Side underride guard

A side underride system configured to be coupled to a trailer is disclosed. The side underride system comprises a support system configured to be positioned below the trailer to provide side underride protection. The support system includes a cable system and a brace system. The cable system is configured to couple to the trailer. The brace system includes a plurality of cross-braces that each extend at least partially across a width of the trailer, are spaced apart at intervals along a length of the trailer, and are configured to capture the cable system.

FIELD OF THE INVENTION

The present invention relates generally to semi-trailers, such as van-type trailers, for example. In particular, the present invention relates to both an aerodynamic side skirt system for reducing drag on such a trailer as well as a side underride system for preventing or reducing the extent to which an automobile may ride under the trailer in the event of a side impact collision, for example.

BACKGROUND

To reduce wind flow resistance and drag on a trailer, truck, semi-trailer, or other vehicle, side skirts that extend downwardly from a bottom of the trailer and/or chassis toward the roadway to partially enclose the floor assembly and undercarriage have been utilized.

Air flow passing under a ground vehicle imparts a drag force to the vehicle when it impinges on and flows around the vehicle undercarriage components attached to or a part of the underside of a vehicle. Side skirt systems are designed to prevent or control the flow of air from entering the undercarriage region from a side of the ground vehicle, such as a trailer of a tractor-trailer truck system, for example. Such reduction on the drag of the ground vehicle may operate to conserve fossil fuels as well as other sources of vehicle drive power for hybrid vehicles, battery-operated vehicles, and/or alternative fuel-based vehicles, for example.

Trailers typically have a higher elevation than passenger vehicles. The higher elevation presents a risk that a passenger vehicle may underride the trailer in an accident, potentially resulting in damage to the underriding vehicle and injury to occupants therein. Accordingly, a side protection device, or underride guard, may be provided for use with a trailer in order to reduce the risk of such passenger vehicles underriding the trailer. Side protection devices are intended to reduce the extent to which a “passenger vehicle” (as defined in 49 C.F.R. Part 571) can intrude under the side of a trailer, diminishing passenger compartment intrusion.

SUMMARY

According to one embodiment of the present disclosure, a side underride system configured to be coupled to a trailer is provided. The side underride system comprises a first skirt wall, a second skirt wall, and a support system. The first skirt wall is configured to be positioned below the trailer near a first side wall of the trailer to reduce airflow under the trailer. The second skirt wall is configured to be positioned below the trailer near a second side wall of the trailer to reduce airflow under the trailer. The support system is configured to be positioned below the trailer and between the first skirt wall and the second skirt wall to provide side underride protection. The support system includes a plurality of cross-braces and a cable system. The plurality of cross braces extend at least partially across a width of the trailer and include a front cross-brace, a middle cross-brace, and a rear cross brace. The cable system includes a cable engaged with the plurality of cross-braces.

In some embodiments, the cable is routed through the plurality of cross-braces.

In some embodiments, the cable is coupled to the plurality of cross-braces.

In some embodiments, the support system includes a cable clamp configured to couple the cable to one of the plurality of cross-braces.

In some embodiments, each of the plurality of cross-braces includes a vertical post and a truss beam, and the cable clamp is configured to be coupled to one of the vertical post and the truss beam.

In some embodiments, the cable clamp is configured to be coupled to the plurality of cross-braces to route the cable one of beside and below the vertical post.

In some embodiments, the side underride system further includes a plurality of brackets configured to couple each of the plurality of cross-braces to a floor assembly of the trailer.

In some embodiments, each of the plurality of brackets are coupled to a bottom surface of a cross member of the floor assembly.

In some embodiments, each of the plurality of cross-braces includes a vertical post, and each vertical post is configured to be coupled to one of the plurality of brackets.

According to another embodiment, a side underride system configured to be coupled to a trailer is disclosed. The side underride system comprises a support system configured to be positioned below the trailer to provide side underride protection. The support system includes a cable system and a brace system. The cable system is configured to couple to the trailer. The brace system includes a plurality of cross-braces that each extend at least partially across a width of the trailer, are spaced apart at intervals along a length of the trailer, and are configured to capture the cable system.

In some embodiments, the cable system includes a cable, the plurality of cross-braces each include a cable clamp configured to engage with the cable, and each cable clamp includes a bracket coupled to a truss beam of the cross brace and a rope clip engaged with the bracket and configured to capture the cable.

In some embodiments, the side underride system also includes a skirt system configured to be positioned below the trailer to reduce airflow under the trailer and the support system is positioned between the skirt system.

