Ultra-lightweight, portable, and extremely low pressure dump system for handling dry or wet materials

A dump system (e.g., for setting in a vehicle's flatbed or trailer) includes a base, a container (for containing material) configured to pivot relative to the base, an inflate membrane coupled to the base and to the container, and a U-frame that extends around the inflate membrane and is configured to pivot relative to the base. The U-frame is configured to restrain outward expansion of the inflate membrane as the inflate membrane expands pushing on the container and causing the container to pivot upward. Some implementations include, in addition to or instead of the U-frame, a wing frame panel configured to collect and contain folds that form from material of the inflate membrane as the inflate membrane deflates and collapses (or when the inflate membrane is in a collapsed or deflated state).

FIELD OF INVENTION

This disclosure relates to a dump system, and more particularly, relates to an ultra-lightweight dump system for handling wet or dry materials.

BACKGROUND

Transporting dry materials, including landscaping materials, and the like on roads can be challenging. Portable dump systems can provide much needed additional load carrying capacity when needed. Dump systems, however, can be very heavy, and difficult and labor intensive to attach and detach. The use of a hydraulic pump and cylinder(s) for tilting a steel dump container, as used on standard dump trucks and dump trailers has been adapted for use on small pickup trucks as an insert. While this dump system configuration functions, it tends to be very heavy (e.g., 800 pounds or thereabouts and up), expensive, and requires a sophisticated hydraulic system with, often, a 1.5 hp motor. Because the unit is so heavy, it typically requires that a pickup truck be dedicated for its use because it requires a fork truck to install and/or remove from the bed of a truck. Also, with many pickup trucks having a payload capacity between 1,200 and 2,300 pounds, the 700 pounds of weight significantly reduces the actual payload a pickup truck can safely and efficiently transport which often causes the user to buy a bigger and less efficient truck.

SUMMARY OF THE INVENTION

In one aspect, a dump system (e.g., for setting in a vehicle's flatbed or trailer) includes a base, a container (for containing material) configured to pivot relative to the base, an inflate membrane coupled to the base and to the container, and a U-frame that extends around the inflate membrane and is configured to pivot relative to the base. The U-frame is configured to restrain outward expansion of the inflate membrane as the inflate membrane expands pushing on the container and causing the container to pivot upward. Some implementations include, in addition to or instead of the U-frame, a wing frame panel configured to collect and contain folds that form from material of the inflate membrane as the inflate membrane deflates and collapses (or when the inflate membrane is in a collapsed or deflated state).

In another aspect, a dump system includes a base, a container configured to pivot relative to the base, an inflate membrane coupled to the base and to the container, and a first wing frame panel adjacent to a first side surface of the inflate membrane. The first wing frame panel is configured to collect and contain folds that form from material of the inflate membrane as the inflate membrane deflates and collapses. In some implementations, the dump system further includes a second wing frame panel adjacent to a second side surface of the inflate membrane. The second side surface of the inflate membrane is opposite the first side surface of the inflate membrane. Moreover, in some implementations, one or more U-frames extend around the inflate membrane and are configured to pivot upward relative to the base as the inflate membrane expands and to pivot downward relative the base as the inflate membrane collapses. Each U-frame is configured to restrain outward expansion of the inflate membrane as the inflate membrane expands pushing on the container and causing the container to pivot upward. The U-frame may include one or more U-frame interior supports that extend through an opening in the inflate membrane.

In yet another aspect, a method includes: providing a dump system configured to fit onto a vehicle's flatbed or trailer to provide dumping capabilities to the vehicle's flatbed or trailer, providing a storage rack for the dump system, providing a vehicle with a flat bed or trailer configured to receive the dump system, positioning the dump system onto the vehicle's flatbed or trailer or onto the storage rack, positioning a rear end of the vehicle's flatbed or trailer adjacent to a loading end of the storage rack, and transferring the dump system between the vehicle's flat bed or trailer and the storage rack in such a manner that the dump system remains in direct physical contact with the vehicle's flat bed or trailer, the storage rack, or both the vehicle's flat bed or trailer and the storage rack. In a typical implementation, during an entirety of the transfer, the dump system remains in direct physical contact with an upper surface of the vehicle's flat bed or trailer, one or more of the rollers of the storage rack, or both.

In still another aspect, a storage rack for storing a dump system is disclosed. The storage rack has rack legs, a rack frame atop and supported by the rack legs, and a pair of roller frame assemblies atop and supported by the rack frame. The roller frame assemblies extend lengthwise along the storage rack parallel to one another and laterally separated from one another so that a first one of the roller frame assemblies is on a right side of the storage rack while a second one of the roller frame assemblies is on a left side of the storage rack. Rollers are supported by each of the roller frame assemblies. Each of the roller frame assembly has an exterior frame and an interior frame. The exterior frame may be higher than the rollers and the interior frame may be lower than rollers (e.g., to guide an object rolling along the rollers). The roller frame assemblies support the rollers. Each of the rollers is parallel to all other rollers supported by the same one of the roller frame assemblies. The storage rack, in some implementations, also has a stop at an end of the storage rack opposite a loading end of the storage rack. The stop may be a rigid panel that extends upwardly to provide a barrier for any object being rolled across the rollers of the storage rack.

In some implementations, one or more of the following advantages are present.

First, implementations of the dump system disclosed herein may enjoy performance characteristics that are surprisingly robust, particularly given the relatively low cost, low operating pressures, and high loads that the dump system can handle and quickly and effectively dump. In an exemplary implementation, the dump system utilizes a very low pressure blower (of the type normally found on a vacuum cleaner) to inflate the inflate membrane in a manner that produces lifting/dumping capacity that is able to lift/dump a large load (e.g., of 2,000 pounds or more) in a container atop the inflate membrane, quickly (e.g., within two or three minutes). The very low pressure blower tends to be very low cost (e.g., about $100) and light weight (e.g., about 5 pounds+/−10%). Moreover, the very low pressure blower may, in some instances, be operable to produce flow of about 100 cubic feet per minute (+/−10%) at less than ½ pounds per square inch (psi). The inflate membrane used in this system typically is large and typically spans across and presses up against a large percentage of the upper surface of the inflate membrane (which may form or be in contact with or apply force to the bottom of the container) to pivot the container up when the inflate membrane inflates. Since the very low pressure (e.g., less than ½ psi) is spread out across the large inflate membrane and across the large interface the cumulative force applied to urge the container upward is sufficient to provide satisfactory and excellent performance.

In an exemplary implementation, these surprising performance characteristics may be realized utilizing a large (e.g., 185 square feet or more) inflate membrane with a low cost blower configured to produce air flow into the inflate membrane of at least 100 cubic feet per minute (cfm) with a pressure of less than ½ pound per square inch (psi). In an exemplary implementation, these surprising performance characteristics may be realized utilizing a large (e.g., 185 square feet or more) inflate membrane with a low cost blower configured to produce air flow into the inflate membrane of at least 100 cfm (+/−20%) with a pressure of less than 1 psi, less than 2 psi, less than 3 psi, or less than 4 psi.

Additionally, for example, some implementations define a low cost, portable, light weight, self-contained dump system that can be inserted and/or easily installed, removed, and/or reinstalled in a vehicle's flat bed or trailer to provide dumping capabilities. The dump system is strong and durable. Moreover, the dumping angle that can be achieved in a typical implementation is very high making the actual dumping of material out of the dump system's container very reliable with little effort. Because of the low weight of the dump system, the weight carrying capacity of the vehicle with the dump system remains high. Moreover, lower power and lower cost vehicles can perform at very high levels of performance.

Moreover, in some implementations, unlike other dump equipment, implementations of the dump system disclosed herein does not have a rigid floor, it is fabric. Some implementations, however, do have an added rigid floor if desired.

Other features and advantages will be apparent from the description and drawings, and from the claims.

Like reference numerals refers to similar elements.

DETAILED DESCRIPTION

This disclosure relates to a dump system, and more particularly, relates to an ultra-lightweight dump system for handling wet or dry materials.

FIGS.1and2are side views showing an implementation of a dump system9that is configured to be placed into a vehicle (e.g., on a flatbed or trailer) to provide the vehicle with dumping capabilities.FIG.1shows the dump system9in a lowered configuration (suitable for holding and/or transporting material), whileFIG.2shows the dump system9in a raised configuration (suitable for depositing or dumping material out of the dump system).

Some of the main components of the illustrated dump system9include a base frame10, a dump frame11coupled to the base frame via a hinge13, a container28(for carrying material) coupled to and supported by the dump frame11, an inflate membrane17between the base frame10and the dump frame11, a blower (not shown inFIG.1but see23inFIG.2) to inflate the inflate membrane17, a U-frame that extends from a frame hinge16around a portion of the inflate membrane17to control a shape of the inflate membrane17when inflated, and wing frames20on opposite sides of the container28to help contain and control the inflate membrane when collapsed. The frame hinge16is physically close to hinge13. Both the frame hinge16and hinge13are at or near (e.g., within 6 inches of) the front end of the dump system9in the illustrated implementation. (SeeFIG.1). Moreover, in the illustrated implementation, both the frame hinge16and hinge13are in the same plane. Thus, both the container28(which pivots about hinge13) and the U-frame15(which pivots about frame hinge16) pivot in the same manner—with their rear ends swinging upwardly and their front ends remaining low.

