Abstract:
The present invention relates to a detachably attachable moving headboard trailer ejector and floor cleaning apparatus for use with a self-unloading trailer having a front end, a rear end, side walls, and either a reciprocating slat conveyor floor or a conveyor belt floor. The invention comprises, in one embodiment, a base, a panel sweeper, one or more panel sweeper support members, a means for traversing the panel sweeper, a tether bar, side flanges, and a base flange. In use, the invention is placed in the front end of a self-unloading trailer and the trailer is loaded with material; when material is ejected from the trailer, the invention transverses or “travels” along the top of the moving floor and pushes the material out of the trailer&#39;s back end. The rubber flanges ensure a snug fit within the trailer and keep post ejection residual material at a minimum.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation-in-part of U.S. patent application Ser. No. 13/465,650, filed May 7, 2012, now U.S. Pat. No. 9,126,520, issued Sep. 8, 2015, which is a continuation-in-part of and claims the benefit of U.S. patent application Ser. No. 12/184,470, filed Aug. 1, 2008, now abandoned, both of which are incorporated herein by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates generally to devices for ejecting bulk materials from trailers. More particularly, the present invention relates to a detachably attachable moving headboard trailer ejector and floor cleaning apparatus for use with a self-unloading trailer having a front end, a rear end, side walls, and either a reciprocating slat conveyor floor or a conveyor belt floor. 
         [0004]    2. Description of the Related Art 
         [0005]    Many bulk commodities and aggregates are transported throughout the United States by various types of trailers, including transport semi-trailers. Materials commonly moved include, but are not limited to, dirt, sand, rock, grain, etc. A truck operator is paid to move material from one location to another—the more material an operator can move in a given period of time, the more profitable the operator&#39;s business will be. 
         [0006]    Many transport trailers used by operators are of the “self-unloading” type. Self-unloading trailers use one of several forms of “moving floors” to eject material from the trailer. Moving floors come in various forms including, but not limited to, reciprocating slat floors and conveyor belt floors. By their automation, these floors substantially decrease the time required to eject material from trailers compared to manual ejection methods. One time consuming drawback of a moving floor, however, is that after ejecting transported material from the trailer, some amount of residual transported material often remains on the trailer floor—material that must be manually swept or shoveled out of the trailer. Removing residual material from a trailer takes time, which increases the total transport time and reduces the operator&#39;s profit. 
         [0007]    Heretofore there has not been available a moving headboard trailer ejector system or apparatus with the advantages and features of the present invention. 
       SUMMARY OF THE INVENTION 
       [0008]    The present invention relates to a detachably attachable moving headboard trailer ejector and floor cleaning apparatus for use with a self-unloading trailer having a front end, a rear end, side walls, and either a reciprocating slat conveyor floor or a conveyor belt floor. The invention comprises, in one embodiment, a base, a panel sweeper, one or more panel sweeper support members, a means for traversing the panel sweeper, a tether bar, side flanges, and a base flange. 
         [0009]    In use, the invention is placed in the front end of a self-unloading trailer and the trailer is loaded with material; when the moving floor is activated and material is ejected from the trailer, the invention “travels” or transverses along the moving floor and pushes the material out of the trailer&#39;s back end. The rubber flanges ensure a snug fit within the trailer and keep post ejection residual material at a minimum. After ejection is complete, the apparatus may be pushed back into place or pulled back into place via the tether bar. The invention may be used with most self-unloading trailers and does not require retrofitting of trailers for proper use. The means for traversing the panel sweeper may include a stationary door, a hinged door, a horizontally sliding panel, or a vertically sliding panel and gives the operator access to the trailer area behind the apparatus without the need to climb over the apparatus and risk injury. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    The drawings constitute a part of this specification and include exemplary embodiments of the present invention illustrating various objects and features thereof. 
           [0011]      FIG. 1  illustrated an exploded perspective view of one embodiment of the invention. 
           [0012]      FIG. 2  illustrates a perspective view of one embodiment of the invention. 
           [0013]      FIG. 3  illustrates a side view of one embodiment of the invention in use loaded with particulate material. 
           [0014]      FIG. 4  illustrates a side view of an embodiment of the invention including unloaded particulate material. 
           [0015]      FIG. 5  illustrates a front perspective view of an embodiment of the invention in a trailer including a reciprocating slat conveyor. 
