Patent Publication Number: US-11639205-B2

Title: Methods and apparatus for a strut assembly for an aerodynamic trucking system

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
     The present application is a continuation-in-part of U.S. Nonprovisional patent application Ser. No. 16/741,886, filed Jan. 14, 2020, entitled “AERODYNAMIC TRUCKING SYSTEMS”, which is a continuation of U.S. Nonprovisional patent application Ser. No. 15/958,342, now U.S. Pat. No. 10,583,873 filed Apr. 20, 2018 entitled “AERODYNAMIC TRUCKING SYSTEMS”, which is a continuation of U.S. Nonprovisional patent application Ser. No. 15/277,172 filed Sep. 27, 2016, now U.S. Pat. No. 9,975,583 entitled “AERODYNAMIC TRUCKING SYSTEMS”, which is a continuation of U.S. Nonprovisional patent application Ser. No. 14/935,647 filed Nov. 9, 2015, now U.S. Pat. No. 9,751,573 entitled “AERODYNAMIC TRUCKING SYSTEMS”, which is a continuation of U.S. Nonprovisional patent application Ser. No. 14/247,504, filed Apr. 8, 2014, now U.S. Pat. No. 9,211,919 entitled “AERODYNAMIC TRUCKING SYSTEMS”, which is a continuation of U.S. Nonprovisional patent application Ser. No. 13/633,013 filed Oct. 1, 2012, now U.S. Pat. No. 8,727,425 entitled, “AERODYNAMIC TRUCKING SYSTEMS”, which claims the benefit of U.S. Provisional Application Ser. No. 61/639,830, filed Apr. 27, 2012, entitled “AERODYNAMIC TRUCKING SYSTEMS”; and is a continuation-in-part of U.S. Nonprovisional patent application Ser. No. 13/117,891 filed May 27, 2011, now U.S. Pat. No. 8,303,025 entitled “AERODYNAMIC TRUCKING SYSTEMS”, which claims the benefit of U.S. Provisional Application Ser. No. 61/374,572, filed Aug. 17, 2010, entitled “AERODYNAMIC TRUCKING SYSTEMS”; and, which claims the benefit of U.S. Provisional Application Ser. No. 61/349,183, filed May 27, 2010, entitled “AERODYNAMIC TRUCKING SYSTEMS”; and incorporates the disclosure of each application by reference. To the extent that the present disclosure conflicts with any referenced application, however, the present disclosure is to be given priority. 
    
    
     BACKGROUND OF THE TECHNOLOGY 
     This technology relates to aerodynamic trucking systems. More particularly, this technology relates to providing a system of aerodynamic apparatus configured to minimize aerodynamic drag and maintain smoother air flow over highway-operated vehicles, particularly long-haul tractor-trailer vehicles. 
     Most large long-haul cargo trailers exhibit less than optimal aerodynamic performance during highway operation. At highway speeds, conventional trailers develop a substantial amount of turbulent airflow in the region between the axles below the trailer box. This turbulence results in significant aerodynamic drag, increasing both fuel consumption and Nitrogen Oxide (NOx) emissions at the motorized towing vehicle. Additionally, temporarily sustained vibration of external vehicle surfaces due to transient wind-force loading is often associated with premature wear, noise, and early failures within such aerodynamic vehicle structures. A system and method to improve the aerodynamic performance of long-haul transport vehicles in the above-noted areas is described below. 
     SUMMARY OF THE PRESENT TECHNOLOGY 
     A strut assembly for mounting an aerodynamic fairing assembly for attachment to a trailer of a tractor-trailer having a centerline, transverse structural support members extending between sides of the trailer, and longitudinal members extending along a length of the trailer. The strut assembly may comprise a mounting plate, a strut body, and a substantially rectangular composite spring. The mounting bracket comprising a mounting plate and a pair of spaced apart sidewalls. The strut body rotatably may be coupled to the pair of spaced apart sidewalls on the mounting bracket. The substantially rectangular composite spring may be coupled to an upper surface of the strut body and configured to contact an underside of the mounting plate of the mounting bracket to resist inward deflection from an external force applied to the strut body. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A more complete understanding of the present technology may be derived by referring to the detailed description when considered in connection with the following illustrative figures. In the following figures, like reference numbers refer to similar elements and steps throughout the figures. 