As suggested above and apparent from the illustrated figures, the dump system9is generally operable to move the container28between a lowered position (shown inFIG.1) and a raised position (shown inFIG.2). The lowered position is convenient for loading material into the container28and for transporting the loaded container28from one location to another (e.g., on the back of a transport vehicle when the dump system9is placed onto the vehicle's flatbed). The raised position is a dumping position and convenient for dumping or depositing loaded material out of the container (e.g., at a desired dumping location). In a typical implementation, the illustrated dump system9moves the container28from a lowered position (e.g., as inFIG.1) to a raised position (e.g., as inFIG.2) by inflating an inflate membrane17that pushes the container28to the raised position when inflated with air. Additionally, in a typical implementation, the illustrated dump system9moves the container28by allowing air to escape from the inflate membrane17thereby deflating the inflate membrane17, which allows the container to drop back (e.g., largely under the influence of gravity) to the lowered position.

Placing the dump system9in back of an ordinary vehicle (e.g., on a flatbed of a truck or on a trailer) essentially converts that ordinary vehicle into a vehicle that has dumping capabilities. With the dump system9positioned on the flatbed of a non-dump truck or trailer, an operator may, for example, load the container28with material at one location while the container28is in the lowered position (e.g., as inFIG.1), drive the dump system9with the loaded container28to a desired destination, and dump the material out of the container28of the dump system9by raising the container28to the raised position (e.g., as inFIG.2) at the desired destination. Typically, the material would flow out the back of the container28when in the raised position. Once emptied, the operator may lower the container28back to the lowered position and drive off with the container28sitting in the back of the vehicle in the lowered position ready to be loaded up again.

In some implementations, one or more of the following advantages are present.

For example, dump system implementations disclosed herein may improve handling, storing, transporting, and discharging various materials. Dump system implementations disclosed herein may provide a marked improvement in equipping trucks and/or trailers that have fixed beds with dump system functionalities. Dump system implementations disclosed herein may be ultra-lightweight and portable. This may include an extremely lightweight frame/base frame and dumping container and, collectively, may weigh 75% less than certain existing dump inserts in the market today. Also, as a result of the current dump inserts that function via a hydraulic cylinder and pump; and weigh between 750 to 900 pounds, the only significant difference between those current dump inserts is the height and shape of the dump containers' sidewalls. Because these dump inserts tend to be very heavy (e.g., having a tare weight of about 800 pounds or thereabouts), they usually require larger model pickup trucks (e.g., ¾-ton capacity pickup trucks, e.g., a Ford F-250, instead of a Ford F-150), which can be very costly (e.g., costing about an additional $7,000 over smaller trucks). Additionally, the heavier weights result in reduced fuel economy/mileage ratings (e.g., from about 22 mpg to about 16 mpg). In addition to the added $7,000 in cost and reduced fuel mileage rating (e.g., to about 16 mpg), industry experts estimate that for every 100 hundred pounds of extra weight a vehicle carries there is a 2% reduction in fuel efficiency. At 800 pounds of extra dead weight on board, that is a further reduction in fuel economy by 16% (potentially bringing mileage to just 13.5 mpg). To make matters worse, typically, these other dump inserts are usually permanently installed on a vehicle (and sold only through dealers that can handle the installation requirements, which results in further extra cost), which means that no matter where the truck is going to be driven, even if empty, the operator is required to buy a more expensive truck and suffer significantly greater costs for fuel. Other requirements of these dump inserts is that some of them can only be used on pickup trucks having only a two person cab (no back seats) and some must have the vehicle's tail gate removed. In various implementations, the dump system disclosed herein overcomes or addresses one or more (or all) of these shortcomings in current systems.

Another significant advantage, in certain implementations, is that the dump system (insert) is very low in weight (weighing approximately 200 pounds) making it easy and safe to install, remove, and/or reinstall quickly (e.g., by one person sometimes as fast as less than a minute). In some implementations, a portable and collapsible storage rack may be provided that can be used not only for storing the insert (e.g., at the truck's home base or some other location) but can also be moved from job site to job site and used like a dumpster. Even when filled with 1,000 or more pounds of cargo (e.g., grass clippings, refuse, mulch, old shingles, salt, and/or other bulk materials), the insert can be pushed back and forth between a vehicle and the storage rack easily. In some instances, the insert may be loaded with material while sitting on the storage rack and then the insert may be rolled (with ease) onto the vehicle for transport to another location and emptied (e.g., dumped) there.

Another feature in certain implementations is that the cargo in the dump body can be weighed (approximately + or −100 lbs.) via the amount of air pressure generated in the inflatable membrane during lifting. Typically, the air pressure required for the dump system to operate effectively is very low (e.g., less than 3 PSI, less than 2 PSI). This ultra-light and portable dump and storage system can be used in a variety of settings including, for example, on any flat surface including the ground, a cement floor as well as on the cargo beds of almost any vehicle such as pick-up trucks, vans, landscape and highway trailers, grain wagons, rail cars, ships, and planes.

One of the more vexing problems and challenges of using low pressures is the use of a large, generally cuboid-shaped inflatable membrane (e.g., with a typical surface area of approximately 185 square feet (+/−10%) compared to other dump systems' footprint (e.g., of only 32 square feet)). Of course, the size of the membrane can vary and the area of material (e.g., fabric) that defines the interior space for receiving air in the inflate membrane can be greater than 185 square feet, especially if the container being lifted/pivoted to dump is especially large. This results in a lot of membrane material to manage, especially when the inflate membrane deflates. Managing such a large amount of inflate membrane material (e.g., PVC coated fabric) may be solved, as described herein, by the use of a pivoting U-Frame and/or guide frames (e.g., wing frames) to not only handle the folds created in the inflate membrane side walls, for example, but to also control the folds so they function in a set and repeatable manner. Another significant advantage of using an extremely large inflate membrane combined with the use of a pivoting U-frame and/or guide frames (e.g., wing frames) is that the maximum dump angle of 45 degrees limitation that is typical in certain current dump inserts is easily surpassed. In some instances, a maximum dump angle of up to 90 degrees can be achieved. As many bulk handling experts and practitioners know, a maximum dump angle of 45 degrees may not steep enough to handle certain materials that are not free-flowing. Materials such as grass clippings, dirt, mulch, and other landscaping materials, especially when damp or wet, may require a dump angle of approximately 60 degrees to 80 degrees for efficient and/or quick and/or easy dumping, emptying, and complete clean out.

Other features and advantages will be apparent from the rest of the description, the drawings, and from the claims.

The base frame10can have any one of a variety of different configurations. In a typical implementation, the base frame10includes four rods arranged in a plane to define an outer, rectangular, perimeter of the base frame10. The four rods include a front rod, a rear rod, and two side rods. The base frame10also may include several other rods that also lie in the plane and extend across an interior of the perimeter of the base frame10(e.g., from side rod to side rod), serving as cross-support members for the base frame10. The cross-support member rods may be parallel to the front rod and the rear rod. Moreover, the front rod, the cross-support member rods, and the rear rod may be evenly spaced from one another in a front-to-back direction. The rods may be coupled to one another in any one of a variety of convenient ways including, for example, by welding or with the use of an adhesive between the rods. Each rod can have any one of a variety of different specific configurations including, for example, being configured as round or square steel tubing, slender bars, or other rigid material.

Likewise, the dump frame11can have any one of a variety of different configurations. In a typical implementation, the dump frame11includes four rods arranged in a first plane to define a rectangular bottom perimeter of the dump frame11, four rods arranged in a second plane (parallel to the first plane) to define a rectangular top perimeter of the dump frame11, and multiple rods that extend between the bottom perimeter rods and the top perimeters rods and support the top perimeter rods. In a typical implementation, the rectangular top perimeter is wider than, and offset in forward direction from, the rectangular bottom perimeter. The top perimeter rods essentially form a top rail14of the dump frame11, and the multiple rods that extend between the bottom perimeter rods and the top perimeter rods act as dump frame posts12a-12h. Again, the rods may be coupled to one another in any one of a variety of convenient ways including, for example, by welding or with the use of an adhesive between the rods. Moreover, each rod can have any one of a variety of different specific configurations including, for example, being configured as round steel tubing, slender bars, or other rigid material. A dump gate rail21extends from each of the frontmost dump posts (e.g., dump post12dand the frontmost dump post on an opposite side of the dump system9from12d) to a corresponding one of the front-to-back extending rods that form one of the sides of the bottom of the dump frame11.