           [0016]      FIG. 6  illustrates a rear view of an embodiment of the invention in a trailer including a reciprocating slat conveyor. 
           [0017]      FIG. 7  illustrates a rear perspective view of a trailer including a reciprocating slat conveyor and an embodiment of the invention having unloaded particulate material. 
           [0018]      FIG. 8  is a perspective view illustrating an embodiment of the present invention placed on top of a reciprocating slat conveyor. 
           [0019]      FIG. 9  is a perspective view illustrating an embodiment of the present invention placed on top of a reciprocating slat conveyor beginning an unload cycle. 
           [0020]      FIG. 10  illustrates an embodiment of the present invention placed on top of a reciprocating slat conveyor at the end of an unload cycle, wherein a first group of reciprocating slats is retracted. 
           [0021]      FIG. 11  is a perspective view illustrating an embodiment of the present invention placed on top of a reciprocating slat conveyor at the end of an unload cycle, wherein a second group of reciprocating slats is retracted. 
           [0022]      FIG. 12  is a perspective view illustrating an embodiment of the present invention placed on top of a reciprocating slat conveyor at the end of a an unload cycle, wherein a third group of reciprocating slats is retracted. 
           [0023]      FIG. 13  is a side elevation of an embodiment of the present invention, illustrating a winch mounted to a wall structure of a trailer connected to the invention embodiment via a tether. 
           [0024]      FIG. 14  is a rear elevation of an embodiment of the present invention, illustrating the attachment of a tether bar to the embodiment. 
           [0025]      FIG. 15  is a perspective view of an alternative embodiment of the present invention, illustrating the base flange locked against a panel sweeper face. 
           [0026]      FIG. 16  is a perspective view illustrating an alternative embodiment of the present invention, illustrating a panel sweeper face including ratchet straps. 
           [0027]      FIG. 17  is a detailed perspective view taken about the circle of  FIG. 16 . 
           [0028]      FIG. 17A  is a partial elevational view thereof. 
           [0029]      FIG. 18  is a perspective view thereof, showing the base flange locked against a panel sweeper face with ratchet straps. 
           [0030]      FIG. 19  is a side elevational view of an alternative embodiment of the present invention showing a releasable restraining chain. 
           [0031]      FIG. 20  is a perspective view of an alternative embodiment of the present invention including an extension panel above the panel sweeper face. 
           [0032]      FIG. 21  is a side elevational view thereof. 
           [0033]      FIG. 22  is a rear elevational view of an alternative embodiment of the present invention including locking plates. 
           [0034]      FIG. 23A  is a side elevational view of the prior art thereof. 
           [0035]      FIG. 23B  is a side elevational view thereof, showing elements of the prior art in a tipping state. 
           [0036]      FIG. 23C  is the alternative embodiment thereof, showing elements of present invention in a tipping state. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     I. Introduction and Environment 
       [0037]    As required, detailed aspects of the present invention are disclosed herein, however, it is to be understood that the disclosed aspects are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art how to variously employ the present invention in virtually any appropriately detailed structure. 
         [0038]    Certain terminology will be used in the following description for convenience in reference only and will not be limiting. For example, up, down, front, back, right and left refer to the invention as orientated in the view being referred to. The words, “inwardly” and “outwardly” refer to directions toward and away from, respectively, the geometric center of the aspect being described and designated parts thereof. Forwardly and rearwardly are generally in reference to the direction of travel, if appropriate. Said terminology will include the words specifically mentioned, derivatives thereof and words of similar meaning. 
         [0039]    The present invention features an ejector system  2  which mounts within an existing trailer  4  and is used to unload material from within that trailer. The present invention may be included in new trailers as a complete ejector trailer system, or it may be retrofitted into existing trailers implementing a “moving floor” or reciprocating slat floor system. 
       II. Preferred Embodiment or Aspect Ejector Trailer System  2   
       [0040]    The embodiments discussed herein are merely illustrative of specific manners in which to make and use the invention and are not to be interpreted as limiting the scope of the instant invention. 
         [0041]    Referring to the drawings in detail,  FIG. 1  illustrates an exploded perspective view of one embodiment of the invention. A rectangular base member  100  with support members  200  mounted thereon supports the panel sweeper  300 . In the preferred embodiment, the base and support members are made of aluminum; the base and support members may, however, be formed of any other appropriate material capable of achieving the desired form and performing the desired function including, but not limited to, plastic, metal, or wood. In the preferred embodiment the panel sweeper is sheet metal; the panel sweeper may, however, be formed of any other appropriate material capable of achieving the desired form and performing the desired function including, but not limited to, plastic, metal, or wood. 
