Abstract:
Truck fairings are connected together with a vibration-isolating bracket device. The device includes three parts: two brackets and a strap. The brackets are a lightweight material such as aluminum. The brackets are formed and configured to be coupled together by the strap without the need for further fasteners such as bolts or rivets. The strap is flexible and elastic and provides vibration isolation as well as coupling.

Description:
BACKGROUND 
     Reduction of aerodynamic drag contributes to increased fuel efficiency of a vehicle, for example, a truck. To reduce aerodynamic drag, fairings are installed to smooth the vehicle&#39;s outer surface which thereby smoothes air flow over the vehicle in motion and reduces drag. Fairings and the associated mounting devices, however, contribute to vehicle weight. Fairing vibration can interfere with vehicle operability and can create noise problems. Weight reduction of these added components is desirable to increase fuel efficiency. Vibration isolation is desirable to improve vehicle operability and noise. 
     First conventional devices for attaching fairings to the vehicle and to each other were brackets attached with simple metal straps. The metal straps often broke in service during normal vehicle operation. One attempt to address the problems described above and the problem of strap breakage is shown in  FIGS. 1 and 2 .  FIG. 1  is an isometric view of a second conventional fairing bracket device.  FIG. 2  is a top view of the second conventional fairing bracket device shown in  FIG. 1 . The design shown in  FIGS. 1 and 2  allows for motion accommodation in the fore-aft direction of the vehicle with, for example, ten times the stiffness in the cross vehicle direction. The design shown in  FIGS. 1 and 2 , however, has an involved and therefore expensive manufacturing process. For example, one of the brackets includes a steel cylinder into which an opening is cut to accommodate the square tubing which is welded into place. The manufacturing process further includes four rivets to attach the fairing strap to a second bracket. A total of six components are part of the complete device in this conventional design. The components are also somewhat heavy. 
     It remains desirable to have a fairing mounting device that is lighter, addresses vibration and noise problems and is easier and less expensive to manufacture. 
     SUMMARY 
     The present invention is directed to a vibration isolator device for vehicle fairings. This isolator device is a lower cost, lighter weight device for connecting center, front and rear fairings, for example, for connecting class 8 truck fairings (e.g., the Kenworth T700 series trucks, Peterbilt trucks, and Paccar trucks). The vibration isolator design has fewer components than some conventional devices and allows for fore-aft displacement. Embodiments of the present vibration isolator device typically have only three components: two brackets and one strap. Embodiments of the present vibration isolator device further eliminate the need for welding and riveting operations which are involved in the manufacture of the conventional devices. In one embodiment, extruded aluminum rod is used in the place of cut steel tubing. This reduces the weight of the present device relative to conventional vibration isolator devices. The use of extruded aluminum instead of steel tubing reduces the weight of the mounting and vibration isolating bracket, for example, from 533 to 422 grams. 
     The present invention together with the above and other advantages may best be understood from the following detailed description of the embodiments of the invention illustrated in the drawings, wherein: 
    
    
     
       DRAWINGS 
         FIG. 1  is an isometric view of a conventional fairing bracket device; 
         FIG. 2  is a top view of the conventional fairing bracket device of  FIG. 1 ; 
         FIG. 3  is an isometric view of the fairing isolator device according to principles of the invention; 
         FIG. 4  is a top view of the fairing isolator device of  FIG. 3 ; 
         FIG. 5  is an isometric view of a cylindrical bracket in the fairing isolator device of  FIG. 3 ; 
         FIG. 6  is a side view of the cylindrical bracket of  FIG. 5 ; 
         FIG. 7  is an isometric view of a Y-bracket in the fairing isolator device of  FIG. 3 ; 
         FIG. 8  is a top view of the Y-bracket of  FIG. 7 ; 
         FIG. 9  is a side view of the Y-bracket of  FIG. 7 ; 
         FIG. 10  is an isometric view of a strap in the fairing isolator device of  FIG. 3 ; 
         FIG. 11  is a top view of the strap of  FIG. 10 ; and 
         FIG. 12  is a side view of the strap of  FIG. 10 . 
     
    
    
