Abstract:
There is provided a securing mechanism for securing a strut portion to an I-beam, the securing mechanism comprising a pair of clamps, each including a gripping portion, a securing portion, an abutting portion and a fastener for applying tension on the clamps toward each other for moving the clamps toward each other. A kit thereof and a method of installing the securing mechanism are also contemplated in the present application.

Description:
CROSS-REFERENCE 
       [0001]    The present application relates to and is a non-provisional application claiming priority from U.S. Provisional Patent Application No. 62/314,062, filed Mar. 28, 2016, entitled BEAM CONNECTOR AND METHOD OF INSTALLATION THEREOF, which is incorporated herein by reference in its entirety. 
     
    
     FIELD OF THE INVENTION 
       [0002]    This invention generally relates to a mechanism for securing aerodynamic apparatus components to a vehicle. More precisely, the invention relates to a structural member connector for securing aerodynamic trailer skirts to a vehicle to improve the aerodynamic efficiency of the vehicle. 
       BACKGROUND OF THE INVENTION 
       [0003]    Road tractors are used to pull semi-trailers on roads to transport cargo. Aerodynamic apparatuses are installed on the road tractor and/or on the semi-trailer in order to reduce the aerodynamic air drag and improve fuel efficiency. 
         [0004]    Trailer aerodynamic skirts are installed on both sides of a semi-trailer to help manage the flow of air around and underneath the trailer. Brackets are affixed to the trailer to secure the skirts thereto in a predetermined position. These aerodynamic skirts are secured to a bottom portion of the trailer, or on the sides of the trailer&#39;s floor, to ensure proper positioning when the vehicle is moving. 
         [0005]    People who are familiar with the trucking industry know that trailers are built in various configurations. Frame portions of trailer can use members and beams of different dimensions. For example, an I-beam, that is commonly used in trailer manufacturing, also known as H-beam, W-beam (for “wide flange”), Universal Beam (UB), Rolled Steel Joist (RSJ), or double-T, is a beam with an I or H-shaped cross-section. The horizontal elements of the “I” are known as flanges, while the vertical element is termed the “web”. I-beams are usually made of structural steel, or aluminum, and are used in construction and civil engineering. The web resists shear forces, while the flanges resist most of the bending moment experienced by the beam. Beam theory shows that the I-shaped section is a very efficient form for carrying both bending and shear loads in the plane of the web. 
         [0006]    The skirts, because of their position under the trailer&#39;s floor and their proximity with the road, are significantly vulnerable and might easily enter in contact with surrounding obstacles. Portions of the securing member holding the skirts, when put under significant stress, plastically bend and/or break to affect the skirts&#39; position in respect to the semi-trailer thus reducing the efficiency of the skirts. Additionally, the assembly can be crooked or not precisely aligned, which is causing additional challenges for securing the aerodynamic skirt assembly to the vehicle. 
         [0007]    Known securing members holding the aerodynamic skirts to the trailer are tedious to install. Tools are required to mount the securing member to the trailer. A significant amount of time is needed to properly locate, adjust and secure the aerodynamic skirts on the trailer. 
         [0008]    Therefore, there exists a need in the art for an improved aerodynamic skirt assembly over the existing art. There is a need in the art for a securing member that is adapted to be installed on members and beams of different sizes and configurations. There is also a need for such a resilient skirt assembly that can be easily installed and economically manufactured. 
       SUMMARY OF THE INVENTION 
       [0009]    It is one aspect of the present invention to alleviate one or more of the drawbacks of the background art by addressing one or more of the existing needs in the art. 
         [0010]    Accordingly, embodiments of this invention provide an improved trailer aerodynamic skirt assembly over the prior art that is efficient to install, adjust and offers a level of flexibility to the aerodynamic skirt assembly. 
         [0011]    An aspect of one or more embodiments of the invention provides a skirt assembly adapted to be installed on semi-trailers of different configurations to reduce the aerodynamic drag produced by the movement of the semi-trailer when pulled by a tractor. 