         [0042]    A base flange  400  and two side flanges  500  are mounted onto the panel sweeper at the bottom and sides of the panel sweeper respectively. The surface of the base flange  400  may be of any area up to and including the same area of the panel sweeper  300  face. In the preferred embodiment, the flanges are made of rubber; the flanges may, however, be formed of any other appropriate material capable of achieving the desired form and performing the desired function. This allows the ejector system  2  to handle material  6  of a high moisture content, as shown in  FIGS. 3 and 4 , such as wood pulp, corn, mulch, grain, or similar products which otherwise would tend to stick to the floor and walls  5  of the trailer  4 . 
         [0043]    In the present embodiment, the flanges are mounted onto the panel sweeper via a plate and screw assembly  600 ; the flanges may also be mounted by any other appropriate means including, but not limited to a plate and rivet assembly, adhesives, or mounting the flanges between the panel sweeper and support members. A means for traversing the panel sweeper may include an access door  700 , such as a hinged door, a horizontally sliding panel, or a vertically sliding panel and provides access to the trailer area behind the apparatus without the need to climb over the apparatus and risk injury. A tether bar  800  is mounted between the support members. In an alternate embodiment, the tether bar may be mounted on the back portion of the panel sweeper itself. In the preferred embodiment, the tether bar is made of aluminum; the tether bar may, however, be formed of any other appropriate material capable of achieving the desired form and performing the desired function including, but not limited to, plastic, metal, or wood. 
         [0044]      FIG. 2  illustrates a perspective view of one embodiment of the invention in its assembled state. 
         [0045]      FIG. 3  illustrates the invention in the bed of a self-unloading trailer  4  that has been filled with material  6  in a position ready to be unloaded. The trailer employs a moving floor system  8  comprised of a number of moving floor slats  10 , such as that provided by the Keith® Walking Floor® system of Keith Mfg., Co. of Oregon, USA. This moving floor system  8  causes the entire load  6  and the ejector system  2  to move toward the open end of the trailer  4 , thereby causing the load  6  to be ejected from the trailer. The ejector system  2  ensures that the entire load  6  is ejected, even if that load is comprised of high-moisture content material. 
         [0046]      FIG. 4  illustrates the invention in the bed of a self-unloading trailer and in the process of ejecting material therefrom.  FIGS. 5-7  illustrate additional views of the invention in the bed of a self-unloading trailer and in use. The ejector system  2  is moved along the internal space of the trailer  4  by the moving floor system  8  in the direction of the arrow  16 . 
         [0047]      FIGS. 8 through 12  demonstrate a method of using the ejector system  2  mounted within a trailer fitted with a reciprocating slat conveyor system  8 . The conveyor system  8  is comprised of a number of reciprocating slats  10 , capable of moving both the ejector system  2  and the material  6  loaded in the trailer  4 . The reciprocating floor system  8  physically moves the ejector system  2  toward the open end of the trailer  4 , thereby pushing the loaded material  6  out of the trailer. 
         [0048]      FIG. 9  shows the beginning of an unloading process, whereby the various reciprocating slats  10  are moved toward the open end of the trailer, thereby advancing the ejector system  2  and any material  6  loaded within the trailer  4 .  FIGS. 10-12  represent the retraction of the various slats  10 , leaving the ejector system  2  and the loaded material  6  in place for the next unloading step as again shown in  FIG. 9 , whereby each of the reciprocating slats moves rearward and further advances the ejector system  2  and the loaded material  6 . This process continues until the material  6  is completely unloaded from the trailer  4 . At this point the ejector system  2  is situated near the open end of the trailer. 
         [0049]      FIGS. 13 and 14  show the tether bar  800 , tether  12 , and winch  14  elements in more detail. The winch  14  is mounted to the end wall  7  of the trailer  4 . An optional pulley  17  may also be mounted to the end wall  7  if desired or necessary. The tether bar  800  is mounted to a pair of upstanding vertical supports  20  connected to the structural supports  200  of the ejector system  2 . The tether bar  800  is affixed to the support  20  using a nylon strap  18  on either end, or some other means of temporarily affixing the tether bar to the supports, such as a nut  22  and bolt  23  arrangement shown in  FIG. 14 . A U-bolt fastener  21  passes through the tether bar  800  to attach the tether  12  securely to the tether bar. Alternatively, the tether bar  800  could be mounted to the existing supports  200 . 
