Patent Application
20180086395
The present disclosure relates generally to tractor-trailers. In particular, the present disclosure relates to an aerodynamic nose device designed to reduce the drag force produced by a standard tractor-trailer.
To reduce wind flow resistance and drag on a trailer, truck, semitrailer, or other vehicle, side skirts which extend downwardly from a bottom of the trailer and/or chassis toward the roadway to partially enclose the floor assembly and undercarriage of the trailer, fairings, and other such structures have been used. Many structures associated with the front of the trailer are provided in order to also reduce the aerodynamic drag on the trailer.
Air flow passing over a semi or other vehicle may come into contact with a flat face of a tractor-trailer, imparting a drag force to the vehicle. Nose fairings and aerodynamic nose devices are designed to prevent or control the flow of air from contacting a leading flat face of a trailer, such as a trailer of a tractor-trailer truck system, for example. They accomplish this goal by providing a curved surface that directs air away from the leading flat face of the trailer. Such reduction on the drag of the ground vehicle may operate to conserve fossil fuels as well as other sources of vehicle drive power for hybrid vehicles, battery-operated vehicles, and alternative fuel-based vehicles, for example. Existing gap reducing and nose fairing structures provide rounded edges to reduce drag force, but may be shaped and positioned such that they create an additional drag force by over-handling the air.
Accordingly, there remains a need for further contributions in this area of technology, including contributions that further reduce drag force, optimize air flow, and allow for improved manufacturability and distribution.
The present disclosure may comprise one or more of the following features recited in the attached claims and combinations thereof, and/or one or more of the following features and combination thereof.
In one aspect, an aerodynamic nose device is configured to be coupled to a front surface of a vehicle and includes a fairing structure configured to be attached to a vehicle surface. The first fairing structure may comprise a curved wall having a first end and a second end, the first end configured for attachment to the vehicle surface, the curved wall having a radius of curvature of between about 11 inches and about 31 inches and a rounded edge having a first end and a second end, the first end of the rounded edge being connected to the second end of the curved wall. The first fairing structure may further comprise a substantially flat wall having a first end and a second end, the first end being connected to the second end of the rounded edge and the second end being connected to a mounting surface that is configured to be attached to the vehicle surface, wherein the flat wall is disposed at an angle of between about 60 degrees and about 90 degrees with respect to the mounting surface.
In some embodiments, the device further includes a mounting flange extending from the first end of the curved wall, the mounting flange configured to be attached to a second vehicle surface extending generally transverse to the first-named vehicle surface.
In some embodiments, the curved wall includes inner and outer curved wall surfaces, the rounded edge includes inner and outer rounded edge surfaces, and the substantially flat wall includes inner and outer flat wall surfaces wherein the curved wall outer surface, the rounded edge outer surface, and the flat wall outer surface form an aerodynamic surface and the curved wall inner surface, the rounded edge inner surface, and the flat wall inner surface form a cavity.
In some embodiments, the device further includes a further first-name fairing structure comprising a second curved wall, a second rounded edge, and a second substantially flat wall, wherein the further first-named fairing structure is nested within the cavity of the first-named fairing structure with an outer surface of the second curved wall adjacent the curved wall inner surface, an outer surface of the second rounded edge adjacent the rounded edge inner surface, and an outer surface of the second substantially flat wall adjacent the flat wall inner surface.
In some embodiments, the device further includes a second fairing structure coupled to the first-named fairing structure, the second fairing structure comprising a second curved wall, a second rounded edge, and a second substantially flat wall, the second fairing structure being coupled to a first end of the first-named fairing structure and positioned at an angle of about 90 degrees with respect to the first-named fairing structure. In some embodiments, the device further includes a third fairing structure coupled to the first-named fairing structure, the third fairing structure comprising a third curved wall, a third rounded edge, and a third substantially flat wall, the third fairing structure being coupled to a second end of the first-named fairing structure and positioned at an angle of about 90 degrees with respect to the first-named fairing structure, wherein the third fairing structure is parallel to the second fairing structure.
