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Patent 2528558 Summary

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(12) Patent: (11) CA 2528558
(54) English Title: TRAILER SKIRT PANEL
(54) French Title: PANNEAU DE PROTECTION DE REMORQUE
Status: Granted
Bibliographic Data
(51) International Patent Classification (IPC):
  • B62D 63/08 (2006.01)
  • B62D 25/02 (2006.01)
  • B62D 35/00 (2006.01)
(72) Inventors :
  • LAYFIELD, BRIAN PETER (Canada)
  • MANCINA, JOSEPH (Canada)
  • HAWS, JAMES DOUGLAS (Canada)
  • PROKUDIN, ANDRIY NICOLAYE (Canada)
(73) Owners :
  • ZF COMPOSITES NORTH AMERICA LTD. (Canada)
(71) Applicants :
  • LAYDON COMPOSITES LTD. (Canada)
(74) Agent: RIDOUT & MAYBEE LLP
(74) Associate agent:
(45) Issued: 2013-04-09
(22) Filed Date: 2005-11-29
(41) Open to Public Inspection: 2007-05-29
Examination requested: 2010-11-09
Availability of licence: N/A
(25) Language of filing: English

Patent Cooperation Treaty (PCT): No

(30) Application Priority Data: None

Abstracts

English Abstract

A skirt panel is provided herein for interconnection to another abutted similar skirt panel for attachment beneath a lower, outer longitudinally-extending edge of a trailer including a rear wheel assembly of a tractor-trailer rig, thereby to provide a continuous fairing extending downwardly from the trailer. The skirt panel includes a monolithic, generally-rectangular composite reinforced thermoplastic structure, having vertical lateral side edges configured and arranged for connection to associated vertical lateral side edges of abutting similar skirt panels. This provides a longitudinally-extending fairing for extending contiguously on each side of the trailer, a front face of the thermoplastic structure being provided with a plurality of longitudinally-extending, vertically-spaced-apart arcuate protrusions. The outer face of the thermoplastic panel preferably also is provided with dimples. The reinforcing comprising a panel secured to an inner face of the skirt panel and is provided with laterally-extending means whereby abutting skirt panels are secured to one another; whereby, when said fairing is secured to a lower portion of said trailer, the fairing extends downwardly from the trailer to from 60% to 80 % of the distance to the road, so that a portion of any impinging air is directed laterally around the wheels of the rear wheel bogeys to reduce the aerodynamic drag of the trailer and of the wheel assembly.


French Abstract

Un panneau de protection est présenté pour l'interconnexion à un autre panneau de protection abouté similaire pour être fixé sous un rebord inférieur, extérieur, se prolongeant longitudinalement d'une remorque comprenant un ensemble de roue arrière d'une attache de remorque, offrant ainsi un raccord s'étendant vers le bas à partir de la remorque. Le panneau de protection comprend une structure thermoplastique renforcée de composite généralement rectangulaire, ayant des bords latéraux verticaux configurés pour un raccord à des bords latéraux verticaux associés des panneaux de protection similaires aboutants. Un raccord s'étendant longitudinalement se prolonge de manière contigüe sur chaque côté de la remorque, une face avant de la structure thermoplastique comportant une pluralité de protrusions courbées espacées verticalement s'étendant longitudinalement. La face externe du panneau thermoplastique comporte préférablement également des dépressions. Le renforcement comprenant un panneau fixé à une face interne du panneau de protection et comprend des moyens s'étendant latéralement où les panneaux de protection aboutants sont fixés l'un à l'autre; lorsque ledit raccord est fixé à une portion inférieure de ladite remorque, le raccord s'étend vers le bas à partir de la remorque de 60 % à 80 % de la distance à la route, de sorte qu'une portion de l'air incident est dirigé latéralement autour des roues des boggies de roue arrière pour réduire la trainée aérodynamique de la remorque et de l'ensemble de roue.

Claims

Note: Claims are shown in the official language in which they were submitted.


CLAIMS
1. A skirt panel for interconnection to another similar skirt panel for
attachment beneath a
lower, outer longitudinally-extending edge of a trailer including a rear wheel
assembly of a
tractor-trailer rig, thereby to provide a continuous fairing extending
downwardly from said
trailer, said skirt panel comprising:
a monolithic, generally-rectangular composite reinforced thermoplastic
structure, having
vertical lateral side edges configured and arranged for connection to
associated vertical lateral
side edges of abutting similar said skirt panels, thereby to provide a
longitudinally-extending
fairing for extending contiguously on each side of said trailer, a front face
of said thermoplastic
structure being provided with a plurality of longitudinally-extending,
vertically-spaced-apart
arcuate protrusions;
said reinforcing comprising an open lattice panel secured to an inner face of
said skirt panel and
being provided with laterally-extending means whereby abutting said skirt
panels are secured to
one another; whereby, when said fairing is secured to a lower portion of said
trailer, said
fairing extending downwardly from said trailer to from 60% to 80 % of the
distance to the road,
so that a portion of any impinging air is directed laterally around the wheels
of the rear wheel
bogeys to reduce the aerodynamic drag of said trailer and of said wheel
assembly.

2. The skirt panel of claim 1, wherein an upper edge of said skirt panel
includes means for
rigidly securing said skirt panel to said trailer.
3 The skirt panel of claim 2, wherein said means for rigidly securing
said skirt panel to
said trailer comprises snap members.

4 The skirt panel of claims 1 to 3, wherein each vertical edge of said
skirt panel includes a
reinforcing and connecting truss having connection points to enable abutting
similar skirt panels
to be rigidly connected to one another.


31

5. The skirt panel of claim 4, wherein said truss is formed of stamped metal.

6. The skirt panel of claims 4 or 5, wherein said truss is of an open lattice
structure.


7 The skirt panel of claims5 or 6, wherein said stamped metal comprises
galvanized steel vertical truss and securement members which are secured to
said
thermoplastic portion of said skirt panel.

8. The skirt panel of claim 1 wherein two lateral vertical side edges extend
inwardly
from the rear face thereof, and wherein upper and lower edges thereof are
integrally
connected to said two inwardly extending lateral edges.

9. The skirt panel of claim 1 or 8, including a support strut connected to
the
interior face at the bottom edge and secured to the interior face adjacent the
top edge
thereof.

10. The skirt panel of claim 9, wherein said support strut includes an I-beam
clamp at
the upper edge thereof.

11. The skirt panel of claims 9 or 10, wherein the inner face of said strut at
the upper
edge thereof includes means to connect said strut to the inner face of said
skirt panel.

12. The skirt panel of claims 1 to 11, wherein said thermoplastic is selected
from the
group consisting of co-extruded ABS with a cap of a styrene acrylonitrile
copolymer
which has been impact-modified with acrylic ester rubber, high molecular
weight
polyethylene, polypropylene and TPO.

13 The skirt panel of claims 1 to 12, including a thinner, more flexible
synthetic
plastic lower panel, said thinner, more flexible synthetic plastic lower panel
being
attached to the lower edge of said skirt panel, thereby to allow panel flexing
over road
objects, e.g., curbs, railroad tracks and below grade loading docks.



32

14. The lower panel of claim 13, wherein said synthetic plastic comprises a
thermoplastic elastomer.

15. The lower panel of claim 14, wherein said thermoplastic elastomer
comprises
flex PVC.

16. The skirt panel of claims 1 to 15, which is about 0.187 inches thin.

17. A method of injection moulding a skirt panel for interconnection to a
similar
said skirt panel for attachment beneath a lower, outer longitudinally-
extending edge of a
trailer including a rear wheel assembly of a tractor-trailer rig, thereby to
provide a
continuous fairing extending downwardly from said trailer, said method
comprising:
providing at least one high pressure mould ; producing a first component face
panel of
said skirt panel by injection moulding a thermoplastic material in said at
least one high
pressure mould; producing a second component support strut of said skirt panel
by
injection moulding a thermoplastic material in said at least one high pressure
mould;
extruding a third component thermoplastic material track of said skirt panel;
attaching
said first component injection moulded face panel and said second component
support
strut to said extruded material track of said skirt panel, thereby to provide
a first
intermediate skirt panel; providing a means to fasten a horizontal edge of
said second
component support strut to said tractor-trailer rig; and providing a means to
fasten a
horizontal edge of said extruded material track to said tractor-trailer rig,
thereby to form
said skirt panel having both vertical and horizontal support structures.


18. A method of injection moulding a skirt panel for interconnection to a
similar said
skirt panel for attachment beneath a lower, outer longitudinally-extending
edge of a
trailer including a rear wheel assembly of a tractor-trailer rig, thereby to
provide a
continuous fairing extending downwardly from said trailer, said method
comprising:
providing a structural web mould; producing a first component face panel of
said skirt
panel by injection moulding a thermoplastic material in said structural web
mould;
providing a high pressure mould; producing a second component support strut of
said
skirt panel by injection moulding a thermoplastic material in said high
pressure mould;
extruding a third component thermoplastic material track of said skirt panel;
attaching
33

said first component injection moulded face panel and said second component
support
strut to said extruded material track of said skirt panel, thereby to provide
a first
intermediate skirt panel; providing a means to fasten a horizontal edge of
said second
component support strut to said tractor-trailer rig; and providing a means to
fasten a
horizontal edge of said extruded material track to said tractor-trailer rig,
thereby to form
said skirt panel having both vertical and horizontal support structures.
19. The method of claims 17 or 18 including the additional steps of
extruding a thin synthetic plastic panel; and attaching said extruded
synthetic plastic
panel to the lower edge of said skirt panel, thereby to provide a final skirt
panel, which
allows panel flexing over road objects and to achieve further fuel savings.
20. The method of claims 17 to 19, wherein said moulds contain inner copper
cooling and heating lines, which aid in the manufacturing method.
21. The method of claims 17 to 20, wherein said moulds contain an insert,
which can
be removed to form a side marker light panel.

