Patent Description:
The use of air diffusers at the rear of vehicles reduces turbulent wake at the back area of SUV's thereby reducing coefficient of drag (Cd) and improving fuel economy. At the lower rearward region of the vehicle are often fin or cover features that are typically static structures that control air flow past the bottom rear side of the vehicle. Sometimes the cover features are active and will move downward toward the road and sometimes they extend past the rear bumper of the vehicle. One problem with the is that current aero devices are specific to vehicle and require a unique design and unique set of tooling, each change of content or vehicle space requires a new design. It is an object of the invention to create a set of components and a design that allows for the positioning of the required components as needed per vehicle along with the adding or subtracting of functional components to meet various vehicle requirements. It is also desirable to provide a rear diffuser that is able to make the middle rear fascia of the vehicle active, while allowing the bottom and top portion of the fascia to stay static.

<CIT> discloses a translation type automobile active diffuser which is installed at the tail of an automobile and comprises a diffuser support fixed relative to an automobile body, a motor fixed on the diffuser support, a gear driven by the motor and a diffuser inner plate, and a rack meshed with the gear is arranged on the diffuser inner plate.

<CIT> discloses a rear diffuser for a vehicle comprising a plate protruding outward from a vehicle by being arranged on the lower side of the switch vehicle when the driving speed of the vehicle is higher than or equal to a predetermined reference speed and is inserted into the vehicle when the driving speed is lower than the reference speed; and a plate tip which is protruding upward from the end of the plate along the outermost circumference of the plate to have a predetermined angle.

<CIT> discloses a spoiler apparatus for a rear bumper of a vehicle comprising a spoiler rod that is selectively movable forward/backward through a hole of a rear back beam, and a spoiler panel coupled to a rear end of the spoiler rod and selectively engaged with the rear bumper, wherein the spoiler panel separates and protrudes backward from the rear bumper, as the spoiler rod moves backward.

The present invention is directed to an active rear diffuser assembly comprising the features of claim <NUM>.

The active rear diffuser assembly may include brackets used to connect the active rear diffuser to a support member of the vehicle. The support member can be the rear bumper or portion of the frame or chassis. In the preferred embodiment of the invention there are two brackets. Connected to each bracket is a rail and an actuator. Connected to the rail is one of two carriers that is connected to one of the two actuators, where each of the carriers is configured to slide relative to the respective rail. Further provided is a link connected between each actuator and the carrier. The link facilitates the movement of the carrier between the stowed position and the extended position. Connected to each carrier is a base that in some embodiments is made of several sections. In one embodiment of the invention one section is connected between the two carriers. The cover, discussed above, is connected to the base, and provide aerodynamic benefit.

The following description of the preferred embodiment is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.

When an element or layer is referred to as being "on," "engaged to," "connected to," or "coupled to" another element or layer, it may be directly on, engaged, connected, or coupled to the other element or layer, or intervening elements or layers may be present.

These terms may be only used to distinguish one element, component, region, layer or section from another region, layer, or section. Thus, a first element, component, region, layer, or section discussed below could be termed a second element, component, region, layer, or section without departing from the teachings of the example embodiments.

Referring now to the figures, an active rear diffuser assembly <NUM> for a vehicle is shown. The active rear diffuser assembly <NUM> actively moves between a stowed position and one or more extended positions. The active rear diffuser assembly <NUM> includes a brackets 12a, 12b connectable to a support member <NUM> of a vehicle, such as the vehicle frame, front end module or other suitable structure. The brackets 12a, 12b each include respective mounting holes 14a, 14b for connecting to the support member <NUM>.

The active rear diffuser assembly <NUM> further includes two rails 18a, 18b each having one of two tracks 20a, 20b that extend longitudinally. One of two carriers 16a, 16b connect to a respective one of the rails 18a, 18b using a retainer 78a, 78b. The bracket 12a, carrier 16a, rail 18a and retainer 78a are shown on the left side of the active rear diffuser assembly <NUM> in <FIG>, while the bracket 12b, carrier 16b, rail 18b and retainer 78b are located is on the right side of <FIG>. <FIG> and <FIG> show in greater detail bracket 12a, carrier 16a, rail 18a and retainer 78a, however, it is to be understood that the bracket 12b, carrier 16b, rail 18b and retainer 78b are a mirror image of what is shown in <FIG> and <FIG>.

While the active rear diffuser assembly shows two brackets 12a, 12b, carriers 16a, 16b, rails 18a, 18b and retainers 78a, 78b it is within the scope of this invention for their to be a greater or a smaller number of sets of these components depending on a particular application. For example, a smaller active rear diffuser assembly might only need a single bracket, carrier, rail, retainer, actuator (described below) and link system (described below), or a larger application might require more than two. Therefore, the present invention is not limited to the two sets of components as described herein and it is within the scope of the invention to have a greater or lesser number depending on the needs of a specific application.