         [0012]    An aspect of one or more embodiments of the invention provides an aerodynamic skirt support mechanism adapted to be manually installed on a semi-trailer to secure a pair of aerodynamic skirt panels on a trailer, the support mechanism being configured to secure an upper portion and a lower portion of the aerodynamic skirt panels. 
         [0013]    An aspect of one or more embodiments of the invention provides a securing member securing a resilient skirt assembly that is adapted to bend when it contacts a foreign object and to self-recover its original position and shape thereafter. 
         [0014]    An aspect of one or more embodiments of the invention provides a connector portion that is adapted to be secured to I-beams of different sizes and/or thicknesses. 
         [0015]    An aspect of one or more embodiments of the invention provides a pair of connector portions achieving a force in a direction that is not aligned with a tension exercised by fasteners securing the pair of connector portions together. 
         [0016]    An aspect of one or more embodiments of the invention provides a gripping portion including an angled beam-contacting portion for transferring pressure on a portion of the I-beam that is applied in two simultaneous different directions. 
         [0017]    An aspect of one or more embodiments of the invention provides a connector portion engaging through a corresponding strut portion for securing the strut portion to a beam. 
         [0018]    An aspect of one or more embodiments of the invention provides a pair of securing connectors mirroring each other, the pair of securing connectors can be secured together with one or more fasteners and with an optional spring member, that can also be an elastic, intervening therebetween to maintain a relative position between the securing connectors. 
         [0019]    An aspect of one or more embodiments of the invention provides a pair of securing connectors mirroring and contacting each other at a lower portion thereof, when securing the connectors together with one or more fasteners, to prevent rotation of the flanges before reaching a desired securing tension with the fastener(s). 
         [0020]    Another aspect of one or more embodiments of the invention provides a beam connector for securing an aerodynamic skirt to a trailer that can be easily installed and economically manufactured. 
         [0021]    An aspect of one or more embodiments of the invention provides a beam connector that is made of sheet metal generally bent in a single plane. 
         [0022]    An aspect of one or more embodiments of the invention provides a beam connector made of two identical connector portions. 
         [0023]    An aspect of one or more embodiments of the invention provides a beam-connector designed to squeeze a flat portion of an I-beam in a beam-receiving portion. 
         [0024]    An aspect of one or more embodiments of the invention provides an aerodynamic skirt support mechanism adapted to be compatible with I-beam of different widths and thicknesses. 
         [0025]    An aspect of one or more embodiments of the invention provides a beam connector adapted to be adjusted by sliding along an I-beam under a trailer. 
         [0026]    An aspect of one or more embodiments of the invention provides an aerodynamic skirt support mechanism adapted to be installed under a trailer without intervening with the land-gear of the trailer. 
         [0027]    Another aspect of one or more embodiments of the invention provides member supports made of a rustproof material. 
         [0028]    One other embodiment of the invention provides a method of installing a skirt assembly on a trailer comprising installing and fastening a portion of a skirt panel, with a securing member, substantially on the edge of a trailer floor and securing a forwardmost portion of the skirt panel at a predetermined position on the trailer to define the shape of the skirt panel. 
         [0029]    One embodiment of the invention provides a securing mechanism for securing a strut portion to an I-beam, the securing mechanism comprising a pair of clamps, each including a gripping portion, a securing portion, an abutting portion and a fastener for applying tension on the clamps toward each other for moving the clamps toward each other. 
         [0030]    One additional embodiment of the invention provides a securing mechanism kit for securing a strut portion to an I-beam, the securing mechanism kit comprising a pair of clamps, each including a gripping portion, a securing portion, an abutting portion and a fastener for applying tension on the clamps toward each other for moving the clamps toward each other. 
         [0031]    Other embodiments and further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description. 
