Roof racks for carrying items on the roof of a vehicle generally consist of two roof rail extrusions which extend parallel to each other along each side of the roof. Roof rail feet are attached to either end of each roof rail extrusion and are firmly secured to the vehicle roof.

Known methods for attaching the roof rail feet to either end of the roof rail extrusions include the use of adhesives which are difficult to work with, ineffective and often result in an unattractive roof rail foot to roof rail extrusion attachment joint.

It is an aim of embodiments of the present invention to address the above problems and to provide a roof rail in which the roof rail foot and roof rail extrusion are secured together in an improved manner.

According to a first aspect of the present invention, there is provided a roof rail for a motor vehicle, the roof rail comprising a roof rail foot attachable to a roof panel of a motor vehicle, and a roof rail comprising an opening in which the roof rail foot may be accommodated, wherein the roof rail foot comprises an opening adapted to receive fixing means to extend into the opening in the roof rail, the roof rail comprising engagement means with which the fixing means may engage thereby securing the roof rail foot to the roof rail.

Advantageously, the roof rail described herein removes the need to use adhesive for attaching the roof rail foot to

the roof rail extrusion as in prior art roof rails.

Advantageously, the roof rail foot is securely attached to the roof rail extrusion.

Preferably, the roof rail comprises a roof rail extrusion.

Preferably, a first end of the roof rail foot is attachable to the roof panel. Preferably, a second end of the roof rail foot is accommodated in the opening of the roof rail.

The fixing means may include a shank operable to extend through the aperture and into the opening, and a head operable to abut the roof rail foot around the aperture.

Preferably, the shank is operable to cut a thread in the engagement means thereby securing the second end of the roof rail foot in the opening of the roof rail extrusion.

Preferably, the fixing means is self-tapping.

Preferably, the engagement means comprises a surface with which the fixing means, preferably the shank thereof, may engage. Preferably, the engagement means comprises a flange extending from an inner surface of the roof rail extrusion and into the opening thereof. Preferably, the flange comprises a seat at one end thereof, which seat comprises a substantially curved inner surface operable for engagement with the fixing means extending through the aperture in the roof rail foot into the opening of the roof rail. Preferably, the inner surface of the seat comprises a curvature substantially the same as the shank of the fixing means.

According to a second aspect of the present invention, there is provided a motor vehicle comprising a roof rail according to the first aspect.

All the features described herein may be combined with any of the above aspects, in any combination.

For a better understanding of the invention, and to show how embodiments of the same may be carried into effect, reference will be made, by way of example, to the accompanying drawings, in which:- Figure 1 shows a schematic perspective view of a roof rail system; Figure 2 shows a schematic partial view of a roof rail foot and roof rail extrusion; Figure 3 shows a schematic cross-sectional view of the roof rail foot and roof rail extrusion; and Figure 4 shows a schematic view of the roof rail foot and roof rail extrusion along the line X as shown in Figure 3.

Referring to Figure 1, there is shown part of a roof 2 of a vehicle. A roof rail system is shown in position on the roof 2 of the vehicle, and consists of two aluminium roof rail extrusions 8 which extend in parallel with each other along each side of the roof 2. Roof rail feet 1 are firmly secured to the roof 2 by suitable fixing devices at sites 22. The roof rail feet 1 are attached to either end of the roof rail extrusions 8 at attachment sites 24 by a mechanism which will be described hereinafter.

Referring to Figure 2, there is shown a roof rail foot 1 having a body 4 and a narrowed projection 10 which extends outwardly from one end thereof. The roof rail foot 1 is secured to a vehicle roof 2 by securing means (not shown) which are passed through apertures 6 on an underside of the body 4. The roof rail foot 1 has an aperture 16 extending therethrough at the junction of the body 4 and the projection 10.

Figure 2 shows a partial view of the roof rail extrusion 8. The extrusion is hollow having a channel 12 extending therealong except for a small flange 18 which extends inwardly and transverse to an outer wall of the rail extrusion 8 into the channel 12. As shown in Figure 4, the end of the flange 18 distal from the outer wall is shaped to form a seat 19 having a curved inner wall profile. The profile of the seat 19 defines a section of the circumference of a circle.

Referring to the Figures, the roof rail foot 1 is attached to the roof rail extrusion 8 by an operator as follows.

The projection 10 of the roof rail foot 1 is suitably shaped to fit tightly inside the channel 12 of the roof extrusion 8 and is pushed therein until the extrusion 8 tightly abuts the body 4 of the roof rail foot 1. A self- tapping screw 14 having a head 14a and a shank 14b is inserted in to the aperture 16 of the roof rail foot 1 until the end of the shank 14b of the screw 14 abuts the seat 19 of the protrusion 18 inside the channel 12 of the roof rail extrusion 8. Rotation of the self tapping screw 14 causes a thread to be cut in to the curved profile of the seat 19 and urges the roof rail extrusion 8 in to

close communication with the roof rail foot 1. The head 14a of the self-tapping screw abuts the foot body 4 around the outer circumference of the aperture 16 and maintains the foot 1 securely attached to the extrusion 8.

Referring to Figure 3, the roof rail foot 1 is shown securely attached to the roof rail extrusion 8. The projection 10 of the roof rail foot 1 is shown in position firmly within the channel 12 of the roof rail extrusion 8.

The shank 14b of the screw 14 has been screwed fully through aperture 16 of the body 4 such that the head 14a of the screw 14 tightly abuts around the circumference of the aperture 16. The screw 14 has cut a screw thread along the curved seat 19 inside the channel 12 of roof rail extrusion 8 thereby securely attaching the projection 10 of the foot 1 to the extrusion 8.

Referring to Figure 4, there is shown an alternative view of the arrangement of the projection 10 of the foot 1 in position inside the extrusion 8 of Figure 3.

Advantages of the present system reside in the simple and effective manner in which the roof rail foot 1 is secured to the extrusion 8. The mechanism dispenses with the need for large amounts of adhesive which tend to result in poor finishes. Also, the use of a self-tapping screw advantageously allows a seat of the rail extrusion to be used for the location of the fixing screw, without a pre- prepared thread.

The reader's attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and

which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.

Each feature disclosed in this specification (including any accompanying claims, abstract and drawings), may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

The invention is not restricted to the details of the foregoing embodiment (s). The invention extend to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.