Referring now to <FIG>, the rails 18a, 18b each have a connection leg 84a, 84b that is used to connect the rails 18a, 18b to a respective one of the brackets 12a, 12b in a stationary manner using fasteners. The tracks 20a, 20b of the rails 18a, 18b form a slidable connection between the tracks 20a, 20b and a respective one of the carriers 16a, 16b that is accomplished by connecting the respective one of the retainers 78a, 78b to the carriers 16a, 16b and rails 18a, 18b. As best shown in <FIG> the retainer 78a has a first plate <NUM> that connects to a second plate <NUM> that has two posts <NUM> positioned in the track 20a allowing the retainer 78a to slide with the carrier 16a along the track 20a of the rail 18a, between the stowed position and the extended position. The carriers 16a, 16b both include a channel portion 92a, 92b formed on the respective one of the carriers 16a, 16b for receiving at least a portion of the respective one of the rails 18a, 18b when the carriers 16a, 16b are moved to the stowed position.

Connected to each brackets 12a, 12b is one of two actuators 22a, 22b that have a bi-directional motor. The actuators 22a, 22b each connect to one end one of two links 31a, 31b. <FIG> show the details of the link 31b and the connection with the carrier 16b and bracket <NUM> and actuator 22b which are shown on the right side of the active rear diffuser <NUM> shown in <FIG>. It is now understood that the structures shown in <FIG> are the mirror images of the left side of the active rear diffuser assembly <NUM> shown in <FIG>, which includes the connection of link 31a, carrier 16a, and bracket 12a. Accordingly, what applies to the right side also applies to the left side without repetition. Each of the links 31a, 31b is connected between one of the two actuators 22a, 22b and to one of two carriers 16a, 16b. When the actuators 22a, 22b are activated the links 31a, pivot and move the carriers 16a, 16b along the respective one of the two rails 18a, 18b.

Each of the two links 31a, 31b include a driven link 70a, 70b pivotally connected at a first end to a respective one of the two brackets 12a, 12b and actuators 22a, 22b. <FIG> shows a torsion rod <NUM> that connects to the actuator 22b, extends through bracket 12b and through a first end <NUM> of driven link 70b. The same connection is present between actuator 22a, bracket 12a and driven link 70a. The actuators 22a, 22b turn the respective torsion rod to cause the driven link 70a, 70b to pivot. A second end 76a, 76b of the driven links 70a, 70b pivotally connects to a first end of a respective one of two moveable links 33a, 33b. A respective second end 35a, 35b of each of the moveable links 33a, 33b is pivotally connected to the respective one of the two carriers 16a, 16b. Activation of the actuators 22a, 22b in a first direction to cause the moveable links 33a, 33b to push the respective one of the carriers 16a, 16b and a cover <NUM> (described in more detail below) to the extended position (shown in <FIG>). Activation of the at least one actuator in a second direction causes the moveable link 33a, 33b to pull the respective one of the two carriers 16a, 16b and the cover <NUM> to the stowed position (shown in <FIG>).

Connected to the carriers 16a, 16b is a base <NUM> that is formed of a left section 26a, middle section 26b, and right section 26c (also referred to collectively as "sections 26a, 26b, 26c"). The sections 26a, 26b, 26c are produced by extrusion and having a selected length. Producing sections 26a, 26b, 26c of the base <NUM> by extrusion allows it to have any desired selected length, thereby contributing to the modularity and scalability of the invention since vehicles have different widths, thereby allowing the active rear diffuser assembly to be sized to any width of vehicle platform. The middle section 26c is connected between the carriers 16a, 16b using fasteners, adhesives, or other suitable connection mechanisms. The left section 26a is connected to the carrier 16a using fasteners, adhesives, or other suitable connection mechanism. The right section 26c is connected to the carrier 16b using fasteners, adhesives, or other suitable connection mechanism.

Referring now to <FIG> the active rear diffuser assembly <NUM> is shown with a cover <NUM> connected to the base <NUM>. The cover <NUM> has an exterior surface <NUM> that in some embodiments has a Class A finish surface, while in other embodiments has a different finish depending on the desired aesthetics of the application. The term "Class A finish surface" as used herein is defined any surface of a vehicle that has styling intent, that is either seen, touched, or both and mathematically has a surface with curvature and tangency alignment. A Class A finish surface as used herein also includes any generally accepted measurable physical features that are agreed to represent a Class A finish surface in the field of automotive design. Also depicted in <FIG> is a wiring harness <NUM> that has a first connector 34a connected to actuator 22a and a second connector 34b connected to actuator 22b. The wiring harness <NUM> provides power to each actuator 22a, 22b of the active rear diffuser assembly <NUM>.

Referring now to <FIG>, the sections 26a, 26b, 26c of the base <NUM> each have closed channels 36a, 36b that extend through the length of the sections 26a, 26b, 26c which add strength and lowering weight of the base <NUM> by forming a closed box structure, while also providing a space for the placement of other structures such as hoses, wires, actuator mounts, etc. While two closed channels 36a, 36b are shown it is within the scope of this invention for a greater or lesser number of channels to be present. Referring also to <FIG>-<NUM> the closed channel 36a as shown also receives inner connection posts 80a, 80b or outer connection posts 82a, 82b extending from the carriers 16a, 16b. The inner posts 80a, 80b and outer posts 82a, 82b have apertures for receiving fasteners that are used to connect the sections 26a, 26b, 26c to the carriers 16a, 16b. Alternatively, adhesives can be applied or welds created between the inner surface of the closed channel 36a and the inner connection posts 80a, 80b or outer connection posts 82a, 82b. The inner connection posts 80a, 80b are used connect the opposing ends of section 26b between carriers 16a, 16b. The outer connection post 82a is used to connect section 26a to the carrier 16a. The outer connection post 82b is used to connect section 26c to carrier 16b.