         [0032]    Additional and/or alternative advantages and salient features of the invention will become apparent from the following detailed description, which, taken in conjunction with the annexed drawings, disclose preferred embodiments of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0033]    Referring now to the drawings which form a part of this original disclosure: 
           [0034]      FIG. 1  is a left side elevation view of a vehicle in accordance with embodiments thereof; 
           [0035]      FIG. 2  is a right-bottom perspective view of a trailer in accordance with embodiments thereof; 
           [0036]      FIG. 3  is an isometric view of a securing member in accordance with embodiments thereof; 
           [0037]      FIG. 4  is a right elevation view of a securing member in accordance with embodiments thereof; 
           [0038]      FIG. 5  is a left elevation view of a securing member in accordance with embodiments thereof; 
           [0039]      FIG. 6  is a front elevation view of a securing member in accordance with embodiments thereof; 
           [0040]      FIG. 7  is a to plan view of a securing member in accordance with embodiments thereof; 
           [0041]      FIG. 8  is an isometric view of a securing mechanism in accordance with embodiments thereof; 
           [0042]      FIG. 9  is an isometric view of a securing mechanism in accordance with embodiments thereof; 
           [0043]      FIG. 10  is a side elevation view of a securing mechanism in accordance with embodiments thereof; 
           [0044]      FIG. 11  is a perspective view of a securing mechanism in accordance with embodiments thereof; 
           [0045]      FIG. 12  is a front elevation view of a securing clamp in accordance with embodiments thereof; 
           [0046]      FIG. 13  is a side elevation view of a securing clamp in accordance with embodiments thereof; 
           [0047]      FIG. 14  is a perspective view of a securing mechanism and a securing member in accordance with embodiments thereof; 
           [0048]      FIG. 15  is a right elevation view of a securing mechanism and a securing member in accordance with embodiments thereof; 
           [0049]      FIG. 16  is a front elevation view of a securing mechanism and a securing member in accordance with embodiments thereof; 
           [0050]      FIG. 17  is a top plan view of a securing mechanism and a securing member in accordance with embodiments thereof; 
           [0051]      FIG. 18  is a partial left elevation view of a securing mechanism and a securing member in accordance with embodiments thereof; 
           [0052]      FIG. 19  is a partial left elevation view of a securing mechanism and a securing member in accordance with embodiments thereof; 
           [0053]      FIG. 20  is a partial perspective view of a securing mechanism and a securing member in accordance with embodiments thereof; 
           [0054]      FIG. 21  is a perspective view of a spacer in accordance with embodiments thereof; 
           [0055]      FIG. 22  is a perspective view of a securing mechanism and a securing member in accordance with embodiments thereof; 
           [0056]      FIG. 23  is a top plan view of a securing mechanism and a securing member in accordance with embodiments thereof; 
           [0057]      FIG. 24  is a partial transversal section view of a securing mechanism with a beam-spacer and a securing member in accordance with embodiments thereof; 
           [0058]      FIG. 25  is an exemplary flow chart illustrating a method of installing the securing member and the securing mechanism to a beam, in accordance with embodiments thereof. 
       
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0059]    A preferred embodiment of the present invention is described below with reference to the drawings. 
         [0060]      FIG. 1  and  FIG. 2  illustrate a road tractor  10  with a semi-trailer  20 , also referred to as a trailer  20 , attached thereto and equipped with a pair of aerodynamic skirt assemblies  30 , installed on each side of the semi-trailer  20  along longitudinal axis  34 , adapted to deflect and direct the airflow around the semi-trailer  20 . Each skirt assembly  30  includes a skirt panel  38 , adapted to be disposed on the side of the semi-trailer  20 , and a plurality of securing members  42  adapted to secure the skirt panel  38  to the semi-trailer  20 . The securing members  42  proximally located on sides of the trailer  20  are visible, although not clearly illustrated, because the left-side skirt panel  38  has been removed in  FIG. 1  and  FIG. 2  and will be discussed in more details below. Once installed on the semi-trailer  20 , the skirt assembly  30  helps channel the flow of air around the semi-trailer  20  to reduce the air drag of the vehicle when the semi-trailer  20  moves forwardly on the road, pulled by the road tractor  10 . 
