Support pad for a load carrier

Patent metadata

Field	Value
Publication number	US-9975494-B2
Application number	US-201514811376-A
Country	US
Kind code	B2
Filing date	Jul 28, 2015
Priority date	Jul 28, 2015
Publication date	May 22, 2018
Grant date	May 22, 2018

Abstract

A support pad for a vehicle roof load support system is disclosed where the support pad includes a base layer, a contact layer for contacting a load disposed on the support pad, and ribs extending between the base layer and the contact layer such that the contact layer is spaced from the base layer. The support pad is configured to flex in multiple directions to support the load disposed on the support pad.

First claim

What is claimed is:

1. A support pad system for a vehicle roof load support system, the support pad system comprising:
a load support configured to be coupled to a load bar on a roof of a vehicle; and
a support pad coupled to the load support, the support pad comprising:
a base layer;
a contact layer for contacting a load disposed on the support pad; and
a plurality of ribs extending between the base layer and the contact layer such that the contact layer is spaced from the base layer,
wherein the support pad is configured to flex in multiple directions to support the load disposed on the support pad, and
wherein the base layer and the contact layer are generally parallel in a first configuration before the load is disposed on the support pad.

2. The support pad system of claim 1 , wherein the support pad further comprises a first channel through the contact layer, wherein the first channel is disposed along a length of the support pad from a first end of the support pad to a second end of the support pad.

3. The support pad system of claim 2 , wherein the support pad further comprises a second channel through the contact layer from the first end to the second end of the support pad, wherein the first channel and the second channel define a first column of hollow cells, a second column of hollow cells, and a third column of hollow cells, and wherein the first column is configured to move independently relative to the second column.

4. The support pad system of claim 3 , wherein the support pad further comprises a longitudinal axis extending through a midpoint of the first end and a midpoint of the second end, wherein the support pad is symmetrical about the longitudinal axis.

5. The support pad system of claim 3 , wherein a first cell has a width that is narrower than a second cell, wherein the second cell is located closer to the second end, and wherein a third cell located closer to the second end than the second cell has a width that is narrower than the second cell.

6. The support pad system of claim 3 , wherein a cell in the first column has a width that is greater than a cell in the second column.

7. The support pad system of claim 1 , wherein the base layer, the contact layer, and the ribs define a plurality of hollow cells.

8. The support pad system of claim 1 , wherein the support pad further comprises a plurality of grooves in an exterior surface of the contact layer, wherein each groove corresponds to a rib directly beneath the groove.

9. The support pad system of claim 1 , wherein the plurality of ribs extend from a first edge of the support pad to a second edge of the support pad.

10. The support pad system of claim 1 , wherein the support pad further comprises a horizontal axis and a longitudinal axis perpendicular to the horizontal axis, wherein a first rib located between a first longitudinal end of the support pad and the horizontal axis is angled toward the first longitudinal end such that an acute angle is formed between the base layer and a side of the first rib closer to the first longitudinal end.

11. The support pad system of claim 10 , wherein a second rib located between a second longitudinal end of the support pad and the horizontal axis is angled toward the second longitudinal end such that an acute angle is formed between the base layer and a side of the second rib closer to the second longitudinal end.

12. The support pad system of claim 1 , wherein the base layer comprises an exterior surface having a ridge extending from the exterior surface and configured to engage a channel in an arm of the load support.

13. The support pad system of claim 1 , wherein the support pad comprises a thermoplastic elastomer.

14. The support pad system of claim 1 , wherein the support pad is configured to support a kayak hull.

15. The support pad system of claim 1 , wherein the base layer and the contact layer are curved in a second configuration before the load is disposed on the support pad.

16. The support pad system of claim 1 , wherein the load support comprises a first arm and a second arm.

17. A support pad for a load carried on a vehicle, the support pad comprising:
a base layer;
a contact layer spaced from the base layer by a plurality of ribs,
wherein the base layer, the contact layer, and the ribs are integrally formed from a thermoplastic elastomer, and
wherein the ribs extend from a first edge to a second edge of the support pad;

a first channel and a second channel through the contact layer from a first end to a second end of the support pad,
wherein the first channel and the second channel define a first column of hollow cells, a second column of hollow cells, and a third column of hollow cells; and

a plurality of grooves in an exterior surface of the contact layer,
wherein the grooves define a plurality of rows of cells, and
wherein a first groove corresponds to a first rib directly beneath the first groove.

18. The support pad of claim 17 , wherein a width of each cell in a first row of cells is narrower than a width of a cell in a corresponding column of a second row of cells that is adjacent to the first row of cells.

19. The support pad of claim 17 , wherein each hollow cell comprises two faces defined by the base layer and the contact layer, two faces defined by ribs, and two open faces.

20. The support pad of claim 17 , wherein at least one of the first end and the second end is convex shaped.

21. The support pad of claim 17 , wherein the base layer, the contact layer, and the ribs are integrally formed as a single molded component.

22. A support pad system for carrying a load on a vehicle, the support pad system comprising:
a load support configured to be coupled to a load bar on a roof of the vehicle; and
a support pad coupled to the load support, the support pad comprising:
a pad body comprising:
a plurality of cells integrally formed therewith and extending from a base layer of the pad body,
wherein the plurality of cells and the base layer are integrally formed as a single molded component, and
wherein each cell is configured to independently move in multiple directions with respect to the other cells.

23. The support pad system of claim 22 , wherein the pad body further comprises at least one channel along a length of the pad body and a plurality of grooves across a width of the pad body together defining columns and rows of cells that collectively form the pad body.

24. The support pad system of claim 22 , wherein the pad body comprises molded foam.

25. The support pad system of claim 22 , wherein the load support comprises a first arm and a second arm.

Assignees

• Thule Sweden Ab

Inventors

• Connors Daniel

Classifications

• B60R9/04

  Carriers associated with vehicle roof (B60R9/08 takes precedence) · CPC title

• B60R9/08

  specially adapted for sports gear (vehicles specially adapted for carrying aeroplanes, for carrying boats B60P) · CPC title

• B60R9/048 Primary

  Carriers characterised by article-gripping {, -covering,}-retaining, or -locking means · CPC title

• B60P3/1008

  on the vehicle roof · CPC title