22. The method of claims 17 to 21, wherein said panels are vertically attached
to
each other by a snap-in feature, without the use of independent fasteners.

23. The method of claims 17 to 21, wherein said panels are moulded with "live

hinge" areas and "V" notched rib structure to allow additional panel flexing.

24. The method of claims 17 or 18, wherein said thermoplastic is selected from
the
group consisting of co-extruded ABS with a cap of a styrene acrylonitrile
copolymer
which has been impact-modified with acrylic ester rubber, high molecular
weight
polyethylene, polypropylene and TPO.



34

25. The method of claims 17 to 24, wherein said heating to a suitable
temperature, is
about 320°F.
26. The method of claim 25, wherein said cooling is down to a temperature of
about
140°F.
27. The method of claim 19, wherein said extruded synthetic polymer is flex
PVC
(polyvinyl chloride).
28. The method of claims 17 to 27, wherein said thermoplastic elastomer is a
thermoplastic elastomer, which can be processed and recycled like
thermoplastic
materials.
29. A trailer of a tractor-trailer rig to which is fastened a fairing
consisting of a
plurality of contiguous skirt panels depending below the right hand and left
hand sides
thereof, to from 60% to 80 % of the distance to the road, so that a portion of
any
impinging air is directed laterally around the wheels of the rear wheel bogeys
to reduce
the aerodynamic drag of said trailer and of said wheel assembly, said skirt
panels having
the structure of any one of claims 1 to 9.
30. The trailer of claim 29, wherein said fairing terminates about 10 inches
from the
surface of the road.



35

Description

Note: Descriptions are shown in the official language in which they were submitted.


CA 02528558 2005-11-29


TRAILER SKIRT PANEL
BACKGROUND OF THE INVENTION
Field of the Invention
[0001] This invention relates to a skirt fairing, which is attachable beneath
a lower,
longitudinal edge of a trailer, and to methods for the production thereof The
present invention
also relates to increased fuel efficiency and greater driving safety by
deflecting and otherwise
altering the airflow e.g., by creating laminar flow along the side and
underneath the trailer of a
tractor trailer rig or the like.
Description of the Prior Art
[0002] Modern cars are quite aerodynamically efficient but limited progress
has been
made with heavy-duty vehicles, trucks and the like. This is unfortunate
principally because the
fuel consumption by such a vehicle is high and any improvement in its
aerodynamics
performance is of great significance to transportation tractor-trailer rigs of
the transportation
industry in improving fuel economy. Acceleration and speed are, in general, of
little interest in
trucking. Existing performance in these fields is considered adequate. However
fuel
consumption is a major concern. It has recently been suggested that higher
fuel prices, coupled
with intense competition, may have the effect of closing down certain
carriers. As the trailer of a
large tractor-trailer rig is pulled forward by the tractor, a great deal of
turbulence is created along
the side and underneath the trailer as the vehicle disturbs the air. This
turbulence results in
increased resistance to forward movement of the tractor-trailer rigs, and thus
to lower fuel
efficiency. Work in a Low Speed Aerodynamics Laboratory in the early 1980's
had
demonstrated that smaller, but useful, drag reductions were still available
from other treatments
to the truck body or trailers than fairings or deflectors. These consisted of
skirts that closed the
body sides down toward the ground and beveled panels that reduced base drag.
The skirts could
provide a drag coefficient reduction of 0.06 per trailer on a tractor-trailer
combination or about
0.02 on a straight truck. The rear panels (or the equivalent body beveling
that has been used on
buses) can produce a drag coefficient reduction of 0.06 on a straight truck,
0.08 on a bus, but

CA 02528558 2005-11-29


only 0.04 on a trailer. The reason for the poor performance on the trailer is
not known with
certainty but may relate to the high-drag configurations on which it was first
tested. The lower
drag straight truck and the even lower-drag bus have much larger savings from
this modification.
[0003] Moving freight by highway trucks has been increasing in volume for
several
years, and it appears that it will continue to increase in the future. This
method of freight
handling has proved to be more efficient and quicker than any other means in a
large majority of
situations. Nevertheless, this method has need of further improvement. A large
problem is the
energy needed to overcome wind resistance. It has been recognized that, by
streamlining,
vehicles can accomplish great savings in fuel expenses. Eddy currents are
produced underneath
the truck and its trailers, which add to the wind resistance. There is thus a
great need to provide a
maximum streamlining effect in order to reduce fuel consumption and operating
costs.
[0004] Trucks, and particularly tractor-trailer rigs having multiple rear
wheels, present a
high resistance to air flow with the rear wheels, suspension, and other
mechanical components at
the rear of the vehicle interfering with the smooth flow of air around and
under the vehicle. This
interference creates turbulence and a high aerodynamic drag, which results in
high fuel use and a
high cost of operation. Furthermore, the turbulent flow can affect the
trailers ability to track
behind the trailer. This reduced driving stability is most prevalent in high
crosswind conditions
or when the trailer is empty. Furthermore, the turbulent flow, caused by yaw
angle air traveling
across the trailer bottom and releasing from the downwind side, creates a
hazard for the drivers
of other vehicles when it is raining or snowing, or the roadway is wet, for in
such a situation, the
rain or snow and any water splashed up from the roadway by the tires swirls
around the tires and
is thrown outwardly by the tires themselves and by the turbulent air flow.
When this splashing
and spraying water strikes the windshields of other vehicles, it lowers
visibility for such
motorists, and can cause them to lose control of their vehicles. Further, the
spray raised by the
rear tires reduces the truck driver's vision of the rear of the truck, making
it more difficult for the
truck driver to handle his vehicle when it's moving in traffic it is therefore
advisable to improve
the visibility of the driver.

2

CA 02528558 2005-11-29


[005] It is well known that the fuel efficiency of any motor driven vehicle is
directly related to
the aerodynamic structure of the tractor-trailer rig and the amount of
atmospheric turbulence
caused by the movement of the vehicle. The greater the air turbulence created
by the vehicle the
greater the resistance, and the more fuel required to move the vehicle. In
today's economy, fuel
efficiency is of major concern and is particularly relevant when considered in
terms of large
tractor trailers used for transporting goods wherein the cost of fuel consumed
moving the goods
directly affects the market price of the goods. It is well known that
improving the aerodynamics
of a vehicle improves many aspects of its performance, particularly
acceleration, top speed, fuel
economy tracking stability and tire wear, driver comfort and ease of driving
in cross winds.
[006] Although fuel efficiency has become a primary concern in the recent
decade because of
fuel cost, a second major consideration is that of increasing the safety of
operation of tractor-
trailer rigs, particularly from the point of view of safety of other motorists
sharing the road with
such rigs. A major disadvantage of tractor trailers on the highway is that,
unaltered, the turbulent
air flow beneath and behind a tractor trailer is generally in a direction
transverse to that of the
movement of the tractor trailer. This means that in wet or snowy conditions,
mist and/or snow is
thrown laterally of the trailer causing a vision and turbulence problem for
any motorist passing
or being passed by the tractor-trailer rig.
[007] Many modifications and accessories have been developed to improve the
streamline of the
airflow around a combined tractor-trailer truck. It is known that the amount
of fuel required to
haul a trailer over long distances can be reduced by equipping the trailer
with a suitable
aerodynamic fairing. An important such design is in the form of side shield or
fairings, which are
extended between the side of the tractor cab and the side of the trailer to
provide a smooth
transition surface there between. The side shields or fairings streamline
airflow past the void
space between the tractor and trailer by eliminating turbulence, which
increases drag on the
truck. Side shields eliminate the yaw angle air between rear of the tractor
and the front of the
trailer. Without side shields the air travels across the trailer face and
releases from the
downwind side. One type of fairing is mounted beneath each of the trailer's
lower, outer
longitudinal edges to extend between the trailer wheel assembly and the wheels
of the tractor
3

CA 02528558 2005-11-29


unit used to haul the trailer. Improved fuel economy is achieved while the
trailer is hauled at
highway speeds over long distances with fairings or side skirts mounted as
aforesaid. Useful
drag reductions were also said to be provided by skirts that closed the body
sides down towards
the ground to provide a reduced drag coefficient, or by bevelled panels that
reduced base drag.
Rear panels or body bevelling also reduced the drag somewhat, but apparently,
not as much as by
the use of skirts.
[008] Many patents have issued which purport to have solved the above-
identified problems.
Among them, are the following:
[009] Grout, Sr. et al, U.S. Pat. No. 3,743,343 disclosed a baffle means to be
mounted on the
undercarriage of the trailer forward of its rear axle(s) which channeled the
airflow toward the
rear and in the direction generally perpendicular to the rotational axes of
the wheels, to mitigate
the turbulence discharge from beneath the trailer in a direction generally
transverse the trailer's
movement. Besides the baffle means mounted on the sides forward of the rear
axle, the Grout
patent also disclosed a so-called "coagulating means" which was mounted to the
undercarriage
of the trailer rearwardly of the rear axle and which was designed to gather
any turbulent
discharge and direct it downwardly towards the road or pavement, thus
attempting to minimize
lateral discharge.
[0010] U.S. Patent No. 4,021,069, patented May 3,1977 by Hersh provided an
aerodynamic drag
reducing apparatus for mounting on the bluff, forward face of the trailing
element of an over the
road vehicle. The apparatus comprises a contoured member carried on the
forward face and
extending outwardly there from with its point of maximum extension
substantially aligned for
impingement by an air stream. The portion of the surface displaced above the
point of maximum
extension describes a perturbed paraboloid of revolution with the rearward
portions of the
apparatus describing three sides of rectangle for aerodynamic merging with the
top and side
edges of the trailing element.
[0011] U.S. Patent No. 4,262,953, patented Apr 21 1981 by McErlane, provided
an airfoil or
deflector panel for being mounted ahead of the rearmost set of wheels of a
vehicle such as a
4