In some embodiments, each of the second and third curved walls comprises a plurality of depressions formed therein.
In some embodiments, the fairing structure comprises a plurality of depressions formed therein.
In some embodiments, the device comprises a thermoplastic olefin (TPO).
In another aspect, an aerodynamic nose device is configured to be coupled to a front surface of a vehicle and comprises a fairing structure configured to be attached to a front surface of a vehicle. The fairing structure comprises a first linear fairing segment comprising a curved wall having a first end and a second end, the first end configured for attachment to the front surface of the vehicle and a substantially flat wall having a first end and a second end, the first end being coupled to the second end of the curved wall. The fairing structure further comprises a second linear fairing segment extending from and substantially perpendicular to a first end of the first linear fairing segment, the second linear fairing segment including an end having a coupling cavity adapted to receive an end of a second fairing structure.
In some embodiments, the device further comprises a second fairing structure, wherein an end of the second fairing structure extends at least partially into the coupling cavity and is coupled to the second linear fairing segment by an interference fit or by one or more fasteners.
In some embodiments, the end of the second linear fairing segment includes a depression and the end of the second fairing structure includes a reduced dimension that conforms to the depression in the end of the second linear fairing segment.
In some embodiments, a portion of the second linear fairing segment and a portion of the second fairing structure have similar cross-sectional shapes.
In some embodiments, the device further comprises a third linear fairing segment extending from and substantially perpendicular to a second end of the first linear fairing segment opposite the first end, the third linear fairing segment comprising an end having a coupling cavity adapted to receive an end of a third fairing structure.
In some embodiments, the device further comprises a third fairing structure, wherein an end of the third fairing structure extends at least partially into the coupling cavity of the third linear fairing segment and is coupled to the third linear fairing segment by an interference fit or by one or more fasteners.
In some embodiments, the end of the third linear fairing segment includes a depression and the end of the third fairing structure includes a reduced dimension that conforms to the depression in the end of the third linear fairing segment.
In still another aspect, an aerodynamic nose device is configured to be coupled to a front surface of a vehicle and comprises a first fairing structure configured to be coupled to a front surface of a vehicle. The first fairing structure comprises a first wall having a first end and a second end with at least one of the first and second ends configured for attachment to the front surface, the first wall further including an inner surface and an outer surface, a first aerodynamic surface at least partially defined by the outer surface, and a first enclosed cavity at least partially defined by the inner surface. The device further includes a second fairing structure configured to be coupled to a front surface of a vehicle, the second fairing structure comprising a second wall having a first end and a second end with at least one of the first and second ends configured for attachment to the front surface, the second wall further including an inner surface and an outer surface, a second aerodynamic surface at least partially defined by the outer surface of the second wall, and a second enclosed cavity at least partially defined by the inner surface of the second wall. The second fairing structure is nested within the first fairing structure with the outer surface of the second wall of the second fairing structure positioned adjacent the inner surface of the first wall of the first fairing structure.
In some embodiments, the first wall comprises a first curved wall section having a first end and a second end, a first rounded edge having a first end and a second end, the first end of the first rounded edge being coupled to the second end of the first curved wall section, and a first substantially flat wall section having a first end and a second end, the first end being coupled to the second end of the first rounded edge and the second end being coupled to a mounting surface that is configured to be coupled to the front surface of the vehicle.
In some embodiments, the second wall comprises a second curved wall section having a first end and a second end, a second rounded edge having a first end and a second end, the first end of the second rounded edge being coupled to the second end of the second curved wall section, and a second substantially flat wall section having a first end and a second end, the first end being coupled to the second end of the second rounded edge and the second end being coupled to a mounting surface that is configured to be coupled to the front surface of the vehicle.