         [0061]    The skirt assembly  30  of the present embodiment is mostly located on the lower side edges, preferably under the semi-trailer  20 , between the wheels  46  of the road tractor  10  and the wheels  50  of the semi-trailer  20 . The skirt panels  38  can alternatively extend forward up to the trailer supports  54 , also known as landing gears, of the semi-trailer, and be secured thereto, thus preventing complex skirt panel  38  arrangements through the securing member  42 . The skirt panels  38  are substantially vertically positioned on each side of the semi-trailer  20  with a clearance with the ground by illustratively about 15-25 centimeters (about 6 to 12 inches) to prevent interferences with the ground under normal operation. The air management around the trailer  20  provided by the skirt assembly  30  reduces the air drag created by the semi-trailer  20  by directing the flow of air around the semi-trailer  20 . The flow of air would otherwise turbulently move around and below the semi-trailer  20  to create substantial turbulences and air drag negatively influencing the aerodynamic efficiency of the vehicle. The airflow management around the semi-trailer  20  provided by the skirt assembly  30  helps maintain laminar airflow around the semi-trailer  20  that helps optimizing the aerodynamic efficiency of the vehicle and diminish fuel consumption of the road tractor  10 . The skirt assembly  30  also improves the safety of the vehicle by providing a barrier that can significantly prevent foreign objects to get under the semi-trailer  20 . 
         [0062]    As illustrated, the skirt panel  38  is shaped with an optional progressive height  62  from a front portion  58  thereof. The skirt panels  38  can alternatively also be installed at a proximal or a distal angle (not illustrated), in respect to the vertical, on the semi-trailer  20  to change the airflow pattern around the semi-trailer  20  and more precisely adjust the aerodynamics to a specific vehicle shape. 
         [0063]    It can be appreciated in  FIG. 2  that each skirt panel  38  is installed directly on the side of the semi-trailer  20  and, when seen from above, the front portion  58  that optionally progressively proximally leans  66  toward the center  34  of the semi-trailer  20 . The recessed front portion  58  of the skirt panel  38  improves the collection of the turbulent airflow generated by the road tractor  10  thus improving the aerodynamic efficiency of the skirt assembly  30 . Additional explanation about the shape of the skirt panel  38  will be provided in further details below. 
         [0064]      FIG. 3  throughout  FIG. 7  are illustrating a securing member  42  including a connector portion  80  and a strut portion  84  both centered along vertical axis  44  and central transversal axis  48 . The connector portion  80  is used to connect the securing member  42  with the trailer  20  and is embodied in these figures to also secure an upper portion  70  of the skirt panel  38 . The strut portion  84  includes a strut member  90  with a lower portion  94  and an upper portion  96  thereof. The securing member  42  of the present embodiment is configured for securing the skirt panel  38  thereon at a lower portion  74  and an upper portion  96  thereof. A planar section  98  includes holes  102  therein for securing the lower portion  94  thereof with fasteners or rivets, for example. The strut portion  84  includes a securing portion  106  to which is connected the strut member  90 . The securing portion  106  is configured to be assembled to the trailer  20  at its upper section with a trailer contacting portion  114 , includes a stabilizer  110  and a skirt panel contacting portion  118  that is generally orthogonally disposed in respect with the skirt panel contacting portion  118  in the illustrated embodiment. The stabilizer  110  is embodied as an extension of the connector portion  80  increasing with a lever effect the securing portion  42  and is extending proximal to the longitudinal axis  34  of the trailer  20  to sustain the loads applied on the strut portion  84  that is also creating a moment on the connector portion  80 . The skirt panel contacting portion  118  of the connector portion  80  includes a planar section  122  provided with a series of holes  126  therein for securing an upper portion  70  to the skirt panel  38  with fasteners or rivets, for example. Both planar section  98 ,  122  are preferably aligned along a unique vertical plane  124  for efficiently contacting the skirt panel  38 . The trailer contacting portion  114  includes openings  130  therein to receive therein a securing mechanism  132  embodied as a pair of opposed clamps  134  to engage the structure of the trailer  20 . 