The inflate membrane17(e.g., an inflatable container or balloon) can have any one of a variety of different configurations. In a typical implementation, the inflate membrane17includes an inflate membrane bottom panel18, an inflate membrane top panel19, and a connecting panel that extends between the inflate membrane bottom panel18and the inflate membrane top panel19to define at least the side walls and rear wall of the inflate membrane. The inflate membrane bottom panel18is secured to the base frame10of the dump system9and extends between the rods that form the base frame10. The inflate membrane top panel19is secured to the dump frame11. More specifically, the inflate membrane top panel19is secured to and extends between the rods that form the bottom of the dump frame11. The inflate membrane bottom panel18and the inflate membrane top panel19are configured such that, when the dump system9is in the lowered configuration (e.g., as inFIG.1), the inflate membrane bottom panel18and the inflate membrane top panel19lie in planes that are parallel to one another. The inflate membrane connecting panel is coupled to both the inflate membrane bottom panel18and the inflate membrane top panel19. The inflate membrane can be made from any one of a variety of materials that are able to be inflated and move between a first configuration such as the one shown inFIG.1(collapsed) to a second configuration such as the one shown inFIG.2(expanded).

The blower23is configured to blow air into the inflate membrane17to inflate the inflate membrane17. Typically, the blower23is a low pressure blower. In some implementations, for example, the blower23has a capacity that can produce pressures up to, but not necessarily exceeding, 4 pounds per square inch (psi). The blower23in the illustrated implementation is configured to draw air from atmosphere (i.e., from the environment outside the dump system9). In an exemplary implementation, the blower23has the capacity to deliver about 100 cubic feet per minute (CFM) into the inflate membrane17at about 3 psi. A variety of different blowers configurations may be suitable for use as the blower23. One example utilizes Ametek Lamb #115923, which, in some implementations, may produce about 85 cfm at 15 inches WC.

The container28can have any one of a variety of different configurations. That said, typically, the container28is supported by the dump frame11and sits above the inflate membrane17. Since the container28is supported by the dump frame11, in a typical implementation, its size and shape is largely dictated by the physical configuration of rods that make up the dump frame11. The container28has a bottom surface (that may be the inflate membrane top panel19), side walls, and a rear wall. Typically, the container28is open at its top and front. Thus, in an example implementation, there is no container material (e.g., fabric) that extends between the rods that make up the top rails14of the dump frame11. Similarly, in an example implementation, there is no container material (e.g., fabric) that extends between the rods that surround the front-facing side end of the dump frame11. The container28can be made of any one of a variety of different materials. In an exemplary implementation, the container28is made of, or includes, a flexible material, such as 40 oz. PVC coated polyester fabric, woven polyester belting, or a rigid material like metal, fiberglass, wood, or plastic. Variations are, of course, possible.

The U-frame15is a physical structure configured to influence the shape and movement of the inflate membrane17as it inflates and deflates. More specifically, for example, as the inflate membrane inflates (see, e.g.,FIG.2), the frame15restrains outward expansion of a mid-section of the inflate membrane17. This makes more of the force of the expanding inflate membrane17available for lifting the container28. As shown inFIG.2, when the inflate membrane17is inflated, the U-frame15wraps around and contains a middle portion of the inflate membrane17thereby restrains its outward expansion beyond the envelope defined by the U-frame15. The U-frame15also may influence the shape and movement of the inflate membrane17as the inflate membrane17deflates and collapses. For example, in some instances, the U-frame15may act as sort of a coat hanger to influence where and how one or more folds in the inflate membrane material are created when the inflate membrane17deflates and collapses.

In a typical implementation, the U-frame15is a long, thin, rigid structure (e.g., lightweight tubing, rod, etc.) that is contoured to approximate the shape of a capital “U”—with two side portions and a curved rear portion that connects the two side portions. The two side portions of the U-frame15roughly correspond to the two side legs of capital “U” and the curved rear portion of the U-frame15roughly corresponds to the curved bottom section of capital “U.” The forwardmost ends of the U-frame (i.e., the “tops” of the two side legs) are attached to one or more U-frame hinges (e.g.,16) that enable the U-frame15to pivot about a pivot point established by the U-frame hinge(s). With the dump system9in a lowered configuration (e.g.,FIG.1), each side portion of the U-frame15extends from its hinge connection point in a generally forward direction alongside, and adjacent to, either the left side or the right side of the inflate membrane17(between the base frame10and the dump frame11). In some implementations, the side portions of the U-frame15are parallel to one another. In some implementations, the side portions flare out a bit relative to one another as they get closer to the curved rear portion of the U-frame15(see, e.g.,FIG.6). The curved rear portion of the U-frame15connects the two side portions to one another and extends around the rear wall of the inflate membrane17. In a typical implementation, the footprint of the U-frame is smaller than the footprint of the bottom portion of the dump frame11. Thus, when the dump system9is in the lowered position (e.g., ofFIG.1), the bottom portion of the dump frame11covers an entirety of the U-frame15. (See alsoFIG.6).

In a typical implementation, the U-frame15is coupled to and configured to move (e.g., up, and down in a pivoting fashion) with the inflate membrane17as the inflate membrane17inflates and deflates. For example,FIG.1shows the inflate membrane17in a deflated state and the U-frame15in that figure is shown lying in a horizontal plane between the base frame10and the bottom portion of the dump frame11. When the inflate membrane17is inflated, it expands (e.g., from the deflated state inFIG.1to the inflated state inFIG.2). As the inflate membrane17expands, the U-frame15pivots upward (about U-frame hinge16), lifted by the expanding inflate membrane17.FIG.2shows the inflate membrane17in an inflated state. The U-frame15inFIG.2is disposed in in an upwardly angled configuration, having pivoted about the U-frame hinge16from its horizontal configuration inFIG.1to its upwardly angled configuration inFIG.2. In a typical implementation, the U-frame15is physically coupled to the inflate membrane17so that when the inflate membrane17expands, the U-frame15is lifted by the expanding inflate membrane17. When the inflate membrane17once again deflates, the inflate membrane collapses back to a deflated configuration such as the one represented inFIG.1. As the inflate membrane17collapses and moves back to its deflated state (FIG.1), the U-frame hinge16drops or may be pulled down by the deflating inflate membrane17back to a lowered position (e.g., a horizontally disposed position, as inFIG.1).

There are a variety of ways that the U-frame15may be coupled to and configured to move with the inflate membrane17as the inflate membrane17expands and collapses. One example is represented inFIG.6where U-frame interior supports30a-30dare provided that extend through the inflate membrane17from one side portion of the U-frame15to the opposite side portion of the U-frame. These U-frame interior supports may help prevent the U-frame15from bending outward and possibly breaking under the force of the inflate membrane17as the inflate membrane17inflates and expands, but they also may help maintain the position of the U-frame15relative to the inflate membrane17as the inflate membrane expands and collapses.

A wing frame20is provided on each side of the dump system9. Each wing frame20is attached to the base frame10(e.g., by welding, adhesive, by integral casting, etc.) and, in a typical implementation, each wing frame20is a mirror image of the other. The specific configuration of the wing frames20can differ depending on a variety of considerations. Typically, the wing frame20is configured so that it can control and contain the inflate sidewall folds (e.g.,31Sa-31Sc inFIG.1) as the inflate membrane17deflates and collapses and when the inflate membrane17is in the deflated state, as represented in the illustrated implementation. The specific wing frame20configuration represented in the illustrated implementation shows each wing frame20including a long, thin, rigid structure (e.g., lightweight tubing, rod, etc.) contoured as shown. Each wing frame20in the illustrated implementation has a front end and a back end. The front end and the back end are connected to the base frame10. Moreover, each wing frame20has a straight front section that extends upward and outward (e.g., at an angle of between 55 degrees and 85 degrees) from its front connection point on the base frame10. The wing frame20then bends rearward into a section that is long and curved. The long curved section ends at another bend, this one downward, into a straight rear section that extends downward and inward to the rear connection point on the base frame10. In the illustrated implementation, the straight rear section is longer than the straight front section. The location and distance between the front connection point and the rear connection point can vary and the height—either the maximum height or the height at various points along the length of the wing frame20—can vary. In the illustrated implementation, the front connection point is close to but just rear of the location of the frontmost vertical dump frame post (e.g.,12d) when the inflate membrane17is in the collapsed state, and the rear connection point is close to but just forward of the location of the rearmost vertical dump frame post (e.g.,12b) when the inflate membrane17is in the collapsed state. Moreover, the distance between the front connection point and the rear connection point is almost (e.g., at least 85%, at least 90%, at least 95%) of the distance between the forwardmost vertical dump frame post (e.g.,12dinFIG.1) and the rearmost vertical dump frame post (e.g.,12binFIG.1). Moreover, the highest point on the wing frame20in the illustrated implementation is high enough to contain the highest point of any of the side folds in the deflated inflate membrane17(see, e.g.,FIG.3). In a typical implementation, this height may be at least 10% the height of the container28, for example.

