Aero-Box   Aerodynamic r
oof boxes

This is what the airflow round a standard car looks like. Its windshield pushes air upwards.
And the result?

The air is bound to press every roof box obliquely from the bottom.                  And the result?
If you place a standard roof box on your vehicle roof, the airflow will be highly turbulent and noisy.                 
What to do then?
Install an Aero-Box on you roof. 

See below

Front view of a standard box

schematic airflow on its front

Front view of Aero-Box 

schematic airflow on its front

Aero-Box guarantees: lower fuel consumption, less noise, increased safety

Comments of an aerodynamics specialist: Improved aerodynamic properties of Aero-Boxes result from the smooth profile of their front part. It is especially important if you consider the “velocity field” which the box on the vehicle roof is in. A majority of standard roof boxes has a geometric fault at the joint of the cover with the floor, up to 20 to 25 mm, which is responsible for the aerodynamic drag. The said geometric fault creates the so-called turbulator in oblique airflow. It is responsible for drag coefficient rise from Cx=0.2 (for a smooth solid) to Cx=0.35. The above values are confirmed both by calculations and by the studies carried out. It is important that standard roof boxes placed in a parallel “velocity field”, e.g. in a wind tunnel, will show Cx values close to 0.2 mentioned above when perceived as isolated objects. After the car roof has been modelled, Cx increases rapidly.

Additional base beams 

In the presented version of Aero-Box optional additional base beams were used. They enable us to carry additional cargo, especially the one with the dimensions exceeding the length of the box itself, e.g. skis or surfboard. In the commercially available surfing boxes the additional base beams are an integral part of the box. In the presented Aero-Boxes the beams are “optional” equipment. They can be installed or not. They can be present on the box permanently in the backward position and moved only when necessary. In the “backward position” both beams make a spoiler and as a combined solid create a minimum drag.

         Aero-Box 550
Aero-Box 550
Technical parameters:
Base beam sparing
Cover raising

- 550 dcm3
- 2020
- 1010
- 400
- 20 kg
- typ „U”
- 550- 800
- hydro-pneumatic
Performance technology
The entire box is made from polyester and glass laminate, moulded manually.

Aero-Box  550 „prima” (in progress)

Information for those interested

    1. Suggested development directions:
      - Development of 2 additional options with the dimensions and design different from the demonstrated ones. It is pointless
         and ineffective to multiply the options.

      - Transfer from the manual moulding technology to the "vacuum" technology, i.e. light RTM. It results in reducing weight by                about 3–4 kg, increasing quality and workmanship repeatability.
      - Replacement of polyester-glass laminates with "ABS" materials - necessary to increase production scale.

      2. Carrying out purposefulness analysis of the “structural and technological leap”
It is necessary to analyse a prospective market with respect to the purposefulness of using the advanced roof box design with a divided cover as per figure below.

      Standard version


      Folded version

Please note: The “unique”, “significant” properties are a subject of application submitted in the Polish Patent Office.