         FIG.  1    representatively illustrates a perspective view of a strut assembly in accordance with various embodiments; 
         FIG.  2    representatively illustrates a perspective view of a strut assembly in a deflected position in accordance with various embodiments; 
         FIG.  3    representatively illustrates an exploded perspective view of a strut assembly in accordance with various embodiments, 
         FIG.  4    representatively illustrates a cross section view take along the line  4 - 4  in accordance with various embodiments; 
         FIG.  5 A  representatively illustrates a perspective view of a body of the strut assembly in accordance with various embodiments; 
         FIG.  5 B  representatively illustrates a side view of a body of the strut assembly in accordance with various embodiments; 
         FIG.  5 C  representatively illustrates a rear view of a body of the strut assembly in accordance with various embodiments; 
         FIG.  6    representatively illustrates a perspective view a spring in accordance with various embodiments; 
         FIG.  7 A  representatively illustrates a perspective view a spacer in accordance with various embodiments; 
         FIG.  7 B  representatively illustrates a top view a spacer in accordance with various embodiments; 
         FIG.  7 C  representatively illustrates a front view a spacer in accordance with various embodiments; 
         FIG.  8 A  representatively illustrates a perspective view of a spring washer in accordance with various embodiments; 
         FIG.  8 B  representatively illustrates a top view of a spring washer in accordance with various embodiments; 
         FIG.  9 A  representatively illustrates a perspective view of a mounting bracket in accordance with various embodiments; 
         FIG.  9 B  representatively illustrates a side view of a mounting bracket in accordance with various embodiments; 
         FIG.  10 A  representatively illustrates a perspective view of a mounting clamp in accordance with various embodiments; 
         FIG.  10 B  representatively illustrates a top view of a mounting clamp in accordance with various embodiments; 
         FIG.  10 C  representatively illustrates a side view of a mounting clamp in accordance with various embodiments; 
         FIG.  11 A  representatively illustrates a perspective view of a roller in accordance with various embodiments; 
         FIG.  11 B  representatively illustrates a top view of a roller in accordance with various embodiments; and 
         FIG.  11 C  representatively illustrates an end view of a roller in accordance with various embodiments. 
     
    
    
     Elements and steps in the figures are illustrated for simplicity and clarity and have not necessarily been rendered according to any particular sequence. For example, steps that may be performed concurrently or in a different order are illustrated in the figures to help to improve understanding of embodiments of the present technology. 
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
     The present technology may be described in terms of functional block components and various processing steps. Such functional blocks may be realized by any number of components configured to perform the specified functions and achieve the various results. For example, the present technology may employ various types of materials, connectors, panel, mounts, and the like for aerodynamic trucking systems, and the system described is merely one exemplary application for the technology. 
     Methods and apparatus for providing a safety system designed to minimize internal deflection of a side skirt on a trailer when side impact from an automobile or other road vehicle occurs. Various representative implementations of the present technology may be applied to any system for minimizing internal deflection of a side skirt on a trailer upon side impact from an automobile or other road vehicle. The present technology may be utilized to minimize internal deflection of a side skirt on a trailer upon side impact from an automobile or other road vehicle so as to limit a vehicles ability to slide underneath a semi-truck trailer when a crash occurs. 
     Generally, an undercarriage of a conventional cargo trailer is comprised of groupings of various components, which generally reside below a cargo-supporting floor deck, customarily having a rectangular shape. The components of a semi-type cargo trailer undercarriage customarily include longitudinal and transverse structural support members. An aerodynamic skirt fairing may be mounted to an undercarriage of a cargo trailer by a panel support or strut assembly. The aerodynamic skirt fairing may be mounted directly to the any portion of the undercarriage of the cargo trailer by any known method. The aerodynamic skirt fairing functions to direct airflow away from the central regions of the trailer undercarriage to reduce drag. A conventional cargo trailer is shown and described in FIGS. 1 and 8 of US Patent Publication No. US-2020-0148288-A1, which is incorporated by reference. 