FIG.1shows the inflate membrane17(completely deflated) positioned between base frame10and dump frame11with inflate membrane bottom panel18secured to base frame10and inflate membrane top panel secured to dump frame11. Inflate membrane sidewall37, which is, in an exemplary implementation, about 40 square feet in area, is shown tucked between wing frame20and dump frame posts12b,12cand12dwith inflate membrane sidewall folds31Sa,31Sb,31Sc, and31Sd gathered and protected within wing frame20. Hinge13is secured to base frame10and dump frame11to allow dump frame pivot up and down for dumping as inflate membrane17is inflated and deflated with low pressure air from blower23(see,FIG.2). Also shown is U-frame15, which is secured to inflate membrane sidewall37and pivots up and down via U-frame hinge16located on or near hinge13in various implementations. Dump frame11is equipped with dump frame posts12a,12b,12c,12d, top rail14and dump gate21as well as dump frame posts12e(not shown),12f(not shown),12g,12hinserted, top rails14and dump gate rail21that all form a framework for securing container28that is typically made of flexible material such as 40 oz. PVC coated polyester fabric, woven polyester belting and/or rigid materials like metal, fiberglass, wood or plastic. For most applications, container28is made of a heavy-duty, abrasion resistant 40 oz. PVC coated polyester fabric having a tensile strength of 725 lbs./inch. Also shown is wheel25, mounted on wheel bracket26that is secured to base frame10for moving dump system9on and off a vehicle or any other flat surface. The bracket26in the illustrated implementation is angled slightly upward so that when the dump system9is installed on a flat surface, such as the cargo bed of a vehicle, the wheel25is slightly above the flat surface. However, in those implementations, the front end of the dump system9can be lifted fairly easily and when that happens, the wheel25gets lowered does and onto the flat surface so that the dump system9can then be rolled along (e.g., the flat surface) to move the dump system with ease. In a typical implementation, hinge13is approximately (or at least)2″ in diameter, which provides enough space between base frame10and dump frame11for inflate membrane17to rest when deflated so that base frame10and dump frame remain in parallel.

As can be seen inFIGS.1and2, for example, and as mentioned above, in a typical implementation, the U-frame15not only holds and restricts the inflate membrane17from going round, almost to an oval shape when a load is placed on it, but also acts as sort of a coat hanger to manage and dictate where and how the folds are created which happens beyond the boundaries of the base frame if allowed. Moreover, the wing frames20collect the folds in a very organized and repeatable fashion. Managing the large inflate membrane17, which produces a lot of force under very low air pressure, also needs to be managed as it deflates and rests between the base frame10and dump frame11. In general, the bigger the bag (that forms the inflate membrane17), the more power and more folds to deal with.

FIG.2shows the dump system9with the dump frame11elevated (e.g., to about an 80 degree angle) as the inflate membrane17is inflated via blower23. In an exemplary implementation, blower23has the capacity to produce about 100 CFM at 3 PSI which typically produces lifting of the container28much faster than conventional hydraulic powered dump inserts. Notice that while inflate membrane17is almost fully inflated for dumping/emptying container28that inflate sidewall membrane fold31remains. This fold31signifies that inflate membrane17is not fully inflated, which in some cases would apply undue and unneeded stress on the seams of inflate membrane17. Even with a pay load of material such as grass clippings, dirt, mulch, or yard debris having a net weight of 1,500 pounds, the air pressure required for lifting and dumping action of container28typically is only about ½ of 1 PSI. Considering that a healthy adult's lung capacity is cable of producing 2 PSI, certain implementations of the inflate membrane17or dump system9is capable of lifting/dumping a payload weighing 9,000 pounds at 3 PSI. With dump system9weighing approximately 200 pounds, an implementation of dump system9can lift/dump a pay load 45 times heavier than its own weight. Additionally, U-frame15provides a type of exterior skeletal support to inflate membrane17as it moves dump frame11and container28up and down in a symmetrical and repeatable manner. Inflate membrane17is inflated and deflated via blower23and inflation hose24coupled to blower outlet52. Also shown is wing frame20equipped with wing frame panel27which provides further protection and side containment to inflate membrane17.

InFIG.3, inflate membrane17is shown completely deflated as inflate membrane sidewall folds31Sa and31Sb rest inside wing frame20awhile inflate membrane sidewall folds31Sc and31Sd rest inside wing frame20b. To provide extra space for inflate membrane sidewall folds31Sa,31Sb,31Sc and31Sd to fit easily, the bottom of the dump frame11can be made narrower than base frame10. In some implementations, base frame is 47 inches wide while the bottom of the dump frame11is 45 inches wide (so, 2 inches shorter), allowing inflate membrane sidewall folds31Sa-31Sd gather easily and without any stress and in a repeatable manner.

InFIG.4, as inflate membrane17is inflated, certain inflate membrane sidewall folds (31Sb and31Sd) are shown actually rising above and beyond dump frame11providing lateral support to dump frame11in a “cradle like” manner. The inflate action and movement of inflate membrane sidewall folds31Sb and31Sd provide support and stability to dump frame11, which, in an exemplary implementation weighs only about 30 pounds and is made of lightweight, round steel tubing, so that it does not twist, bend, and/or possibly break—especially if there is a heavy and/or uneven load in container28. Notice that inflate membrane sidewall folds31Sa and31Sc also extend beyond the width of at least the bottom of dump frame11providing extra support as it provides for a wide base. Together with wing frames20aand20b, U-frame15helps to keep inflate membrane17in a symmetrical, balanced, centered and repeatable position between base frame10and dump frame11.

InFIG.5, inflate membrane17is further inflated and as the front end dump frame11extends upward on a repeatable and vertical plane due to the support U-frame15, inflate membrane sidewall folds31Sa,31Sb,31Sc, and31Sd shrink and disappear in a symmetrical and repeatable manner. Even with a pay load of as much as 3,000 pounds in container28, the air pressure inside inflate membrane17in an exemplary implementation may be only around 1 PSI which results in virtually stress-free operation of the inflate membrane17.

FIG.6is a top view showing the use of U-frame interior supports30a,30b,30c, and30dwhich, in some implementations, allows U-frame15to be made of lightweight tubing (instead of needing to be sturdier and heavier). In keeping with the ultra-lightweight nature of certain implementations of the dump system9, U-frame interior supports30ato30dhelp prevent U-frame15from bending outward and possibly breaking under the force of the inflate membrane17as the inflate membrane17expands via inflation from blower23(see, e.g.,FIG.2). Note that, in the illustrated implementation, U-frame15is narrower than dump frame11. In some implementations, U-frame15is about 35 inches wide at its widest and dump frame11is 45 inches wide. In some implementations, this helps ensure inflate membrane17will rise vertically to a desired (or required) height as well as providing for controlled folding of inflate membrane17as the inflate membrane17deflates. U-frame interior support(s)30ato30dmay be made of steel cable connected to threaded eye hook fasteners and lock nuts30Xa to30Xh that attach to opposite sides of the U-frame. U-frame interior supports30ato30dcan also be made of rigid material such as steel, aluminum, or plastic. In a typical implementations, there are small holes in the side panels of inflate membrane17that allow for passage of the U-frame interior supports30ato30dand/or their fasteners to pass into and out of inflate membrane17. Typically, those holes are only large enough to allow the requisite hardware to pass through them with very little space around the hardware.

FIG.7is a side view of dump system9with an extension wall46secured to the dump system9atop the top rail14of dump frame11. The illustrated extension wall46includes an extension wall frame and extension wall panel coupled to and supported by the extension wall frame. The extension wall frame includes an upper extension wall rail45a, a lower extension wall rail45b, and a plurality of extension wall posts44a-44d. The upper extension wall rail45ais at or near the top of the extension wall46and the lower extension wall rail45bis near the bottom of the extension wall46and parallel to the upper extension wall rail45a. Each extension wall post44a-44dextends between and connects the upper extension wall rail45aand the lower extension wall rail45b. Each extension wall post44a-44dis parallel to, and spaced apart from in a longitudinal direction, the other extension wall posts. Moreover, each extension wall post44a-44dis perpendicular to the upper extension wall rail45aand the lower extension wall rail45b. The extension wall panel, which is coupled to and supported by the extension wall frame, may be made of a flexible material such as PVC coated fabric or a rigid material such as steel, aluminum, plastic, or wood.

The extension wall46may be part of an extension accessory47that can be attached to the top of the dump frame11(as shown) to increase the effective storage capacity of the dump system and the container28. In an exemplary implementation, the extension accessory47may include four extension walls, only one of which (extension wall46) is shown inFIG.7. These extension walls may be arranged relative to one another to define an additional, extension storage space that is cubic in shape, extending upward from an open top of container28, and surrounded by the four extension walls. The extension accessory47may have an open or closed (e.g., with a fabric or other material cover) top.

Each of the four walls may be rectangular in configuration, with the extension wall opposite extension wall46having a configuration that is a mirror image of the configuration of extension wall46. The other two extension walls—one at the front of the extension storage space and one at the rear of the extension storage space—are also typically rectangular, but typically smaller in overall width than extension wall46. The extension walls may be coupled to one another in any one of a variety of different ways, including ways that are similar to those indicated herein for coupling together the walls of container28.

The extension wall, in the illustrated implementation, is coupled to the top of the dump frame9with a coupling configuration that includes sidewall extension brackets22a-22dand lock pins48a-48d. In various implementations, the sidewall extension brackets22a,22b,22cand22dmay be permanently or temporarily attached to top rail14to accept extension wall posts44d,44a,44band44crespectively. As shown, extension wall rails45aand45bare secured to extension wall posts44d,44a,44band44cto form a frame to hold extension wall46, which, as mentioned above, may be made of a flexible material such as PVC coated fabric or a rigid material such as steel, aluminum, plastic or wood. To hold extension wall46in place and secure to top rail14, the lock pins48d,48a,48band48cmay be placed through sidewall extension brackets22a,22b.22C and22das well as extension wall posts44d,44a,44band44crespectively. Additionally, as mentioned above, the extension accessory, with the extension wall46, may also be in the form of a closed enclosure with top and back panels (not shown) and also may have one or more closable openings for handling ground up leaves and other materials in bulk. The closable openings may be in the top or any other panel and may include one or more fabric (or other material) flaps or covers that can be moved or swung (e.g., on a hinge) out of the way to allow access through an opening in the extension access into an interior space.

