Roof assemblies for trailers

A multi-piece roof assembly for a trailer includes: a first section configured with a sandwich panel having a convex shape; and at least one additional section configured with a flexible sheet panel coupled to the first section and to at least one top rail assembly.

BACKGROUND

Field of the Invention

The present invention relates to truck trailers, and more specifically, to roof assemblies for the truck trailers.

Background

Conventional composite sandwich panel roof assemblies for trailers are configured with a sandwich panel typically made up of a composite material including a plastic core and steel outer layers surrounding the core. Although the roof configured with the sandwich panel provides strong support for the load (e.g., a person walking on the roof), it does not provide good flexibility for the curved surface of the roof, while providing easy coupling to the flat surface of the top rail assemblies. Thus, the curved or cambered surface of the sandwich panel roof coupling to the flat surface of the top rail assemblies may leave a gap which needs to be filled.

One of the common roof assemblies for trailers is made of a composite sandwich panel, plywood or similar material. This type of roof is shaped and has the convex side oriented up. This is a self-supporting roof and it does not require any additional support (roof bows). The roof is only attached along the perimeter. Since the side edges of the roof are straight lines, attaching the roof to the side upper rails is rather easy. However, attaching stiff cambered roof shell to the flat front upper rail and flat rear rail/header require installation of spacers to fill the gap between the flat rail and convex roof shell.

SUMMARY

The present disclosure describes roof assemblies for trailers.

In one embodiment, a multi-piece roof assembly for a trailer is disclosed. The multi-piece roof assembly includes: a first section configured with a sandwich panel having a convex shape; and at least one additional section configured with a flexible sheet panel coupled to the first section and to at least one top rail assembly.

In another embodiment, a roof assembly for a trailer coupled to a front top rail assembly and a rear frame header is disclosed. The roof assembly includes: a cambered sandwich panel; a first sheet panel coupled to the cambered sandwich panel and the front top rail assembly; and a second sheet panel coupled to the cambered sandwich panel and the rear frame header.

Other features and advantages of the present disclosure should be apparent from the present description which illustrates, by way of example, aspects of the invention.

DETAILED DESCRIPTION

As stated above, conventional roof assemblies for truck trailers are curved (or cambered), while the top rail assemblies are typically configured as a single piece rail that is flat at the top. However, the cambered design of the roof assemblies does not interface well with the flat-top design of the top rail assemblies. Thus, the interface can leave a gap between the top rail and the cambered roof panel. The disadvantage of leaving the gap between the cambered roof panel and the top rail is that contaminants, such as snow or rain, may be hard to remove once the contaminants are in the gap.

Embodiments of the present disclosure are configured to substantially reduce the necessity of filling the gap between the flat rail/header and the cambered roof by adding a front section and/or a rear section made with thin aluminum or other flexible sheets and coupling the section(s) to the stiff cambered roof shell. These flexible sheets can be attached to the flat surfaces of the front top rail (which can also be referred to as “front top rail assembly”) and/or the rear frame header (which can also be referred to as “rear top rail assembly”).

In one embodiment of the present disclosure, a multi-piece roof assembly is disclosed. The multi-piece roof assembly includes a sandwich panel and at least one aluminum sheet panel coupled to the sandwich panel at the front section and/or the rear section of the roof. Thus, the multi-piece roof assembly can be configured into one of three configurations: (1) an aluminum sheet panel at the front section of the trailer roof and a sandwich panel attached to the aluminum sheet panel; (2) an aluminum sheet panel at the rear section of the trailer roof and a sandwich panel attached to the aluminum sheet panel; and (3) a first aluminum sheet panel at the front section of the trailer roof, a second aluminum sheet panel at the rear section of the trailer roof, and a sandwich panel attached to both the first and the second aluminum sheet panels. In one embodiment, the aluminum sheet panel can be replaced with other flexible material including thin steel sheets, polymers, and fiberglass-reinforced plastic.

The sandwich panel can be configured with a composite material including a plastic core and steel outer layers surrounding the core. Each of the at least one aluminum sheet panel can be bonded (or attached by other means) to the front and side top rails, as well as to the rear header using bonding material. Each aluminum sheet panel also can be crimped around the top rails and rear header in addition to being bonded.

