Abstract:
A removable mud flap includes a panel member having a curved top mounting edge, and a reinforced malleable engagement channel attached along the curved top mounting edge and adapted to frictionally engage a fender flange. The reinforced malleable engagement channel includes an interior U-shaped gripping surface defining a cavity, a plurality of opposed gripping lips protruding into the cavity, a plurality of gripping ribs protruding into said cavity, an exterior surface and an intermediate malleable U-shaped channel disposed between the interior U-shaped gripping surface and the exterior surface. The reinforced malleable engagement channel securely grips a fender flange without damaging the finish of the fender. The mud flap may be removed, without tools and without damaging the fender, by pulling it from the fender.

Description:
RELATED APPLICATION 
   This application claims the benefit of priority to U.S. Provisional Application No. 60/631,720 filed Nov. 30, 2004, the entire contents of which are incorporated herein and made a part hereof. 

   FIELD OF THE INVENTION 
   This invention generally relates to mud flaps, and more particularly, to a pliant mud flap that may be bent and releasably, yet securely, installed on a fender flange of a vehicle without damaging the flange. 
   BACKGROUND 
   Mud flaps are well known in the art. While they generally protect a vehicle from damage due to debris thrown from wheels, conventional mud flaps suffer several shortcomings. First, installation typically entails drilling holes and clamping, bolting or screwing the mud flaps into place. Such processes may materially compromise the finish, corrosion resistance and resale value of a vehicle. A related problem is that removal can be tedious and often leaves bare metal exposed to the elements. Yet another problem with conventional mud flaps is that they are relatively rigid and do not accommodate a range of fender configurations and sizes. Thus, manufacturers and retailers must supply countless different versions. 
   In view of these shortcomings, many vehicle operators simply forgo mud flaps. This holds true particularly for classic car enthusiasts, who tend to contemn any aftermarket, non-original equipment. In such cases, road grime and flying gravel can wreak havoc on fine vehicle finishes, not to mention the finishes and windshields of vehicles following behind. 
   The invention is directed to overcoming one or more of the problems as set forth above. 
   SUMMARY OF THE INVENTION 
   To solve one or more of the problems set forth above, in an exemplary implementation of the invention, a removable mud flap is provided. In one aspect of an exemplary implementation of the invention, the mud flap is provided with a panel member having a top mounting edge, and a malleable (i.e., pliant) engagement channel attached at the top mounting edge and adapted to frictionally and releasably engage a fender flange. The top mounting edge is curved to generally conform to the shape of a vehicle fender. The malleable engagement channel includes a generally u-shaped gripping surface and a plurality of opposed projections extending from said gripping surface and adapted to frictionally and releasably engage a fender flange without damaging the flange. An interior U-shaped gripping surface of the malleable engagement channel is devoid of screws, bolts, metallic clips and rivets, and other mechanical fastening items that may damage a finish of the gripped flange portion. 
   In another aspect of an exemplary implementation of the invention, the plurality of opposed projections may include a first gripping lip at or near the first free end and a second gripping lip at or near the second free end of the u-shaped gripping surface. The first gripping lip is angled away from the first free end and the second gripping lip is angled away from the second free end. The plurality of opposed projections may also include a first gripping rib and a second gripping rib opposite said first gripping rib. The first gripping rib may be angled away from the first free end and the second gripping rib may be angled away from the second free end. 
   In yet another aspect of an exemplary implementation of the invention, the malleable engagement channel may include an interior U-shaped gripping surface, an intermediate malleable U-shaped channel and an exterior surface, with the intermediate malleable U-shaped channel being sandwiched between the interior U-shaped gripping surface and the exterior surface. The intermediate malleable U-shaped channel is comprised of a malleable metallic material to provide pliancy to the channel. The interior U-shaped gripping surface and the exterior surface are comprised of a rubber, plastic or polymeric material. Likewise, the projections extending from the gripping surface are comprised of a rubber, plastic or polymeric material. 
   An optional aspect of an exemplary implementation of the invention includes a panel member comprised of a thermochromic, photochromic and/or phosphorescent additive. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The foregoing and other aspects, objects, features and advantages of the invention will become better understood with reference to the following description, appended claims, and accompanying drawings, where: 
       FIG. 1  shows a first side view of an exemplary mud flap according to principles of the invention; and 
       FIG. 2  shows a perspective view of an exemplary reinforced malleable engagement channel for a mud flap according to principles of the invention; and 
       FIG. 3  shows a second side view of an exemplary mud flap according to principles of the invention; and 
       FIG. 4  shows a vehicle equipped with an exemplary mud flap according to principles of the invention; and 
       FIG. 5  shows a close-up perspective view of an exemplary reinforced malleable engagement channel for a mud flap according to principles of the invention. 