CA 02528558 2005-11-29


truck or tractor-drawn trailer to direct air flow in a manner which reduces
the relatively negative
air pressure normally occurring behind a moving vehicle. The surface of the
deflector, which is
presented in the direction of vehicle motion, has a bilateral or compound
convex curve a
deflector panel of compound convexity mounted just forward of the rear axle or
axles of a
tractor drawn trailer.
[0012] U.S. Pat. No. 4,486,046, patented Dec 4, 1984, by Whitney et al taught
an airstream
deflector assembly that mounted on the underside of a large vehicle, e.g., a
semi-trailer or the
like, to reduce drag, improve fuel economy, and reduce turbulence of rain or
snow on a roadway
traveled by the vehicle. Such assembly included a main panel which was
essentially flat and was
situated well forward of the following tires of the vehicle and deflecting the
airstream
downwardly primarily below the following axle and centers of such following
tires. Such main
deflection panel had mounted thereon four lateral airstream deflectors, two
outboardly and two
inboardly of the panel which served to concentrate the deflected airstream
laterally toward the
following tires of the vehicle and away from the "tunnel" between the tires.
Both the main
deflection panel and lateral deflectors were preferably angularly adjustable,
either manually or
remotely, with the preferred angularity of the main panel being with it lying
in a plane which
intersected the following tires slightly below their axis of rotation, and
with the preferred
angularity of the lateral deflectors being with them lying in planes
substantially intersecting the
inner faces of the following tires of the vehicle, e.g. at preferred angles
relative to the direction
of movement of the vehicle.
[0013] U. S. Patent No 4,518,188, patented May 21, 1985, by Witten provided an
airflow
improvement device for improving aerodynamic characteristics of a tractor-
trailer truck. Such
improvement included a side panel extending between the side of the tractor
and the side of the
trailer. A first end of the side panel was fixed to one of the tractor or
trailer and the other end of
the side panel was slidably restrained in a pocket structure mounted to the
other of the tractor or
the trailer so that the side panel will bend to form a smooth curved
transition surface between the
sides of the tractor and the trailer when the truck articulates to make a
turn.

5

CA 02528558 2005-11-29


[0014] U.S. Patent No.4,640,541, patented Feb.3, 1987 by FitzGerald et al,
provided an air
deflector for the rear wheels of vehicles, e.g., trucks and trailers. The
deflector consisted of a
fairing suspended beneath the truck or trailer body immediately in front of
the rear wheels and
extending completely across the width of the body. The surface of the fairing
was curved in both
a lateral and a vertical direction to deflect impinging air and entrained
water or snow around or
under the wheels. In a preferred form, the device was formed with a plurality
of generally vertical
grooves angled toward the centerline of the vehicle. The grooves directed
impinging air
downwardly and between the rear wheels. The air deflector served to suppress
splashing and
spraying of water from the roadway and of rain or snow, and reduced
aerodynamic drag to
improve handling and reduce fuel consumption.
[0015] U.S. Pat. No. 4,746,160 patented May 24, 1988 by Wiesemeyer, was
directed to a
highway truck with a semi-trailer and taught streamlined skirts on both sides
of the vehicle that
extended immediately above ground level, between the wheels.
[0016] U.S. Patent No.5, 689,384, patented Mar 111997, by Loewen provided a
fairing for use
on a trailer. The trailer had a first member of the first edge that was
hingedly attached to the
trailer of the first edge. A second member had a first edge also hingedly
attached to the trailer at
that edge. A third member had a first edge hingedly attached to the trailer
and arranged adjacent
to the second member. The third member was telescopically receivable within
the second
member. The fairing was arranged along the lower edge of a trailer, adjacent
the wheel.
[0017] U.S. Patent No.5, 921,617, patented July 13,1999 by Loewen eta!
provided a fairing
attachable beneath a lower, outer longitudinal edge of a trailer. The fairing
had longitudinally
extending forward and rearward sections. The rearward section can be moved
longitudinally to
adjustably locate its rearward edge in a selected position forward of the
trailer's wheel assembly.
Such adjustable positioning occurred automatically if the rearward section was
coupled to, and
longitudinally movable with, the support frame for the trailer's wheel
assembly, thus maintaining
the rearward edge of the fairing in the selected position whenever the
trailer's wheel assembly is
longitudinally adjusted relative to the trailer. A hinge mechanism coupled
between the trailer
6

CA 02528558 2005-11-29


and the fairing allowed pivotal displacement of each fairing section between
lowered and raised
positions. The lowered position was for long distance haulage of the trailer
in order to achieve
fuel economy. The raised position was for situations in which the trailer must
be maneuvered
over ramps, uneven terrain, etc. which might contact the underside of or
otherwise interfere with
the fairing.
[0018] US Patent No 6,257,655, patented July 10,2001 by G.L.Selby, et al
provided a protective
skirt for an open frame trailer adapted to transport vehicles. The trailer
included a wheeled
chassis supporting a frame and track assembly. The trailer had a front-end
adapted to be
mounted in towing engagement on a tractor truck, a rear end adapted for
receiving vehicles to be
carried, and a middle section including the frame and track superstructure for
supporting the
vehicles. The protective skirt included a pair of first skirt sections mounted
one on each side of
the chassis in screening position at the trailer front end, a pair of second
skirt sections mounted
on the chassis one on each side thereof in screening position at the trailer
middle section, a pair
of third skirt sections mounted in screening position one on each side of the
chassis above the
wheels, and a pair of fourth skirt sections mounted on the chassis one on each
side in screening
position at the trailer rear section. The skirt assembly protected vehicles
carried on the trailer
against damage from rocks and road debris.
[0019] U.S. Patent No. 6,644,720, patented Nov 11,2003 by Long et al, provided
a streamlined
highway truck including a tractor with a cab having a roof and two side
sections and a semi
trailer having a front, a top and two side sections and being pivotally joined
by a fifth wheel to
the tractor. The tractor had a top panel extending from the roof to adjacent
the front edge of the
top of the semi trailer and two side panels extending from the side sections
of the tractor to the
front edges of the respective side sections of the semi trailer. The side
panels extended vertically
from adjacently above ground level to a juncture with the top panel. Each of
the side panels
included a rigid portion connected to the side section of the cab and a
vertical strip portion
hingedly connected to the rigid portions and adapted to swing outwardly to
accommodate a
specific angular relationship between the side panel of the tractor and the
adjacent side section
of the semi trailer. The strip portions were spring biased to remain aligned
with their respective
7

CA 02528558 2005-11-29


rigid portions. The semi trailer had side panels extending downwardly from the
bottom of the
side sections to adjacently above ground level from adjacent the tractor
wheels under the front of
the semi trailer to adjacent the semi trailer wheels adjacent the rear of the
semi trailer. Each of
the above patented devices, though providing improvements in the art, have
failed to adequately
provide an aerodynamic side panel structure which presented a durable and easy
to use fixed
structure for accomplishing airflow improvement around a tractor-trailer
truck. Some disclosed
structures used very rigid side panels, which were difficult to maintain in
position, and were
awkward to handle. Some structures required cumbersome tensioning means to
maintain the
skirt or deflector in position.
SUMMARY OF THE INVENTION
[0020] The present invention seeks to improve on the prior art.
[0021] The principal aim of the present invention is to provide structures for
reducing
aerodynamic drag on road vehicles, and, more particularly, to providing air
deflector structures
for creating better laminar air flow along the sides of vehicles, and,
directing air flow around the
rear suspension, axles, wheels, tires, brake chambers, slack adjusters, and
hangers under
vehicles, e.g., trucks and trailers. Specifically, this invention aims to
provide relatively- flexible
side panels, which extend under a trailer to within 0.8 of the distance to the
road surface, to
provide improved aerodynamic airflow characteristics.
[0022] It is an object of one aspect of the present invention to overcome the
problem of splash
and spray of water by the rear wheels of trucks and trailers. It is an object
of another aspect of
the invention to provide an air deflector for vehicles to reduce the outward
spraying of road
water and rain.
[0023] An object of another aspect of the invention is to reduce the
aerodynamic drag of
vehicles, e.g., trucks and tractor-trailer rigs.



