AU2019100322C4

AU2019100322C4 - Mudflap

Info

Publication number: AU2019100322C4
Application number: AU2019100322A
Authority: AU
Inventors: Luke Hepworth; Ian McKee
Original assignee: Truckmate Australia Pty Ltd
Current assignee: Truckmate Australia Pty Ltd
Priority date: 2019-03-26
Filing date: 2019-03-26
Publication date: 2022-08-25
Anticipated expiration: 2027-03-26
Also published as: AU2019100322B4; AU2019100322A4

Abstract

Disclosed herein is a mudflap 100 for a vehicle. The mudflap 100 comprises a body being substantially in the form of a pliable flap 102 having an operatively upper end 104, an operatively lower end 106, an operatively left side 108 and an operatively right side 110. The flap 102 has a first major surface 112 and an opposite second major surface 114. A mounting portion 116 is provided at the operatively upper end 104, the mounting portion having apertures 116a therein to receive fasteners for connecting the mudflap 100 to the vehicle. The first major surface 112 has a first recessed area 112a for receiving a retroreflective label 120.

Description

"Mudflap"

Technical Field

[0001] The disclosure herein relates to a mudflap having a retroreflective panel. The mudflap has been developed primarily to improve the visibility of a motor vehicle or trailer to which it is attached.

Background

[0002] Throughout this specification: the word "comprise", and variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps; and the word "retroreflective" means configured to reflect an incident light beam directly back to its source.

[0003] It is known to provide various types of reflectors, including retroreflective panels, on the rear of heavy vehicles and trailers in order to improve their visibility. Known retroreflective panels typically comprise a metal plate with a retroreflective label applied thereto. These retroreflective panels are typically retrofitted to a body of the vehicle or trailer using mechanical fasteners, such as bolts, screws or rivets. However, it is also known to retrofit the panels to a vehicle, including to a rear mudflap on a vehicle, using double sided adhesive tape.

[0004] Problems with known mounting methods for retroreflective panels include: in the case of panels attached using mechanical fasteners: difficulty in positioning the panel in a location that complies with relevant safety regulations; installation of the panel being time consuming, therefore increasing costs; an air gap between the panel and an underlying surface causing the panel to bend; poor positioning of the panel resulting in part of the panel being obscured by the body of the vehicle or by accessories mounted to the vehicle; and

the panel obscuring other items or features, such as other safety markings or reflectors, or indicia of other types, such as branding, and in the case of panels attached using double-sided adhesive tape: difficulty in positioning the panel in a location that complies with relevant safety regulations; poor positioning of the panel resulting in part of the panel being obscured by the body of the vehicle or by accessories mounted to the vehicle; the panel obscuring other items on the vehicle, such as other safety markings or reflectors, or indicia of other types, such as branding; and poor adhesion of the panel, resulting in the panel detaching from the vehicle and thereby increasing risk to other road users.

[0005] Any discussion of documents, acts, materials, devices, articles or the like which has been included in the present specification is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present disclosure as it existed before the priority date of each of the appended claims.

Summary

[0006] Disclosed herein is a method of manufacturing a mudflap for a vehicle, the method comprising: providing a body of the mudflap, the body being substantially in the form of a pliable flap having a first major surface and an opposite second major surface; providing a label having a first major surface that is retroreflective and an opposite second major surface that is coated with an adhesive; and applying the label to the first major surface of the flap, with the second major surface of the label facing the first major surface of the flap, before the mudflap is supplied to a customer for application to a vehicle.

[0007] Also disclosed herein is a method of manufacturing a mudflap for a vehicle, the method comprising: providing a body of the mudflap, the body being substantially in the form of a pliable flap having a first major surface and an opposite second major surface; providing a label having a first major surface that is retroreflective and an opposite second major surface that is coated with an adhesive; and applying the label to the first major surface of the flap, with the second major surface of the label facing the first major surface of the flap, while the flap is at a temperature above ambient temperature.

