Method of manufacturing a mounting frame for a vehicle wind deflector

Abstract

The present invention provides a method of mounting a fairing to a roof of a vehicle and a method of manufacturing a mounting frame for mounting a fairing to a roof of a vehicle. The mounting frame has a lower portion for mounting to the roof of the vehicle and an upper portion for securing the fairing. The mounting frame is formed by determining a contour of the mounting surface, creating a mould for moulding the lower portion of the mounting frame having a bottom edge configured generally complementary to the contour of at least a portion of the mounting surface, and moulding an upper portion affixed to the lower portion and having an outer face configured generally complementary to an interior surface of the fairing.

Description

FIELD OF THE INVENTION[0001]This invention relates to vehicle wind deflectors. In particular, this invention relates to wind deflectors for trucks.BACKGROUND OF THE INVENTION[0002]A fairing, or wind deflector, is a device that changes the airflow around a vehicle. An effective fairing will reduce wind resistance while the vehicle is in motion, and consequently increase stability and fuel efficiency. Many types of vehicles use fairings beneficially, but an effective fairing is especially advantageous in the heavy truck industry.[0003]Semi-trailer trucks, also called “tractor-trailers,” are common in the heavy truck industry. The tractor, which includes a towing engine, is typically not as tall as the trailer, which carries the freight. The portion of the trailer extending above the roof of the tractor presents a large surface area which is vertical and perpendicular to the motion of the truck, and thus will be generally perpendicular to the flow of air when the truck is in motion at ...

AI Technical Summary

Benefits of technology

[0016]The use of a custom mounting frame as an interface enables the use of a standardized or generic fairing, which may be a unitary or a modular fairing, for several different tractor styles. Thus, instead of using a different custom fairing for each brand of truck, a single standard fairing is mounted to a custom mounting frame. The mounting frame is a significantly smaller component than the fairing, and accordingly it is substantially less expensive to produce a mounting frame specific to the tractor desired to be outfitted with a fairing. Thus, a manufacturer may reduce costs by utilizing the mounting frame of the invention.

[0017]Because the mounting frame is much lighter than the fairing and therefore easier to align with the tractor roof for mounting, the present invention also simplifies the mounting process and requires less tools. The mounting frame of the invention shortens the fairing installation process considerably and helps to prevent scratching of the tractor roof. Also, in a preferred embodiment the mounting frame includes a plurality of generally equidistant attachment points, which spread the load evenly about the perimeter of the fairing to improve stability and strengthen the attachment of the fairing to the roof of the tractor. The perimeter flange further supports the assembly to prevent oil canning effects.

[0018]In the preferred embodiment, the mounting frame is formed from 30% glass-filled polypropylene. Other materials may be used, but nylon and polypropylene are preferred as they have some flexibility, so the mounting frame can flex to fit the truck roof contour if necessary. The use of polypropylene or other plastics makes the mounting frame substantially lighter than a metal frame, and is less likely to scratch the surface of the roof of the tractor. Preferably the mounting frame is formed in two halves, reducing the required mould to a more practical size.

Problems solved by technology

Without a fairing, this configuration encounters considerable wind resistance from wind passing over the top of the tractor and hitting the vertical front face of the trailer.

Providing a custom fairing design with a different lower edge profile for each tractor style, which is the conventional method, is costly.

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