8

= CA 02528558 2005-11-29

[0024] An object of a further aspect of the present invention is to provide an
air deflector for
vehicles to provide a smooth flow of air around the rear wheels and suspension
thereof to reduce
air deflector drag.
[0025] An object of another aspect of the present invention is to reduce the
aerodynamic drag of
vehicles e.g., trucks and tractor-trailer rigs.
[0026] An object of another aspect of the present invention is to provide
increased fuel efficiency
and greater driving safety by deflecting and otherwise altering the airflow to
create laminar
airflow along the sides of the trailer of a truck trailer rig or the like.
[0027] An object of another aspect of the present invention is to provide
greater trailer tracking,
stability and reduced tire wear of vehicles, e.g., trucks and tractor-trailer
rigs.
[0028] An object of another aspect of the present invention is to eliminate
the yaw angle air
crossing under the trailer and releasing from the downwind side of the
trailer.
[0029] The present invention relates, in general, to devices for reducing
aerodynamic drag on
road vehicles, and, more particularly, to an air deflector to eliminate the
yaw angle air crossing
under the trailer and releasing from the downwind side of the trailer, and,
for directing air flow
around the rear suspension, axles, wheels, tires, brake chambers, slack
adjusters, and hangers
under vehicles e.g., trucks and trailers.
STATEMENTS OF INVENTION
[0030] One embodiment of the present invention provides a skirt panel for
attachment beneath a
lower, outer longitudinal right hand and left hand edges of a trailer of a
tractor-trailer rig
including optional right hand and left hand rear wheel bogeys. The skirt panel
includes a
monolithic, generally-rectangular composite thermoplastic/metal reinforcing
structure, having
longitudinally-extending forward and rearward sections for connection to
associated sections of
similar said skirt panels to provide a generally-rectangular skirt panels for
extending
contiguously on each side of the trailer. The thermoplastic portion includes a
facing provided
9

CA 02528558 2005-11-29


with a plurality of longitudinally-extending, vertically-spaced-apart arcuate
protrusions and
preferably also dimples within the flat portion of the facing and/or the
arcuate protrusions. The
metallic portion is a reinforcing backing. The skirt panel is configured and
arranged to extend
downwardly up to about 60% to about 80% , or about no more than10 inches of
the distance to
the road surface from the trailer, so that a portion of any impinging air is
directed laterally along
the trailer and the rear wheel bogeys and the remaining impinging air is
directed laterally around
the wheels of the rear wheel bogeys to reduce the aerodynamic drag of said
trailer and of said
wheel assembly.
[0031] By an aspect of this embodiment of the present invention, the skirt
panel further includes
bracket means for rigidly securing the skirt panel to the trailer.
[0032] By an aspect of this embodiment of the present invention, the
thermoplastic material of
the skirt panel is co-extruded ABS (acrylic/butadiene/styrene resin) with a
cap of a styrene
acrylonitrile copolymer which has been impact-modified with acrylic ester
rubber.
[0033] By an aspect of this embodiment of the present invention the metal
portion of the skirt
panel comprises stamped and formed steel vertical truss and clamp angles which
are fastened in
a suitable manner to the thermoplastic portion.
[0034] By an aspect of this embodiment of the present invention, the skirt
panel includes an
optional synthetic plastic component attached to the lower edge of the skirt
panels to allow panel
flexing over road objects, e.g., curbs, railroad tracks and below grade
loading docks.

[0035] By an aspect of this embodiment of the present invention synthetic
plastic is a
thermoplastic polymer. The thermoplastic polymer may preferably be flex PVC
(polyvinyl
chloride) or extruded Santoprene (the Trademark of Advanced Elastomer Systems
LP for its
brand of TPE-thermoplastic elastomers- a diverse family of rubber-like
materials which can be
processed and recycled like thermoplastic materials).


0

CA 02528558 2005-11-29


[0036] By an aspect of this embodiment of the present invention, the thickness
of the
thermoplastic material of the skirt panel is about 0.187".
[0037] Another embodiment of the present invention provides a trailer which is
equipped with
a plurality of contiguous skirt panels depending below the right hand and left
hand sides thereof,
the skirt panels having the structure as described hereinabove.
[0038] Yet another embodiment of the present invention provides a first method
of vacuum
forming a skirt panel. The method includes the following steps: providing an
aluminum mould;
providing a thin sheet of thermoplastic material; clamping the thin sheet of
thermoplastic
material in a clamp frame; introducing the clamped thin sheet of thermoplastic
material into a
heating oven; heating the oven to a temperature greater than the softening
temperature of said
thermoplastic material; placing the heated thin sheet of thermoplastic
material over the
aluminum mould; forcing the mould into the hot thin sheet of thermoplastic
material until a
sealing flange air seal is formed around the outer edge of said mould; drawing
a vacuum from
inside the mould, thereby to force the hot sheet of thermoplastic material to
form around the
contours of the mould.; reducing the temperature of the hot sheet of
thermoplastic material to a
suitable temperature below the softening temperature of the thermoplastic
material; opening the
clamp frame and removing the moulded first intermediate skirt panel from the
mould,. trimming
off excess material from the moulded first intermediate skirt panel and
drilling suitable
mounting holes therein, thereby to provide a second intermediate skirt panel;
providing a metal
reinforcement which is stamped and formed; bolting the stamped and formed
metal
reinforcement to the interior of the second intermediate skirt panel, thereby
to form vertical truss
and clamp angles on the interior of the second intermediate skirt panel,
thereby to form a third
intermediate skirt panel; extruding a synthetic plastic panel; and attaching
the extruded
synthetic plastic panel to the lower edge of the third intermediate skirt
panel, thereby to provide
a final skirt panel, which allows panel flexing over road objects.
[0039] Yet another embodiment of the present invention provides a second
method of vacuum
forming a skirt panel. The second method includes the following steps:
providing a double
11

CA 02528558 2005-11-29


aluminum mould; providing two thin sheets of a thermoplastic material;
clamping an associated
thin sheet of the thermoplastic material in each of an associated clamp frame;
fixing the two
clamp frames in spaced-apart relationship one above the other with minimal
clearance there
between; introducing the two spaced-apart clamped thin sheets of thermoplastic
material into a
heating oven; heating the oven to a temperature greater than the softening
temperature of the
thermoplastic material; placing each heated sheet of thermoplastic material
over an associated
half of the aluminum moulds; forcing each mould half into an associated each
hot sheet of
thermoplastic material until a sealing flange air seal is formed around the
outer edge of each
mould half; drawing a vacuum from inside each mould half; while the hot thin
sheet of
thermoplastic material is still hot, clamping the two mould halves together;
applying enough
pressure to the clamped two mould halves to bond the areas of contact between
said two hot
thermoplastic materials to form a permanent single hollow skirt pane; reducing
the temperature
of thermoplastic material to a suitable temperature below the softening
temperature of the hot
thermoplastic material; opening the two mould halves; opening the clamps and
removing the
moulded first intermediate skirt panel from said mould; .trimming off excess
material off from
the moulded first intermediate skirt panel and drilling suitable mounting
holes therein, thereby
to provide a second intermediate skirt panel; providing a metal reinforcement
which is stamped
and formed, bolting the stamped and formed metal reinforcement which to the
interior of the
second intermediate skirt panel, thereby to form vertical truss and clamp
angles on the interior of
said formed second intermediate skirt panel, and thereby to form a third
intermediate skirt panel;
extruding a synthetic plastic panel; and attaching the extruded synthetic
plastic panel to the
lower edge of the third intermediate skirt panel, thereby to provide a final
skirt panel, which
allows panel flexing over road objects.
[0040] Yet another embodiment of the present invention provides a third method
of forming a
skirt panel. The third method includes the following: providing a high
pressure mould; producing
a first component face of said skirt panel by injection moulding a
thermoplastic material in the
high pressure mould; producing a second component support strut of said skirt
panel by injection
moulding a thermoplastic material in the high pressure mould; extruding a
third component
thermoplastic material track of said skirt panel; attaching the extruded
thermoplastic track to the
12

CA 02528558 2005-11-29


underside of the trailer; attaching the injection moulded face to the extruded
material track of the
skirt panel, attaching the injection moulded strut to the extruded material
track and panel face of
the skirt panel, thereby to provide a first intermediate skirt panel;
providing and attaching an
injection moulded face to the extruded material track of the skirt panel,
attaching the injection
moulded strut to the extruded material track and panel face of the skirt
panel, attaching by means
of snaps or suitable fasteners to the lateral side of the first intermediate
skirt panel, thereby to
form a second intermediate skirt panel having vertical trusses; extruding a
third synthetic plastic
panel; attaching the extruded synthetic plastic panel to the lower edge of the
second
intermediate skirt panel thereby to form an optional final skirt panel having
a strut and a
depending thermoplastic material panel on the lower edge thereof, thereby to
allow panel
flexing over road objects and achieve maximum aerodynamic drag reduction.
[0041] Yet another embodiment of the present invention provides a fourth
method of forming a
skirt panel. The fourth method includes the following: providing a structural
web mould;
producing a first component face of the skirt panel by injection moulding a
thermoplastic
material in the structural web mould, producing a second component support
strut of the skirt
panel by injection moulding a thermoplastic material in the structural web
mould; extruding a
third component thermoplastic material track of said skirt panel; attaching
the injection moulded
face to the extruded material track of the skirt panel, attaching the
injection moulded strut to the
extruded material track and panel face of the skirt panel, thereby to provide
a first intermediate
skirt panel; providing and attaching an injection moulded face to the extruded
material track of
the skirt panel, attaching the injection moulded strut to the extruded
material track and panel
face of the skirt panel, attaching by means of snaps or suitable fasteners to
the lateral side of the
first intermediate skirt panel, thereby to form a second intermediate skirt
panel having vertical
trusses; extruding a third synthetic plastic panel; attaching the extruded
synthetic plastic panel
to the lower edge of the second intermediate skirt panel thereby to form an
optional final skirt
panel having a strut and a depending thermoplastic material panel on the lower
edge thereof,
thereby to allow panel flexing over road objects and achieve maximum
aerodynamic drag
reduction.

