SE1550012A1 - Panel primarily made of thermoplastic material - Google Patents

Abstract

The invention relates to a panel assembly (2) comprising parts (5,6) made of a thermoplastic material, primarily intended for installation/use as an air/wind deflector on a heavy commercial vehicle, such as a truck, for improving the aerodynamic air flow around the cab (3a) and the trailer (3b). The invention is achieved by that at least one profile (7) is arranged to support the panel assembly (2), connecting the different parts (4-6) of the panel assembly (2), and the profile (7) is arranged with at least two elongated mounting holes (11) adapted for installing a clip/spacer (8) connecting the panel parts (4-6) to the profile (7), in order to provide a panel assembly (2) with required characteristics, such as sufficient stiffness and permitting thermal expansion of the panel parts (4-6) .(Fig 4)

Description

PANEL PRIMARILY MADE OF THERMOPLASTIC MATERIAL TECHNICAL FIELD The present invention relates to a panel assembly where the panel primarily is made of a thermoplastic material. The invention generally relates to design of panels e.g. for installation as an air/wind deflector on a heavy commercial 10 vehicle, such as a truck e.g. for improving the aerodynamic air flow around the cab and the trailer. The invention particularly relates to a reinforcing assembly of panels in order to provide panels/air deflectors with the required characteristics, such as sufficient stiffness, permitting thermal expansion etc. The invention also relates to a vehicle provided with a panel according to the invention.

BACKGROUND ART Modern vehicles are designed to be as aerodynamically efficient as possible. This is especially important when it comes to heavy-duty vehicles, such as trucks, as these vehicles are large, heavy and driven long distances. Trucks represent an important part of today's traffic, and the fuel consumption of these vehicles is of a major concern. Any improvement in the vehicles aerodynamics performance is of significance interest in order to improve the fuel economy.

When a truck run a great deal of turbulence is created along the vehicle. This disturbs the air flow resulting in increased resistance moving the truck and thus to a higher fuel consumption. By streamlining, vehicles may accomplish significant savings in fuel consumption and improving the aerodynamics of a vehicle improves also other aspects of the vehicles performance, particularly its acceleration, top speed, tracking stability, tire wear, driver comfort etc.

Many modifications and accessories have been developed to improve the streamline of the airflow around vehicles. One such product category is air/wind deflectors. Since the justification for installing air deflectors on a vehicle/truck is to reduce costs, the deflectors themselves also have to be manufactured cost efficient and installed to a reasonable cost. 10 Today's air deflector panels are normally made of SMC (Sheet Moulding Composite) which is a ready to mould composite of glass-fiber reinforced thermosetting resin, i.e. a polyester mixed with glass fiber, and primarily used in compression moulding. Typical applications of this composite material include demanding corrosion resistant need, structural automotive components etc.

Fiberglass is a relatively expensive material and expensive to mold and it limits in some degree the design freedom. It is also a brittle material that may crack when exposed to external forces which may result in that the products, e.g. panels on a truck, have to be exchanged.

However SMC material has high rigidity, high e-module, and is not affected by thermal expansion which are important advantageous. A reason to replace the SMC material for panels and making them of thermoplastics instead is that thermoplastics has a better recyclability, gives a design quality improvement, increase the freedom to design more advanced forms and the possibility to paint the products without using a primer.

However switching to thermoplastic material in such panels, or in similar products, require a different design of the assembly due to the thermoplastic material characteristics, such as a higher exposure to thermal expansion, a lower e-module etc. But the change to thermoplastics also result in better recyclability, the possibility for more sophisticated design geometries and freedom to choose an advanced stylish design of the product. Of these reasons it is desirable to redesign the panel assembly in such a way that the panel may be manufactured of thermoplastic material.