In some embodiments, the device further comprises a right vertical fairing structure configured to be coupled to the first fairing structure and positioned at an angle of about 90 degrees with respect to the first fairing structure and/or a left vertical fairing structure configured to be coupled to the first fairing structure and positioned at an angle of about 90 degrees with respect to the first fairing structure, wherein the left vertical fairing structure is configured to be parallel to the right vertical fairing structure.
In some embodiments, the device further comprises a second right vertical fairing structure nested within the right vertical fairing structure and a second left vertical fairing structure nested within the left vertical fairing structure.
These and other features of the present disclosure will become more apparent from the following description of the illustrative embodiments.
Corresponding reference characters indicate corresponding parts throughout the several views. Although the drawings represent embodiments of the present disclosure, the drawings are not necessarily to scale and certain features may be exaggerated in order to better illustrate and explain the embodiments of the present disclosure.
Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.
The following discussion is presented to enable a person skilled in the art to make and use embodiments of the invention. Various modifications to the illustrated embodiments will be readily apparent to those skilled in the art, and the generic principles herein can be applied to other embodiments and applications without departing from embodiments of the invention. Thus, embodiments of the invention are not intended to be limited to embodiments shown, but are to be accorded the widest scope consistent with the principles and features disclosed herein. The following detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. The figures, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of embodiments of the invention. Skilled artisans will recognize the examples provided herein have many useful alternatives and fall within the scope of embodiments of the invention.
For the purposes of promoting an understanding of the principles of the present disclosure, reference will now be made to a number of illustrative embodiments shown in the attached drawings and specific language 11 be used to describe the same. While the concepts of this disclosure are described in relation to an aerodynamic nose device for use in a semi-truck vehicle or a semi-truck vehicle trailer, it will be understood that it is equally applicable to other trailers and vehicles.
Turning now to
The tractor-trailer assembly 20 further comprises an aerodynamic nose device 100. The aerodynamic nose device 100 may be positioned such that it protrudes outwardly from the leading face 26 of the pup trailer 24 or full-length trailer as it travels forward with the tractor 22. In some embodiments, the aerodynamic nose device 100 may be placed only on the trailer 24 immediately behind the tractor 22, while others may include an aerodynamic nose device 100 on the front surface 26 of each trailer 24 in the assembly. Further, in some examples, the aerodynamic nose device 100 may be placed only on a trailer 24 that is directly coupled to another trailer 24. While a semi-tractor trailer 20 having two pup trailers 24 is depicted, the aerodynamic nose devices disclosed herein may be utilized with semi-tractor trailers having only a single trailer 24 of any length.
In some embodiments, the aerodynamic nose device 100 includes a mounting section that is substantially parallel to a top surface 28 of a trailer 24. In other embodiments, the aerodynamic nose device 100 may include a component that is aligned substantially flush with or parallel to the top surface 28 of a trailer 24. Referring now to
The aerodynamic nose device 100 acts as a gap reducer to reduce aerodynamic drag generated by air coming into contact with the leading face 26 of a trailer 24. More particularly, the aerodynamic nose device 100 reduces the gap B to create an effective gap A, which may reduce the air flow that contacts the front face 26 of the trailer 24 as it is traveling forward. While a low pressure zone between the tractor 22 and trailer 24 may still urge some air downward, the aerodynamic nose device 100 can be shaped such that air is redirected away from the front face 26 of the trailer, thereby reducing the overall drag experienced by the assembly.
In a tractor-trailer assembly without an aerodynamic nose device, the gap B between the tractor 22 and the trailer 24 is large enough to create an area of low pressure between the tractor 22 and the trailer 24. Air is sucked down into the gap B because of the pressure differential between the air in the gap B and ambient air, thereby causing pressure drag. In addition to the pressure drag created, the air that flows into the gap then contacts the leading flat surface 26 of the trailer 24, which creates additional drag on the tractor-trailer assembly 20.
