Aerodynamic systems and fairings with fairing caps

• US 10,654,529 B2
• Filed: 06/25/2018
• Issued: 05/19/2020
• Est. Priority Date: 06/24/2017
• Status: Active Grant

• Current Assignee: Flow Below Aero, Inc.
• Original Assignee: Flow Below Aero, Inc.
• Inventors: Butler, Joshua, Walker, Kyle
• Primary Examiner(s): Morrow, Jason S
• Application Number:
  US16/017,591
• Publication Number:
  US 20180370580A1
• Time in Patent Office: 694 Days
• Field of Search: 2961804
• CPC Class Codes: B62D 35/001 For commercial vehicles or tractor-trailer combinations, e.g. caravans
• CPC Class Codes: B62D 35/008 Side spoilers B62D35/001 takes precedence
• CPC Class Codes: B62D 37/02 by aerodynamic means

Abstract

A fairing assembly adapted to control flow proximate to a vehicle wheel, the fairing assembly having an aerodynamic outer surface to direct flow. The fairing assembly comprises a fairing having a fairing outboard surface. The assembly further comprises a fairing cap coupled to the fairing to cover at least a portion of the fairing outboard surface.

Claims

1. A fairing assembly adapted to couple to a vehicle, the fairing assembly comprising:

a fairing, the fairing having a fairing outboard surface; and

a fairing cap coupled to the fairing to at least partially cover at least a portion of the fairing outboard surface, the fairing assembly having an aerodynamic outer surface adapted to direct flow, wherein the fairing cap and faking cooperate to form a duct.

2. The faking assembly of claim 1, wherein the fairing cap has an inboard surface shaped to conform to the fairing outboard surface.

3. The fairing assembly of claim 2, wherein the fairing cap is adhered to the fairing outboard surface.

4. The fairing assembly of claim 2, wherein the fairing cap is captured in a recess of the faking by a geometric feature.

5. The fairing assembly of claim 1, the faking cap comprising a fairing cap outboard surface that cooperates with the fairing outboard surface to provide the aerodynamic outer surface.

6. The fairing assembly of claim 1, wherein the fairing and fairing cap are formed of different materials.

7. The fairing assembly of claim 1, further comprising mounting hardware to mount the fairing to a support structure, wherein the fairing cap is coupled to the fairing by attachment to the mounting hardware.

8. The fairing assembly of claim 1, the fairing cap comprising:

an upper fairing cap wall;

a lower fairing cap wall; and

a sidewall extending from the upper fairing cap wall to the lower fairing cap wall, the sidewall having an inboard surface that is spaced from and faces the fairing outboard surface to form the duct.

9. The fairing assembly of claim 8, the upper fairing cap wall and lower fairing cap wall each comprising an inboard end and the fairing comprising geometric features to capture the inboard ends of the upper fairing cap wall and the lower fairing cap wall.

10. The fairing assembly of claim 1, wherein the fairing comprises a rear fairing.

11. The fairing assembly of claim 1, wherein the fairing comprises a middle fairing.

19. The fairing assembly of claim 1, wherein the duct has a front and a rear, and wherein the duct has a shape that narrows from the front to the rear of the duct.

20. The fairing assembly of claim 8, wherein the duct has a front and a rear, and wherein the fairing assembly comprises one or more ribs to form multiple channels from the front to the rear of the duct.

12. A wheel fairing method comprising:

mounting a fairing to a support arm, the fairing having a fairing outboard surface;

coupling a fairing cap to the fairing to cover at least a portion of the fairing outboard surface and to form a fairing assembly, the fairing assembly having an aerodynamic outer surface adapted to direct flow, wherein coupling the fairing cap to the fairing comprises coupling the fairing cap to the fairing to form a duct; and

positioning the fairing assembly proximate to a wheel of a vehicle.

13. The method of claim 12, wherein coupling the fairing cap to the fairing further comprises placing the fairing cap in a recess defined by the fairing outboard surface, wherein the fairing cap has an inner surface shaped to conform to the fairing outboard surface.

14. The method of claim 13, wherein coupling the fairing cap to the fairing comprises adhering the fairing cap to the fairing outboard surface.

15. The method of claim 12, wherein coupling the fairing cap to the fairing comprises catching a portion of the fairing cap with a geometric feature of the fairing.

16. The method of claim 12, wherein the fairing cap is more rigid than the fairing.

17. A fairing assembly adapted to couple to a vehicle, the fairing assembly comprising:

a fairing, the fairing having a fairing outboard surface; and

a fairing cap coupled to the fairing to at least partially cover at least a portion of the fairing outboard surface, the fairing assembly having an aerodynamic outer surface adapted to direct flow, wherein the fairing cap comprises a hinge, and wherein a portion of the fairing cap is rotatable about the hinge to reveal the at least a portion of the fairing outboard surface.

18. The fairing assembly of claim 17, wherein the fairing cap further comprises first, second, and third walls that form a pocket and the fairing comprises a section adapted to nest in the pocket of the fairing cap.