Each of the sections 26a, 26b, 26c further include an open channel <NUM> that extends along the length of one side of each of the sections 26a, 26b, 26c. The open channel <NUM> has an end opening <NUM> and side opening <NUM> that allows for the attachment of components to the open channel <NUM>. As shown in <FIG>, <FIG> there are several cover supports <NUM> each having a stem <NUM> that extends from a connection surface <NUM> of the cover support <NUM> and terminates at a knob <NUM>. Each cover support <NUM> connects to the open channel <NUM> by sliding the knob <NUM> into the end opening <NUM> of the open channel <NUM> so that the stem <NUM> extends through the side opening <NUM> and the knob <NUM> then holds the respective cover support <NUM> in place along the open channel <NUM>. Each cover support <NUM> can be moved along the length of the open channel <NUM> by sliding the cover support <NUM> to the desired position. The cover support <NUM> is then frictionally held in place by the knob <NUM>, however, it is within the scope of the invention to use fasteners, adhesives, or welding to more permanently lock the cover support <NUM> into place along the length of the base <NUM>.

Each cover support <NUM> include a bottom surface <NUM> and two angled surfaces 54a, 54b contact an inside surface <NUM> of the cover <NUM>. During assembly the cover <NUM> is connected to the base <NUM> and each cover support <NUM>. The connection between the cover <NUM>, the base <NUM> and each cover support <NUM> is accomplished using variety of mechanisms including snap fittings, adhesives, welding, and fasteners depending on the design requirements. The cover <NUM> is usually thin and sometimes has flexibility that requires the cover <NUM> to be supported on the backside. Also, since a lot of the air flow comes from the bottom of the vehicle the bottom surface <NUM> provides support along a bottom side <NUM> of the cover <NUM> to minimize wind deflection. While <FIG> shows a total of eight cover supports <NUM>, it is within the scope of this invention for a greater or lesser number of cover supports to be used depending on the size and shape of the cover <NUM>.

Referring now to <FIG> show the details of a rear side <NUM> of a vehicle <NUM> having the active rear diffuser assembly <NUM> connected. The connection between the active rear diffuser assembly <NUM> and the vehicle is accomplished using fasteners or clips placed through the mounting holes 14a, 14b in the brackets 12a, 12b. The brackets 12a, 12b are connected to apertures on a support member <NUM> (Shown in <FIG>), which can be a chassis or bumper beam of the vehicle <NUM>. The active rear diffuser assembly <NUM> is connected behind the rear fascia <NUM> so that the rails 18a, 18b, actuator 22a, 22b, wiring harness <NUM>, links 31a, 31b and portions of the carrier 16a, 16b are behind an inside surface <NUM> of the rear fascia <NUM> or behind the rear fascia <NUM> external surface <NUM>, when the active rear diffuser assembly <NUM> is in the stowed or extended position. When the active rear diffuser assembly <NUM> is in the extended position the base <NUM>, cover <NUM> and portions of the carrier 16a, 16b extend through the opening <NUM> when the active rear diffuser assembly <NUM> is in the extended position. Also, when the active rear diffuser assembly <NUM> is in the extended position and the cover <NUM> is extending the opening <NUM> in the rear fascia <NUM>, the cover <NUM> is positioned below a bumper portion <NUM> of the rear fascia <NUM>.

Claim 1:
An active rear diffuser assembly (<NUM>) comprising:
a base (<NUM>) produced by extrusion;
at least one rail (18a, 18b);
at least one carrier (16a, 16b) connected to the at least one base (<NUM>) and the at least one rail (18a, 18b), wherein the at least one carrier (16a, 16b) and base (<NUM>) move on the at least one rail (18a, 18b) between a stowed position and an extended position;
a cover (<NUM>) connected to the base (<NUM>), wherein the cover (<NUM>) moves between the stowed position and the extended position; characterized in that the active rear diffuser further comprises
a track (20a, 20b) formed on the at least one rail (18a, 18b) and a slidable connection between the track (20a, 20b) and the at least one carrier (16a, 16b);
a retainer (78a, 78b) connected to the at least one carrier (16a, 16b) and the at least one rail (18a, 18b), wherein the retainer (78a, 78b) has at least one post (<NUM>) slidably positioned in the track (20a, 20b) allowing the retainer (78a, 78b) to slide with the at least one carrier (16a, 16b) along the track (20a, 20b) between the stowed position and the extended position; and
a channel portion (92a, 92b) formed on the at least one carrier (16a, 16b) for receiving at least a portion of the at least one rail (18a, 18b) when the at least one carrier (16a, 16b) is moved to the stowed position.