CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a PCT International Patent Application and claims benefit of United States Provisional Patent Application No. 63/394,484, filed August 2, 2022. The disclosure of the above application is incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to an active spoiler shade assembly adapted for attachment to a vehicle.

BACKGROUND OF THE INVENTION

There is a considerable loss of aerodynamic efficiency in vehicles due to the airflow around a vehicle. Conventional structures, such as fixed panels, are known and do not meet desired requirements.

If fabric were to now be used instead, a challenge becomes how to properly support fabric between support areas and also matching up with the vehicle body.

Accordingly, providing the use of fabric to deploy and to form to the vehicle body shape instead of large plastic panels with linkages is desired.

SUMMARY OF THE INVENTION

An active spoiler shade assembly including fabric that is driven by actuators linearly, by moving a long-extruded bar that can be bent. A plastic roll-off edge can support the fabric to match the body shape. A retractable lattice structure supports the fabric as well as straps on the underside of the fabric.

The overall purpose is to deploy fabric on the rear spoiler to manage the airflow rearward.

Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:

Figure 1 is a top view of an active spoiler shade assembly in an exemplary stowed position, in accordance with the present invention;

Figure 2 is a top view of the active spoiler shade assembly in an exemplary deployed position, in accordance with the present invention;

Figure 3 is a rearview of the active spoiler shade assembly in an exemplary stowed position, in accordance with the present invention;

Figure 4 is a cross sectional view of the active spoiler shade assembly with fabric deployed, in accordance with aspects of the present invention;

Figure 5 is a cross sectional view of the active spoiler shade assembly with fabric stowed, in accordance with aspects of the present invention;

Figure 6 is a cross sectional view of the active spoiler shade assembly, in accordance with the present invention;

Figure 7 is a plan view of an exemplary roll-off edge of the active spoiler shade operably adaptable to match predetermined vehicle body environments, in accordance with aspects of the present invention;

Figures 8-9 are cross sectional views of exemplary exterior trim including attachment to at least one actuator, in accordance with aspects of the present invention;

Figure 10 is a cross sectional view of an exemplary lattice of the active spoiler shade, in accordance with aspects of the present invention;

Figure 11 is a cross sectional view of an exemplary lattice of the active spoiler shade, in accordance with aspects of the present invention; and

Figure 12 is a cross sectional view depicting exemplary deployable corner baffles, in accordance with aspects of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

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

Referring to Figures 1-12 generally, there is provided an active spoiler shade assembly, indicated generally at 10, in accordance with the present invention, including at least one spoiler shade member 12 operably adapted to selectively deploy from at least one opening 15 in at least one spoiler body 14 and retract to a stowed position. The spoiler shade member 12 includes predetermined spoiler shade material. The spoiler shade member 12 preferably includes at least one predetermined fabric material. Fabric is used instead of plastic for effective selective elongation of the spoiler under predetermined conditions.

At least one tube 16 is provided with at least one spring 18 inside, which allows the predetermined material, e.g., fabric, to selectively operably wind up for stowing the spoiler shade material 12 in a stowed position (e.g.., Figs. 1 , 4-5, and 8) and unwind to extend the length a predetermined amount for deployment of the spoiler shade material 12 to at least one deployed position (e.g., Figs. 2-3 and 10). Figures 3 and 5 include a coiled spring 18 inside of the tube 16 that keeps the tube 16 pulling spoiler shade material 12 in tension. The spoiler shade material 12 is operably coupled toward one end to the tube 16.

At least one roll-off edge 20 is provided operably adapted to support the spoiler shade material 12 to generally keep the shape of the body, e.g., vehicle body. The rolloff edge 20 is preferably a molded predetermined shape suitable for the application to match any vehicle aesthetics. The roll-off edge 20 can be molded to match any vehicle body environment depending on the application, such that the spoiler shade material 12, e.g., fabric, substantially matches or compliments predetermined vehicle contour and dimensions. The roll-off edge 20 preferably operably keeps the spoiler shade material 12 taunt.

The at least one roll-off edge 20 is preferable a molded edge and is operable to support the spoiler shade material 12, e.g., soft material panel, to allow the material 12 to be taunt in coordination with the biased member 16 during retraction and deployment of the material 12, and the roll-off edge 20 is operably adapted to provide the spoiler shade material panel 12 with at least one predetermined contour and angle, e.g., aerodynamic shape, matching vehicle shape, etc.

