Air deflector with improved drainage

An air deflector for a vehicle includes a pair of side air deflectors joined by an intermediate air deflector, and one or more drainage apertures offset from a sealed outboard corner of each of the pair of side air deflectors. The air deflector further includes one or more draining surfaces adapted to promote movement of liquids and solids to the one or more drainage apertures. The one or more drainage apertures may be defined by a non-planar margin defined in the intermediate air deflector member and/or the pair of side air deflectors. The one or more draining surfaces include a plurality of crowned and sloped surfaces adapted for directing movement of liquids and solids to the one or more drainage apertures.

TECHNICAL FIELD

This disclosure relates generally to airflow deflectors. More particularly, the disclosure relates to an air deflector for a vehicle, including a plurality of features and surfaces adapted to provide improved drainage.

BACKGROUND

Air deflectors such as side air deflectors designed for use at the interface of a vehicle air intake and cooling pack (radiator, fan, etc.) are typically slotted or disconnected at the corners. This promotes fit and drainage, and further advantageously reduces imposition of potentially excessive forces by the air deflector on the cooling pack, such as when an impact to the air deflector is received or forces imposed by relative movement of a vehicle chassis to elements of the vehicle engine compartment such as the cooling pack.

However, such slotting or disconnection at the corners reduces efficiency of airflow. Particularly for small-package and high-efficiency air cooling systems wherein it is necessary to maintain smoothness and integrity of airflow passing through the vehicle front air intake, through the deflector, and to the cooling pack, such unsealed air deflector corner portions allow unacceptable airflow leakage that negatively impacts efficiency of the airflow-based cooling.

Accordingly, a need in the art exists for vehicle air deflectors providing highly efficient airflow seals to meet modern cooling standards.

SUMMARY

In accordance with the purposes and benefits described herein, in one aspect of the present disclosure an air deflector is provided, comprising a pair of side air deflectors joined by an intermediate air deflector. The air deflector includes one or more drainage apertures offset from a sealed outboard corner of each of the pair of side air deflectors. The air deflector further includes one or more draining surfaces adapted to promote movement of liquids and solids to the one or more drainage apertures. In embodiments, the one or more drainage apertures are defined by a non-planar margin defined in the intermediate air deflector member and/or the pair of side air deflectors.

The one or more draining surfaces comprise a plurality of crowned and sloped surfaces interacting to efficiently move liquids and solids to the one or more drainage apertures. In embodiments, the plurality of crowned and sloped surfaces includes an intermediate air deflector crowned surface adapted for directing movement of liquids and solids to the one or more drainage apertures. The plurality of crowned and sloped surfaces may further include a crowned and sloped channel adapted for directing movement of liquids and solids from the sealed outboard corner to the one or more drainage apertures.

In embodiments, the pair of side air deflectors each further comprise a sloped surface including at least one channel for collecting and directing liquids and solids therethrough. The sloped surface in embodiments includes a first channel adapted for collecting and directing liquids and solids to the crowned and sloped channel and/or the one or more drainage apertures. In embodiments, the sloped surface further includes a second channel adapted for collecting and directing liquids and solids to an outboard end of the intermediate air deflector crowned surface.

In other aspects, an air deflector is provided, comprising a pair of side air deflectors each having a sealed outboard corner and joined by a crowned intermediate air deflector. One or more drainage apertures are disposed offset from the sealed outboard corners and defined by a non-planar margin defined in the crowned intermediate air deflector and/or the pair of side air deflectors. The air deflector includes draining surfaces comprising a plurality of crowned and sloped surfaces as described above.

In yet other aspects, an air deflector is provided, comprising a pair of side air deflectors each having a sealed outboard corner and joined by a crowned intermediate air deflector. One or more drainage apertures are provided in an offset position relative to the sealed outboard corners. The air deflector further includes one or more side air deflector draining surfaces as described above, adapted to promote movement of liquids and solids to the one or more drainage apertures. The draining surfaces may be substantially as described above. In embodiments, the one or more drainage apertures are defined by a non-planar margin defined in the crowned intermediate air deflector and/or the pair of side air deflectors.

In the following description, there are shown and described several preferred embodiments of the described air deflector. As it should be realized, the described air deflector is capable of other, different embodiments and its several details are capable of modification in various, obvious aspects all without departing from the device as set forth and described in the following claims. Accordingly, the drawings and descriptions should be regarded as illustrative in nature and not as restrictive.

Reference will now be made in detail to the present preferred embodiments of the vehicle air deflector as disclosed, examples of which are illustrated in the accompanying drawing figures.

DETAILED DESCRIPTION

Preliminarily, the presently disclosed air deflector is finds utility in a variety of vehicle types and airflow deflection systems, including the body-on-frame vehicle disclosed in U.S. Pat. No. 9,636,996 owned by the present Assignee, Ford Global Technologies, LLC. The present disclosure describes the air deflector in use in that type of vehicle. However, the skilled artisan will readily appreciate that the described air deflector equally finds utility in any small-package/high-efficiency air cooling system wherein it is necessary to maintain smoothness and integrity of airflow, regardless of vehicle type or chassis/body interaction. Accordingly, the descriptions herein will not be taken as limiting in that regard.