     In accordance with various embodiments and referring now to  FIGS.  1 - 4   , a strut assembly will  100  be discussed. Generally, the strut assembly  100  may be coupled to a semi-type cargo trailer undercarriage (not shown) to restrict movement of the aerodynamic skirt fairing inwardly if impacted by an automobile, motorcycle, or other object. Further, the strut assembly  100  may be coupled to one of a longitudinal structural support member and/or transverse structural support member of the undercarriage to restrict movement of the aerodynamic skirt fairing inwardly if impacted.  FIGS.  1  and  3    show the strut assembly  100  in the standard operating position while  FIG.  2    shows the strut assembly  100  in a deflected position. 
     In various embodiments, the strut assembly  100  may comprise a mounting bracket  102 , a spring  104 , and a strut body  106 . The strut body  106  may be rotatably coupled to the mounting bracket  102 . The spring  104  may be coupled to the mounting bracket  102  and configured to resist inward rotation of the strut body  106  toward a longitudinal centerline of the trailer upon impact from an automobile or any other foreign object. 
     In various embodiments, the strut assembly  100  may be rotatably coupled to the undercarriage of a cargo trailer. In another embodiment, the strut assembly  100  may be rotatably coupled to one of the longitudinal and/or transverse structural support members. 
     Each of the components may be constructed from industry-standard materials selected to comprise a structural rigidity sufficient to support the required air deflection function, while offering a level of mechanical flexibility sufficient to deflect resiliently under small to moderate impact loads, thereby reducing the need for repair or replacement due to permanent impact damage. Materials suitable for use in the strut assembly  100  may comprise, such as, for example, steel, stainless steel, aluminum, composite materials, UHDPE, molded polymer, polymer-based composite, fiber-reinforced polymer, and injection molded polycarbonate, acrylonitrile butadiene styrene (“ABS”) plastic, polypropylene, polyethylene, and polystyrene, polyvinyl chloride (“PVC”) or any suitable combination or mixture thereof. In one embodiment, the material for the strut assembly  100  may comprise an injection molded mixture of polycarbonate and ABS plastic. One of ordinary skill in the art will appreciate that, under appropriate circumstances, considering such issues as cost, user preference, etc., other material selections for the strut assembly  100  may be used. 
     In various embodiments, as shown in  FIGS.  1  and  9 A -B, the mounting bracket  102  may be coupled to one of the longitudinal and/or transverse structural support members by a clamping mechanism  108 . In various embodiments, the mounting bracket  102  may be made steel, stainless steel, alloy steel, carbon steel, chromoly, aluminum, various composite materials and the like. 
     In various embodiments, as shown in  FIGS.  9 A-B  the mounting bracket  102  may comprise a mounting plate  110 . The mounting plate  110  may comprise a central portion  112  containing a positional adjuster comprising an aperture  114  and at least one slotted aperture  116 . In one embodiment, the positional adjuster of the mounting plate  110  may comprise a single circular aperture  114  and multiple slotted apertures  116 . The apertures  114 ,  116  are configured to assist with the mounting of the strut assembly  100  to one of the longitudinal and/or transverse structural support members. The apertures  116  may be slotted or curved to assist with the mounting of the strut assembly  100  to the trailer. 
     The mounting plate  110  may comprise a pair of opposed sidewalls  118  configured to couple the strut body  106  to the mounting bracket  102 . The opposed sidewalls  118  project downwardly from the mounting plate  102 . The sidewalls  118  may comprise a pair of forward apertures  120  and a pair of rear apertures  122 . The forward apertures may receive a pin  124  to couple the strut body  106  to the mounting bracket  102 . The rear apertures  122  may receive a fastener  126  to couple a roller  128  to the mounting bracket  102 . 
     In one embodiment, the sidewalls  118  each contain an angled notch  130 . The angled notch  130  serves to limit the rotation of the strut body  106  inwardly towards a centerline of the trailer upon impact from a foreign member. 