Turning now to
The aerodynamic nose device 100 may optionally comprise additional fairing structures, such as a first side fairing structure 104 and a second side fairing structure 106. In some embodiments, the second fairing structure 104 and the third fairing structure 106 are coupled to top fairing structure 102, as will be discussed in more detail below. The first side fairing structure 104 and second side fairing structure 106 may be aligned such that they are substantially perpendicular with the top fairing structure 102. Similarly, the first side fairing structure 104 and the second side fairing structure 106 may be aligned such that they are substantially parallel to one another. In such cases of angular location, substantially may mean within ten degrees, five degrees, or within two degrees.
The first side fairing structure 104 and the second side fairing structure 106 may be configured to be coupled to the trailer 24. In some embodiments, the first and second side fairing structures 104 and 106 may be coupled to the top surface 28 of a trailer 24 or other vehicle, a front surface 26 of a trailer 24 or other vehicle, a side surface 30 of a trailer 24 or other vehicle, or any combination of these surfaces. Additionally, it is contemplated that some trailers 24 or other vehicles may have rounded edges 32, which may also be suitable for coupling one or both of the first and second side fairing structures 104 and 106, and are similarly contemplated by the present disclosure.
In some embodiments, the top fairing structure 102, the first side fairing structure 104, and the second side fairing structure 106 are configured to align with a portion of the outer perimeter of the front surface 26 of the trailer 24. In some embodiments, the first side fairing structure 104 and second side fairing structure 106 are mounted inside rounded edges 32, on front surface 26. In some embodiments, each of the first side fairing structure 104 and the second side fairing structure 106 extends along vertical edges of the front surface 26 of the trailer 24. In other embodiments, the first and second side structures 104 and 106 extend away from top fairing structure 102 such that only about half of the perimeter of the front face 26 of the trailer 24 is defined by components of an aerodynamic nose device 100, as seen in
Turning now to
The aerodynamic nose device 100 may be mounted to one or more surfaces of the trailer 24 or other vehicle surface in a number of ways. In some embodiments, the aerodynamic nose device 100 comprises a plurality of mounting flanges. For instance, as seen in
The first and second side structures 104, 106 may also be equipped with mounting flanges. In some embodiments, as best seen in
Still referring to
The first and second side fairing structures 104, 106 may also optionally include a bottom mounting tab 131, as shown in
Any of the top fairing structure 102, the first side fairing structure 104, and the second side fairing structure 106 may comprise depressions 120. The depressions 120 may take on a number of shapes and positions, including a frustotriangular shape such as that shown in the
While depressions 120 may add a certain aesthetic element to the fairing structures and aerodynamic nose device 100 overall, some shapes can provide additional structural support to the fairing structures, should they experience axial loading while in use. For example, it is possible that a rear surface of a tractor 22 could come into contact with the aerodynamic nose device 100. The axial loading experienced by the aerodynamic nose device 100 may cause deflection. By having additional support from the depressions 120, the aerodynamic nose device 100 may be able to withstand additional axial loading without permanently deforming.