13

CA 02528558 2005-11-29


[0041A] A broad aspect of the present invention provides a skirt panel for
interconnection to
another similar abutting skirt panel for attachment beneath a lower, outer
longitudinally-
extending edge of a trailer including a rear wheel assembly of a tractor-
trailer rig, thereby to
provide a continuous fairing extending downwardly from said trailer. The skirt
panel includes,
firstly, a monolithic, generally-rectangular composite reinforced
thermoplastic structure, having
vertical lateral side edges which are configured and arranged for connection
to associated
vertical lateral side edges of abutting similar skirt panels, thereby to
provide a longitudinally-
extending fairing for extending contiguously on each side of said trailer. The
front face of the
thermoplastic structure being provided with a plurality of longitudinally
extending, vertically
spaced apart arcuate protrusions. The front face of the thermoplastic
structure is also preferably
provided with a plurality of dimples, on the flat face and/or the arcuate
protrusions. Secondly,
the skirt panel is provided with reinforced lateral edges, the reinforcing
panel comprises a panel,
preferably an open lattice panel, which is secured to an inner face of the
skirt panel. The
reinforcing panel is provided with laterally extending means, whereby abutting
such skirt panels
are secured to one another. Thus, when the fairing is secured to a lower
portion of the trailer, the
fairing extends downwardly from said trailer to from 60% to 80 % of the
distance to the road,
preferably to no closer than 10 inches from the road surface. Because of such
fairing structure a
portion of any impinging air is directed laterally around the wheels of the
rear wheel bogeys to
reduce the aerodynamic drag of said trailer and of said wheel assembly. By a
variant thereof, an
upper edge of said skirt panel includes means for rigidly securing the skirt
panel to the trailer.
[0041B] By a variant thereof, the means for rigidly securing the skirt panel
to the trailer
comprises snap members.
[0041C] By a variant thereof, each vertical edge of the skirt panel includes a
reinforcing and
connecting truss or flange having connection points to enable abutting similar
skirt panels to be
rigidly connected to one another.
[0041D] By a variant thereof, the truss is formed of stamped metal.
[0041E] By a variant thereof, the truss is of an open lattice structure.

14

CA 02528558 2005-11-29



[0041F] By a variant thereof, the stamped metal comprises galvanized steel
vertical truss and
securement members, which are secured to the thermoplastic portion of the
skirt panel.

[0041G] By a variant thereof, two lateral vertical side edges extend inwardly
from the rear face
thereof, and wherein upper and lower edges thereof are integrally connected to
the two inwardly
extending lateral edges.

[0041H] By a variant thereof, the skirt panel includes a support strut
connected to the interior
face at the bottom edge and secured to the interior face adjacent the top edge
thereof.

[0041J] By a variant thereof, the support strut includes an I-beam clamp at
the upper edge
thereof

[0041K] By a variant thereof, the inner face of said strut at the upper edge
thereof includes
means to connect the strut to the inner face of the skirt panel.

[0041L] By a variant thereof, the thermoplastic is selected from the group
consisting of co-
extruded ABS with a cap of a styrene acrylonitrile copolymer which has been
impact-modified
with acrylic ester rubber, high molecular weight polyethylene, polypropylene
and TPO.

[0041M] By a variant thereof, the skirt panel includes a thinner, more
flexible synthetic plastic
lower panel, the thinner, more flexible synthetic plastic lower panel being
attached to the lower
edge of said skirt panel, thereby to allow panel flexing over road objects,
e.g., curbs, railroad
tracks and below grade loading docks.

[0041N] By a variant thereof, the synthetic plastic comprises a thermoplastic
elastomer.
[0041P] By a variant thereof, the thermoplastic elastomer comprises flex PVC.
[0041Q] By a variant thereof, the skirt panel is about 0.187 inches thin.

[0041R] Another broad aspect of the present invention provides a method of
vacuum forming a
skirt panel for interconnection to an abutting similar skirt panel for
attachment beneath a lower,
outer longitudinally-extending edge of a trailer including a rear wheel
assembly of a tractor-

15

CA 02528558 2005-11-29


trailer rig, thereby to provide a continuous fairing extending downwardly from
said trailer. The
method includes the following sequential steps: providing an aluminum mould;
providing a thin
sheet of thermoplastic material; clamping the thin sheet of thermoplastic
material in a clamp
frame; introducing the clamped thin sheet of thermoplastic material into a
heating oven;
heating the oven to a temperature greater than the softening temperature of
the thermoplastic
material; placing the heated thin sheet of thermoplastic material over said
aluminum mould.;
forcing the mould into the hot thin sheet of thermoplastic material until a
sealing flange air seal
is formed around the outer edge of the mould; drawing a vacuum from inside the
mould,
thereby to force the hot sheet of thermoplastic material to form around the
contours of the
mould.; reducing the temperature of the hot sheet of thermoplastic material to
a suitable
temperature below the softening temperature of the thermoplastic material;
opening the clamp
frame and removing the moulded formed first intermediate skirt panel from the
mould;
trimming off excess material from the formed first intermediate skirt panel
and drilling suitable
mounting holes therein, thereby to provide a second intermediate skirt panel;
providing a metal
reinforcement which is stamped and formed; securing the stamped and formed
metal
reinforcement to the interior of the formed skirt panel, thereby to form
vertical truss and clamp
members on the interior of the formed second intermediate skirt panel, and
thereby to form the
skirt panel.
[0041S] Another broad aspect of the present invention provides a method of
vacuum forming a
skirt panel for interconnection to a similar abutting skirt panel for
attachment beneath a lower,
outer longitudinally-extending edge of a trailer including a rear wheel
assembly of a tractor-
trailer rig, thereby to provide a continuous fairing extending downwardly from
the trailer. The
method includes the following sequential steps: providing a double aluminum
mould; providing
two thin sheets of a thermoplastic material; clamping an associated thin sheet
of the
thermoplastic material in each of an associated clamp frame; fixing the two
clamp frames in
spaced-apart relationship one above the other with minimal clearance
therebetween; introducing
the two spaced-apart clamped thin sheets of thermoplastic material into a
heating oven; heating
the oven to a temperature greater than the softening temperature of the
thermoplastic material;
placing each such heated sheet of thermoplastic material over an associated
half of said
16

CA 02528558 2005-11-29


aluminum mould; forcing each such mould half into an associated each such hot
sheet of
thermoplastic material until a sealing flange air seal is formed around the
outer edge of each
said mould half;
thawing a vacuum from inside each such mould half; while such hot thin sheet
of thermoplastic
material is still hot, clamping the two mould halves together; applying enough
pressure to the
clamped two mould halves to bond the areas of contact between the two hot
thermoplastic
materials to form a permanent single hollow skirt panel; reducing the
temperature of the
thermoplastic material to a suitable temperature below the softening
temperature of the hot
thermoplastic material; opening the two mould halves; opening the clamps and
removing of
the moulded first intermediate skirt panel from the mould; trimming off excess
material from
the moulded first intermediate skirt panel and drilling suitable mounting
holes therein, thereby
to provide a second intermediate skirt panel; providing a metal reinforcement
which is stamped
and formed; securing the stamped and formed metal reinforcement to the
interior of the formed
skirt panel, thereby to form vertical truss and clamp members on the interior
of the formed
second intermediate skirt panel, and thereby to form the skirt panel.
[0041T] Another broad aspect of the present invention provides a method of
injection moulding
a skirt panel for interconnection to a similar abutting skirt panel for
attachment beneath a lower,
outer longitudinally extending edge of a trailer including a rear wheel
assembly of a tractor-
trailer rig, thereby to provide a continuous fairing extending downwardly from
the trailer. The
method includes the following sequential steps: providing at least one high
pressure mould;
producing a first component face panel of the skirt panel by injection
moulding a thermoplastic
material in said at least one high pressure mould; producing a second
component support strut of
the skirt panel by injection moulding a thermoplastic material in at least one
high pressure
mould;
extruding a third component thermoplastic material track of said skirt panel;
attaching the
injection moulded face panel to said extruded material track of said skirt
panel, thereby to
provide a first intermediate skirt panel; providing a means to fasten a
vertical edge of the first
intermediate skirt panel to said tractor; and fastening such means to fasten a
vertical edge of the

17

CA 02528558 2005-11-29


first intermediate skirt panel to the tractor to the vertical edge of the
first intermediate skirt
panel, thereby to form the skirt panel having both vertical and horizontal
support structures.
[0041U] Another broad aspect of the present invention provides a method of
injection moulding
a skirt panel for interconnection to a similar said skirt panel for attachment
beneath a lower,
outer longitudinally-extending edge of a trailer including a rear wheel
assembly of a tractor-
trailer rig, thereby to provide a continuous fairing extending downwardly from
the trailer. The
method includes the following sequential steps: providing a structural web
mould; producing a
first component face panel of the skirt panel by injection moulding a
thermoplastic material in
the structural web mould; providing a high pressure mould; producing a second
component
support strut of the skirt panel by injection moulding a thermoplastic
material in the high
pressure mould; extruding a third component thermoplastic material track of
the skirt panel;
attaching the first component injection moulded face panel and the second
component support
strut to the extruded material track of said skirt panel, thereby to provide a
first intermediate
skirt panel; providing a means to fasten a horizontal edge of the first
intermediate skirt panel to
said trailer; and the means to fasten a vertical edge of the first
intermediate skirt panel to the
vertical edge of the second intermediate skirt panel, thereby to form said
skirt panel having both
vertical and horizontal support structures.
[0041V] By a variant thereof, the method includes the additional steps of.
extruding a thin
synthetic plastic panel; and attaching the extruded synthetic plastic panel to
the lower edge of the
skirt panel, thereby to provide a final skirt panel, which allows panel
flexing over road objects
and to achieve further fuel savings.
[0041W] By a variant thereof the moulds contain inner copper cooling and
heating lines which
aid in the manufacturing method.
[0041X] By a variant thereof the moulds contain an insert which can be removed
to form a side
marker light panel.