FIG.8is a schematic side view representation of dump system9that shows various features of dump system9including some that help prevent the inflate membrane17from becoming over-pressurized, which otherwise might present a risk of rupturing.

The inflate membrane17inFIG.8is almost fully inflated between base frame10and dump frame11creating a dump angle of about 85 degrees. The phrase dump angle refers to the angle between the base frame10and the dump frame11. As shown, blower23is mounted over wheel25aoff to the side of rear end of base frame10so that inflate membrane folds31Ra,31Rb,31Rc and31Rd (not shown) have a convenient place for storage when deflated. Even though dump system9may be designed to lift payloads in the 1,500 to 2,500 pound range under very low air pressures (e.g., 1·WC or 1 inch of water for every 100 pounds), blower23may, in some implementations, have the capacity to produce pressures of up to 4 PSI. At 4 PSI of air pressure, especially when no load is present in dump system9, inflate membrane17could cause damage to U-frame15, base frame10, dump frame11and/or to itself. With inflate membrane17having a surface area of approximately 185 square feet and at 4 PSI (576 lbs./sq. ft.×185 square feet) could build an outward force of approximately 106,560 pounds. To prevent an over-pressurized condition of inflate membrane17, blower23and inflate membrane17are governed by safety provisions utilizing high pressure switch54, pressure relief valve61, and blower shut off switch56. In various implementations, any one or more (or all) of these safety provisions may be incorporated into the dump system.

Referring again to the illustrated implementation, a max dump cable59is connected between a cable anchor63bon a bottom surface of dump frame11and the blower shut off switch56. The blower shut off switch56is configured to shut off the blower23when the max dump cable59pulls on the blower shut off switch56. When dump frame11reaches a maximum dump angle, the max dump cable59becomes taut and pulls on the blower shut off switch56, which causes the blower23to shut off. Max dump cable59is located inside of inflate membrane and runs through rear wall of inflate membrane (e.g., via an airtight opening in a rear surface of the inflate membrane17) to blower shut off switch56. In a typical implementation, the length of the max dump cable59, along with the position of the cable anchor63band the position of the cable's connection point to blower shut off switch56determine the maximum dump angle in a particular implementation.

In some implementations, safety provisions involving the pressure relief valve61provide a backup to the safety provisions related to the blower shut off switch56just discussed. In the illustrated implementation, the safety provisions involving the relief valve61include the relief valve61itself, a pressure relief cable60that extends from the pressure relief valve61to a cable anchor63aon a bottom surface of the dump frame11. The pressure relief valve61is a valve mounted to an opening in a rear surface of the inflate membrane17. The pressure relief valve61is configured to be normally closed, but to open in response to being pulled by pressure relief cable60. Thus, in such an implementation, if the max dump cable59and/or blower shut off switch56were to fail, dump frame11would continue to move upward at a steeper angle pulling pressure relief cable60taut causing pressure relief valve61to open eventually allowing the air to exhaust from the inflate membrane17. In a typical implementation, the length of the pressure relief cable60, along with the position of the cable anchor63aand the position of the cable's connection point to pressure relief valve61determine the dump angle, at which the pressure relief valve61opens, in a particular implementation.

Safety provisions involving high pressure switch54provide another safety measure against the inflate membrane17becoming over-pressurized. In the illustrated implementation, the safety provisions involving the high pressure switch54include the high pressure switch54itself, and a high pressure tube55that extends between the high pressure switch54and an opening in a surface of the inflate membrane17. The high pressure tube55serves as a fluid communication path that conveys pressure from the inside of the inflate membrane17to a pressure sensing element of the high pressure switch55, which is configured to shut down the blower23in response to a sensed pressure reaching a predetermined pressure shut down value. Thus, in a typical implementation, to prevent over pressurization of inflate membrane17, pressurized air from inflate membrane17runs through high pressure tube55to high pressure switch54. High pressure switch54may be adjusted according to the type of load and weight capacity of a vehicle to prevent operation of dump system9from being overloaded. For example, if a certain truck has the capacity to haul a maximum payload of 2,000 pounds, then pressure switch can be set to 20·WC (2,000/1·WC/100 lbs.) so if pressure exceeds that, blower shuts off and most importantly dump system9will not dump adding another level of safety. In this case, the operator would have to remove part of the load until it was under 2,000 pounds and less than 20·WC of air pressure. This added safety feature also allows the operator to weigh his/her payload before leaving a job site with a heavy and unsafe load. While dump system9is being loaded, the operator can turn the blower23to see if high pressure switch54is activated and shuts down blower23or by monitoring a pressure gauge (not shown) on dump system9. The pressure gauge could be attached, for example, to the high pressure tube55or to the inside of the inflate membrane17via some other tube. In some implementations, the safety provisions involving high pressure switch54provide a backup in case the safety provisions related to the blower shut off switch56and/or pressure relief valve61fail.

The illustrated implementation includes a zipper opening62in the inflate membrane17. The zipper opening62is an opening in a wall of the inflate membrane17with a zipper configured to effectively close or open the opening. Opening the zipper enables a user to access an interior of the inflate membrane17, the space therein, and any components of the dump system9that are inside the inflate membrane17. Closing the zipper closes off such access. In an exemplary implementation, the zipper opening62provides access to adjust and/or to perform repairs to inflate membrane17, max dump cable59, pressure relief cable60, pressure relief valve61, and/or exhaust valve57. In some implementations, a swab of removable caulk is applied over zipper opening62to prevent air from leaking out of the inflate membrane17through the zipper opening62. In an exemplary implementation, blower23is a 115V fractional horsepower vacuum cleaner type motor requiring about 12 amps which can create a flow of pressurized air at about 100 CFM at 20 degrees C. Blower23is equipped with power cord65. Experience has shown that at 100 CFM, blower23is capable of performing the dumping of dump system9even if small leaks are present in inflate membrane17.

The illustrated implementation also has a hand-operated exhaust valve57configured to control flow through an exhaust opening in inflate membrane17. The hand-operated exhaust valve57has an exhaust valve handle58that is movable between a closed position, in which the exhaust valve57prevents air flow through the exhaust opening in the inflate membrane17, and an open position, in which the exhaust valve57permits air flow through the exhaust opening in the inflate membrane17(and through the exhaust valve itself). Operation of the hand-operated exhaust valve57gives the user the opportunity, for example, to manually relieve pressure from the inflate membrane17.

In some implementations, including those in which an exhaust valve57is present, inflation hose24is equipped with a one-way check valve (not shown inFIG.8) to prevent the back flow of air out of inflate membrane17via inflation hose24and blower23to atmosphere. The use of one-way check valve in this regard will help hold the dump angle of dump frame11fixed in place. In this configuration, dump frame11and container28can be lowered by opening exhaust valve57to allow air inside of inflate membrane17to vent to atmosphere. To speed up the deflation process, exhaust valve57may be equipped with (or connected to) an auxiliary blower (not shown) operating in a vacuum mode (e.g., to suck air out of the inflate membrane17more quickly than air would passively flow out of inflate membrane17through the exhaust valve57alone. In some implementations, the inflation hose24does not have a check valve. In those implementations, the inflate membrane17can be deflated by simply shutting off the blower23and allowing air to exit the inflate membrane17through the inflation hose24and blower23to atmosphere.

FIG.9is a partial, schematic, end view of a dump system9in a cargo bed71of a vehicle.

According to the illustrated implementation, base frame10of dump system9, which may be against the cab of the vehicle, is installed between wheel wells70aand70bon the cargo bed71(e.g., between cargo bed walls72aand72b). Wing frames20aand20bin the illustrated implementation are fixed to base frame10at about a 68° angle so that they clear wheel wells70aand70bbut stick out enough from base frame10to catch and store inflate membrane folds31Sd to31Sh (not shown inFIG.9but see, e.g.,FIG.1andFIG.3) of inflate membrane17(not shown inFIG.9) when deflated. In some implementations, dump system9can be powered by the vehicles' 12V battery and separate power inverter system (preferably located on the back window of the vehicles' cab either inside or outside) via the use of a rigid or flexible enclosure with suction cups, in some implementations such as the illustrated implementation, base frame10of dump system9can be equipped with battery bracket69to hold battery66, power inverter67. and battery charger68for operation independent of the vehicle. Also shown is blower bracket64fixed to base fame10which holds blower23and high pressure switch54. Notice that the center area above base frame10is open for inflate membrane folds31Ra,31Rb,31Rc and31Rd (not shown inFIG.9but see, e.g.,FIG.1).