[0008] The label may be applied to the first major surface of the flap while the flap is at a temperature of between 30°C and 45°C. The area of the first major surface to which the label is applied may be treated prior to application of the label. The treatment may comprise cleaning, such as wiping with a solvent such as isopropyl alcohol, and/or flame treating the area of the first major surface to which the label is applied.

[0009] The step of providing the body may comprise moulding the body in a plastic moulding machine, which may be an injection moulding machine. The label may be applied to the first major surface of the flap shortly after the body has been moulded in the plastic moulding machine. The label may be applied to the first major surface of the flap shortly after the body has been moulded in the plastic moulding machine but before the moulded body has cooled to ambient temperature.

[0010] Also disclosed herein is a method of manufacturing a mudflap for a vehicle, the method comprising: providing a body of the mudflap, the body being substantially in the form of a pliable flap having: a first major surface and an opposite second major surface, an operatively upper end, an operatively lower end, an operatively left side and an operatively right side, and a mounting portion at the operatively upper end, the mounting portion having apertures therein to receive fasteners for connecting the mudflap to the vehicle, the first major surface having a first recessed area with sidewalls extending therearound that extend from a base of the first recessed area to terminate in a rim extending around the first recessed area, and the pliable flap being of unitary, one-piece construction; providing a label having a first major surface that is retroreflective and an opposite second major surface that is coated with an adhesive, wherein the label has a non-metallic substrate and/or has a thickness of less than 1mm; and applying the label to the base of the first recessed area, with the second major surface of the label facing the base of the first recessed area to bring the adhesive into contact with the base of the first recessed area.

[0011] The proportions of the label relative to the base maybe such that the label substantially covers the base.

[0012] The first recessed area may have a depth, measured between the base and the rim, of up to 5mm, such as between 1 and 4mm, or approximately 3mm. The base may be substantially oblong and may have a major dimension of approximately 600mm, such as a major dimension of approximately 605mm. The mudflap may be configured such that, in use, the major dimension is substantially horizontal. The base may have a minor dimension of approximately 150mm, such as a minor dimension of approximately 155mm.

[0013] The flap may have a second recessed area with sidewalls extending therearound that extend from a base of the second recessed area to terminate in a rim extending around the second recessed area. The second recessed area may have a depth, measured between the base and the rim, of up to 5mm, such as between 1 and 4mm, or approximately 3mm. The base of the second recessed area may be substantially oblong and may be approximately 600mm measured along one of its major and minor axes. The mudflap may be configured such that, in use, said one of its major and minor axes is substantially horizontal. The mudflap may be configured such that, in use, the second recessed area is located closer to the operatively lower end than the first recessed area is to the operatively lower end. The base of the second recessed area may be at least 200mm measured along the other of its major and minor axes, such as at least 220mm measured along the other of its major and minor axes, or around 240mm measured along the other of its major and minor axes. Raised indicia, such as branding, may extend from the base of the second recessed area.

[0014] A maximum thickness of the flap measured between the first and second major surfaces may be less than 12mm, such as less than 10mm or around 8mm. A length of the flap measured between its operatively upper end and its operatively lower end may be at least 400mm, at least 420mm, at least 440mm, or around 460mm. A width of the flap measured between its operatively left side and its operatively right side may be at least 615mm, at least 620mm, at least 630mm, or around 635mm.

[0015] The sidewalls of the recessed area(s) may have a draft angle to facilitate removal of the mudflap from a mould. Corners defined between the sidewalls and/or between the sidewalls and the base may have a radius.

[0016] The base of the first recessed area maybe treated prior to application of the label thereto. The treatment may comprise cleaning the base of the first recessed area, such as by wiping with a solvent such as isopropyl alcohol, and/or flame treating the base.