18

CA 02528558 2005-11-29


[0041Y] By a variant thereof the thermoplastic is selected from the group
consisting of co-
extruded ABS with a cap of a styrene acrylonitrile copolymer, which has been
impact-modified
with acrylic ester rubber, high molecular weight polyethylene, polypropylene
and TPO.
[0041Z] By a variant thereof the heating to a suitable temperature, is about
320 F.
[004 IAA] By a variant thereof the cooling is down to a temperature of about
140 F.
[0041BB] By a variant thereof the extruded synthetic polymer is flex PVC
(polyvinyl chloride).
[0041CC] By a variant thereof the thermoplastic elastomer is a thermoplastic
elastomer which
can be processed and recycled like thermoplastic materials.
[0041D134] Another broad aspect of the present invention provides a trailer of
a tractor-trailer rig
to which is fastened a fairing consisting of a plurality of contiguous skirt
panels depending
below the right hand and left hand sides thereof to from 60% to 80 % of the
distance to the road,
so that a portion of any impinging air is directed laterally around the wheels
of the rear wheel
bogeys to reduce the aerodynamic drag of the trailer and of the wheel
assembly, the skirt panels
having the structure as described above for the broad aspect and the variants
thereof
[004 lEE] By a variant thereof the fairing terminates about 10 inches from the
surface of the road
[0042] By an aspect of the first and second method embodiments of the present
invention, the
moulds contain inner copper cooling and heating lines, which aid in the
manufacturing method.
[0043] By an aspect of the first and second method embodiments of the present
invention, the
moulds contain an insert, which can be removed to form a side marker light
panel.
[0044] By an aspect of all the method embodiments of the present invention,
the thermoplastic
material is co-extruded ABS (acrylic/butadiene/styrene resin) with a cap of a
styrene acrylonitrile
copolymer which has been impact-modified with acrylic ester rubber.
[0045] By an aspect of all the method embodiments of the present invention,
the thermoplastic
material can be TPO, HMWPE, PP, PC/ABS, glass reinforced PP or glass
reinforced ABS.
19

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[0046] By an aspect of all the method embodiments of the present invention,
the heating to a
suitable temperature is about 320 F for ABS material.
[0047] By an aspect of all the method embodiments of the present invention,
the cooling is
down to a temperature of about 140 F.
[0048] By an aspect of all the method embodiments of the present invention,
the extruded
synthetic polymer is flex PVC. (polyvinyl chloride).
[0049] By an aspect of all the method embodiments of the present invention,
the extruded
synthetic polymer is a thermoplastic elastomer, which can be processed and
recycled like
thermoplastic materials.
[0050] Thus, as noted above, aspects of the present invention overcome the
afore-mentioned
inadequacies by providing a pair of semi-flexible side panels for a tractor-
trailer rig which
extend under the tractor-trailer rig at both side surfaces thereof to improve
their airflow
dynamics when traveling at high speeds and reduce drag. The panels are
sufficiently rigid to be
substantially self-supporting from an attachment to the tractor-trailer rig,
while retaining
sufficient flexibility to bend when the rig maneuvers over objects. e.g.
curbs, railway tracks,
below grade loading docks, etc. The directed air flows parallel to the
horizontal axis of the trailer
in a laminar fashion, and causes air to release at the rear of the tractor-
trailer rig. The laminar
airflow also serves to allow water, which has been splashed by the tires to
exit along the
horizontal axis of the trailer, thereby substantially reducing the outward
spray of water normally
produced by the tires.
BRIEF DESCRIPTION OF THE DRAWINGS
[0051] The invention is illustrated, by way of example, in the drawings in
which:



20

CA 02528558 2005-11-29


[0052] FIG. 1 is an isometric frontal view of a typical skirt panel with one
form of reinforcing
and interconnection means, according to one embodiment of the present
invention, and
including, as
[0053] FIG 1A, an enlarged view of the extruded cap and one connection point;
[0054] FIG. 2 is an isometric rear view of the typical skirt panel of FIG. 1;
[0055] FIG. 3 is an isometric interior underside view of a portion of a
tractor-trailer rig having a
plurality of contiguous skirt panels as depicted in FIG. 1 attached thereto;
[0056] FIG. 4 is another isometric interior underside view of a portion of a
tractor-trailer rig
having a plurality of contiguous skirt panels as depicted in FIG. 1 attached
thereto;
[0057] FIG. 5 is an isometric interior view of the I-beams of the tractor-
trailer rig, having a
plurality of contiguous skirt panels as depicted in FIG. 1 attached thereto,
showing one means for
fastening the skirt panel to the tractor-trailer rig;
[0058] FIG. 6 is yet another isometric interior underside view of a portion of
a tractor-trailer rig
having a plurality of contiguous skirt panels as depicted in FIG. 1 attached
thereto, and showing
another means for fastening the skirt panel to the tractor-trailer rig;

[0059] FIG. 7 is a further isometric interior underside view of a portion of a
tractor-trailer rig
having a plurality of contiguous skirt panels as depicted in FIG. I attached
thereto, and showing
a further means for fastening the skirt panel to the tractor-trailer rig;
[0060] FIG. 8 is still another isometric interior view of a portion of a
tractor-trailer rig having a
plurality of contiguous skirt panels as depicted in FIG. 1 attached thereto,
and including, as FIG
8A, an enlarged view of the support strut connection detail;



21

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[0061] FIG. 9 is an isometric exterior view of one of a plurality of
contiguous skirt panels as
depicted in FIG. 1, showing one means for fastening the skirt panel to I-beams
of the tractor-
trailer rig by way of a support strut;
[0062] FIG.10 is an isometric interior view of a typical support strut
construction detail; and
[0063] FIG. 11 is an isometric rear view of another typical skirt panel with
another form of
reinforcing and interconnection means, according to one embodiment of the
present invention,
and including, as FIG 11A, an enlarged view of an I-beam connection clamp;
[0064] FIG.12 is an isometric exterior view of a series of interconnected
skirt panels showing
the connection to the I-beam of the tractor-trailer rig; and
[0065] FIG13 is a side elevational view of a tractor-trailer rig equipped with
a plurality of
contiguous skirt panels as depicted in FIG. 1;
DESCRIPTION OF THE DRAWINGS
DESCRIPTION OF FIGS 1, 1A AND 2
[0066] As seen in FIGS 1, 1A and 2, the skirt panel 10 is a generally
rectangular flat piece of
thin thermoplastic material, e.g., ABS (acrylic/butadiene/styrene resin) with
a separate extruded
but secured, as by thermoplastic fusion, LURAN or CENTREX UV-resistant cap12.
The exterior
face 14 of the skirt panel 10 is formed with integral, spaced-apart,
horizontal arcuate protrusions
16. The lower edge 18 of the skirt panel 10 has secured thereto by any
suitable means, e.g., by a
Plastite screw combination, a monolithic base of an extruded, flexible lower
panel component 20
of e.g., SANTOPRENE or PVC. As previously described, this allows flexing of
the final skirt
panel 10 over road objects (e.g., curbs, rail road tracks and below grade
loading docks).

[0067] As seen in FIG. 1A, the cap extrusion 12 is suitably secured to the top
edge 22 and the
top face 24 of the skirt panel 10 in any suitable manner, e.g., by
thermoplastic fusion. The
exterior facing edge 26 of the reinforcing and connecting truss 28 is provided
with a plurality of
22

CA 02528558 2005-11-29


outwardly extending connection points 30. By means of these connection points
30 two abutting
skirt panels 10 may be interconnected by suitable means, e.g., Plastite screws
(not seen).
[0068] The rear face 32 of the skirt panel 10, seen more clearly in FIG. 2,
has secured thereto by
any suitable means, a pair of lateral edge vertical reinforcing trusses 36.
These trusses 36
include, not only the plurality of outwardly-extending connection points 30,
but also a plurality
of internal connection points 38, integrally formed between two spaced-apart
vertical bars 40,
42. These internal connection points 38 also serve as means to connect two
abutting skirt panels
by suitable means, e.g., Plastite screws (not seen).
DESCRIPTION OF FIG 3
[0069] As seen in FIG 3, this isometric interior underside view shows a
plurality of abutting
skirt panels 10 have been secured together by means of the reinforcing and
connecting trusses
36. The so-formed interconnected panels 10 are secured to the I-beams 44 of
the tractor-trailer
rig (not seen here) through the intermediary of the extruded cap 12, which is
superposed below
the I-beams 44, and clips (to be described later).
DESCRIPTION OF FIG 4
[0070] As seen in FIG 4, this isometric interior underside view shows a
plurality of abutting
skirt panels 10 have been secured together by means of the reinforcing and
connecting trusses
36. The so-formed interconnected panels 10 are secured to the I-beams 44 of
the tractor-trailer
rig (not seen here) through the intermediary of the extruded cap 12, which is
situated below the
I-beams 44, and clips (to be described later).
DESCRIPTION OF FIG 5
[0071] As seen in FIG 5, this isometric interior view shows one means of
connecting the I-
beams 44 to the extrusions 12 of the skirt panel 10. Theses means are a clip
46 one end 48 of
which rests atop the lower edge of the I-beam 44, while the other end 50 is
secured to the
extrusion 12 by means of a screw 52.