   

   Those skilled in the art will appreciate that the figures are not intended to be drawn to any particular scale. The invention is not limited to the exemplary embodiments depicted in the figures or the shapes, relative sizes, proportions or materials shown in the figures. 
   DETAILED DESCRIPTION 
   Referring to the accompanying drawings, there is illustrated a mud flap generally indicated by reference numeral  100 . The mud flap  100  is intended for use with a vehicle as in conventional mud flaps. The mud flap  100  is particularly suited for vehicles having flanged fenders  410  forming a wheel well of a body of the vehicle  400 , as shown in  FIG. 4 . In the illustrated exemplary embodiment, only a driver side mud flap  100  is shown, however those skilled in the art will readily appreciate that the passenger side embodiment is a mirror image of the driver side embodiments shown. 
   The mud flap  100  is generally comprised of a panel member  120  which provides a shield for debris. The panel  120  may be formed of any durable sheet-like material, such as metal and/or plastic. In an exemplary implementation, the panel  120  is comprised of a rigid rubber, plastic or polymeric material, such as polyvinyl chloride (PVC), polyethylene, polypropylene, polystyrene, acrylics, cellulosics, acrylonitrile-butadiene-styrene terpolymers, urethanes, thermo-plastic resins, thermo-plastic elastomers (TPE), acetal resins, polyamides, polycarbonates and polyesters. While many other materials may be used alone or in combination with the aforementioned materials and/or other materials, without departing from the scope of the present invention, preferably the material is corrosion and weather resistant, impact resistant, durable, easy to clean, produces an aesthetically pleasing product and is relatively inexpensive and easy to manufacture. The material may further include additives to provide desired properties such as desired colors, structural characteristics, glow-in-the dark properties and thermal reactivity (e.g., color changes according to heat). 
   Optionally, by way of example and not limitation, the panel  120  may be formulated to change color when it reaches a predetermined or higher temperature. This can be accomplished by mixing a thermochromic additive to the panel  120  material in an amount that is sufficient to achieve a desired color changing range. As an example, a mixture of approximately 5% to 30% (pbw) of Matsui International Co., Inc.&#39;s Chromicolor® concentrate may be introduced to the panel  120  material, to provide a plastic structure that visibly changes color at a determined elevated temperature, such as approximately 90 degrees Fahrenheit or higher. 
   Alternatively, a photochromic additive may optionally be added to the panel  120  material in an amount that is effective to achieve a desired color change when the panel  120  is exposed to certain lighting conditions. As an example, a mixture of approximately 5% to 35% (pbw) of Matsui International Co., Inc.&#39;s Photopia® additive may be introduced to the panel  120  material, to provide a plastic structure that visibly changes color in the presence of sunlight or ultraviolet light. 
   As another alternative, phosphorescent polymer additives, such as aluminate based phosphors, may optionally be added to the panel  120  material to adsorb light energy and continue to release that energy as visible light after the energy source is removed. Advantageously, such an embodiment provides a panel that is easy to locate in darkened conditions, making the vehicle easy to spot even at nighttime. 
   The panel  120  may be formed with a substantially flat front side and backside, with textured or smooth surfaces and with or without ornamental features. Optionally, various reinforcing structures (e.g., reinforcing ribs) may be included, such as on the side of the panel facing the wheel, to increase structural integrity of the panel member  120  without compromising aesthetics of the mud flap  100 . A curved top mounting edge  120   a  of the panel member  120  is arranged to be supported against a flanged portion of a vehicle fender, while a bottom free end  120   b  is arranged to be suspended downwardly from the vehicle as in conventional mud flaps. The outer side edge  120   c  of the panel member  120  is arranged to be positioned approximately adjacent to an outer side wall of the fender of the vehicle body when mounted on the vehicle so that the panel member  120  projects slightly outwardly. The inner side edge  120   d  of the panel member  120  is arranged to be positioned in the wheel well of the vehicle when the mud flap  120  is mounted on the vehicle. 
   The panel  120  may be produced using any suitable manufacturing techniques known in the art for the chosen material, such as (for example) injection, compression, structural foam, blow, or transfer molding; polyurethane foam processing techniques; vacuum forming; and casting. Preferably, the manufacturing technique is suitable for mass production at relatively low cost per unit, and results in an aesthetically acceptable product with a consistent acceptable quality. 
   A reinforced malleable engagement channel  110  is provided along the curved top mounting edge  120   a  of the panel member  120  of the mud flap  100 . The reinforced malleable engagement channel  110  may be contoured to the shape of a fender flange. The channel  110  frictionally engages the flange to secure the mud flap to the fender. The channel  110  may be attached to the panel  120  using chemical or thermal bonding, mechanical fasteners or other attachment means. The channel  110  may be attached to the panel  120  at a few specific points, allowing the unattached portions to be bent slightly to the contour of a fender flange  410 . 