[0017] The label may be non-metallic. The label may be in the form of a sheet or film. The label may have a thickness of less than Imm or of less than 0.8mm. The label may comprise a polymer substrate, such as a PVC substrate. The label may be substantially oblong and may have a major dimension of approximately 600mm and a minor dimension of approximately 150mm. The adhesive may be a pressure-sensitive adhesive. Applying the label to the base of the first recessed area may comprise pressing the label against the base of the first recessed area. The pressing may comprise pressing the label against the base of the first recessed area using a roller or a straight edge, such as a straight edge on a bar or squeegee.

[0018] The first major surface of the label may comprise red transparent stripes on a yellow retroreflective background.

[0019] Also disclosed herein is a mudflap for a vehicle, the mudflap comprising: a body being substantially in the form of a pliable flap having: an operatively upper end, an operatively lower end, an operatively left side and an operatively right side, a first major surface and an opposite second major surface, and a mounting portion at the operatively upper end, the mounting portion having apertures therein to receive fasteners for connecting the mudflap to the vehicle, the first major surface having a first recessed area with sidewalls extending therearound that extend from a base of the first recessed area to terminate in a rim extending around the first recessed area, and the pliable flap being of unitary, one-piece construction; and a retroreflective label adhered to the base of the first recessed area, wherein the label has a non-metallic substrate and/or has a thickness of less than Imm.

[0020] The base of the first recessed area may be substantially oblong and have a major dimension of approximately 600mm.

[0021] The first recessed area may have a depth, measured between the base and the rim, of up to 5mm, such as between 1 and 4mm, or approximately 3mm. The major dimension may be approximately 605mm. The mudflap may be configured such that, in use, the major dimension is substantially horizontal. The base may have a minor dimension of approximately 150mm, such as a minor dimension of approximately 155mm.

[0022] The first major surface may have a second recessed area with sidewalls extending therearound that extend from a base of the second recessed area to terminate in a rim extending around the second recessed area. The second recessed area may have a depth, measured between the base and the rim, of up to 5mm, such as between 1 and 4mm, or approximately 3mm. The base of the second recessed area may be substantially oblong and may be approximately 600mm measured along one of its major and minor axes. The mudflap may be configured such that, in use, said one of its major and minor axes is substantially horizontal. The mudflap may be configured such that, in use, the second recessed area is located closer to the operatively lower end than the first recessed area is to the operatively lower end. The base of the second recessed area may be at least 200mm measured along the other of its major and minor axes, such as at least 220mm measured along the other of its major and minor axes, or around 240mm measured along the other of its major and minor axes. Raised indicia, such as branding, may extend from the base of the second recessed area.

[0023] A maximum thickness of the flap measured between the first and second major surfaces may be between 3mm and 12mm, such as between 3mm and 10mm, or around 8mm. A length of the flap measured between its operatively upper end and its operatively lower end may be at least mm greater, or in some cases at least 20mm greater or at least 30mm greater or at least 40mm greater, than the minor dimension of the first recessed area (or, in embodiments that have a second recessed area, than the sum of the minor dimension of the first recessed area and the dimension of the second recessed area measured parallel to the minor dimension of the first recessed area), such as at least 400mm, at least 420mm, at least 440mm, or around 460mm. A width of the flap measured between its operatively left side and its operatively right side may be at least 10mm greater, or in some cases at least 20mm greater, than the major dimension of the first recessed area, such as at least 615mm, at least 620mm, at least 630mm, or around 635mm.

[0024] The sidewalls of the recessed area(s) may have a draft angle to facilitate removal of the mudflap from a mould. Corners defined between the sidewalls and/or between the sidewalls and the base may have a radius.

[0025] The retroreflective label may substantially cover the base of the first recessed area. The label may be secured to the base by a pressure-sensitive adhesive. The label may be non metallic. The label may be in the form of a sheet or film. The label may have a thickness of less than 1mm or of less than 0.8mm. The label may comprise a polymer substrate, such as a PVC substrate. The label may be substantially oblong and may have a major dimension of approximately 600mm and a minor dimension of approximately 150mm. The label may comprise red transparent stripes on a yellow retroreflective background.