23

CA 02528558 2005-11-29


DESCRIPTION OF FIG. 6
[0072] As seen in FIG 6, this isometric interior view shows that a plurality
of abutting skirt
panels 10 have been secured together by means of the reinforcing and
connecting trusses 36. The
so-formed interconnected panels 10 are secured to the I-beams 44 of the
tractor-trailer rig (not
seen here) through the intermediary of I-beam clamps 54 secured to the top 56
of support strut
58. The construction of support strut 58 will be described in detail with
reference to FIG 10
DESCRIPTION OF FIG. 7
[0073] As seen in FIG 7,this isometric interior underside view shows that a
plurality of abutting
skirt panels 10 have been secured together by means of the reinforcing and
connecting trusses
36. The so-formed interconnected panels 10 are secured to the I-beams 44 of
the tractor-trailer
rig (not seen here) through the intermediary of I-beam clamps 54 secured to
the top 56 of support
strut 58. The I-beam clamps 54 include two spaced-apart elements 60 between
which the two
spaced-apart lower horizontal portions 62 of the I-beam 44 are placed. The two
spaced-apart
elements 60 of the I-beam clamps 54 are urged together and then secured in
place, thereby
locking the I-beam 44 to the support strut 58.
DESCRIPTION OF FIG. 8 AND FIG. 8A
[0074] As seen in FIG 8, this isometric interior view shows that a plurality
of abutting skirt
panels 10 have been secured together by means of the reinforcing and
connecting trusses 36. The
so-formed interconnected panels 10 are secured to the I-beams 44 of the
tractor-trailer rig (not
seen here) through the intermediary of I-beam clamps 54 secured to the top 56
of support strut
58. The I-beam clamps 54 include two spaced-apart elements 60 between which
the two spaced-
apart lower horizontal portions 62 of the I-beam are placed. The two spaced-
apart elements 60 of
the I-beam clamps 54 are urged together and then secured in place, thereby
locking the I-beam
44 to the support strut 58.
[0075] FIG 8A shows the structure of the I-beam clamp 54 more clearly and
shows how screws
66 secure the I-beam clamp 54 to the top edge 64 of the strut 58.
24

CA 02528558 2005-11-29


DESCRIPTION OF FIG. 9
[0076] FIG 9 shows how the support strut 58 is secured to the skirt panels 10.
The securement is
by way of two tapped cylindrical projections 68 extending outwardly from the
interior face 59 of
the strut 58. These cylindrical projections 68 are inserted through two spaced-
apart drilled holes
(unnumbered) in skirt panel 10 and are secured therein by means of screws 70.
DESCRIPTION OF FIG. 10
[0077] FIG 10 shows the construction of the strut 58. As seen, strut 58
included a pair of
spaced-apart vertical members 160, which are braced by horizontal cross-
members 162. The
lower edge 164 of strut 58 includes a pair of cylindrical protrusions which
act as screw points
166. The upper edge 168 of the strut 58 includes a reinforcing rectangular
lattice 170. At each
corner thereof is a cylindrical protrusion 172 that act as screw points.
Projecting outwardly from
the forward edge of the lattice 170 are the hereinbefore-described projecting
cylindrical
members 68, which act as screw points.
DESCRIPTION OF FIGS 11, AND 11A
[0078] FIG 11 shows another embodiment of the skirt panel 110.As seen in FIG
11, the skirt
panel 110 is a generally-rectangular flat of thin thermoplastic material e.g.,
ABS
(acrylic/butadiene/styrene resin) with an integral cap112. The exterior face
of the skirt panel 110
is formed with integral, spaced-apart, horizontal arcuate protrusions 116. The
lower edge 118 of
the skirt panel 110 includes an integral base 120. While not shown, base 120
may include a
flexible depending panel, which, as previously described allows flexing of the
final skirt panel
110 over road objects (e.g., curbs, rail road tracks and below grade loading
docks).
[0079] As seen in FIG. 11A, the embodiment of the I-beam clamp 154 is made of
a suitable
plastic material e.g., NYLON 6
DESCRIPTION OF FIG. 12
[0080] FIG 12 is an isometric exterior view of a series of interconnected
skirt panels 10, which
shows the exterior of the lower edge of the tractor-trailer rig (not seen)
with the plurality of
25

CA 02528558 2005-11-29


interconnected skirt panels 10 secured to the I-beams 44. The securement is by
way of a plurality
of Plastite screws 72 which connect the skirt panel 10 to the I-beam clamp 54.
DESCRIPTION OF FIG 13
[0081] As seen in FIG 13, a tractor-trailer rig 300 provided with right and
left (not seen) rear
wheel bogeys 302 is attached to a vehicle cab 304 equipped with right and left
(not seen) front
wheels 306 and right and left (not seen) rear wheel bogeys 308 by means of a
fifth wheel 310.
The trailer 300 is provided with a plurality of contiguous skirt panels 312,
which generally have
the structure of the skirt panels described in FIG 1. However, the front skirt
panel 314 provides a
facing for a depending strut 316 of the trailer 300. The skirt panel 318,
which is immediately
forward of front panel 316 is generally trapezoidally shaped to provide an
aerodynamic profile to
the contiguous skirt panels 312. Moreover, a special arrangement of skirt
panels 320 is disposed
around the rear wheel bogeys 302.
VACUUM FORMED PANEL METHOD
[0082] By this method, the skirt panels are produced using three aluminum
moulds. The moulds
contain inner copper cooling and heating lines, which aid in the manufacturing
method. The
mould also contains an insert, which can be removed to form a side marker
light panel. Each
mould can produce either the right panel or the left panel.
[0083] The skirt material used in this method is a thin sheet, e.g. about
0.187 "thin, of a
thermoplastic material, e.g., co-extruded ABS (acrylic/butadiene/styrene
resin) with a
CENTREX or LURAN cap. (Luran is the Trademark of BASF for its brand of a
styrene
acrylonitrile copolymer which has been impact-modified with acrylic ester
rubber.) The thin
sheet of thermoplastic material is held in a clamp frame, which is introduced
to a heating oven.
The thin sheet of thermoplastic material is heated to a suitable temperature,
e.g., for ABS about
320 F. The heated thin sheet of thermoplastic material is then placed over the
aluminum mould.
The mould is forced into the hot thin sheet of thermoplastic material until an
air seal is formed
around the outer edge of the mould (such air seal being known as a "sealing
flange"). A vacuum
is then drawn from inside the mould, which forces the hot thin sheet of
thermoplastic material,
26

CA 02528558 2005-11-29


e.g., ABS, to form around the contours of the mould. Cooling fans then reduce
the temperature
of the thin sheet of thermoplastic material to a suitable temperature, e.g.,
for ABS, a temperature
down to about 140 F. The clamp frame is opened and the formed first
intermediate skirt panel is
removed from the mould. Excess material is trimmed off from the formed first
intermediate skirt
panel, and suitable mounting holes are drilled.
[0084] The first intermediate skirt panel is further fabricated by cutting a
metal, e.g., galvanized
steel sheet which is stamped, and formed thereto to form the vertical truss'
and clamp angles of
the second intermediate skirt panel.

[0085] The fabrication of the final skirt panel is optionally completed by
attaching extruded flex
PVC, (polyvinyl chloride) or extruded Santoprene (the Trademark of Advanced
Elastomer
Systems LP for its brand of TPE-thermoplastic elastomers- a diverse family of
rubber-like
materials which can be processed and recycled like thermoplastic materials) to
the lower edge of
the second intermediate skirt panels. This allows flexing of the final skirt
panel over road objects
(e.g., curbs, rail road tracks and below grade loading docks). This also
provides a means to
achieve further fuel savings.
TWIN SHEET VACUUM FORMED PANEL METHOD
[0086] In this method, the skirt panels are produced using three double
aluminum moulds. Each
mould has a smooth outer skin side and a ribbed inner skin side. Both halves
of the moulds
contain inner copper cooling and heating lines, which aid in the manufacturing
method. The
mould also contains an insert, which can be removed to form a side marker
light panel. Each
mould can produce either the right panel or the left panel.
[0087] The skirt material used in this method is a thin sheet, e.g. about
0.100 "thin, of a
suitable thermoplastic material, e.g., co-extruded ABS
(acrylic/butadiene/styrene resin) with a
CENTREX or LURAN cap. (Luran is the Trademark of BASF for its brand of a
styrene
acrylonitrile copolymer which has been impact-modified with acrylic ester
rubber.) Two sheets
of such thin thermoplastic material are required to produce each single panel.
Each single sheet
27