   Referring now to  FIGS. 2 and 5 , a perspective view of a reinforced malleable engagement channel  110  is provided. The channel  110  is comprised of generally U-shaped flange gripping strip. Generally, the channel  110  includes an interior U-shaped gripping surface  205 , gripping lips  220  and  230  and ribs  240  and  250 , an intermediate malleable U-shaped channel  260  and an exterior surface  210 . Thus, the intermediate malleable U-shaped channel  260  is sandwiched between the interior U-shaped gripping surface  205  and the exterior surface  210 . 
   The intermediate malleable U-shaped channel  260  provides rigidity to the channel  110  for securely engaging a fender flange, while allowing deformation of the channel  110  to a desired fender shape. The malleable U-shaped channel  260  may be comprised of a malleable metal such as steel, aluminum or other malleable metal or alloys thereof. The intermediate malleable U-shaped channel  260  provides a narrow reinforcing channel. The width across the channel is such that it provides a relatively tight fit in the interior channel opening so as to enable a fender flange  410  to be held therein merely by friction. The intermediate malleable U-shaped channel  260  may be provided with suitable coatings to prevent corrosion. 
   The interior U-shaped compartment of the channel  260  includes a plurality of projections  220 ,  230 ,  240  and  250  for frictionally engaging a flange. In particular, lips  220  and  230  and ribs  240  and  250  frictionally engage the fender flange  410 . The free end of the lips  220  and  230  and ribs  240  and  250  are angled away from the entrance of the U-shaped channel to facilitate a smooth entry of the fender flange and to resist backing out. In a preferred implementation, free ends of opposed projections (e.g., lips and/or ribs) contact each other. As most fender flanges include a rolled bulbous edge, angled ribs and lips advantageously resist withdrawal of the flange. However, the invention is not limited to such angularly arranged protrusions. Frictionally engaging projections having other shapes and configurations may be utilized without departing from the scope of the invention. While two ribs  240  and  250  are shown on the same side of the interior U-shaped compartment, those skilled in the art will appreciate that other numbers of ribs, including zero ribs, may be used on each side of the interior U-shaped compartment without departing from the scope of the invention. However, preferably, each opposed side of the U-shaped channel includes at least one protrusion in the form of a lip, rib or other frictionally engaging projection to securely grip the flange. 
   By way of example and not limitation, the U-shaped gripping surface  205 , gripping lips  220  and  230  and ribs  240  and  250  and exterior surface  210  may all be formed of a rubber, plastic, or polymeric material such as vulcanized, non-foam EPDM rubber by extrusion molding, injection molding, casting, or the like. EPDM exhibits excellent weather resistance, ozone resistance, durability, and impact resistance. EPDM also exhibits excellent high and low temperature characteristics. 
   The reinforced malleable engagement channel  110  may be formed using various manufacturing techniques. The malleable intermediate U-shaped channel  260  may be sandwiched between an exterior layer and an interior layer. Chemical and/or thermal bonds may securely attach the layers. Alternatively, the exterior and interior layers of the channel may be extrusion molded, injection molded, dip-formed or cast directly onto the malleable intermediate U-shaped channel  260 . Methods of forming weather stripping for motor vehicles may be applied to produce a reinforced malleable engagement channel  110  according to principles of the invention. 
   To use a mud flap according to principles of the invention, the mud flap is positioned with the curved top mounting edge  120   a  of the panel member  120  adjacent to a flanged fender  410  portion of a vehicle  400 , at the vehicle&#39;s wheel well. The reinforced malleable engagement channel  110  is matingly forced onto the flange  410  so that the channel engulfs a portion of the flange. The interior U-shaped gripping surface  205  protects the engaged flanged portion from scratching and damage. Gripping lips  220  and  230  and ribs  240  and  250  frictionally engage the flanged portion and resist withdrawal. The intermediate malleable U-shaped channel  260  allows the channel  110  to be deformed to match the contour and width of the engaged flanged portion. If necessary, the opening of the intermediate malleable U-shaped channel  260  may be contracted to facilitate release. 
   Removal of a mud flap according to principles of the invention entails exerting force to pull the mud flap from the flange. If necessary, the opening of the intermediate malleable U-shaped channel  260  may be expanded to facilitate release. 
   Although the invention has been described in its preferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form can be changed in the details of construction and in the combination and arrangement of parts without departing from the spirit and the scope of the invention as hereinafter claimed. The physical embodiments described above merely exemplify the invention, which may be embodied in other specific structure within spirit and scope of the claims appended hereto.