According to a further embodiment, a side underride support subassembly is disclosed. The side underride support subassembly includes a cross brace and a first and second cable clamps. The cross-brace includes first and second vertical posts and first and second truss beams. The first and second vertical posts are opposite one another. The first and second truss beams are connected to the first and second vertical posts. The first and second truss beams diagonally cross one another. The first and second cable clamps are connected to the cross-brace.

In some embodiments, the first cable clamp is connected to the first vertical post and the second cable clamp is connected to the second vertical post.

In some embodiments, one or more of the first and second cable clamps extend outwardly from the cross-brace.

In some embodiments, one or more of the first and second cable clamps extend downwardly from the cross-brace.

In some embodiments, one or more of the first and second vertical posts defines a recess and one or more of the cable clamps is connected to the cross brace inboard of the recess.

In some embodiments, one or more of the first and second vertical posts has a closed face and an outwardly-facing side and the recess is defined in a lower portion of the closed face inboard of the outwardly-facing side.

In some embodiments, the first cable clamp is connected to the first truss beam; and the second cable clamp is connected to the second truss beam.

In some embodiments, each of the first and second cable clamps includes a bracket connected to the cross brace, and a rope clip connected to the first bracket and configured to compress a cable toward the bracket.

In some embodiments, the cable clamp is below the vertical support.

In some embodiments, one or more of the first and second vertical posts has an outwardly-facing side, and the cable clamp is inboard of the outwardly-facing side.

DETAILED DESCRIPTION

As used herein, unless otherwise specified or limited, “at least one of A, B, and C,” and similar other phrases, are meant to indicate A, or B, or C, or any combination of A, B, and/or C. As such, this phrase, and similar other phrases can include single or multiple instances of A, B, and/or C, and, in the case that any of A, B, and/or C indicates a category of elements, single or multiple instances of any of the elements of the categories A, B, and/or C.

For the purposes of promoting an understanding of the principles of the invention, reference will now be made to a number of illustrative embodiments shown in the attached drawings and specific language will be used to describe the same. While the concepts of this disclosure are described in relation to a box-type trailer, it will be understood that they are equally applicable to many types of trailers, semi-trailers, and tanks generally, and more specifically to conventional flat-bed trailers, box or van type trailers, and/or pup trailers, as well as straight truck bodies, small personal and/or commercial trailers and the like. Furthermore, while the concepts of this disclosure may be described in relation to a box-type trailers, it will be understood that that they are equally applicable to other trailers generally and any type of over-the-road storage container. Accordingly, those skilled in the art will appreciate that the present invention may be implemented in a number of different applications and embodiments and is not specifically limited in its application to the particular embodiments depicted herein.

Generally, some embodiments of the disclosure provide an integrated system of an aerodynamic side skirt and side underride protection in one common system. The system incorporates both an aerodynamic side skirt for reducing air drag on a trailer and a side underride guard for preventing or reducing the extent to which a vehicle may ride under the trailer, as well as preventing or reducing the extent to which a trailer body may intrude into the passenger compartment of the vehicle. In some embodiments, there is no clear division between the skirt and the guard; in other embodiments, the side underride guard may be retrofit with existing skirt systems; in yet other embodiments, the side underride guard may be a standalone system without a skirt. Generally, the systems described herein can help generate a retardation or restriction force to decelerate an impacting vehicle and absorb the vehicle's kinetic energy to prevent or reduce passenger compartment intrusion (PCI).

FIG. 1depicts a trailer10including an aerodynamic skirt system or assembly12coupled to and extending downwardly from each side wall14of the trailer10. Illustratively, the skirt system12operates to improve the aerodynamic efficiency of the trailer10by reducing drag and wind flow under the trailer10. In particular, the skirt system12operates to reduce airflow under the trailer10while the trailer10is traveling down a road (e.g., being towed by a tractor, as a tractor/trailer combination). Reduction of airflow under the trailer10may increase the fuel efficiency, or the efficiency of any other such source of vehicle drive power, of the tractor/trailer combination. Illustratively, the skirt system12, as well as other skirt systems described herein, extends below a side wall14of the trailer10at least partially along a length of the trailer. In particular, in some embodiments, the skirt system12extends generally between a landing gear24and a rear wheel assembly22of the trailer10. However, the skirt systems described herein may be modified to extend along a greater or a lesser length of the trailer10than what is illustratively shown in the figures. In other words, the skirt systems disclosed herein may be modified to extend along the entire, or substantially the entire, length of the trailer10or may be modified to extend along only a small portion of the length of the trailer10. Further, any of the skirt systems disclosed herein may be for structural and/or aerodynamic purposes.