Turning now to
The curved wall 136 may extend away from the mounting flange 142, at a radius of curvature of between about 11 inches and about 31 inches when the curved wall 136 (or the mounting flange 142) is mounted to the vehicle surface. A first end 137 of a rounded edge 138 is connected to the second end 135 of the curved wall 136, wherein the rounded edge 138 may have a radius of curvature ranging from between about 0.1 inches and about 2 inches. In some embodiments, the radius of curvature of the rounded edges 138 is different than the radius of curvature of the curved wall 136. A substantially flat wall 140 extends from a second end 139 of the rounded edge 138. In some embodiments, the substantially flat wall 140 extends toward a vehicle mounting surface (when attached to a vehicle), which could be a variety of different surfaces. For example, an end 143 of the substantially flat wall 140 may be connected to the mounting flange 126 or to one or more mounting tabs, as discussed previously. The substantially flat wall 140 may be disposed at an angle A1, as seen in
The top fairing structure 102 may be designed to be entirely enclosed throughout the entire structure, or with one or more open surfaces. The top fairing structure 102 may be solid throughout, hollow throughout, or a combination of filled and unfilled. In some embodiments, a cavity 170 is defined by the shape of the fairing structure 102. In such embodiments, the curved wall 136 may have a curved wall inner surface and a curved wall outer surface, the rounded edge 138 may have inner and outer rounded edge surfaces, and the substantially flat wall may include inner and outer surfaces as well. In such embodiments, the curved wall outer surface, rounded edge outer surface, and substantially flat wall outer surface form an aerodynamic surface, while the curved wall inner surface, rounded edge inner surface, and substantially flat wall inner surface form a cavity 170. The thickness of the curved wall 136, rounded edge 138, and substantially flat wall 140 may be held constant throughout these surfaces or may vary, depending on the desired structure and manufacturing method used. In some embodiments, the thickness of each of the curved wall 136, the rounded edge 138, and the flat wall 140 may be between about 0.002 inch and about 0.25 inch or thicker.
Referring again to
The second and third linear fairing segments 108 and 109 may also comprise curved walls, rounded edges, and substantially flat walls, similar to the first linear fairing segment 107. In some embodiments, a portion of the second (and optionally the third) linear fairing segment 108 and a portion of the first linear fairing segment 107 have substantially similar geometry, and may have similar cross-sectional shapes. In some embodiments, portions of the second linear fairing segment 108 and the third linear fairing segment 109 may have substantially similar geometry to portions of the second or third fairing structures 104 and 106, as discussed in more detail below. In some embodiments, the cross-sectional shape of second and third linear fairing segments 108 and 109 is substantially similar to the cross-sectional shape of a portion of second fairing structure 104 or third fairing structure 106. Optionally, the second linear fairing segment 108 and the third linear fairing segment 109 may include depressions as well. In some embodiments, the second linear fairing segment 108 and third linear fairing segment 109 may comprise a coupling cavity, which is described in greater detail below.
Turning now to
With reference to
Referring to
Turning now to
The first side fairing structure 104 may be configured to be coupled with the top fairing structure 102, or may be functional without being coupled to another fairing structure. Similar to top fairing structure 102, the first side fairing structure 104 comprises a curved wall 154. The curved wall 154 may have a first end 151 and a second end 153, and the first end may extend towards a mounting feature, such as outer mounting flange 132. The second end 153 of the curved wall 154 may extend towards a first end 155 of rounded edge 156. A second end 157 of the rounded edge 156 may extend towards a first end 159 of substantially flat wall 158. The substantially flat wall 158 may then extend away from the rounded edge towards a second end 161, which may be connected to a mounting surface, such as inner mounting flange 134.
The radius of curvature of the curved wall 154 may be between about 11 inches and 31 inches. In some embodiments, the radius of curvature of the curved wall 154 and the radius of curvature of the curved wall 136 are substantially similar. For example, the radius of curvature of the curved wall 154 and radius of curvature of the curved wall 136 may vary from each other by less than six inches. In some embodiments, they may vary from each other by less than one inch, or by less than a quarter inch. The radius of curvature of the rounded edge 156 may be between about 0.1 inches and about 2 inches, or may vary. In some embodiments, the radius of curvature of the rounded edge 156 is about one inch. The substantially flat wall 158 may be disposed at an angle of between about 60 degrees and about 90 degrees, or between about 70 and about 90 degrees, or between about 80 and about 90 degrees, with respect to the mounting surface.
The first side fairing structure 104 may have an angled coupling section 150, which can be configured to nest within the coupling cavity 145 of the top fairing structure 102. To fit within the coupling cavity 145, the radius of curvature of a curved surface 149 or other dimensions of the angled coupling section 150 may be reduced slightly. This allows the angled coupling section 150 to pass through a portion of the coupling cavity 145, as will be discussed in more detail below.