     In various embodiments, as shown in  FIGS.  1 - 3   , the mounting bracket  102  may be configured to be adjustably mounted to a transverse structural support member of a cargo trailer by the clamping mechanism  108 . The clamping mechanism  108  along with the mounting bracket  102  may be configured to be adjustable along multiple linear and rotational axes to facilitate the above-noted optimized aerodynamic positioning of respective aerodynamic skirt fairings mounted to the strut assembly  100  within a specific tractor-trailer setup. The clamping mechanism  108  and positional adjuster of the mounting plate  110  comprising the apertures  114 ,  116  allow the mounting bracket  102  to be adjustable in multiple directions. Another example is shown and described in FIG. 7 of US Patent Publication No. US-2020-0148288-A1, which is incorporated by reference. 
     In various embodiments, referring to  FIGS.  1 ,  3 , and  10 A- 10 C , the clamping mechanism  108  may comprise a pair of spaced apart clamps  132 . The clamps  132  may comprise a mounting portion  134  and a raised portion  136 . The mounting portion  134  may comprise a pair of apertures  138 , which align with the apertures on the positional adjuster on the mounting plate  110  of the mounting bracket  102 . 
     In one embodiment, when coupled to the mounting bracket  102 , a clamp spacer  140 , shown in  FIGS.  3  and  7 A -C is placed between the mounting bracket  102  and the clamping mechanism  108 . The clamp spacer  140  may comprise a pair of cutout portions  142 , that generally align with the apertures  138  on the mounting porting  134  of the clamps  132  and the apertures  114 ,  116 . The raised portion  136  of the clamps  132  and the clamp spacer  140 , when assembled create a mounting channel  144 . The mounting channel  144  may comprise a space between a lower surface of the raised portion  136  and the central portion  112  of the mounting bracket  102  and may be configured to receive one of the longitudinal and/or transverse structural support members on the trailer. 
     In various embodiments, and referring to  FIG.  5 A-C , the strut body  106  may comprise a mounting surface  146  and a panel support  148 . The mounting surface  146  is a generally horizontal surface used to couple the strut body  106  to the spring  104 . 
     The panel support  148  may comprise a downwardly-projecting support member  150  pivotally coupled to the mounting bracket  102 , which is coupled to the transverse structural support member on the cargo trailer (not shown). The downwardly-projecting support member  150  of the strut body  106  may comprise a pair of spaced apart side walls  152 , each having a mounting aperture located at an upper end and a rear wall  154  which is configured to sturdy the strut body  106  to support the mounting of a side skirt panel. 
     In various embodiments, the strut body  106  may be made from any suitable material that would resist side impact. Some examples include steel, stainless steel, alloy steel, carbon steel, chromoly, aluminum, composite materials, UHDPE, molded polymer, polymer-based composite, fiber-reinforced polymer, and injection molded polycarbonate, acrylonitrile butadiene styrene (“ABS”) plastic, polypropylene, polyethylene, and polystyrene, polyvinyl chloride (“PVC”) or any suitable combination or mixture thereof. In one embodiment, the material for the strut body  106  may comprise an injection molded mixture of polycarbonate and ABS plastic. 
     Referring now to  FIGS.  1 ,  3 ,  4  and  6   , the spring  104  will be discussed. The spring  104  may be from a fabric material and is configured to resist movement of the strut body  106  inwardly upon deflection from an external impact. In one embodiment the fabric spring may comprise a Gordon Spring, manufactured by Gordon Holdings. In various embodiments, the spring  104  may be constructed from an advanced composite material comprising vinyl Ester or epoxy resins and unidirectional fiber reinforcement technologies. Some combinations include glass/vinyl ester and/or glass/epoxy. In various embodiments, the spring  104  may comprise a composite spring. These formulations achieve long-lasting, consistent flexing performance in a variety of applications. Composite springs (also referred to as flat springs, flippers, energizers, slats, and exciters) are engineered with proprietary vinyl ester or epoxy resins and unidirectional glass or carbon fiber reinforcement technologies. These formulations achieve long-lasting, deep, and consistent flexing performance in a variety of cantilevered applications, from vibratory sorting and conveying systems to furniture. Still further, applications requiring high cyclic fatigue resistance, repeatability, and high performance are well served by composite springs. The types of materials for the fabric spring are similar to those made from PolyOne Corporation and/or Avient Corporation https://healthcare.polyone.com/products/advanced-composites/pultrusion-and-continuous-filament-winding-technology/advanced-composite-springs. 
