath or baby bed, chair, table, shelter.
In a last aspect, the invention provides additional uses for the foldable roof box system. Preferably the watertight and foldable roof box system is also provided with a pattern of folding lines for use of the panel to obtain an additional three-dimensional object. The functionality of the system is increased.
Preferably a roof box system according to an embodiment of the invention, is used as a foldable towbar cargo carrier or a foldable furniture. The invention is further illustrated by means of examples. These examples are non- limiting.
EXAMPLES A first example of a rectangular closed box 200 according to the prior art, is provided in Fig. 1. The box is obtained from a cross-shaped material with a rectangular pattern of folding lines displaying a central part 201 and four side wall parts 202, 203, 204,
205. At the upstanding corners, the box 200 is not watertight.
A second example of a rectangular closed box 300 according to the prior art, is provided in Fig. 2. The box is obtained from a substantially rectangular material. Four side wall parts 302, 303, 304 and 305, are connected by four corner regions with a fold in the middle 306, 307, 308, 309. The resulting box is rectangular in shape. No curvatures are present.
A third example of a rectangular closed box 400 according to the prior art, is provided in Fig.3. A desired three-dimensional shape 400, is deconstructed into individual elements 401, 402, 403, 404. The elements need to be put together with hinges. This requires extra materials and work.
A first example of an embodiment of a watertight and foldable roof box system 600 according to the invention, is schematically represented in Figure 4, in unfolded (Fig. 4A) and folded (Fig. 4B) state. A substantially rectangular shaped panel is provided with a folding pattern only comprising four gusset folds 603, 603’, 603”, 603" in the respective corners of the panel. The gusset fold comprises two straight lines 603a, 603b that intersect at a sharp angle. The 3D shape obtained from the panel is curve shaped, which is clearly visible in the roof part 610. The gusset folds 603’, 603” provide support to the structure.
A second example of an embodiment of a watertight and foldable roof box system 1 according to the invention, is schematically represented in Figure 5. Fig. 5 shows panel with a folding pattern comprising four gusset folds 3, 3’, 3”, 3” and five parallel lines 19, 19’, 19", 19, 19”,
A third example of an embodiment of a watertight and foldable roof box system 1 according to the invention, is schematically represented in Figure 6. The flat material panel displayed in Fig. 6 comprises strengthening means 20, 20’, 20", 20”. The strengthening means are positioned parallel with borders of the panel. They are positioned longitudinally and transversally. A fourth example of an embodiment of a watertight and foldable roof box system 1 according to the invention, is schematically represented in Figure 7. The flat material panel displayed in Fig. 7 comprises regions 21, 21’ wherein the panel has been thinned. The reduced material thickness helps shape the 3D roof box. In a fifth example of an embodiment of a watertight and foldable roof box system 1 according to the invention (A: top view, B: side view), as depicted in Fig. 8A, a flat panel of rectangular shape is shown. The pattern of fold lines comprises two curve shaped fold lines 2, 2%, segmenting the panel in a central segment 7 and two flanking segments 8, 9 positioned on opposite sides of the central segment 7. In Fig. 8B an alternative version of the watertight and foldable roof box system 1 of Fig. 8A is displayed. It shows a rectangular panel with a folding pattern for a bottom part I and a top part II. Both parts are made from the same panel. The bottom part has a central segment 13 and four wall segments 14, 14’, 14’, 14”. A sixth example of an embodiment of a watertight and foldable roof box system 1 according to the invention, is shown in Fig. 9. Fig 9A shows a schematic representation of a panel material with a folding pattern comprising four gusset folds 3, 3’, 3”, 3" in the corner of a substantially rectangular panel and two curved shaped folds 2, 2”. The pattern of folds has mirror-symmetry, in both the longitudinal and transversal direction of the panel. Note the absence of any further folds. By elimination of additional folding lines, stress is induced in the whole sheet material creating curved instead of flat surfaces in the 3D shape. The version depicted in Fig. 9B, in addition has a set of parallel folding lines, transversal to the longitudinal axis of the panel. The parallel folds 4, 4’ are used for folding up the panel in a more compact and easier transportable shape.
In example 7, as depicted in Fig. 10, a substantially rectangular panel is provided with gusset folds 3, 3’, 3”, 3” in each corner of the panel 1 and two curve-shaped folds 2, 2" are provided on either side of the longitudinal axis of the panel. In addition, the panel is provided with two additional folds 5, 5’, positioned in parallel to the longitudinal axis of the panel 1, that do not touch any other folds. The pattern of folds has mirror-symmetry.