Reference is now made toFIG. 1illustrating a prior art body-on-frame vehicle100including a chassis element102which supports the vehicle drivetrain (not shown) decked to a body frame104carrying/supporting a variety of body panels and vehicle elements (not shown). Modern body-on-frame vehicles100rely on multiple sealing parts in the vehicle front end and under the vehicle to direct cooling air to the vehicle cooling pack (radiator(s), condenser, oil cooler, transmission cooler, power steering cooler, etc.) and/or to underbody components requiring cooling, and present unique design challenges relating to installation of certain sealing components on the vehicle chassis102(referred to herein as the upper sealing system), installation of other sealing components on portions of the vehicle body frame104(referred to herein as the lower sealing system), and installation of still other sealing components which are required to bridge the lower and upper sealing systems, all while compensating for relative movement between the vehicle chassis102and the vehicle body frame104and any sealing components installed on those elements.

The vehicle100includes an upper airflow deflecting assembly106having at least side deflectors108which on vehicle assembly are attached to a grille opening reinforcement (not shown for convenience) and an upper airflow deflector110. A lower airflow deflecting assembly112may include a front airscoop/deflector114, which when the vehicle is assembled is disposed substantially behind a vehicle front bumper (not shown). In the fully decked position, i.e. on mounting of the body104to the chassis102, an interface116is defined between the upper airflow deflecting assembly106and the lower airflow deflecting assembly112. This interface must be sealed to provide a smooth, uninterrupted airflow through the upper and lower airflow deflecting assemblies106/112. Such airflow deflecting assemblies also require suitable drainage to move collecting liquids and solids such as debris, gravel, and others out of the vehicle air intake(s). However, particularly in small-package and high-efficiency air cooling systems including side air deflectors108as described above, providing conventional drainage systems such as drain holes disposed at corner portions of the side air deflectors or side air deflectors that are disconnected from other elements of the airflow deflector assemblies can interfere with smooth airflow.

To solve this and other problems, with reference toFIG. 2an air deflector200is provided, comprising a pair of side air deflectors202joined by an intermediate air deflector204. The intermediate air deflector204includes a crowned surface205(see line A) adapted to move liquids and solids (particulates, debris, etc.) in a vehicle-outboard direction and towards a drainage portion of the air deflector200that will be described in greater detail below.

FIG. 3shows a one of the pair of side air deflectors202in greater detail. Each side air deflector202includes a plurality of draining surfaces (see arrows illustrating flow of liquids and/or solids) adapted to move liquids and solids to at least one drainage aperture206. The depicted side air deflector202includes also a sealed corner portion208and a variety of crowned and sloped surfaces adapted to move liquids and solids to the at least one drainage aperture206as will now be described.

These crowned and sloped surfaces include a crowned and sloped channel210(see alsoFIG. 4showing the crowned portion210aof the crowned and sloped channel210in greater detail) which is adapted to move liquids and solids from the sealed corner portion208to the at least one drainage aperture206.

The side air deflector202further includes a sloped surface212that includes one or more channels214adapted for collecting and directing liquids and solids therethrough. The sloped surface212is joined to a side wall213whereby the sealed corner portion208is provided. In the depicted embodiment, the sloped surface212includes a first channel214aadapted for collecting and directing liquids and solids towards the crowned and sloped channel210. The depicted sloped surface212may include a second channel214b, adapted for collecting and directing liquids and solids towards a vehicle-outboard end of the intermediate air deflector204.

With reference toFIG. 5, each drainage aperture206is defined by a non-planar margin216provided by certain of the various crowned and sloped surfaces as described above. As will be appreciated, the three-dimensional configuration provided for the drainage aperture206by the non-planar margin216provides improved drainage while allowing a smaller two-dimensional footprint for the drainage aperture than would otherwise be required by using a planar drainage aperture.

In conjunction, as shown by the liquid/solid flow directions promoted by the various crowned and sloped surfaces as represented by arrows inFIGS. 3 and 5, fluid and solid flow is promoted from the intermediate air deflector204via crowned surface205in a vehicle-outboard direction and towards the drainage apertures206. Likewise, by the crowned and sloped surfaces as described, fluid and solid flow is promoted towards a bottom end of the sloped surface212including towards the sealed corner portion208, and therefrom by crowned and sloped channel210to the drainage aperture206. By the three-dimensional shape provided to the drainage aperture206by non-planar margin216, greater movement of fluids/solids is possible compared to a two-dimensional drainage aperture.

This is all accomplished while preserving the airflow integrity of sealed corner portions208, compared to corner portions of conventional side air deflectors including slotted or disconnected areas to allow drainage. Because drainage is promoted to the offset drainage apertures206as described above, airflow at the sealed corner portions208experiences reduced turbulence, promoting a smoother airflow through an airflow deflecting assembly incorporating the described air deflector200. In turn, by providing the sealed corner portions208, an air deflector200providing an improved fit, improved dimensions, and indeed more complex shapes at a terminal end of the deflector is made possible.