The problem with using thermoplastic in molding panels is that 10 the stiffness of long slender panels, such as side air deflectors, will be relatively low. This creates low natural frequencies that may easily lead to vibrations and exhaustion of the material in the panels. Another problem is that the thermal expansion of thermoplastic materials is high, about 0.5%, which leads to that the product/panel may be easily deformed in a visual unfavorably way, if rigidly fixed. It is also problematic to connect two or more thermoplastic panels to each other in a sustainable way as it usually requires many fastening elements e.g. in the form of threaded inserts in the plastic or metal clips. To increase the stiffness of the panel the injection molding tool often needs many movable parts that in turn result in increased production cost. If a rigid metal profile is used for reinforcing the panel assembly and for making it more rigid, or for installing two or more thermoplastic panels together, the thermal forces will easily deform the panels.

Many attempts have been made to provide a simple and functional solution to the problems mentioned. Some solutions are based on local reinforcing members of steel while other solutions are complex and contain a number of components, which makes the panel assembly expensive to manufacture and install.

US2012/0074728 illustrates an example of a vehicle provided with aerodynamic skirt fairings designed to minimize aero- dynamic drag and for maintaining a smoother air flow around the vehicle. The invention relates to a support attachable to the cargo-supporting platform and structured to support an air-flow director. The support comprises a position adjuster 5 arranged to adjust the position of the air-flow director. This design is not primarily intended for reinforcing a panel assembly of thermoplastic materials as according to the present invention. 10 US2012003247illustrates another example of a resilient or flexible skirt panel assembly for installation on a trailer. The invention relates to a brace that provides structural support to the skirt panels. The brace is positioned on the interior surface of the skirt panel and attaches the panel to 15 the trailer base. This design is not either intended for reinforcing a panel assembly of thermoplastic materials.

Still another solution is disclosed in US2007/0120397. A skirt panel is here provided for interconnection to another abutted 20 similar skirt panel for attachment below a lower outer edge of a trailer in order to provide a continuous fairing extending downwardly from the trailer. The panels are provided with a plurality of longitudinally-extending, vertically spaced apart arcuate protrusion for reinforcing the panels. The panels are 25 secured to a lower portion of a trailer by laterally extending means. This solution does not disclose any supporting profile according to the present invention.

A number of similar solutions, regarding air deflector panels, 30 exist in the market but none of these prior known systems illustrates an air deflector panel that is reinforced in a way as according to the invention.

SUMMARY OF THE INVENTION One object of the present invention is to solve the above mentioned problems and to provide a simple panel assembly design which easily may be used for manufacturing and installing panels of thermoplastic material.

Another object of with the present invention is to connect at least two thermoplastic panels together in a rigid manner and at the same time prevent them from deforming due to thermal effects.

Another object of the present invention is to assemble the panels together with an edge strip made of e.g. rubber.

Another object of the present invention is to make it possible to reinforce the panel assembly with a rigid profile.

Another object of the present invention is to make it possible to install the rigid profile by means of an appropriate fastening element.

Another object of the present invention is to provide a panel assembly containing few components.

Another object of the present invention is to provide a panel that is mechanically stable and sustainable in use.

Another object of the present invention is to provide a panel assembly for attachment to a truck cab.

These and further objects and advantages is achieved by the invention by a panel assembly designed in accordance with the features recited in claim 1.

The present invention thus generally relates to a panel assembly where the at least one of the parts is made of a thermoplastic material. The assembly is primarily intended for installation behind the cab as an air deflector on a heavy 5 commercial vehicle, such as a truck.

The basic feature of the panel assembly is that a rigid profile, e.g. a metal profile like an extruded aluminum profile, is used for assembling the parts. Such a rigid profile could 10 be made of different material, also reinforced plastic, a composite material etc.

The inventive design provides the following functions: 15 Making the panel parts more rigid after assembling. Distributed clamping means along the panel parts.

Easy installation of the profile due to clips/spacers provided with snapping means.

Easy connections between the panels and the profile due to 20 protruding elements molded in the panels plastic material. Slots in the profile for allowing thermal expansion and movement of the panels.

The assembly may be used as a handle when opening the side air deflector in order to access the trailer.