The spoiler shade material 12 is deployable by the material, e.g., fabric, being operably held to at least one rod 22. The spoiler shade material 12 is operably coupled toward the other end 25 to the rod 22 (e.g., using at least one channel 23 in the rod 22, channel and welt arrangement, at least one fastener, adhesive, sewn extrusion I channel arrangement, welded, clamped, captured fabric, fabric lip in the channel 23, sewn lip, bracket, etc., and any combinations thereof), which rod 22 operably selectively pulls the spoiler shade material 12 generally outward to at least one deployed position. Preferably, the rod 22 is an aluminum extrusion. At least one exterior trim 24 is provided to close out to the outside of the vehicle and operably matches the predetermined vehicle environment. The exterior trim 24 also operably attaches to the rod 22. Preferably, a gap is substantially eliminated from view when the assembly 10 is in the stowed position by the at least one exterior trim 24 closing out to the outside of the vehicle.

At least one actuator, indicated generally at 26 (e.g., preferably an actuator overmold), operably couples to the exterior trim 24 and/or rod 22 adapted to operably drive the system 10, e.g., between the stowed/closed position and at least one deployed/open position. The actuator 26 most preferably incorporates a linear actuator. Preferably, at least one drive rod portion 28 is provided. At least one predetermined exterior trim portion, indicated generally at 30, has predetermined shape and includes at least operable coupling to the actuator, e.g., linear actuator.

Referring more particularly to Figures 10-1 1 , according to aspects of the present invention, there is provided at least one extending lattice, indicated generally at 32. The lattice supports the spoiler shade 12, e.g., fabric shade, cross-car to keep the predetermined desired shape of the shade 12. The lattice 32 can fold up (or otherwise suitably configure) and hold the predetermined shape of the spoiler shade 12 as it encounters wind and moving air.

The spoiler shade 12, e.g., of fabric material, is operably driven by at least one actuator linearly, e.g., see also 26, 28, Figs. 5, 8, by moving the at least one rod 22, e.g., a long extruded bar, that can have a predetermined bend depending on the particular applications to meet predetermined vehicle body shapes. The roll off edge 20, preferably of plastic, is operably adapted to support the fabric 12 to match the body shape. The retractable lattice structure 32 operably supports the spoiler shade material 12 as well as any predetermined optional straps on the underside of the spoiler shade 12.

Referring more particularly to Figure 12, according to aspects of the present invention, there is provided at least one corner cover, indicated generally at 34. Preferably, a pair of corner covers 34 is adapted to be connected at opposing positions adjacent opposing pillars of the vehicle. The corner cover 34 is movable between a stowed position and at least one deployed position, e.g., indicated generally by arrows in Fig. 12. The corner cover 34 is deployed to cover the corner with material to be deployed with the shade to block the corner air flow. Preferably, the assembly 10 incorporates D- pillar deployment of at least one corner baffle 34, that is deployed at predetermined speeds to reduce the drag on the vehicle. There is preferably one on each side of the vehicle, preferably in the D-pillar area. The corner baffles 34 operably deploy a sheet of material, indicated generally at 36, operable to divert wind rearward of the corner of the vehicle. Material sheet 36 and spoiler shade panel 12 may be one piece, according to aspects of the present invention.

Referring to Figures 1-12 generally, it is understood that the spoiler shade 12 material may be flexible, semi-flexible, one material or different materials, fabric, soft material, sail material, or any other suitable material and combinations thereof, depending on the application without departure from the scope of the present invention.

While a rearward spoiler and D-pillar area of deployment is shown and described throughout the application, it is understood that the system 10 is operably adaptable for any predetermined area of the vehicle depending on the application without departure from the scope of the present invention.

According to exemplary aspects of the present invention, the fabric 12 is retracted until the vehicle reaches a predetermined speed, e.g., of about 30 miles per hour, then the fabric 12 (and/or corners 34) are extended and stay deployed until the vehicle drops back down to below the predetermined speed, or until other predetermined conditions for continued deployment are no longer met.

The overall benefits of the present invention include, but are not limited to, deploying fabric on the rear spoiler to operably manage the airflow rearward. Fabric is preferably used instead of plastic for elongation of the spoiler. The tube with the use of spring inside allows the fabric to wind and unwind to extended length. The exterior trim closes out to the outside of the vehicle, attaches to the aluminum extruded rod. The aluminum rod has the fabric installed and pulls the fabric outward. The actuator overmold- operably attaches to the exterior trim and aluminum rod to drive the system. The roll off edge’s molded shape matches the vehicle aesthetics. The extending lattice can fold up and hold the shape of the fabric from wind blowing on it. The corner cover is deployable to cover the corner with material to be deployed with the spoiler to block the corner air flow.

The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.