         [0065]    The securing mechanism  132  embodied two opposed clamps  134  illustrated in  FIG. 8  throughout  FIG. 13  are configured to be secured together with, for instance, two fasteners  138 . The two opposed clamps  134  are securing together the trailer contacting portion  114  of the connector portion  80  with a lower portion of an I-beam as illustrated in  FIG. 14  throughout  FIG. 20 . Each clamp  134  uses an inclined member  160  and two contacting portions  162 ,  166  for securing the connector portion  80  with the I-beam  142 . We will first describe in further details the connector portion  80  before discussing the interaction between the strut portion  84 , the connector portion  80  and the I-beam  142 . 
         [0066]    The connector portion  80  of the illustrated embodiment is using two similar opposed clamps  134  to simplify the assembly and lower the manufacturing cost. The clamps  134  are made of a strong material capable of withstanding significant mechanical loads and can be shaped with a punch and die process. Metal, or the like, can be used. A material resistant to corrosion, or a protective layer, is also desirable given the condition of use of the connector portion  80  to prevent rust to undesirably attack the connector portion  80 . 
         [0067]    Each clamp  134  is, in the present embodiment, made of bent sheet metal that is forming a gripping portion  146 , a securing portion  150  and an abutting portion  154 . The gripping portion  146  includes a beam-engaging portion  158  including an inclined member  160  that is preferably positioned at an angle a, that is illustratively about between 30 degrees and 40 degrees, and more preferably about 34 degrees in the illustrated embodiment, to collect therein sections of I-beams  142  having different dimensions and thicknesses. The gripping portion  146  merges into a first contacting portion  162 , configured to laterally abut sides of an I-beam  142 , that merges into a second contacting portion  166  configured to vertically contact a surface of the I-beam  142 . A securing portion  170  is formed between a first protruding member  174  and a second protruding member  178 . Both protruding members  174 ,  178  are proximally extending about a similar distance to allow leveled abutment of the two clamps  134  when secured and pulled toward each other. The second protruding member  178  is also helpful to prevent premature rotation of the assembly when tightening the fasteners  138  by its lever action and touching each other along a line to provide resistance to rotation to the assembly. Additional bents  182  are performed on the clamp  134  to increase mechanical strength thereof. An elastic member  186 , embodied as an elastic band in the present embodiment, is used to keep both clamps  134  together in clamping position for facilitating the positioning of the clamps  134  prior to secure the clamps  134  to the I-beam  142 . Helical springs  188  can optionally be used to pretense the assembly as illustrated in  FIG. 9 . The pre-assembly of the two clamps  134  are allowing suspending the two clamps  134  to the I-beam  142  to connect the parts of the aerodynamic skirt assembly  30  in place before adjusting the layout and securing them in a final operating configuration. Distance  190 . 1  is preferably configured to be close to zero (0) when the two clamps  134  are secured toward each other and a distance  194  is preferably configured to be a little wider than distance  190  from first and second protruding portions  174 ,  178  to accommodate a central member of the I-beam  142  between the two clamps  134  when the clamps  134  are secured to an I-beam  142 . Distance  190  is likely going to be smaller when the clamps  134  are secured to a narrow I-beam  142 . Conversely, distance  190 . 1  is going to increase when the clamps  134  are secured to a wider I-beam and distance  190 . 2  is going to diminish accordingly. Holes  198  are made in the securing portion  170  to accommodate fasteners  138  therein to secure both clamps  134  together. The interaction of the securing member  42  with an I-beam  142  is depicted in  FIG. 14  throughout  FIG. 20 . 
         [0068]    It can be appreciated from  FIG. 14  throughout  FIG. 17  the gripping portion  146 , with the inclined member  160 , is compressing together vertically and laterally the trailer-contacting portion  114  with a lower portion  202  of the I-beam  142 . The illustrated structure also has the capacity to adapt to a variety of I-beams  142  sizes. The lower portion  202  (bottom flange) can be wider  206  and/or thicker  210  and still be captured and secured with the connector portion  80  of the securing member  42 . Typically, the lower portion  202  of the I-beam  142  is varying from about 41 mm to about 85 mm width, and thickness of about 3 mm to about 13 mm. This is illustrated in  FIG. 18  and in  FIG. 19 . 