To solve the problem of thermal expansion special clips/spacers has been designed. After that the profile has been located correctly on the panels the clip/spacers are pressed down between the profiles upraised edges and snaps 30 into the profile by means of elastic elements/legs, above the oval holes in the profile. Thus the plastic panels are allowed to move in their expanding direction. The clips/spacers are fixed by means of e.g. plastic screws.

Assembling is thus performed as follows: The panels are placed on a table and are hooked together.

Extension panels, e.g. the edge strip of rubber, are hooked to the main panels in a similar manner.

Clips/spacers with elastic legs are preinstalled, snapped/clipped, into the profile.

The profile is pressed down to the plastic panels.

The clip/spacer is evenly distributed in relation to the screw towers in the panels and holds all parts together.

The profile and the clips/spacers are primarily screwed 10 with plastic screws.

Two of the screws are used to fix the position of the panels and the profile and are thus not provided with clips/spacers.

The solution according to the invention provides: Increased stiffness of the panel as aluminum profiles is used in combination with clips/spacers and screws. This makes the thermoplastic panel more rigid.

- Resolves problems arising from thermal expansion when long slim thermoplastic panels are joined together. Clip/spacers and oval holes allow for thermal expansion of the panels.

Enables simplified installation and guiding of the panels.

Provides a method of assembling several panels and air deflector extensions with a single assembly compared to using pop rivets.

Reduces the need for clips and threaded inserts which result in lower costs.

The profile may be used as door opening handle for the side air deflector.

The main advantages of the inventive solution are that the panel assembly according to the invention is advantageously reinforced but still contains few components which make it cost effective to manufacture and install. By using few components and by using lightweight aluminum, the weight of an air deflector will be relatively low.

Further features and advantages of the invention will be apparent from the following, more detailed description of the invention, the accompanying drawings and the claims.

BRIEF DESCRIPTION OF THE DRAWINGS The invention is described below in some preferred embodiments 10 illustrated in the accompanying drawings.

Figure 1 illustrates a side view of a conventional heavy commercial vehicle provided with a side air deflector according to the invention.

Figure 2 illustrates a perspective view from behind of a part side air deflector, comprising the main part and a lower extension part as well as with its edge strip of rubber and a profile keeping all together.

Figure 3 shows from below a part of the profile and the clip/spacer as well as a screw, as illustrated in figure 2, in more detail.

Figure 4 illustrates an end view of the lower panel part, the rubber strip and the profile assembled together by means of a screw and a clip/spacer according to the invention.

Figure illustrates an exploded view of the assembly parts according to the invention.

DESCRIPTION OF PREFERRED EMBODIMENTS The present invention relates to a panel assembly where the at least one of the panel parts is made of a thermoplastic material.

Figure 1 illustrates a side view of a conventional heavy commercial vehicle 1 provided with a side air deflector 2 according to the invention. The deflector 2 is here installed on the side and behind the cab 3a and in front of the trailer 3b. Such a deflector 2 is long and slim and needs to be of a rigid design. The air deflector 2 is arranged with a rear edge 10 strip/panel 4 by e.g. rubber and the deflector 2 may be assembled by two or more plastic panels.

Figure 2 illustrates a perspective view from behind of a part of a side air deflector 2, comprising a main part 5, a lower 15 extension part 6, an edge strip 4 of rubber and a profile 7 of e.g. metal/aluminum keeps all parts together. To solve the problem of thermal expansion special clips/spacers 8 are arranged in the profile 7. Before the profile 7 has been located correctly on the panels 5,6, and the edge strip 4 if 20 any, the clips/spacers 8 are pressed down between the profiles 7 upraised legs 7a,b, the profile 7 describes an H in cross-section, and snaps into the profile 7 by means of elastic legs 10 above oval holes 11 (see figure 3) arranged in the profile 7. By means of the holes 11 and the clips/spacers 8 the 25 plastic panels 5,6 are allowed to move in their longitudinal expanding direction. The clips/spacers 8 and the profile 7 are finally fixed by means of e.g. plastic screws 12.