As shown inFIG. 1, the trailer10includes side walls14, a front end wall16, a rear end wall18, and a roof20defining an inside storage portion (not shown) able to store various articles or goods therein. The trailer10further includes the rear wheel assembly22and the front support or landing gear24each coupled to a bottom wall or floor assembly26of the trailer10. Illustratively, the floor assembly26of the trailer10includes various laterally-extending cross members40and right and left base rails28coupled to the cross members40and extending along a length of the trailer10. In some embodiments, the front end of the trailer10is configured to be coupled to a tractor (not shown) for towing the trailer10thereon, thus providing a tractor-trailer assembly. In other embodiments, a cab is integral with the storage compartment, for example, in refrigerated and dry truck bodies. Illustratively, while the specific trailer10is shown and described herein, other trailers including other components, such as composite floor assemblies, for example, which may or may not include any cross members40are contemplated as well.

As shown inFIG. 1, the skirt system12is coupled to the floor assembly26of the trailer10and extends downwardly from the base rail28of the trailer10. Illustratively, the side skirt system12is positioned between the rear wheel assembly22and the front support24in order to prevent air from flowing laterally under the floor assembly26of the trailer10as the trailer10is towed by a tractor. It should be understood that while the aerodynamic side skirt system12is shown for use with a trailer10, the side skirt system12and/or side underride guards disclosed herein may be coupled to any vehicle to reduce the drag thereon. Still further, while the embodiments disclosed herein are shown as being utilized with trailers, any of the embodiments disclosed herein may be coupled to any vehicle.

It should be noted that the trailer10ofFIG. 1includes two aerodynamic skirt systems12. In particular, one system12is coupled to one side of the floor assembly26of the trailer10to extend downwardly from the floor assembly26generally parallel to the corresponding side wall14of the trailer10, while the other system12is coupled to the other side of the floor assembly26to extend downwardly from the floor assembly26generally parallel to the corresponding side wall14of the trailer10. In other words, a first skirt system12is configured to be positioned below the trailer10near a first side wall14, and a second skirt system12is configured to be positioned below the trailer10near a second side wall14. For purposes of the description herein, only one skirt system12will be described. However, it should be understood that the two skirt systems12of the trailer10are substantially identical or identical in configuration and function. Also, while the skirt systems12are shown as being parallel to the corresponding side walls14, the skirt systems12may be angled or curved inwardly or outwardly relative to the side walls14at forward (toward the tractor) ends thereof, as further described below. In yet other embodiments, any suitable skirt system may be utilized.

Generally, the skirt system12may include a side skirt wall30provided in the form of one or more wall panels32. For example, as shown inFIG. 1, the side skirt wall30may include three wall panels32coupled to each other. The wall panels32may be secured to each other and/or to the trailer10by one or more mounting bracket assemblies and/or other coupling mechanisms. The mounting bracket assemblies and/or other coupling mechanisms may include, but are not limited to, those structures described in U.S. Pat. No. 8,162,384, the entire content of which is incorporated herein by reference. Additionally, while the illustrated skirt system12includes three wall panels32, it is within the scope of this disclosure to provide a skirt system12having any number of wall panels32, or a single, unitary wall panel32(e.g., as shown inFIG. 2).

In some embodiments, the mounting bracket assemblies or other coupling mechanisms may allow the skirt system12to tilt laterally both inwardly and outwardly relative to the floor assembly26of the trailer10, for example, for the skirt wall30to potentially avoid damage when the trailer10traverses into or over a fixed, immovable obstacle. In other embodiments, however, the skirt system12may be sufficiently rigidly mounted to the floor assembly26such that the skirt system12is generally prevented from tilting under normal wind and road air forces. Additionally, as shown inFIG. 1, the skirt system12may further include a flexible flap36(or multiple flexible flaps) coupled to the bottom edge of the wall panels32to provide additional airflow resistance. The flexible flap36may also prevent damage to the skirt wall30by being configured to bend or flex in response to forces applied vertically, such as in situations where the trailer10may traverse over a curb or railroad track where the road surface is not flat.