FIG.10is a top view of base frame10with inflate membrane bottom panel attached around its perimeter via rod anchors5ato5xwelded to base frame10with rods4ato4dextending through rod loops38(not shown inFIG.10but see, e.g.,FIG.11andFIG.12) on the edge of inflate membrane bottom panel18as well as rod anchors5ato5x(e.g., in a similar manner as to hanging a curtain on a curtain rod), resulting in relatively equal tension with no significant concentrated loads which could rip and/or damage inflate membrane bottom panel18. Also shown are base frame cross supports33a,33b,33c, and33dwhich are added to base frame10and/or dump frame11in some implementations. For some applications it may be desirable and/or required to use a rigid floor panel99between inflate membrane bottom panel18, inflate membrane top panel and/or between the bottom side of container28and frame cross supports33a,33b,33cand33d. Rigid floor panel99can be made of metal sheet, Fiberglass FRP panels or wood. Also, in some applications metal sheet, rubber sheet, conveyor belting, wood and FRP can be used on the floor and interior sidewalls of container28. Inflate membrane sidewall perimeter joint/seam35is where inflate membrane sidewall37(seeFIGS.11and12) is attached to inflate membrane bottom panel18(e.g., via gluing, heat sealing and/or sewing) is generally rectangular in shape, its corners are rounded to also help prevent concentrated loads in those areas when inflate membrane is pressurized. Notice hinges13aand13bon the right side of base frame10with wheel brackets26a,26b,26cand26don the opposite end. In addition to using the rod4, rod anchor5and rod loop flap38method around the perimeter of inflate membrane17to prevent concentrated loads is that inflate membrane17can also be easily and quickly removed simply removing rods4ato4dwith no tools required.

FIG.11is a close up end view showing an exemplary implementation of how the base frame10is coupled to the inflate membrane17.

Base frame10tubing, according to the illustrated implementation, is shown with rod anchor5welded on with rod4extended through it as well as through rod loop38of inflate membrane bottom panel18. Rod loop38is secured via stitch39band adhesive40b. Also shown is inflate membrane sidewall37attached to inflate membrane bottom panel18via stitch39awith adhesive40aunder inflate sidewall flap43. To prevent air from leaking through stitch39a, a sealant (e.g.,41) such as foam butyl tape is secured over it (e.g., at the interface of inflate membrane sidewall37and inflate membrane bottom panel18). Normally, inflate devices need to be glued or heat sealed to prevent air leakage through seams, however, because inflate membrane17is designed to operate at such low air pressures (0 to 1 PSI) there is very little stress on stitched seam39aanother advantage in using extremely low air pressure for operation.

FIG.12is a close up end view showing an alternative exemplary implementation of how the base frame10is coupled to the inflate membrane17. The arrangement represented inFIG.12is similar in several respects to the arrangement represented inFIG.11. However, theFIG.12implementation includes a spring49connected at one end between rod4and rod loop38and connected at the opposite end to rod anchor5. This arrangement may help provide added tension to inflate membrane bottom panel18if desired.

While inflate membrane sidewall37can be made from a 22 oz. PVC coated fabric, for example, because it tends to fold easier and is less bulky than certain other fabrics, inflate membrane bottom panel18may, in some implementations, be made of a much heavier 40 oz. Polyester woven fabric having a tensile strength almost twice that of the 22 oz. Fabric. Unlike PVC coated Nylon woven fabric that can stretch up to 4%, PVC coated polyester woven fabric tends to be more stable (e.g., less stretchable).

FIGS.13,14, and15show an exemplary implementation of a storage rack77(e.g., for dump system9).

Some of the main components of the illustrated storage rack77include rack legs81a,81b, a rack frame (e.g.,80a,80b,78,90a,90b) atop and supported by the rack legs, a roller frame assembly100a,100batop and supported by the rack frame, rollers85a-85hsupported by the roller frame assembly100a,100b(a roller exterior frame83portion of the roller frame assembly100a,100bextends above and surrounds the rollers), and a stop89at a far end of the storage rack77.

The rack legs81a,81bare configured to contact a vertical surface (e.g., the ground) and to support the rest of the storage rack77and any dump system (e.g.,9) that may be placed stop the storage rack77. Each rack leg81a,81bin the illustrated implementation has a leg coupler79a,79bthat contacts the surface that the rack leg rests upon. Each rack leg has a locking pin (e.g.,86b) that helps secure the rack leg to the leg coupled79a,79b. Leg sleeves (e.g.,82a,82b) are provided at an upper end of each rack leg81a,81band contact a bottom side of rack frame elements80a,80b. Lock chains87a,87bare connected to the legs and to a lock flange88, as shown.

Rack frame includes rack frame elements80a,80bthat extend inwardly from opposite lateral edges of the storage rack77(above the rearmost leg sleeves82a,82b), a frame coupler78(with a locking pin86a) between and connecting the inner edges rack frame elements80a,80b, beams90a,90bthat extend from and connect the inner ends of the rack frame elements80a,80bto front portions of the roller frame assemblies100a,100b, respectively (e.g., near the frontmost leg sleeves82b,82d). More specifically, in the illustrated implementation, beam90ais fixed to rack frame80band roller frame assembly100a, and beam90bis fixed to rack frame80aand roller frame assembly100b.

The roller frame assemblies100a,100bextend lengthwise along the storage rack77parallel to one another and laterally separated from one another so that one of the roller frame assemblies is on a right side of the storage rack77while the other one of the roller frame assemblies is on a left side of the storage rack77. Each roller frame assembly100a,100bhas a roller interior frame (e.g.,84a,84b), a roller exterior frame (e.g.,83a,83b), and a roller (e.g.,85a-85b). In a typical roller frame assembly (e.g., as shown in the figures), the roller interior frame and the roller exterior frame cooperate (e.g., which each having a corresponding supporting/bearing surface) to support a shaft of the corresponding rollers. Each roller is supported on that shaft and able to rotate about an axis defined by its shaft. Moreover, each roller frame assembly100a,100bis configured so that an object, such as dump frame9(see, e.g.,FIGS.13and14) can be supported on and roll along the top of the storage rack77via the rollers, which rotate as the dump frame9moves along across the top of the storage rack77. More specifically, in the implementation represented inFIGS.13and14, it can be seen that the base frame10of the dump system9contacts the rollers and causes them to rotate (or roll) as the dump system9is moved onto or off of the storage rack77.

Each roller frame assembly100a,100btypically supports multiple rollers and each of those rollers is parallel to all the other rollers supported by the roller frame assembly. For example, in the illustrated implementation, roller frame assembly100asupports four longitudinally-displaced rollers85a-85dand roller frame assembly100bsupports four other longitudinally-displaced rollers85e-85h. Rollers85a-85dare parallel to one another and rollers85e-85hare parallel to one another. Each roller is located laterally across from and aligned with another roller. For example, roller85ais located laterally across from and aligned with roller85e, roller85bis located laterally across from and aligned with roller85f, roller85cis located laterally across from and aligned with roller85g, and roller85dis located laterally across from and aligned with roller85h.

The stop89is a rigid panel at a front end of the storage rack77that extends upwardly to provide a barrier for any object (e.g., dump system9) being rolled onto the storage rack77.

FIGS.13,14, and15are various views of how an implementation of storage rack77(e.g., for dump system9) interfaces with truck6to accommodate the loading and unloading of dump system9.FIG.13shows storage rack77placed so that its upper support surface is slightly above and so that the storage rack77is against tailgate51of truck6with the right end of dump system9resting on roller85aof storage rack77while wheel25on dump system rests on cargo bed71. Because roller85ais higher than truck bed71, dump system9is elevated above truck bed71so it can roll easily and supported via by wheels (25) and rollers (85). Once dump system9is moved past wheel85a(moving onto truck6), it will slide down slide bracket91for placement on truck bed71. Also, because dump system9is light (e.g., weighing in some implementations only 200 pounds) and has wheels (e.g., 25), it is easy to reposition, if necessary, on truck bed71by the user. Even when loaded with up to 1,000 pounds of cargo, for example, dump system9is very easy and safe to move between rack77and cargo bed71. Storage rack77is supported via adjustable rack legs81aand81bwith adjustable lock chains87aand87bconnecting to lock flange88.

In view of the foregoing, it can be seen that a user who has the storage rack77, a vehicle6with a flatbed or a trailer, and the dump system9may position the dump system9on the vehicle's6flatbed or trailer or onto the storage rack77, positioning a rear end of the vehicle's6flatbed or trailer adjacent to a loading end of the storage rack77, and transfer the dump system9back and forth between the vehicle's6flat bed or trailer with ease (e.g., without having to lift the entire dump system9in the air). As is apparent from the exemplary implementation represented inFIG.13, no matter where in the transfer the dump system9is, the dump system9is in direct physical contact with either a surface of the vehicle's6flatbed or trailer, the storage rack77, or both. More specifically, at every point of time during such a transfer (between the vehicle's6flatbed or trailer and the storage rack77), some portion of the dump system9is in contact with an upper surface of the vehicle's6flatbed or trailer or some portion of the rollers85a-85hon the storage rack77. Moreover, although the illustrated implementation shows an implementation of dump system9disclosed herein being moved between the vehicle's6flatbed or trailer and the storage rack77, it should be understood that the storage rack77could be utilized in this manner with any one of a variety of other types of dump systems9including, for example, those that utilize a hydraulic system, rather than an air pressure system, to move the container (e.g., up and down). The power inverter67is shown inFIG.13located near rear window98of truck6.