         [0050]    After a load  6  has been completely emptied from the trailer  4 , the winch  14  and tether  12  pull the ejector system  2  back to its starting position at the end wall  7  of the trailer. During this retraction phase, if the ejector system  2  encounters an obstruction or material which has somehow wound up between the ejector  2  and the end wall  7  of the trailer, the ejector system will tip over rearwards (toward the end wall  7  of the trailer). This feature accomplishes three things; (1) it notifies the user that an obstruction is present; (2) it prevents the obstruction from jamming between the ejector  2  and the trailer  4 ; and (3) it allows the user quick access to remove the obstruction. 
         [0051]    If the ejector system  2  tips over and the obstruction is removed, the ejector may be tipped back to its upright position or it may be retracted while laying down. If it is retracting while laying down, the tether  12  will pull the ejector system  2  back to its vertical starting position upon reaching the starting position. A plastic flange may be affixed to the bottom surface of the rectangular base member  100  to reduce friction between the ejector system  2  and the reciprocating slats  10  while the ejector system is being retracted. 
         [0052]    As stated previously, this system is suited for bulk flowing materials. These flowing materials tend to stick to the surfaces of trailers during normal unloading processes. The reciprocating floor combined with the ejector system  2  including the floor flange  400  and wall flanges  500  allows the present system to produce a better method for ejecting flowing material from a trailer. The flanges actively remove residual material from the walls and floor while the load is ejected, thereby negating much of the necessity to clean the trailer out between loads. This results in a more efficient unloading process. 
       III. Alternative Embodiment: Locking Base Flange  402   
       [0053]    In an alternative embodiment of a ejector system  52 , the user may opt to load a trailer  4  with a load that protrudes above the top of trailer walls  5 , thus potentially causing materials to lodge between top of floor &amp; crossbows connecting trailer walls, forcing materials behind the ejector system  52  while it travels underneath the crossbows, such as with a load of tree limbs. In such an instance, the user may fold the flange  402  up against the panel sweeper  300  and lock the flange in place using a locking mechanism  54 , such as a pair of tabs. 
         [0054]    Because of the flexible nature of the base flange  402 , the flange could simply be tucked under a pair of tabs  54 , as shown in  FIG. 15 . The flange  402  may be of any size including having a surface area up to and equal to the surface area of the panel sweeper face  300 . Alternatively, the flange could be snapped to the panel sweeper face  300  with some sort of temporary snapping means. Another alternative includes magnetically affixing the flange to the panel sweeper face. It is necessary that the flange  402  remain locked against the face  300  during the entire unloading process of the material which may otherwise jam underneath of the flange. After unloading, the locking means  54  must quickly release the flange  402  for the next load, if it is needed. 
         [0055]    An alternative system for lifting and locking the base flange  402  includes a fully adjustable winch and strap system with a hook, wherein the hook engages the base flange  402  to sweeper panel  300  to keep in an upright locked &amp; loaded position. The winch lifts the flange and secures it in place, and is further capable of lowering the flange  402  back into its original position when desired. A number of winches may be used, wherein the straps and hooks are affixed to the flange at various points along the length of its front end. 
         [0000]    IV. Alternative Embodiment Side Panel Protectors  104  and/or Ratchet Straps  106  with Hooks  108   
         [0056]      FIGS. 16 ,  17 ,  17 A, and  18  show an alternative embodiment of the above invention including side panel protectors  104 . These panel protectors are ideally manufactured from ultra-high molecular weight (UHMW) plastic, or a similar composite, for low-friction and high-resilience. The purpose of the protectors  104  is to prevent the trailer walls from coming into contact with the headboard, coupled with unloading the trailer on un-even terrain, which tends to cause over-rotation of the ejector system  2  within the confines of the trailer  4  as the system operates. Most trailers are designed to flex (also referred to as “racking”). While doing so, the protectors  104  keep forceful engagement with the headboard, thus preventing damage to the outer walls. The panel may tend to tilt perpendicular to the forward and backward movement of the ejector system, which could cause the structural elements  100 ,  200 ,  500  of the sweeper to come into contact with the side walls  5  or roof of the trailer  4 , damaging one or both pieces of equipment. The protectors  104  ensure that the panel cannot rotate further than a few degrees, as shown by  FIG. 17A , and are manufactured from suitable materials to prevent the panel from buckling or pivoting when contact with the walls does occur. 