Brief Description of Drawings

[0026] An embodiment will now be described, by way of example only, with reference to the accompanying drawings, in which:

FIG. 1 is a front elevational view of a mudflap embodying principles disclosed herein;

FIG. 2 is a front elevational view of the mudflap of FIG. 1, shown without its label; and

FIG. 3 is a cross-sectional view taken along line 3-3 of FIG. 2.

Description of Embodiments

[0027] Referring to the drawings, there is shown a mudflap 100 for a vehicle. The mudflap 100 comprises a body being substantially in the form of a pliable flap 102 having an operatively upper end 104, an operatively lower end 106, an operatively left side 108 and an operatively right side 110. The flap 102 has a first major surface 112 and an opposite second major surface 114. A mounting portion 116 is provided at the operatively upper end 104, the mounting portion having apertures 116a therein to receive fasteners for connecting the mudflap 100 to the vehicle.

[0028] The first major surface 112 has a first recessed area 112a with sidewalls 112b extending therearound that extend from a base 112c of the first recessed area to terminate in a rim 112d extending around the first recessed area. The base 112c is substantially oblong and has a major dimension of approximately 605mm and a minor dimension of approximately 155mm. The first recessed area 112a has a depth, measured between the base 112c and the rim 112d, of approximately 3mm. In use, with the mudflap 100 secured to the vehicle via the mounting portion 116, the major dimension of the base 112c is substantially horizontal (i.e., parallel to operatively upper end 104).

[0029] The first major surface 112 has a second recessed area 112g with sidewalls 112h extending therearound that extend from a base 112i of the second recessed area to terminate in a rim 112j extending around the second recessed area. The second recessed area 112g has a depth, measured between the base 112i and the rim 112j, of approximately 3mm. The base 112i is substantially oblong and has one of its major and minor axes parallel to the major axis of the base 112c, the base 112i having a dimension of approximately 600mm measured along that axis. The base 112i has a dimension of approximately 240mm measured perpendicular to the major axis of base 112c. In use, the second recessed area 112g is located closer to the operatively lower end 106 than the first recessed area 112a is to the operatively lower end 106. The pliable flap 102 may comprise raised indicia, such as branding, extending from the base 112i.

[0030] A maximum thickness of the flap 102 measured between the first and second major surfaces 112, 114 is around 8mm. A length of the flap 102 measured between its operatively upper end 104 and its operatively lower end 106 is around 460mm. A width of the flap 102 measured between its operatively left side 108 and its operatively right side 110 is around 635mm.

[0031] As is conventional for plastic moulded products, the sidewalls 112b, 112h of the recessed area have a draft angle to facilitate removal of the mudflap 100 from a mould. Corners defined between the sidewalls 112b, the sidewalls 112h, between the sidewalls 112b and base 112c, and between the sidewalls 112h and base 112i have a radius.

[0032] A retroreflective label 120 is provided for application to the base 112c of the first recessed area 112a. Label 120 comprises a substrate in the form of an oblong polymer sheet, such as a PVC sheet, having opposite first and second major surfaces. The first major surface of label 120 is retroreflective, comprising red transparent stripes on a yellow retroreflective background. The second major surface of label 120 comprises an adhesive, which may be a pressure-sensitive adhesive, to facilitate bonding of the label 120 to the first recessed area 112a. The adhesive is pre-applied to the second major surface of label 120, thereby making the label 120 self-adhesive. The label 120 has a major dimension of approximately 600mm and a minor dimension of approximately 150mm such that, upon its application to the base 112c, with the second major surface of label 120 facing the first major surface 112 of the flap 102 (specifically, the base 112c) it substantially covers the base 112c. The label 120 is around 0.5mm to 0.8mm thick. The label 120 is applied to the base 112c before the mudflap 100 is supplied to a customer for application to a vehicle. Applying the label 120 to the base 112c of the first recessed area 112a comprises pressing the label against the base of the first recessed area. Such pressing may comprise rolling a roller against the label 120 to press it onto the base 112c or scraping a straight edge, such as a straight edge on a bar, block or squeegee, against the label 120 to press it onto the base 112c.

