AIR SPOILER

Abstract: Disclosed is an air spoiler 20 with light weight, high mechanical strength and good and stable quality comprising of three layers which comprise a core body 22 made of foamed material, a solid thermosetting resin layer 24 surrounding the core body and an outer layer 26 made of synthetic resin covering the solid thermosetting resin layer.

Description: BACKGROUND OF THE INVENTION Field of the Invention This invention relates to an air spoiler mounted on the rear deck lid of a vehicle so as to enhance the stability of a vehicle. Prior Art As the speed of a vehicle increases, the vehicle tends to lift from the surface of the road, thus the controllability of the vehicle deteriorates. In order to solve this problem, an air spoiler 10 as shown in Fig. 3 is mounted on the upper surface at the extreme rear of the trunk lid of a vehicle. This air spoiler provides a downward force to the vehicle when the vehicle is operated at a relative fast speed as air, when passing over the vehicle, front to rear, comes into contact with this air spoiler, thus providing greater stability. To enhance fuel economy, it is desirable that a vehicle is kept as light weight as possible therefore it is indispensable that an air spoiler is also constructed of light weight materials. As prior art, an air spoiler made of foamed material having a low density has been disclosed in Japan published unexamined utility model applications No.60-6685 and No.61-12885. Fig. 4 is a cross section of the former example of an air spoiler 11 which comprises a core body 12 made of low density foamed material and a polyurethane foam 13 covering the core body 12. Fig. 5 is a cross section of the latter example of an air spoiler 14 which comprises a core body 15 made of a low density foamed material, a resin outer layer 16 and a metal reinforcing member 17 between the core body 15 and the resin outer layer 16. Although the air spoiler 11 of the former prior art is light weight, the mechanical strength of the product is weak and the bond between the core body 12 and the outer layer (polyurethane foam) 13 is also weak. On the other hand, the latter prior art 14 has the mechanical strength, but the bond among members, especially between the core body 15 and the metal reinforcing member 17 is weak and the air spoiler 14 is not light weight. Moreover, in both prior art, the air spoilers are produced as follows. The core body and the metal reinforcing member is set at a center of a molding case. Then resin is injected into a molding case to constitute the outer layer. In this procedure, however, the injecting pressure can bring about deformation of the core body or biasing of the core body in the product. As a result, it was difficult to produce a good and stable quality air spoiler. SUMMARY OF THE INVENTION In the present invention, an air spoiler is provided which avoids all of the above-noted problems. Objects of the present invention are to provide a good quality, light weight air spoiler with high mechanical strength. Other objects and advantages of the present invention will become apparent from the detailed description to follow. The air spoiler of the present invention is a three-layer-composite which includes a core body made of foamed material, a solid thermosetting resin layer surrounding the core body and an outer layer made of synthetic resin covering the solid thermosetting resin layer. The core body made of foamed material is light weight, but does not have mechanical strength, on the other hand, the solid thermosetting resin layer has mechanical strength, therefore the core composite which is the foamed core body covered by the solid thermosetting resin layer has good mechanical strength. If the solid thermosetting resin layer includes reinforcing fibers, then the mechanical strength is further enhanced. Employing this type of construction provides greater strength with a reduced weight as metal used for strength is not required. The solid thermosetting resin layer covering the core body is a shaped flat cylinder. That shape of flat cylinder further enhances the mechanical strength of the spoiler. When manufacturing an air spoiler, the core composite is set at the center of the mold and the solid thermosetting resin is injected around this cylinder. In this invention, as the core composite has a high mechanical strength, the product is not deformed or biased because of the injecting pressure, thus the quality of the air spoiler becomes stable. The solid thermosetting resin layer has a much smoother surface and fewer air voids on the surface than the core body of the foamed material, thus when the raw material of the outer synthetic resin layer is injected into the mold, the raw material goes smoothly without making air bubbles along the solid thermosetting layer, thus preventing any deterioration of quality. As a result, a finished product has a fine appearance and good quality, the surface of which is smooth. Furthermore, the solid thermosetting resin layer and the outer layer made of synthetic resin strongly adhere to each other. The bond among the core body, the solid thermosetting resin layer and the outer layer is strong, of good mechanical strength. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 and Fig. 2 relate to an embodiment of this invention. Fig. 1 is a cross sectional view of a spoiler of Fig. 2 taken on line I-I; Fig. 2 is a perspective view of an air spoiler; Fig. 3 is a partial perspective view of the trunk of a vehicle; and Fig. 4 and Fig. 5 are sectional views of prior art air spoilers. DETAILED DESCRIPTION OF PREFERRED EMBODIMENT Set forth is an explanation of a preferred embodiment of the present invention based on the attached drawing. This air spoiler 20 comprises three layers which are a core body 22 made of foamed material, a solid thermosetting resin layer 24 surrounding the core body 22 and an outer layer 26 made of synthetic resin covering the solid thermosetting resin layer 24. The core body 22 may be made of rigid polyurethane foam, polypropylene foam, polyethylene foam, polysthyrene foam, or polyethylene-polystylene copolymer foam having a density of 0.02 to 0.5 g/cm³. The solid thermosetting resin layer 24 surrounding the core body 22 is shaped flat cylinder and may be made of epoxy resin, unsaturated polyester resin, polyurethane resin, or polyisocyaurate resin. The layer 24 may be reinforced by the fibers. As reinforcing fibers, glass fibers such as chopped strand fibers, continuous strand mat, non woven fabric mat or woven fabric mat are preferable. It is desirable that the solid thermosetting resin layer 24 have the thickness of 1 to 3 mm. Rigid polyurethane foam, semi-rigid polyurethane foam with a rigid skin (integrally stiffened skin foam) or the like having a density of 0.4 to 1.0 g/cm³ is suitable for synthetic resin constituting the outer layer 26. The shape of an air spoiler is not limited to an example of this embodiment as shown in Figs.1 and 2. Any shape can be employed in accordance with the shape of the vehicle. For example, an air spoiler 10 shown in Fig. 3 can be made with the above inventive structure. In some cases, depending upon the shape of the vehicle, some fittings to the body (not shown) are mounted between the outer layer 26 and the solid thermosetting resin layer 24. This type of air spoiler 20 is manufactured as follows: The core body 22 is formed by foamed material, the core body 22, made of foamed material, is put on a fiber mat laid on a first mold whose cavity is greater than the core body. After another fiber mat covers the core body 22, the first mold is closed, raw material for solid thermosetting resin layer 24 is injected and cured into the first mold. The core composite 27, which is the core body 22 covered by the fiber reinforced thermosetting resin layer 24, is demolded from the first mold and is set at a center of a second mold whose cavity is greater than the core composite 27. Raw material for synthetic resin layer 26 is injected and is cured into the second mold. Obviously, many modifications and variations of the present invention are possible in the light of above teaching. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.