         [0057]      FIGS. 16 and 18  also feature hooks  108  suspended from ratchet straps  106  which may connect with receivers  112  of the base flange  400 , similar to the concept shown in  FIG. 15 . However, the previous embodiment disclosed in  FIG. 15  tends to allow the flexible base flange  400  to sag in the middle, which could cause material to be caught between the sagging flange  400  and the face  300  of the sweeper panel. The ratchet straps  106  are connected to a rigid beam  110  or other structural element and allow the straps to be pulled tight, thereby removing the flexing of the base flange  400  and preventing material from being forced between the flange and the sweeper panel face  300 . The receivers  112  may simply be holes within the base flange, or they may be protected holes, such as metal rings passing through the flange, or they may be other structural elements affixed to the top face of the flange  400 . Otherwise, once the flange  400  is pulled tight against the face  300  of the sweeper, the system functions similarly to the embodiment disclosed above and in  FIG. 15 . 
       V. Alternative Embodiment Releasable Restraining Chain  124  and Hook  122   
       [0058]      FIG. 19  features an alternative embodiment of the ejector system  2  which includes a restraining chain  124  affixed to the structural support of the ejector, such as the vertical supports  20 . The chain terminates in a releasable hook  122 , such as a carbineer, a hook with a hinged safety latch, or a hook with a threaded safety latch. The hook  122  can connect to a receiver  120 , such as an eyehook, connected to the front wall  7  of the trailer  4 . This prevents the ejector system  2  from moving away from the front wall  7  when unloading the trailer or when on a tipping platform or hauling other debris (e.g. tree limbs) which may protrude over the top of the side walls of the trailer. It also prevents the ejector system  2  from tipping or moving while the trailer  4  is in transport or if there are high winds. 
         [0000]    VI. Alternative Embodiment with Extension  302   
         [0059]      FIGS. 20 and 21  show an alternative embodiment ejector system  2  having an extension  302  placed above the sweeper panel face  300  to increase the capacity of the ejector system  2 , allowing the system to move more material loaded into the trailer  4 . As shown, the extension extends above the original sweeper panel face  300 . The extension may be any shape, but is shown having a slight arc to correspond with an amount of material as it would typically appear within a trailer. Supports  304  hold the extension  302  up, and may be bolted or otherwise temporarily or permanently affixed to the supports of the original ejector system  2 . 
         [0060]    Alternatively, the extension  302  may be connected directly to the sweeper panel face  300 , such as via screws or other fasteners. This essentially places the extension against the sweeper panel face  300 , but the extension  302  will extend above where the original face  300  extended. 
         [0000]    VII. Alternative Embodiment with Locking Panels  356   
         [0061]      FIGS. 22-23C  disclose an alternative embodiment ejector system including locking panels  356  as distinguishable from the previously disclosed ejector system  2  without locking panels.  FIGS. 22 and 23C  disclose the alternative embodiment, whereas  FIGS. 23A and 23B  disclose the previous embodiment and prior art. 
         [0062]    In  FIG. 22  the locking panels  356  are shown as rectangular plates pivoting about a pivot point, such as a bolt. These panels lock in a vertical orientation such that they are in proximity with the headboards  352  of the trailer  4  side walls. When the panels are in an unlocked orientation  358 , the entire ejector system can be tilted forward to clean material from behind the panel; however, when locked in the locked position as indicated by  356 , the panel cannot tilt past the headboards  352 , as shown in  FIG. 23C . The locking panels either directly come into contact with the headboards  352  or they come into contact with a stopping element affixed to those beams (not shown). 
         [0063]      FIGS. 23A and 23B  show what happens if the ejector system is allowed to tilt freely. Sometimes high winds can cause the ejector system  2  to tilt forward, as shown in  FIG. 23B , without the operator desiring that motion to occur. This can damage equipment or cause potential injuries to the operator. However, the ability for the entire ejector system  2  to tilt forward for cleaning purposes is desirable, so the alternative embodiment shown in  FIGS. 22 and 23C  is preferred. 
         [0064]    It is to be understood that while certain embodiments and/or aspects of the invention have been shown and described, the invention is not limited thereto and encompasses various other embodiments and aspects.