In some embodiments, the first and/or second side fairing structures 104, 106 may be designed to be entirely enclosed throughout the entire assembly 20, or with one or more open surfaces. The first side fairing structure 104 may be solid throughout, hollow throughout, or a combination of filled and unfilled. In some embodiments, a cavity 180 is defined by the shape of the fairing structure 104. In such embodiments, the curved wall 154 may have a curved wall inner surface and a curved wall outer surface, the rounded edge 156 may have inner and outer rounded edge surfaces, and the substantially flat wall 158 may include inner and outer surfaces as well. In such embodiments, the curved wall outer surface, rounded edge outer surface, and substantially flat wall outer surface form an aerodynamic surface, while the curved wall inner surface, rounded edge inner surface, and substantially flat wall inner surface form a cavity 180. The thickness of the curved wall 154, rounded edge 156, and substantially flat wall 158 may be held constant throughout these surfaces or may vary, depending on the desired structure and manufacturing method used. In some embodiments, the thickness of the walls in the fairing structure 104 may be 0.002″ or thicker and about 0.25 inch or thicker.
Referring to
Referring now to
Now turning to
Turning now to
The curved wall 202 may extend away from the mounting flange 208, at a radius of curvature between about 11 inches and about 31 inches. In some embodiments, the radius of curvature may vary throughout. The radius of curvature of the rounded edge 204 may vary as well, or can be between about 0.1 inches and about 2 inches. In some embodiments, the radius of curvature of the rounded edge 204 is about one inch. The substantially flat wall 206 may be disposed at an angle of between about 60 degrees and about 90 degrees, or between about 70 and about 90 degrees, or between about 80 and about 90 degrees, with respect to the mounting surface.
Similar to the mounting surfaces discussed earlier, the mounting surfaces 208 and 210 may take on a variety of different forms. The mounting surfaces may comprise several apertures for attaching fasteners, may provide a smooth surface for applying adhesive, or may provide any mounting surface deemed suitable for use by those skilled in the art. The mounting surfaces 208 and 210 may provide a single mounting surface, a plurality of mounting tabs, or other possible configurations. The mounting surfaces may be configured to mount parallel or substantially parallel to a surface of a trailer, or could be arranged differently, if desired.
Turning now to
It should be appreciated that a number of different materials and construction methods are contemplated by the present disclosure. In some embodiments, a resilient material may be desirable. In some embodiments, a thermoplastic olefin, (TPO), may be used to produce aerodynamic nose devices contemplated within the present disclosure. Such a material selection may provide resistance to possible axial loading, while providing resilience, should some deflection in a fairing structure occur. These deformable materials may allow the device to withstand impacts and return to its original shape. In some instances, thin sheet metal, polymers, composites, and other materials may also provide desirable qualities for aerodynamic nose devices, and can be used to form such devices. In some embodiments, an aerodynamic nose device may comprise several materials.
Additionally, a number of different manufacturing processes are capable of producing the structures described herein and other structures that fall within the confines of the present disclosure. Thermoforming, injection molding, blow molding, compression molding, and other polymer processes may be capable of producing such fairing structures. Similarly, metalworking processes like casting, forging, and machining are just some examples of processes that may be used to produce metal parts within the present disclosure.
While the aerodynamic nose devices of the present disclosure are shown as being attached to a trailer of, for example, a semi tractor-trailer, any of the aerodynamic nose devices disclosed herein may be attached to truck bodies, dry van or refrigerated trailers, refrigerated dry vans, flat beds, tanks, or any other vehicles.
While the disclosure has been illustrated and described in detail in the foregoing drawings and description, the same is to be considered as exemplary and not restrictive in character, it being understood that only illustrative embodiments thereof have been shown and described and that all changes and modifications that come within the spirit of the disclosure are desired to be protected.