     DESCRIPTION 
     A fairing vibration isolator device connects vehicle fairings together in such a way that vibration is isolated. The fairing vibration isolator device enables forward and back movement of the fairings. Embodiments of the fairing vibration isolator device include three parts: a cylindrical bracket, a y-bracket and a strap. The brackets are, for example, made of extruded aluminum and the strap is for example, made of rubber. 
       FIG. 3  is an isometric view of an embodiment of the fairing isolator device.  FIG. 4  is a top view of the fairing isolator device. The fairing isolator device  100  has a cylindrical bracket  105  coupled to a Y-bracket  110  by a flexible strap  115 . Both brackets  105 ,  110  are, for example, extruded aluminum. The strap  115  is generally also elastic as well as flexible. The strap  115  is, for example, made of rubber. 
       FIG. 5  is an isometric view of the cylindrical bracket  105  in the fairing isolator device embodiment shown in  FIGS. 3 and 4 .  FIG. 6  is a side view of the cylindrical bracket  105 . The cylindrical bracket  105  has a first near-cylindrical portion  205 , that is, a cylinder having a flattened portion  210 . A post  215  extends from the flattened portion  210 , where the post  215  is rounded at the far end  220 . The post  215  includes two holes  225  for attachment to a vehicle fairing. 
     The cylindrical bracket  105  is, for example, extruded aluminum. The aluminum is a lighter weight material than the steel used in conventional devices. In an alternative embodiment, the cylindrical bracket is made of 30% glass-filled nylon. Design elements further reduce the weight of the cylindrical bracket  105 . In the present embodiment, the weight-reducing design elements are cutouts  230  along the post and another cutout  235  at the part of the post  215  that meets the flattened portion  210  of the cylinder. The form and configuration of the cylindrical bracket enables the bracket to be extruded as a single piece thereby saving several manufacturing steps over conventional devices such as the steps of cutting components and welding them together. The present embodiment is suitable to be machined to a desired width after extrusion. 
       FIG. 7  is an isometric view of the Y-bracket  110  in the fairing isolator device shown in  FIGS. 3 and 4 .  FIG. 8  is a top view of the Y-bracket  110 , and  FIG. 9  is a side view of the Y-bracket  110 . The Y-bracket  110  has a leg  305  and two arms  310  configured to form a “Y” shape. The leg  305  has a portion  315  that is thicker than the rest that also includes tapped holes  320  for making a connection to a fairing. In the conventional Y-bracket shown in  FIGS. 1 and 2 , the holes are untapped and nuts are welded over holes. The tapped holes  320  provide the benefit of accurate placement which is difficult in the welded nuts method. The end  325  of each arm  310  of the Y-bracket is curled back on itself in the direction of the leg, forming a channel  330 . 
     The Y-bracket is, for example, extruded aluminum. Like the cylindrical bracket, use of aluminum results in a lighter weight piece than in many conventional devices. The Y-bracket of the present embodiment is formed and configured to enable the Y-bracket to be extruded as a single piece also saves manufacturing steps over manufacture of conventional devices. In an alternative embodiment, the Y-bracket is made of 30% glass-filled nylon. In a further alternative embodiment, the end of each arm of the Y-bracket is thicker than the lower section in order to form a narrower entrance to the channel. 
       FIG. 11  is an isometric view of the strap  115  in the fairing isolator device shown in  FIGS. 3-5 .  FIG. 12  is a top view of the strap  115 , and  FIG. 13  is a side view of the strap  115  of  FIG. 12 . The strap  115  has a long, flat section  405  that has a first and a second enlarged and rounded end  410 ,  412 . The top  415  and bottom  420  of each enlarged end  410 ,  412  are bulbous. The flat section  405  has two cutouts  425  close to the first enlarged end  410 . The flat section  405  further includes two slots  430 ,  435 . One of the slots  430  is rectangular in shape and is arranged and configured on the flat section  405  to accommodate the post  215  of the cylindrical bracket  105 . The second slot  435  is closer to the second enlarged end  412  and is rounded. Further, the second slot  435  is arranged and configured to enable the first enlarged end  410  to pass through it so that the strap  115  can be wrapped around the cylindrical bracket  105 . The width of the slot  435  is substantially the width of the strap  115  in the section  440  having the cutouts  425 . The strap  115  is flexible and elastic. The strap is made of, for example, rubber. 
     Returning to consideration of  FIG. 3 , the cylindrical bracket  105  and Y-bracket  110  are coupled with the strap  115 . The strap  115  is wrapped around cylindrical bracket  105  with the post  215  extending through the rectangular slot  430 . The first end  410  of the strap  115  is passed through the rounded slot  435  to form a loop around the cylinder portion  205  of the cylindrical bracket  105 . One enlarged end  410  of the strap  115  is inserted into the channel  330  formed by the curled-back portion of one arm  310  of the Y bracket  110 . The arm  310  is then crimped to hold the strap  115  in place. The other enlarged end  412  of the strap  115  is inserted into the curled-back portion of the other arm  310  of the Y-bracket  110 . This other arm is then crimped to hold the strap in place. In an alternative embodiment, the enlarged ends are press fit into the arms of the Y-bracket. In one arrangement, the arm end is thicker in order to form a narrower channel entrance in order to more effectively accomplish a press fit. The bulbous top and bottom of the enlarged ends help position the strap ends on the Y-bracket and keep the ends from slipping out of the bracket arms. This means for engaging the strap with the Y-bracket obviates the need for bolts or rivet connections with the Y-bracket. 
     Embodiments of the brackets described above are made of aluminum, however one of skill in the art will understand that alternative materials such as plastic are possible within the scope of the invention. One such plastic is glass-filled nylon. While 30% glass-filled nylon is cited in the description above with regard to the Y-bracket and the cylindrical bracket, one skilled in the art will understand that higher percentages of glass filler are possible within the scope of the invention, for example 40% glass-filled nylon or 60% glass-filled nylon. 
     It is to be understood that the above-identified embodiments are simply illustrative of the principles of the invention. The depicted embodiments may not be drawn to scale and are to be understood as illustrative of the invention and not as limiting in any way. Various and other modifications and changes may be made by those skilled in the art which will embody the principles of the invention and fall within the spirit and scope thereof.