Illustratively, each wall panel32is made of a composite material. For example, the composite material may include a plastic core and metal outer skins coupled to the plastic core. Such a composite material provides a rigid, but lightweight and durable material. Illustratively, for example, each wall panel32may be made of a DURAPLATE® composite panel provided by Wabash National Corporation of Lafayette, Ind. DURAPLATE® composite panels are constructed of a high-density polyethylene plastic core bonded between two high-strength steel skins. It should be understood that other suitable composite materials may alternatively or additionally be used. For example, the wall panels32may be made of a sandwich composite including a honeycomb core and metal or plastic outer sheets, or the wall panels32may be made of a rigid or semi-rigid fiber-reinforced plastic composite. Further, the wall panels32may be of any number of suitable, non-composite materials such as metals, metal alloys, and/or plastics, for example.

In some embodiments, the above skirt system12may be structurally reinforced to provide additional side protection that may reduce the risk of an automobile underriding the trailer10. For example, the skirt system12may be combined with a rigid and/or compressible support system54positioned underneath the trailer10and between the side skirt walls30. As shown inFIGS. 2-7, a support system54is provided under the floor assembly26of the trailer10to form a side underride system50. This combination skirt system12and support system54can thus provide dual functions of potentially improving aerodynamic efficiency and providing side underride protection. Alternatively, some support systems described herein may form standalone side underride systems that operate to provide side underride protection without a skirt system.

In some instances, the support system54may be retrofit into existing skirt systems12or installed with new skirt systems12or additional aerodynamic systems other than what is herein described. Alternatively, the support system54alone (that is, without a skirt system) may form the side underride system50. In other words, the support system54may be an OEM side underride system design (that is, not for use as a retrofit with an existing skirt system) or, alternatively, may be used as a retrofit with existing skirt systems. For example, the support system54alone may potentially improve aerodynamic efficiency (i.e., by reducing air flow under the trailer10) and may provide side underride protection. In particular, side underride systems may be contemplated within the scope of this disclosure to include side skirts or any other structures of any configuration and shape to provide a first outer surface positioned below the trailer10near the first side wall14and a second outer surface positioned below the trailer10near the second side wall14to reduce airflow under the trailer, where the surfaces permit any of the structures described herein to be positioned therebetween to potentially provide side underride protection.

Referring now toFIGS. 2-5, according to one illustrative embodiment, a side underride system50may include a skirt system52and a support system54with a brace system56and a cable system58. While the skirt system52may provide aerodynamic properties, the brace system56is designed to provide resistance generally perpendicular to, or at other angles relative to, the side walls14, and the cable system58may provide stability to the brace system56and additional strength generally parallel to the side walls14.

Illustratively, the skirt system52is coupled to the floor assembly26of the trailer10to extend downwardly from the side wall14and the base rail28at least partially along a length of the trailer10. In some embodiments, as shown inFIG. 2, the skirt system52is positioned generally between the rear wheel assembly22and the landing gear24in order to prevent air from flowing laterally under the floor assembly26as the trailer10is towed by a tractor. In one specific application, the length may be about 16 feet. However, the skirt system52(or other skirt systems described herein) may be modified to extend along a greater or a lesser length of the trailer10than what is illustratively shown in the figures. In other words, the skirt systems disclosed herein, or the side underride systems or support systems disclosed herein, may be modified to extend along the entire, or substantially the entire, length of the trailer10(such as from the landing gear24to a rear impact guard (not shown) extending downward from the rear end wall18), or may be modified to extend along only a small portion of the length of the trailer10.

As depicted inFIG. 2, the skirt system52includes a skirt wall60. The skirt wall60may include similar structure and function as the skirt wall30described above. For example, the skirt wall60may be coupled to the floor assembly26(such as to the cross members40and/or the base rail28) via one or more mounting bracket assemblies or other suitable coupling mechanisms, such as other suitable hinge(s), longitudinal straps, bars, and/or connectors. Additionally, in some embodiments, the base rail28may be modified to provide a direct coupling surface for the skirt wall60. For example, the base rail28may extend further downward past the cross members40to provide a suitable surface to which the skirt wall60may be coupled.

Furthermore, the skirt wall60may include a single, substantially rigid or semi-rigid flat or curved wall panel32, or multiple wall panels32coupled together. Generally, with respect to the integrated underride and skirt systems disclosed herein, the skirt wall60may be of any configuration and shape to form a uniform surface optimized to control air flow around the trailer sides to minimize the air drag on the trailer10. In other words, the skirt wall60, or any other structure, may be of any configuration and shape to provide a first outer surface positioned below the trailer10near the first side wall14and a second outer surface configured to be positioned below the trailer10near the second side wall14to reduce airflow under the trailer10, where the surfaces permit any of the structures described herein to be positioned therebetween to provide side underride protection.