CA 02528558 2005-11-29


of thin thermoplastic material is held in a separate clamp frame. These two
clamp frames are
fixed in spaced-apart relationship one above the other with minimal clearance
between them.
The two sheets of such thin thermoplastic material in such clamp frames are
then placed in a
heating oven. The thin sheets of thermoplastic material are heated to a
suitable temperature, e.g.,
for ABS about 320 degrees F. The heated thin, sheets of thermoplastic material
are then place
one over each half of a respective aluminum mould. Each heated sheet of thin
thermoplastic
material is forced on to the associated separate mould halves until an air
seal is formed around
the outer edge of the mould. This is known as the sealing flange. A vacuum is
then drawn from
within each mould half. While the hot thin sheets thermoplastic material (ABS)
is still hot, the
two mould halves are clamped together. Enough pressure is applied to bond the
areas of contact
between the two materials to form a permanent single hollow first intermediate
skirt panel.
Cooling fans then reduce the temperature of the mould and the thermoplastic
material to a
suitable temperature, e.g., for ABS about 140 degrees F. The two mould halves
and clamps are
then opened to allow removal of the moulded first intermediate skirt panel.
Excess material is
then trimmed off from the formed first intermediate skirt panel and mounting
holes are also
drilled therein.
[0088] The first intermediate skirt panel is further fabricated by cutting a
metal, e.g., galvanized
steel sheet which is stamped, and formed thereto to form the vertical truss'
and clamp angles of
the second intermediate skirt panel.
[0089] The fabrication of the skirt panel is completed by attaching an
optional extruded flex
PVC, (polyvinyl chloride) or extruded Santoprene (the Trademark of Advanced
Elastomer
Systems LP for its brand of TPE-thermoplastic elastomers- a diverse family of
rubber-like
materials which can be processed and recycled like thermoplastic materials) to
the lower edge of
the second intermediate skirt panels. This allows flexing of the final skirt
panel over road objects
(e.g., curbs, rail road tracks and below grade loading docks). This also
provides a means to
achieve further fuel savings.
INJECTION MOULDED PANEL METHOD
28

CA 02528558 2005-11-29


[0090] These skirt panels are produced from a high-pressure injection mould or
from a
structural web injection mould.
[0091] A high-pressure mould is the typical steel male/female mould, which
requires
considerable pressure, e.g., about 2900 tons of clamping pressure, to force
the molten
thermoplastic material, e.g., ABS, PP, HMWPE, or TPO into the mould.
[0092] A structural web mould requires about 1/3 the amount of clamping
pressure, e.g., about
970 tons of clamping pressure compared to the high pressure mould to force the
molten
thermoplastic material, e.g., ABS, PP, HMVVPE, or TPO into the mould. This
method also
creates small voids within the wall structure, which act as a webbing in the
formed first
intermediate skirt panel. For this reason a slightly better stiffness for a
given wall thickness can
be achieved.
[0093] The advantage of injection moulding over the two above-described
thermoforming
methods includes the following: use of less raw material, thus reducing cost;
provides quicker
cycle times and a net increase in formed parts; provides a finished part upon
de-moulding; no
additional production steps are required; provides a reduction in the amount
of support structure
and fastening required; provides the ability to increase the speed and ease of
product installation;
and provides the ability to offer greater flexing of the panel as it passes
over road objects (e.g.,
curbs, rail road tracks and below grade loading docks) due to live hinges
and/or notches in panel
ribs. The panel can also use snap-in features verses nut/bolt fastening.
[0094] In this method, the skirt panel is composed of two or optionally three
or four eventually
monolithic components. The first component is the face panel and one is
required for each skirt
panel. This face panel is produced using a high-pressure injection mould. The
thermoplastic
material is preferably ABS, HMW polyethylene, PP or TPO.
[0095] The second component is a support strut and one is required for each
skirt panel. This
strut is produced using a high-pressure injection mould. The thermoplastic
material is preferably
ABS, HMW polyethylene, PP or TPO.
29

CA 02528558 2005-11-29



[0096] The third optional component is a track. The track is an extruded
thermoplastic material
component of e.g., ABS, 1-IMW polyethylene, PP or TPO.

[0097] The support strut is integrated optionally to the track and to the face
panel to form an
intermediate skirt panel.

[0098] The fourth optional component is an extruded flexible lower panel
component of e.g.,
SANTOPRENE or PVC. This lower panel component is attached to the lower edge of
the
intermediate skirt panel to provide the final skirt panel. This allows flexing
of the final skirt
panel over road objects (e.g., curbs, rail road tracks and below grade loading
docks). This also
provides a means to achieve further fuel savings.

CONCLUSION

[0099] As will be readily appreciated from the foregoing, the skirt panel of
aspects of the
present invention is a lightweight, dimpled or scaled surface, slightly curved
structure designed
to control airflow on the lower sides of a conventional trailer. The slightly
curved structure is
positioned parallel to and below the sides of the trailer extending from
forward of the trailer
wheels to just after the tractor wheels, and it extends as close as practical
to the ground. The
skirt can extend around the trailer wheels and/or aft of the trailer wheels
extending back to the
rear tailgate. The skirt panel optionally includes a lower flexible panel,
which allows flexing of
the final skirt panel over road objects (e.g., curbs, rail road tracks and
below grade loading
docks).

Representative Drawing
A single figure which represents the drawing illustrating the invention.
Administrative Status

For a clearer understanding of the status of the application/patent presented on this page, the site Disclaimer , as well as the definitions for Patent , Administrative Status , Maintenance Fee  and Payment History  should be consulted.

Administrative Status

Title Date
Forecasted Issue Date 2013-04-09
(22) Filed 2005-11-29
(41) Open to Public Inspection 2007-05-29
Examination Requested 2010-11-09
(45) Issued 2013-04-09

Abandonment History

There is no abandonment history.

Maintenance Fee

Last Payment of $236.83 was received on 2023-08-29


 Upcoming maintenance fee amounts

Description Date Amount
Next Payment if standard fee 2024-11-29 $624.00
Next Payment if small entity fee 2024-11-29 $253.00

Note : If the full payment has not been received on or before the date indicated, a further fee may be required which may be one of the following

  • the reinstatement fee;
  • the late payment fee; or
  • additional fee to reverse deemed expiry.

Patent fees are adjusted on the 1st of January every year. The amounts above are the current amounts if received by December 31 of the current year.
Please refer to the CIPO Patent Fees web page to see all current fee amounts.

Payment History

Fee Type Anniversary Year Due Date Amount Paid Paid Date
Registration of a document - section 124 $100.00 2005-11-29
Application Fee $200.00 2005-11-29
Maintenance Fee - Application - New Act 2 2007-11-29 $50.00 2007-11-29
Maintenance Fee - Application - New Act 3 2008-12-01 $50.00 2008-11-13
Maintenance Fee - Application - New Act 4 2009-11-30 $50.00 2009-11-18
Request for Examination $400.00 2010-11-09
Maintenance Fee - Application - New Act 5 2010-11-29 $100.00 2010-11-09
Maintenance Fee - Application - New Act 6 2011-11-29 $100.00 2011-08-31
Maintenance Fee - Application - New Act 7 2012-11-29 $100.00 2012-11-14
Final Fee $150.00 2013-01-18
Maintenance Fee - Patent - New Act 8 2013-11-29 $100.00 2013-11-04
Maintenance Fee - Patent - New Act 9 2014-12-01 $100.00 2014-11-03
Maintenance Fee - Patent - New Act 10 2015-11-30 $125.00 2015-10-29
Maintenance Fee - Patent - New Act 11 2016-11-29 $250.00 2016-10-31
Maintenance Fee - Patent - New Act 12 2017-11-29 $250.00 2017-11-14
Maintenance Fee - Patent - New Act 13 2018-11-29 $250.00 2018-11-26
Maintenance Fee - Patent - New Act 14 2019-11-29 $250.00 2019-08-30
Maintenance Fee - Patent - New Act 15 2020-11-30 $450.00 2020-09-02
Maintenance Fee - Patent - New Act 16 2021-11-29 $459.00 2021-09-08
Maintenance Fee - Patent - New Act 17 2022-11-29 $458.08 2022-08-12
Registration of a document - section 124 $100.00 2022-08-19
Maintenance Fee - Patent - New Act 18 2023-11-29 $236.83 2023-08-29
Owners on Record

Note: Records showing the ownership history in alphabetical order.

Current Owners on Record
ZF COMPOSITES NORTH AMERICA LTD.
Past Owners on Record
HAWS, JAMES DOUGLAS
LAYDON COMPOSITES LTD.
LAYFIELD, BRIAN PETER
MANCINA, JOSEPH
PROKUDIN, ANDRIY NICOLAYE
Past Owners that do not appear in the "Owners on Record" listing will appear in other documentation within the application.
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Document
Description 
Date
(yyyy-mm-dd) 
Number of pages   Size of Image (KB) 
Abstract 2005-11-29 1 36
Description 2005-11-29 30 1,695
Drawings 2005-11-29 13 283
Claims 2005-11-29 8 327
Representative Drawing 2007-05-22 1 17
Cover Page 2007-05-22 1 55
Claims 2012-09-07 5 213
Cover Page 2013-03-13 2 62
Abstract 2013-03-20 1 36
Assignment 2005-11-29 7 183
Prosecution-Amendment 2010-11-09 1 24
Fees 2007-11-29 1 24
Fees 2008-11-13 1 24
Fees 2009-11-18 1 25
Correspondence 2011-08-17 2 50
Correspondence 2011-08-30 1 14
Correspondence 2011-08-30 1 20
Fees 2011-08-31 1 201
Fees 2010-11-09 1 23
Prosecution-Amendment 2012-03-07 2 57
Prosecution-Amendment 2012-09-07 7 275
Correspondence 2013-01-18 1 36