     The spring  104  comprises a pair of apertures  156  located adjacent a first end. The spring  104  is generally rectangular shaped and flat, although any suitable shape and configuration may be used depending on the configuration of the other components. The spring  104  is mounted between the lower surface of the mounting bracket  102  and the mounting surface  146  of the strut body  106 . In one embodiment, and as shown in  FIGS.  3  and  4   , the spring  104  is coupled to the mounting surface  146  of the strut body  106  by a spring washer  158  ( FIGS.  8 A-B ) at a first end. The spring  104  may be received between the spring washer  158  and the mounting surface  146  of the strut body  106  and coupled there between by fasteners  160 . The fasteners  160  are received in apertures  156  on the spring  104 , apertures  162  on the spring washer  140 , and apertures  164  on the mounting surface  146  of the strut body  106 . 
     A second end of the spring  106  is configured to slide on an underside of the roller  128 , when deflected. The roller  128 , shown in  FIGS.  12 A-C , may be made from any suitable low friction material comprising composite materials, UHDPE, molded polymer, polymer-based composite, fiber-reinforced polymer, and injection molded polycarbonate, acrylonitrile butadiene styrene (“ABS”) plastic, polypropylene, polyethylene, and polystyrene, polyvinyl chloride (“PVC”) or any suitable combination or mixture thereof. 
     Referring now to  FIGS.  8 A-C , the spring washer  158  may comprise a protrusion  166  that is received within the angled notch  130  on the mounting bracket  102 . The angled notch  130  serves to limit the rotation of the strut body  106  inwardly towards a centerline of the trailer upon impact from a foreign member. The notch  130  only allows the strut body  106  to be deformed by a specific amount due to the configuration of the protrusion  166  contained therein. 
     In operation, the spring  104  along with the protrusion  166  and angled notch  130  serve to limit the rotation of the strut body  106  with respect to the mounting bracket  102 . Upon deflection, the strut body  106  is moved inwardly and upwardly. Rotation continues until the protrusion  166  contacts the angled notch  130 . The mounting surface  146  of the strut body  106  contacts the spring  104 , which restricts the movement of the strut body  106  along with the protrusion  166  and angled notch  130 . The spring  104  provides resistance while the protrusion  166  and angled notch  130  provide a hard stop. 
     In the foregoing description, the technology has been described with reference to specific exemplary embodiments. Various modifications and changes may be made, however, without departing from the scope of the present invention as set forth. The description and figures are to be regarded in an illustrative manner, rather than a restrictive one and all such modifications are intended to be included within the scope of the present invention. Accordingly, the scope of the technology should be determined by the generic embodiments described and their legal equivalents rather than by merely the specific examples described above. For example, the steps recited in any method or process embodiment may be executed in any appropriate order and are not limited to the explicit order presented in the specific examples. Additionally, the components and/or elements recited in any system embodiment may be combined in a variety of permutations to produce substantially the same result as the present invention and are accordingly not limited to the specific configuration recited in the specific examples. 
     Benefits, other advantages and solutions to problems have been described above with regard to particular embodiments. Any benefit, advantage, solution to problems or any element that may cause any particular benefit, advantage or solution to occur or to become more pronounced, however, is not to be construed as a critical, required or essential feature or component. 
     The terms “comprises,” “comprising,” or any variation thereof, are intended to reference a non-exclusive inclusion, such that a process, method, article, composition or apparatus that comprises a list of elements does not include only those elements recited, but may also include other elements not expressly listed or inherent to such process, method, article, composition or apparatus. Other combinations and/or modifications of the above-described structures, arrangements, applications, proportions, elements, materials or components used in the practice of the present technology, in addition to those not specifically recited, may be varied or otherwise particularly adapted to specific environments, manufacturing specifications, design parameters or other operating requirements without departing from the general principles of the same.