Aerodynamic and protective vehicle panel assembly and method of constructing same

• US 8,210,599 B2
• Filed: 05/24/2010
• Issued: 07/03/2012
• Est. Priority Date: 05/24/2010
• Status: Active Grant

• Current Assignee: Flow Below Aero, Inc.
• Original Assignee: Joshua Butler
• Inventors: Butler, Joshua
• Primary Examiner(s): Morrow, Jason S
• Application Number:
  US12/785,715
• Publication Number:
  US 20110285167A1
• Time in Patent Office: 771 Days
• Field of Search: 296/180.1, 296/180.4, 296/180.5, 296/181.5
• US Class Current: 296/180.1
• CPC Class Codes: B62D 35/001 For commercial vehicles or tractor-trailer combinations, e.g. caravans

Abstract

An aerodynamic panel assembly with surface macrostructure is provided for a land vehicle. The panel assembly includes a first plurality of slats each having a longitudinal length greater than its width, and a second plurality of slats each having a longitudinal length greater than its width. The first and second plurality of slats are interwoven, thereby providing significant structural strength while increasing the versatility of the panel assembly to be used on various types of vehicles. Various types of attachment mechanisms are provided for attaching a panel assembly to the vehicle.

Claims

1. An aerodynamic panel assembly for the underbody of a land vehicle, comprising:

a first plurality of slats each having a longitudinal length greater than its width, a front face, and an opposing rear face;

a second plurality of slats each having a longitudinal length greater than its width, a front face and opposing rear face, the first and second plurality of slats being interwoven such that both the front and rear faces of each of the first plurality of slats engage faces on the second plurality of slats, and the front and rear faces of each of the second plurality of slats engage faces on the first plurality of slats; and

an attachment device including one or more of a mounting bracket , a hinge, and a fastener for attaching the first and second plurality of slats to the underbody of the vehicle.

2. An aerodynamic panel assembly as defined in claim 1, further comprising:

one or more of the first plurality of slats and the second plurality of slats being a mounting slat extending from the panel for attaching the mounting slat to the vehicle.

3. An aerodynamic panel assembly as defined in claim 1, wherein each of the first plurality of slats has a substantially uniform width along its length with a reduced width adjacent a reduced width portion of one of a second plurality of slats.

4. An aerodynamic panel assembly as defined in claim 1, wherein each of the first plurality of slats has a substantially uniform thickness, with formed bends along an axial length of the first slat forming a recess in the first slat for receiving one of the second plurality of slats.

5. An aerodynamic panel assembly as defined in claim 1, wherein one or more of the first plurality of slats includes one or more longitudinally extending ribs for structural reinforcement.

6. An aerodynamic panel assembly as defined in claim 1, wherein one or more of the first plurality of slats includes one or more preformed bends in the slat each substantially perpendicular to the longitudinal length of the first slat, the bends being formed before assembly of the first plurality of slats and the second plurality of slats.

7. An aerodynamic panel assembly as defined in claim 1, wherein one or more of the first plurality of slats includes one or more air ducts for directing air flow through or past the panel assembly.

8. An aerodynamic panel assembly as defined in claim 1, wherein one or more of the first plurality of slats has a varying width.

9. An aerodynamic panel assembly as defined in claim 1, wherein one or more of the first plurality of slats and the second plurality of slats extends laterally from intersecting slats, and a lateral extension of the slat passes through an opening in the vehicle for attaching the panel assembly to the vehicle.

10. An aerodynamic panel assembly as defined in claim 1, further comprising:

one or more of the first plurality of slats and the second plurality of slats being a reinforcing slat having a bending stiffness greater than the other of the plurality of slats.

11. An aerodynamic panel assembly as defined in claim 10, wherein the reinforcing slat is positioned between opposing slat faces, and a stop member on the reinforcing slat limits travel of the reinforcing slat with respect to the opposing slat faces .

12. An aerodynamic panel assembly for the underbody of a land vehicle, comprising:

a first plurality of slats each having a longitudinal length greater than its width, a front face, and an opposing rear face;

a second plurality of slats each having a longitudinal length greater than its width, a front face and opposing rear face, the first and second plurality of slats being interwoven such that both the front and rear faces of each of the first plurality of slats engage faces on the second plurality of slats, and the front and rear faces of each of the second plurality of slats engage faces on the first plurality of slats, the width of each of the first and second plurality of slats being at least twice the thickness of the slat; and

one or more attachment mechanisms including one or more of a mounting bracket , a hinge, and a fastener for attaching the first and second plurality of slats to the underbody of the vehicle.

13. An aerodynamic panel assembly as defined in claim 12, further comprising:

one or more of the first plurality of slats and the second plurality of slats being a mounting slat extending from the panel for attaching the mounting slat to the vehicle.

14. An aerodynamic panel assembly as defined in claim 12, wherein each of the first plurality of slats has a substantially uniform thickness, with formed bends along an axial length of the first slat each substantially perpendicular to the axial length of the first slat forming a recess in the first slat for receiving one of the second plurality of slats.

15. A method of providing a panel assembly to the underbody of a land vehicle to reduce aerodynamic drag, comprising:

providing a first plurality of slats each having a longitudinal length greater than its width, a front face, and an opposing rear face;

providing a second plurality of slats each having a longitudinal length greater than its width, a front face and opposing rear face;

interweaving the first and second plurality of slats such that both the front and rear faces of each of the first plurality of slats engage faces on the second plurality of slats, and the front and rear faces of each of the second plurality of slats engage faces on the first plurality of slats; and

attaching the first and second plurality of slats to the underbody of the vehicle using one or more of a mounting bracket , a hinge, and a fastener.

16. A method as defined in claim 15, further comprising:

extending one or more of the first plurality of slats and the second plurality of slats from the panel to form a slat extension; and

attaching the slat extension to the vehicle.

17. A method as defined in claim 15, wherein one or more of the first plurality of slats and the second plurality of slats extends laterally from an intersecting slat, and a lateral extension of the slat passes through a slot secured to the vehicle for attaching the panel assembly to the vehicle.

18. A method as defined in claim 15, wherein each of the first plurality of slats has a substantially uniform thickness, with formed bends along a longitudinal length of the first slat each forming a recess in the first slat for receiving one of the second plurality of slats.

19. A method as defined in claim 15, further comprising:

one or more of the substantially horizontal slats and the substantially vertical is a reinforcing slat having a bending stiffness greater than the other of the plurality of slats.