Claims: An air spoiler (20) comprising: a core body (22) made of foamed material; a solid thermosetting resin layer (24) surrounding the core body; and an outer layer (26) made of synthetic resin and covering the solid thermosetting resin layer. An air spoiler according to claim 1 wherein the solid thermosetting resin layer comprises reinforcing fibers. An air spoiler according to claim 2 wherein the reinforcing fibers comprise chopped strand fibers, continuous strand mat, non woven fabric mat or woven fabric mat. An air spoiler according to claim 3 wherein the thickness of the solid thermosetting resin layer is 1 to 3 mm. An air spoiler according to claim 4 wherein the solid thermosetting resin layer is shaped flat cylinder. An air spoiler according to claim 5 wherein the core body is made of rigid polyurethane foam, polypropylene foam, polyethylene foam, polystyrene foam or polyetylene-polystylene copolymer foam having a density of 0.02 to 0.5 g/cm³. An air spoiler according to claim 6 wherein the solid thermosetting resin layer is made of epoxy resin, unsaturated polyester resin, polyurethane resin, or polyisocyanurate resin reinforced by the fibers. An air spoiler according to claim 7 wherein the outer layer is made of rigid polyurethane foam having a density of 0.4 to 1.0 g/cm³ or semi-rigid polyurethane foam with a rigid skin. A manufacturing method of an air spoiler comprising steps of: preparing a core body from foamed material; laying a fiber mat on a first mold whose cavity is greater than the core body by a predetermined thickness; putting the core body on the fiber mat; further laying a fiber mat on the core body; closing the first mold; injecting raw material of solid thermosetting resin into the first mold and curing the raw material; demolding a core composite which is the core body covered by the fiber reinforced solid thermosetting resin from the first mold; setting the core composite at a center of a second mold whose cavity is greater than the core composite by a predetermined thickness; injecting raw material of synthetic resin in the second mold and curing the raw material.

Inventors: FUJI, HIROSHI C/O INOUE MTP KABUSHIKI KAISHA, KOZAKI, NORIO C/O INOUE MTP KABUSHIKI KAISHA, SUGIURA, TOSHIMITSU C/O INOUE MTP KABUSHIKI KAISHA, TERANISHI, AKINORI C/O INOUE MTP KABUSHIKI KAISHA
Applicants: INOAC CORPORATION
Application year: 1988
Main classification: B62D35
IPC codes: B62D37, B62D35