         [0069]    One can appreciate the I-beam  142  is parallel with the central axis  144  of the I-beam  142  in  FIG. 14  throughout  FIG. 17 . The connector portion  80  is designed to allow misalignment of the strut portion  84  with the I-beam  142  of the trailer  42  to properly locate the skirt panel  38  in an aerodynamic configuration or to compensate a particular “I-beam”  142  structure. The alignment between the clamps  134  can be made by contacting the abutting portions  154  together. However, in a case of a wider I-beam  142 , a spacer  220  can be required to space apart the abutting portions  154 . The spacer  220  is sized and designed to distance the pair of clamps  134  from each other to allow the clamps  134  to be in the right orientation for optimal clamping force. In other words, the clamps  134  are optimally positioned when they are substantially parallel to each other. The spacer  220 , better seen in  FIG. 20  and  FIG. 21  can be made of different material having suitable mechanical properties like steel, aluminum or plastic. The spacer  220  includes optional voids  224  and ribs  228  to lighten the spacer  220  and reinforce desirable areas thereof. The spacer further includes fastener-receiving portions  232  configured to receive therein  138 . 
         [0070]    A misalignment between the strut portion  84  and the I-beam  142  of the trailer  42  can occur if the trailer  20  has I-beams  142  that are not perfectly aligned and, depending of the installation configuration of the skirt panel  38  along the trailer  20 , the front portion  58  of the skirt panel  38  can proximally lean toward the center of the trailer  20  hence progressively curving or bending and be located at an angle with the I-beam  142  of the trailer  20  as illustrated in  FIG. 22  and  FIG. 23 . The size of the openings  130  is designed to accommodate the installation of the pair of clamps  134  at an angle β thereof. 
         [0071]    I-beams  142  can have various configurations and thicknesses. In so doing, the securing mechanism  132  can be used in conjunction with an optional beam-spacer  236  as illustrated in  FIG. 24 . The beam-spacer  236  can come in different shapes, sizes and thicknesses without departing from the scope of the present invention. The beam-spacer  236  is preferably used between the I-beam  142  and the trailer-contacting portion  114  of the securing member  42  to adjust the size of the clamped material for optimizing the position and angle of the pair of opposed clamps  134  when the width  206  and/or the thickness  210  of the lower portion  202  of the I-beam  142  do not optimally fit the size of the securing mechanism  132 . For example, a beam-spacer  236  could be required in case where the I-beam  142  thickness  210  is about 4.8 mm or less and the width  206  is about 44 mm or less. 
         [0072]      FIG. 25  is an exemplary flow chart illustrating a series of steps for locating and securing a pair of opposed clamps  134  on an I-beam  142 . The pair of clamps  134  are engaged with respective openings  130  of a securing member  42 ,  250 . The pair of opposed clamps  134  are distanced from each other  154  by stretching an elastic member  186  to install the pair of opposed clamps on a beam  142 ,  258 . Releasing the elastic member  186  to engage the beam  142  with the opposed clamps  134 . Sliding the pair of opposed clamps  134  along the beam  142  to locate the clamps  134  and the securing member  42  at a desired position along the beam  142 ,  266 . Securing the pair of clamps  134  on the beam  142 ,  270  and securing trailer-contacting portions  114  of the securing member  42  to the beam  142 ,  274 . 
         [0073]    While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments and elements, but, to the contrary, is intended to cover various modifications, combinations of features, equivalent arrangements, and equivalent elements included within the spirit and scope of the appended claims. Furthermore, the dimensions of features of various components that may appear on the drawings are not meant to be limiting, and the size of the components therein can vary from the size that may be portrayed in the figures herein. Thus, it is intended that the present invention covers the modifications and variations of the invention, provided they come within the scope of the appended claims and their equivalents.