FIG.14is a front view of an implementation of dump system9(having container28made of metal sheet fixed to dump frame11with wheels25aand25bshown along with hinges13aand13b) resting rack frame80on rack frame sections80aand80bheld together via frame coupler78and locking pin86a. Also shown is leg coupler79and locking pin86bthat holds rack legs81aand81b. For disassembling, locking pins86aand86bcan be removed from frame coupler78and leg coupler79. Once couplers78and79are unfastened, rack leg81aand rack leg81bcan be removed from leg sleeves82aand82b.

As a safety feature so that dump system9does not slide off storage rack77, roller exterior frames83aand83bin the illustrated implementation are higher than rollers85aand85band extend above base frame10while roller interior frames84aand84bare lower than rollers85aand85bso as not to impede or block dump system9from being moved on or off storage rack77.

Also shown are tie downs straps29aand29bsecured to wing frame20aand20bfor securing dump frame9to storage rack77(or elsewhere). Ratchet adjusters74aand74bare shown secured to the tie down straps29aand29bfor tightening and loosening purposes.

FIG.15is a top view of storage rack77showing leg sleeves82aand82bfixed to roller exterior frame83aand roller interior frame84awith rollers85a,85b,85cand85dinstalled. Leg sleeves82cand82dare fixed to exterior roller frame83band interior roller frame84bwith rollers85e,85f,85gand85hinstalled. To provide further support to rack frame77, beam90ais fixed to rack frame80band roller frame assembly100aand beam90bis fixed to rack frame80aand roller frame assembly100b. Notice that center area of rack frame77is open for the user to pull and push dump system9on and off storage rack77.

FIGS.16,17and18are side views of different models of pick-up trucks6with dump system9installed in each one.

InFIG.16, dump system9is installed in pick-up truck6having a driver and passenger seat only with a long cargo bed. This truck6, which is generally a one-ton, super duty model (generally used for a hydraulic, 900 pound dump insert) has dump system9installed. In this configuration, the tailgate is removed. Adjustable dump gate97is placed in a vertical position before tailgate.

InFIG.17, truck6is a ½ ton model with a small bench seat behind the driver's seat with dump system9installed and extending onto tailgate51. In this configuration, adjustable dump gate97is also secured in front of tailgate51.

FIG.18is truck6which is a model with a quad cab design also with adjustable dump gate97position and secured in front of tailgate51to also keep the payload over the cargo bed and not on the tailgate for safe driving.

FIG.19is a side view of truck6and low boy, flatbed trailer94with dump system containers28a,28band28csecured to trailer via tie down straps29a,29b,29c,29d,29eand29f. In this configuration, dump systems9a,9band9care equipped with container top enclosures96a,96band96cwith fill hatch openings93a,93band93cinstalled, respectively. For hauling materials like dirt that can be dumped directly on the ground rather than into specialized conveying system, containers28a,28band28ccan be combined as a single container28, measuring approximately 8′ wide×40′ long, for example. For materials that require a contamination-free environment, a poly liner (not shown) may be used inside containers28a,28band28c.

FIG.20is and end view of dump system9installed on cargo bed71of trailer94. As shown, in this configuration, container28is an enclosed metal structure with dump gate92that is configured to open (e.g., by swinging about a hinge) as inflate membrane17is inflated during the dumping/emptying process. In some implementation, the illustrated dump system9may include a latch or the like to keep the dump gate92in a closed position until dumping is desired and intended. U-frame bracket15and wing frame20, for example, help allow inflate membrane17to be large and operate under very low pressure. Base frame10is secured to cargo bed for safe and secure transport as well allowing dump frame11to incline safely. The dumping direction in the illustrated figure is to the side (not the back) of the illustrated vehicle. In some implementation, a dump system may be configured to include a container with a rear discharge (as shown and described in connection with some other drawings) as well as one or more side discharges (right side and/or left side) as shown and described in connection withFIG.20.

FIG.21is a side view of dump system9with inflate membrane17partially inflated with U-frame15and wing frame20aworking together to facilitate operation of large inflate membrane17. For many applications, a rigid and solid floor of dump frame10and/or dump frame11is not required because the inflate membrane bottom panel18, inflate membrane top panel19and container floor28X are fitted tightly to base frame10and dump frame11in a taut manner using a very heavy duty (e.g., 40 oz.) PVC coated polyester woven fabric having high tensile strength (e.g., about 725 pounds per inch). The actual container floor28X can easily accommodate a payload of several hundred pounds/sq. ft. of bulk materials because the three layers of heavy-duty fabric have a combined tensile strength of approximately 2,175 pounds per square inch. As shown, all fabric components including inflate membrane bottom panel18, inflate membrane top panel19, and container28of dump system9are attached to base frame10, dump frame11and top rail14of dump frame11via a system made up of rod(s)4, rod anchor(s)5and rod loop(s)38. The container in the illustrated implementation has a container top96and a fill hatch opening93.

FIG.22is a top view of a cargo bed71of a truck6with base frame10of dump system9shown installed. Note that base frame10, which is about 47 inches wide in the illustrated implementation, fits between wheel wells70aand70bwhile also allowing the top sections of wing frames20aand20bto extend above wheel wells70aand70b. As shown, wheels25aand25bare located next to cab75end of cargo bed wall72b. Note that hinges13aand13bare located close the right edge of tailgate51. To hold base frame of dump system9secure on cargo bed71of truck9, one end of tie down straps29aand29bare secured to ends of wing frames20awhile the opposite end of cargo straps are secured to cargo bed anchors73aand73brespectively. Also shown are ends of tie down straps29cand29dsecured to wing frame20band the other ends secured to cargo bed anchors73cand73drespectively. To anchor base frame10securely on cargo bed71, tie down straps29a,29b,29cand29dare equipped with ratchet adjusters74a,74b,74cand74d.

FIG.23is a side view of a truck6having a large cargo bed71designed for handling piece goods such as bagged material (on or off pallets), lumber, pipe, steel, cars, machinery, and the like. By placing dump system9on cargo bed71, truck6can now haul bulk materials such as dirt, mulch, stone, grass clippings. etc. Base frame10of dump system9is secured to cargo bed71via tie downs29a,29b,29cas well as others on the opposite side of the dump system (not shown). For this application, because base frame10, dump frame11and container28are relatively long (e.g., 20′ vs.8′), inflate membrane17ais equipped with multiple U-frames15a,15b, and15cto prevent inflate membrane37from becoming oval and round in shape thereby reducing the height of inflate membrane17a. Each U-frame15a,15b,15cis configured and connected to the inflate membrane in a manner similar to the U-frames otherwise disclosed herein. Moreover, each U-frame15a,15b,15cin the illustrated implementation is configured so that when the inflate membrane is fully inflated, for example, the angular distance between the rear ends (e.g., opposite the hinges) are equal between adjacent U-frames, between the uppermost U-frame15aand the bottom portion of dump frame11, and between the lowermost U-frame15and the base frame10. Also, because of the long base frame10, dump frame11and container28, dump system9may require air pressures of several PSI (e.g., 2 or more) to dump heavy loads, inflate membrane17amay be equipped with additional (e.g., two or more) plies of PVC coated fabric such as used in inflate membrane17b. Notice wing frame20a(another is on the opposite side, not shown) are used in conjunction with U-frames15a,15band15cto manage collection and storage of side wall folds (not shown) that form in the side walls of inflate membrane17aand17b.

FIG.24is an end view of a dump system9equipped with a multiple-wall inflate membrane that includes inflate membrane17bstowed inside partially inflated membrane17a. In this configuration, inflate membrane17bcan be used if, for example, inflate membrane17ahas suffered damage and substantial leaks. Notice inflate membrane is inflated/deflated via inflation hose24awhile inflate membrane17bis inflated/deflated via inflation hose24b. One would switch between these inflation hoses—by connecting one or the other to the blower. Both typically include a built in check valve that prevents air flow out through the hose. Inflate membrane17bcan be a separate component entirely from inflate membrane17a. Alternatively, inflate membrane17bmay be formed by securing walls of inflate membrane17bto the upper and lower surfaces of inflate membrane17a.

FIG.25is an end view of dump system9equipped with inflate membrane17and U-frames15aand15b. In this configuration, U-frames15aand15bare equipped with U-frame restraint cables30Za,30Zb,30Zc and30Zd respectively which are connected to base frame10inside inflate membrane17. As shown, as inflate membrane17is inflated and as it expands upward, the upward movement of U-frames15aand15bare limited in their upward movement, as well as being used for lateral support to keep U-frames15aand15bcentered, via U-frame restraint cables30Za,30Zb,30Zc and30Zd in an effort to further stabilize the dump process of dump frame11and container28. In a typical implementation, the U-frame restraint cables may be attached to the U-frames and/or to the base frame10with cable anchors at either end thereof. The cables or anchors extend through small openings in the inflate membrane17to reach the U-frames and extend through small openings at the opposite ends to reach the base frame.