Example 8, as depicted in Fig. 11 shows a side view on a schematic representation of a roof box system 10 according to an embodiment of the invention (Fig. 11A). Fig. 11B is a schematic 3D-representation of the roof box system 10 of Fig. 11A, with a side wall segment 11, 12, a top segment 7, and a curve shaped fold line 2.
Example 9, as depicted in Fig. 12, provides an alternative template for a roof box system according to an embodiment of the invention. The plate with length L and height H has a folding pattern for both a bottom part and a roof part. The overall shape of the panel is substantially rectangular. The side wall segments in the bottom part are small in height in relation to the length L of the panel. Both parts have parallel folds 16 to obtain a compacter form for easy transport. The roof part has two curve shaped folds 2, 2’. In use, a narrow rectangular segment 14 may be used for attachment of the roof part and the bottom part.
Fig. 13-16 are pictures of a motor vehicle 100 with a roof box system 1 mounted on the roof of the vehicle. The roof box system 1 is according to an embodiment of the invention.
Fig 13 provides a top view on the top part 7 of the roof box system in opened position. One of the side wall segments 8 is in horizontal position and provides access to the useful interior space 15 for storage of objects. The side wall segment 8 comprises a circular opening 19 which may be used for opening/closing of the wall segment 8. The curved fold lines 2, 2’ have the effect that the wall panel may be in two positions which are at minimal potential energy, i.e. in which they are at rest. There is some mechanical energy needed to bring the side wall from its one state (the closed state) to the other state (the open state) and vice versa.
Fig. 14 provides a side view on the car with roof box system as displayed in Fig. 13. Two wall segments 14, 14’ of the bottom segment are visible. Fig. 15 provides a side view on the roof box system 1 of Figs. 13-14 in closed position.
Fig. 16 provides a motor vehicle 100 with a roof box system 1 in use as well as in unused condition, folded up in a compact and easily transportable shape 6 by means of parallel folds 16. The roof box system is closed off with a key lock 17.
Fig. 17 shows the footprint of several roof boxes in the folded shape. Fig. 17a, 17b, and 17c provides footprints with curved edges. The disadvantage of such curved edges is that no upward folds can be created. Fig 17d 17e and 17f have substantially straight edges. In a preferred embodiment of the present invention, stress is induced in the surface of the roof box system using curve shaped folding lines or gusset folds, thereby creating curved surfaces. Curved surfaces will generally result in curved lines in the open end/footprint of the (upper part) of the folded top box. See therefore Fig. 4h). It is therefore preferred to add reinforcement elements at the edges of the curved panel edges, to create substantially straight edges in the folded position (such as in Fig. 6). Such straight edges create an open end/footprint with substantially straight edges. The reinforcement may be created by adding material such as bars or profiles to the edges, or by overfolding the sheet material at the edges, locally creating a piece of sheet material of double thickness. The advantage of a footprint with straight edges is that the bottom part of the top box will have straight edges as well. In case the bottom panel is also made from sheet material, additional folding lines may be created at these edges in the bottom panel, which generate upstanding border walls in the folded position. Such upstanding border walls are shown in Fig. 8b, represented by numbers 14, 14’ and 14” and 14”.
Such upward border walls in the bottom part are useful for increasing the bending stiffness of the bottom part. Furthermore, such upstanding border walls may be useful as a mating face when the top part is brought into closed position, touching the upstanding borders of the bottom part. Locking and securing mechanisms may be attached to the upstanding border walls.
Fig. 18 shows an alternative roof box system according to an embodiment of the invention. Fig. 18A shows the single panel 1 with fold pattern consisting of one curve shaped fold 2, two gusset folds 3 and 3’, and one straight line fold 40 connecting opposite edges 50, 50’ of the panel. Edges 50, 50’ run parallel with the longitudinal axis of the panel. Edges 60, 60’ are perpendicular to the longitudinal axis of the panel. Fig. 18B shows the roof box system 10 in folded state. The curve shaped fold 2 provides a curved front segment 70 and curved roof segment 110. Structural support is provided by the gusset folds 3, 3".
Claims (22)
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| NL2022930A NL2022930B1 (en) | 2019-04-11 | 2019-04-11 | Roof box system, motor vehicle with roof box system and method for roof box manufacturing and assembly |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| NL2022930A NL2022930B1 (en) | 2019-04-11 | 2019-04-11 | Roof box system, motor vehicle with roof box system and method for roof box manufacturing and assembly |
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| NL2022930B1 true NL2022930B1 (en) | 2020-10-20 |
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| NL2022930A NL2022930B1 (en) | 2019-04-11 | 2019-04-11 | Roof box system, motor vehicle with roof box system and method for roof box manufacturing and assembly |
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