Commercial Vehicle Axle Fairing Assembly with Composite Materials
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Solution Overview
Problem
Existing fairing assemblies for commercial vehicles do not effectively achieve optimal aerodynamics while maintaining durability and structural integrity, leading to inefficient drag reduction and vehicle performance.
Innovation Solution
A fairing assembly for commercial vehicles utilizing a combination of different materials for its portions, where a semi-rigid material like TPO is used for the primary aerodynamic shape and a semi-flexible material like EPDM for flexible extensions, allowing for increased surface area and impact absorption without compromising durability, and is designed to guide air effectively around the vehicle's wheels and trailer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If a single rigid material is used for the fairing, then structural integrity is maintained, but aerodynamic surface area is limited and impact resistance is reduced
Solution Approach 1:
The fairing is constructed using composite materials with different rigidity characteristics - a rigid first portion (e.g., polypropylene) for structural integrity and a flexible second portion (e.g., thermoplastic elastomer) for extended aerodynamic surface area. This composite construction allows the fairing to maintain structural strength while achieving greater surface area for improved aerodynamics.
Solution Approach 2:
Different portions of the fairing are assigned different material properties based on their functional requirements. The first portion requires high rigidity for structural support, while the second portion requires flexibility for extended surface area and impact absorption. This local differentiation of material quality resolves the contradiction between overall structural integrity and localized surface area expansion.
2Shape
If the fairing surface area is extended into collision zones, then aerodynamic performance improves, but durability upon impact deteriorates
Solution Approach 1:
The fairing incorporates a flexible second portion specifically in regions that extend into collision zones. This localized flexibility allows the aerodynamic shape to extend further while the softer material absorbs impact energy, preventing damage to the rigid first portion and maintaining overall durability.
Solution Approach 2:
The flexible second portion is designed to be a sacrificial element that absorbs impact damage rather than protecting the main structural portion. When impacts occur in collision zones, the flexible material deforms and absorbs energy, converting the harmful impact into beneficial energy dissipation that protects the rigid first portion from damage.
3Stability of the object's composition
If a rigid material is used for the fairing, then aerodynamic shape stability is maintained, but impact absorption capability is reduced
Solution Approach 1:
The fairing uses a composite material system where the rigid first portion (e.g., polypropylene) maintains aerodynamic shape stability during normal operation, while the flexible second portion (e.g., thermoplastic elastomer) provides impact absorption capability. This composite approach allows both shape stability and impact resistance to coexist.
Solution Approach 2:
The flexible second portion acts as a pre-positioned cushioning element in regions susceptible to impact. This beforehand cushioning is built into the fairing structure, allowing it to absorb impact energy before it can reach and damage the rigid first portion, thereby protecting the overall aerodynamic structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution significantly enhances aerodynamic performance, reducing drag and improving vehicle efficiency by deflecting air around critical areas while maintaining structural integrity and allowing for flexible impact absorption, resulting in improved aerodynamic flow and reduced drag by over 50%.
Implementation Method 1
a fairing assembly for at least one axle of a commercial vehicle... configured to be arranged at least partially in front of a drive wheel... to guide air effectively around the vehicle's wheels and trailer... reducing drag and improving vehicle efficiency by deflecting air around critical areas
Data Source
AI summary
A fairing assembly for at least one axle of a commercial vehicle is disclosed. The fairing assembly includes at least one forward fairing configured to be arranged at least partially in front of a drive wheel of the axle with respect to the longitudinal direction of the vehicle and at least one rear fairing configured to be arranged at least partially aft of the drive wheel. Each of the fairings includes at least one first portion made of a first material and at least one second portion adjoining the respective first portion where the second portion is made of a second material different from the first material.