FIGS.26,27and28are various views of an implementation of inflate membrane components including inflate membrane sidewall panels37aand37b, inflate membrane rear sidewall37x, as well as inflate membrane bottom panel18and inflate membrane top panel19. The inflate membrane sidewall panels37aand37bin the illustrated implementation are integrally formed with the rear sidewall37so that one single piece of material37will form the entire sidewall of the inflate membrane. Each of the bottom panel18and top panel19in the illustrated implementation is a single piece of material too, separate from the sidewall piece of material37.

In the illustrated implementation, the sidewall piece of material has a section37X that corresponds to the rear sidewall of the inflate membrane. The sidewall piece of material has other sections37a,37bthat correspond to the side surfaces of the inflate membrane. The rear sidewall section37X is trapezoidal, with edges that define a top and a bottom that are parallel to one another and oppositely sides that are angled as shown. Sidewall panel37ais attached to one of the angled sides of the rear sidewall panel37X and sidewall panel37bis attached to the other one of the angled sides of the rear sidewall panel37X. In some implementations, the sidewall panels37a,37bare integrally formed with the rear sidewall panel37X. In some implementations, the sidewall panels37a,37bare separately formed from, and later attached to, the rear sidewall panel37X.

Sidewall panel37a, for example, has an edge that defines a flat bottom that aligns with and extends outward from the flat bottom of rear sidewall panel37X, a 90 degree upward bend at the end of the flat bottom to define an outer edge, a 90 degree bend back toward the trapezoidal rear sidewall section37X to define a top edge of inflate membrane front wall seam100a, and an upwardly angled bend at the inner end of the top edge of the inflate membrane front wall seam100ainto an upwardly angled section that extends between the inner end of the top edge of the inflate membrane front wall seam100aand the top end of the angled sidewall of the trapezoidal rear sidewall section37X. Sidewall panel37bis a mirror image of sidewall panel37a.

In side panel37a, for example, U-frame restraint cable opening30Ya is the closest of all the U-frame restraint cable openings to the rear sidewall section37X. Moreover, the U-frame restraint cable opening30Ya is at a height above the bottom edge of the sidewall panel37athat is between about 35% and 65% (or 40% to 60%) of the distance of the angled side edge of the rear sidewall section37X. The other U-frame restraint cable openings30Yb,30Yc, and30Yd are aligned with U-frame restraint cable opening37Ya and with one another along an imaginary line that extends downward and outward from the position of U-frame restraint cable opening37a. In side panel37b, U-frame restraint cable openings30Ye,30Yf,30Yg, and30Yh are arranged as a mirror image of the U-frame restraint cable openings30Ya,30Yb,30Yc, and30Yd on inflate membrane sidewall37b.

Also shown are zipper62, max dump cable opening59Z, pressure relief cable opening60Z and inflation hose coupling hole24Z on inflate membrane rear sidewall37X. Pressure relief cable opening60A and inflation hose coupling hole24Z are side-by-side (and at the same height above the bottom edge of the rear sidewall panel37as one another). The inflation hose coupling hole24Z is at a lower position than pressure relief cable opening60Z and inflation hose coupling hole24Z. In a typical implementation, during assembly of an inflate membrane, prior to attaching inflate membrane sidewall37to inflate membrane bottom panel18and inflate membrane top panel19, inflate membrane front wall seams100aand100bmay be joined together.

The bottom panel18of the inflate membrane inFIG.27has an outer edge that defines a flat rear portion, two flat side portions that are parallel to each other and perpendicular to the flat rear portion, and a front portion that is flat except for two notches (for accommodating hinges13a,13b). The top panel19of the inflate membrane inFIG.28has the same basic shape as the bottom panel18inFIG.27.FIG.27identifies, according to one implementation, where on the bottom panel18the sidewall perimeter joint35c(i.e., the joint between the bottom panel18and the sidewall panel37) will be located when the inflate membrane is assembled. Likewise,FIG.28identifies, according to one implementation, where on the top panel19the sidewall perimeter joint35d(i.e., the joint between the top panel19and the sidewall panel37) will be located when the inflate membrane is assembled. The surfaces of the bottom panel18and top panel19within the sidewall perimeter joints35cand35dinFIGS.27and28are the surfaces that will be exposed to air pressure within the inflate membrane, after the inflate membrane has been assembled and when a dump system (e.g., 9) is operating using the assembled inflate membrane. Thus, it can be seen that, during operation, air pressure from within the inflate membrane will be applied across a large percentage of the bottom panel18and the top panel19(as determined by the percentage of surface area of bottom panel18and top panel19encompassed within the sidewall perimeter joint lines inFIGS.27and28. For example, in various implementations, the percentage of the upper surface area of the top panel18, for example, that falls within the line35cthat defines the sidewall perimeter joint is more than 60%, more than 70%, more than 80% or more than 90% or more than 95%. In a typical implementation, the same thing can be said of the top panel19. This sort of arrangement contributes greatly to the amount of lifting force available in the dump system9, even with very low air pressure in the inflate membrane. Moreover, it can be seen fromFIGS.27and28that the top and bottom of the interior space of the inflate membrane, when assembled, is at least substantially rectangular (e.g., the outline35cand the outline35dfollow a path that is rectangular with rounded corners and a slightly smaller width at a front end thereof than the back end thereof). In some implementations, the top and/or bottom of the interior space of the inflate membrane, when assembled, will be completely rectangular.

InFIG.27, inflate membrane sidewall perimeter joint35cof inflate membrane bottom panel is matched and secured with inflate membrane sidewall perimeter joint35a. InFIG.28, inflate membrane sidewall perimeter joint35bof inflate membrane sidewall37is matched and secured to inflate membrane sidewall perimeter joint37dof inflate membrane top panel19. Also shown are cable anchors63aand63bfor securing ends of pressure relief cable60and max dump cable59. Also shown are seams100aand100bof inflate membrane sidewall37matching location of seams100aand100bon inflate membrane bottom panel18inFIG.27as well as inflate membrane front wall seams100aand100bmatching location of seams100aand100bon inflate membrane top panel19inFIG.28.

FIG.29is a top view of alternative implementation of a bottom portion of dump frame11equipped with frame springs101aand101bnear end of frame11where hinges13aand13bare located. In a typical implementation, springs101aand101ballow dump frame11to flex and twist if necessary or desired.

FIG.30is a partial side view of dump system9showing dump gate rail21equipped with dump gate attachment holes92Xa,92Xb,92Xc,92Xd and92Xe for providing attachment of dump gate92, which may be made of rigid material such as metal or flexible material such as 40 oz. PVC coated woven polyester fabric. Locking pins86band86c(not shown) can be used to secure dump gate flanges92Z and92Zb (not shown) to dump gate attachment holes92Xa,92Xb,92Xc,92Xd and/or92Xe for closure of dump gate92to dump system9.

The wing frame20(and other components of the dump frame9) can vary in configuration.FIG.31, for example, shows a view of an exemplary dump system9with an alternative wing frame20configuration. In the illustrated implementation, the wing frame9forms a symmetrical (e.g., with a constant radius) from its forwardmost point to its rearmost point (e.g., where it connects to the base frame). In the illustrated implementation, the wing frame has a width of 62 inches (which can vary, e.g., +/−20% or more) and a height of 12 inches at its midpoint or high point (which can vary, too, e.g., +/−20% or more). The alternative wing frame configuration is shown (and labeled) inFIG.31superimposed on the wing frame configuration previously described. In reality, only one or the other of the wing frame configurations shown inFIG.31would be present (not both).

For example, the dump system can be utilized to store, transport (in the back of a vehicle, for example), and dump at a destination virtually any kind of material including, for example, landscaping materials such as grass clippings, mulch, dirt, gravel, leaves, tree branches, dry granulated materials and powders, and other debris. The dump system and any one or more of its various components can vary in size, shape, and configuration. Moreover, a variety of different types of materials may be used to manufacture the dump system and its various components.

The storage rack may be used with implementations of the dump system disclosed herein or with virtually any other dump systems including those that utilize hydraulic pressure, instead of air pressure, to raise and lower their material storage containers. The storage rack and any one or more of its various components can vary in size, shape, and configuration.

Unless otherwise indicated, relative terminology used herein (e.g., “upper”, “lower”, “above”, “below”, “front”, “rear”, etc.) is solely intended to describe particular implementations shown in the drawings or otherwise disclosed herein and is not intended to limit the scope of the disclosure to require particular positions and/or orientations. Moreover, certain relative terminology (e.g., “horizontal,” “vertical,” and the like) assume a normal upright orientation. If a normal upright orientation is not applicable, then the surfaces, components, subcomponents, etc. described as being “horizontal,” “vertical,” or the like, may not be. These terms, therefore, should be considered as merely describing particular illustrated implementations and, unless otherwise indicated or claims, not otherwise limiting to the scope of the present application. Unless otherwise indicated, none of the relative terminology used herein should be construed to limit the scope of the present application. Additionally, terms such as substantially, and similar words, may be used herein.

Similarly, while operations and/or processes are disclosed herein as occurring in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all indicated operations be performed in order to achieve desirable results. In certain circumstances, multitasking or parallel processing may be advantageous.

Other implementations are within the scope of the claims.