[0033] The flap 102 is injection moulded from PVC in an injection moulding machine. Ideally, label 120 is applied to the flap 102 shortly after the flap has been moulded in the injection moulding machine and before the flap 102 has cooled to ambient temperature. For example, the flap 120 may be at a temperature of between 30°C and 45°C when label 120 is applied. The present inventors consider that applying the label 120 to the flap 102 while the flap is at an elevated temperature may assist the adhesive carried on the label 120 to provide a good bond between the label 120 and the flap 102.

[0034] In some embodiments, the base 112c of the first recessed area 112a is treated prior to application of the label 120 thereto, thereby to improve adhesion of the label. Such treatment may comprise cleaning the base 112c by wiping it with a solvent such as isopropyl alcohol, and/or flame treating the base 112c to increase its surface energy.

[0035] It will be appreciated that providing the recessed area 112a for the label 120 facilitates accurate positioning of the label 120 on the flap 102 and provides a degree of protection to the label 120 during handling and use of mudflap 100. It will also be appreciated that pre-application of the label 120 to the flap 102, before the mudflap 100 is supplied to a customer, reduces the risk of the label 120 being inaccurately positioned on the flap 102 and/or being otherwise non optimally attached to the flap 102.

[0036] It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the above-described embodiments, without departing from the broad general scope of the present disclosure. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.

Claims

CLAIMS:

1. A method of manufacturing a mudflap for a vehicle, the method comprising: providing a body of the mudflap, the body being substantially in the form of a pliable flap having: a first major surface and an opposite second major surface, an operatively upper end, an operatively lower end, an operatively left side and an operatively right side, and a mounting portion at the operatively upper end, the mounting portion having apertures therein to receive fasteners for connecting the mudflap to the vehicle, the first major surface of the flap having a first recessed area with sidewalls extending therearound that extend from a base of the first recessed area to terminate in a rim extending around the first recessed area, and the pliable flap being of unitary, one-piece construction; providing a label having a first major surface that is retroreflective and an opposite second major surface that is coated with an adhesive, wherein the label has a non-metallic substrate and/or has a thickness of less than Imm; and applying the label to the base of the first recessed area, with the second major surface of the label facing the base of the first recessed area to bring the adhesive into contact with the base of the first recessed area.

2. The method of claim 1, wherein the label is applied to the base of the first recessed area while the flap is at a temperature of between 30°C and 45°C.

3. A mudflap for a vehicle, the mudflap comprising: a body being substantially in the form of a pliable flap having: an operatively upper end, an operatively lower end, an operatively left side and an operatively right side, a first major surface and an opposite second major surface, and a mounting portion at the operatively upper end, the mounting portion having apertures therein to receive fasteners for connecting the mudflap to the vehicle, the first major surface having a first recessed area with sidewalls extending therearound that extend from a base of the first recessed area to terminate in a rim extending around the first recessed area, and the pliable flap being of unitary, one-piece construction; and a retroreflective label adhered to the base of the first recessed area, wherein the label has a non-metallic substrate and/or has a thickness of less than Imm.

4. The mudflap of claim 3, wherein the first major surface has a second recessed area with sidewalls extending therearound that extend from a base of the second recessed area to terminate in a rim extending around the second recessed area, and wherein the mudflap is configured such that, in use, the second recessed area is located closer to the operatively lower end than the first recessed area is to the operatively lower end.

5. The method of claim 1 or claim 2, or the mudflap of claim 3 or claim 4, wherein the label substantially covers the base of the first recessed area.