Figure 3 shows from below a part of the profile 7 and the 30 clip/spacer 8 as well as a screw 12, as illustrated in figure 2, in more detail. The profile 7 is arranged with oval holes 11 in which the clips/spacers 8 are located. The clips/spacers 8 are arranged with an oval part 13 fitting in the oval holes 11, but in such a manner that the clip/spacer 8 may move/glide 35 in the axial/longitudinal direction of the profile 7. The clip/spacer 8 and profile 7 is finally connected/fixed to the panels 5,6 by screws 12.

Figure 4 illustrates an end view of a lower panel part 5,6, the outer edge strip 4 of rubber and the profile 7 assembled 5 together by means of a screw 12 and a clip/spacer 8 according to the invention. The clip/spacer 8 is provided with at least two elastic elements/legs that may be fastened/snapped into/-against grooves or edges 14 arranged in the profile 7, on the inside of the upstanding legs 9a,b of the profile 7. The lower leg 7c of the H-formed profile 7 is arranged to engage into a recess 9 arranged in the outer edge strip 4 and fixes/locks thereby this part to the air deflector assembly 2. The profile 7 rests on a rib 15 with screw towers 15a molded in the panel 5,6 integrated as a unitary construction with the panel 5/6. 15 The clip/spacer 8 may also be integrated with a screw (not shown).

Figure illustrates an exploded view of the parts of the deflector assembly 2 according to the invention. The profile 7 20 locks the parts together, the main panel 5, the lower extension panel 6 and the edge strip 4 of rubber by means of clips/spacers 8 and plastic screws 12. The panels 5,6 are designed with protruding ribs 16 providing rigidity to the deflector assembly 2 during use.

The above description is primarily intended to facilitate the understanding of the invention. However the invention is of course not in any way restricted to only the disclosed embodiments, but many possibilities to modifications would be apparent to a person skilled in the art within the scope of the invention without departing from the basic idea of the invention as defined in the appended claims.

Claims (10)

CLAIMS 1. Panel assembly (2) comprising parts (5,6) made of a thermoplastic material, primarily intended for installation/use as an air/wind deflector on a heavy commercial vehicle, such as a truck, for improving the aerodynamic air flow around the cab (3a) and the trailer (3b), characterized by that

1. at least one profile (7) is arranged to support the panel 10 assembly (2), connecting the different parts (4-6) of the panel assembly (2), 2. the profile (7) is arranged with at least two elongated mounting holes (11) adapted for installing a clip/spacer (8) connecting the panel parts (4-6) to the profile (7), in order to provide a panel assembly (2) with required characteristics, such as sufficient stiffness and permitting thermal expansion of the panel parts (4-6).

2. Panel assembly (2) according to claim 1, characterized by that the clip/spacer (8) is arranged to fix the profile (7) to the panel parts (4-6) and is provided with at least two elastic elements/legs (10).

3. Panel assembly (2) according to claim 1 or 2, characterized by that the clip/spacer (8) is arranged to be snapped in place into the profile (7) by means of the elastic elements/legs (10) and 30 the inside edges/grooves (14) of the profiles legs (7a,b).

4. Panel assembly (2) according to any preceding claims, characterized by that the clip/spacer (8) is made of plastic.

5. Panel assembly (2) according to any preceding claims, characterized by that 12 the clip/spacer (8) is integrated with a screw (12).

6. Panel assembly (2) according to any preceding claims, characterized by that that the profile (7) is H-formed in cross-section.

7. Panel assembly (2) according to any preceding claims, characterized by that the profile (7) is provided with at least two upstanding legs (7a,b) arranged with inside edges (14).

8. Panel assembly (2) according to any preceding claims, characterized by that the profile (7) is made of metal, such as extruded aluminium.

9. Panel assembly (2) according to any preceding claims, characterized by that the profile (7) is arranged to engage into a recess (9) provided in the outer edge strip (4) and fixes/locks thereby this outer edge strip (4) to the air deflector assembly (2).

10. Vehicle provided with a panel assembly (2) according to any of the claims 1-9. T 2Id 9 17T \N £ 2!A ET TT ZT'-------------, eL I aL _ S 2IA 91 L ZT X