FIG. 1is a perspective view of a roof assembly100in accordance with one embodiment of the present disclosure. The illustrated embodiment ofFIG. 1shows the front section of the roof assembly100including an aluminum sheet panel110at the front of the trailer roof and a sandwich panel112attached to the aluminum sheet panel110.FIG. 1also shows the aluminum sheet panel110attached to the top front rail120and the top side rail130. The top front rail120can also include rounded-end corners122,124. The rounded-end corners122,124enable the top front rail to smoothly couple (along line132) to the top side rails (including rail130).

FIG. 2is a cross-sectional view of the roof assembly100sliced along the lines A-A′ shown inFIG. 1. The cross-sectional view shows the details of coupling the roof assembly100to the top front rail120.

In the illustrated embodiment ofFIG. 2, the roof assembly100includes a sandwich panel112attached to an aluminum sheet panel110using attachment means or bonding material150. In one embodiment, the sandwich panel112is configured with a composite material including a plastic core116and steel outer layers114surrounding the core116. This configuration provides strong support for the load placed on the roof. However, this configuration does not provide flexibility needed to couple the cambered roof (including the sandwich panel) to the top rails of the trailer (e.g., the top front rail120). Thus, the aluminum sheet panel110is provided and added at the front (and, in some embodiments, at the rear shown, for example, inFIG. 5) to provide the flexibility. Accordingly, inFIG. 2, the aluminum sheet panel110attaches to the sandwich panel112and the top front rail120using attachment means and/or bonding material150,152, respectively. The attachments means can be any combination of adhesives, mechanical fasteners, and other attachment means and methods including welding.

FIG. 3is a cross-sectional exploded view of a multi-piece roof assembly100showing the aluminum sheet panel110placed between the sandwich panel112and the top front rail120. In the illustrated embodiment ofFIG. 3, the top surface300of the top front rail120is configured to be flat, while the surface310of the sandwich roof panel112is configured to be cambered or curved (e.g. a convex shape). Accordingly, the sheet panel110acts as a connector between the cambered roof112and the flat top rail120. In some embodiments, a similar configuration can be added to the rear section, as shown inFIGS. 4 and 5.

FIG. 4is a perspective view of a roof assembly400in accordance with one embodiment of the present disclosure. The illustrated embodiment ofFIG. 4shows the rear section of the roof assembly400(similar to roof assembly100which shows the front section) including an aluminum sheet panel410at the rear of the trailer roof and a sandwich panel412attached to the aluminum sheet panel410.FIG. 4also shows the aluminum sheet panel410attached to the rear header420and the top side rail430.

FIG. 5is a cross-sectional view of the roof assembly400sliced along the lines B-B′ shown inFIG. 4. The cross-sectional view shows the details of coupling the roof assembly400to the rear header420.

In the illustrated embodiment ofFIG. 5, the roof assembly400includes a sandwich panel412attached to an aluminum sheet panel410using attachment means450. The attachments means can be any combination of adhesives, mechanical fasteners, and other attachment means and methods including welding.

In one embodiment, the sandwich panel412is configured with a composite material including a plastic core416and steel outer layers414surrounding the core416. Similar to the front section, the top surface500of the rear frame header420is configured to be flat, while the surface510of the sandwich roof panel412is configured to be cambered or curved (e.g. a convex shape). Accordingly, the sheet panel410acts as a connector between the cambered roof412and the flat top rear frame header420. This configuration provides strong support for the load placed on the roof, while providing flexibility needed to couple the cambered roof to the rear frame header of the trailer.

The descriptions of the disclosed embodiments are provided to enable any person skilled in the art to make or use the disclosure. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles described herein can be applied to other embodiments without departing from the spirit or scope of the disclosure. Thus, it is to be understood that the description presented herein represent embodiments representative of the subject matter which is broadly contemplated by the present disclosure.

Examples of embodiments are shown on the following pages. All features of each example are not necessarily required in a particular embodiment. Other solutions can also be used (off the shelf or custom made). Suggestions for requirements refer to a particular embodiment and not necessarily all embodiments.

Additional variations and embodiments are also possible. Accordingly, the technology is not limited only to the specific examples noted herein.