Illustratively, the skirt wall60may be made of any material to minimize weight, cost, and aid in equipment assembly, servicing, and maintenance. Example skirt wall materials, for use with any of the skirt walls described herein, may include, but are not limited to, DURAPLATE® composite panels, a continuous composite laminate, a molded composite sandwich panel (MCS) including a light-weight core and laminate webbing sandwiched between laminate outer skins, a metallic material sheet (such as an aluminum sheet), etc. Other suitable composite materials may alternatively or additionally be used, including, but not limited to, a sandwich composite including a honeycomb core and metal or plastic outer sheets, or a rigid or semi-rigid fiber-reinforced plastic composite. Further, the skirt wall60may be of any number of suitable, non-composite materials such as metals, metal alloys, and/or plastics, for example. Further, the skirt may include a textile or fabric such as a canvas or reinforced canvas that may be stretched and attached to the support system54. However, any material may be used to form a substantially smooth continuous aerodynamic surface with suitable strength to be an integral part of the side underride system50, as well as to form suitable connections to the trailer10. Additionally, the skirt wall60, or any skirt wall described herein, may be substantially rigid or substantially flexible.

With respect to the support system54, generally, the brace system56may be substantially rigid and arranged perpendicular to the side wall14, and the cable system58may be coupled to a lower portion of the brace system56to limit movement of and help transfer loads across the brace system56. More specifically, as shown inFIGS. 3-5, the brace system56may include a plurality of first example cross-braces62that may provide side underride protection. The plurality of first example cross-braces62may be coupled to the floor assembly26along a length of the trailer10, each oriented substantially vertically and spaced apart with respect to each other.

With further reference to the brace system56, each of the first example cross-braces62may be a separate subassembly unit of the support system54and spaced apart along a length of the trailer10, for example, between the landing gear24and the rear wheel assembly22, as shown inFIGS. 3-5, to provide impact protection along that length. Alternatively, the cross-braces62may span across the entire, or substantially the entire, length of the trailer10(such as from the landing gear24to the rear impact guard29or rear end of the trailer). In some embodiments, the cross-braces62may be spaced apart along a length equal to a length of the skirt wall60. Alternatively, the cross-braces62may be spaced apart along a length less than or more than the length of the skirt wall60. Additionally, the cross-braces62may extend downwardly from the floor assembly26far enough to provide substantial side impact protection, but still permit the trailer10to clear obstacles on a roadway. For example, in one application, the cross-braces62may extend downwardly from the floor assembly26so that a ground clearance from the bottom of the cross-braces62is approximately 16 inches to approximately 22 inches.

Illustratively, the cross-braces62may be spaced apart at specific intervals to increase the chances that a passenger vehicle colliding with the skirt wall60will engage at least one of the cross-braces62upon impact to prevent the vehicle from moving under the trailer10. More specifically, to potentially increase the chances that a passenger vehicle colliding with a skirt wall60will engage at least one of the cross-braces62upon impact, the cross-braces62may be spaced apart along the length of the trailer10at intervals less than an average car width.

In one example, as shown inFIG. 5, the side underride system50may include first, second, third, fourth, and fifth cross-braces62a, b, c, d, espaced apart at approximately four-foot (1.2 meter) intervals, with the forward-most cross-brace62elocated adjacent, or at, the landing gear24and the rearward-most cross-brace62alocated adjacent, or forward of, the rear wheel assembly22. Notably, in some embodiments, the rearward-most cross-brace62amay include a different structure that is configured to accommodate a spare tire carrier100, as shown inFIGS. 3and5. Further, other cross-braces62may be provided with a mechanism to hold the spare tire carrier100. In another example, the side underride system50may include four cross-braces spaced apart at five-foot intervals. It should also be noted that other interval widths (e.g., constant or variable) may be contemplated within the scope of this disclosure.

Furthermore, each of the cross-braces62a-eextends across a width of the trailer10. In some applications, all the cross-braces62a-espan an entire width between side walls14of the trailer10. In other applications, some or all of the cross-braces62a-espan less than the entire width between side walls14, and/or each of the cross-braces62a-espans the same or different widths. For example, in applications where each skirt wall60is coupled directly below and parallel to a respective side wall14, the cross-braces62a-emay each span the entire width between side walls14(e.g., about eight feet in one application). In applications where the skirt walls60form an angled or curved profile from the front of the trailer10to the rear of the trailer10, as shown inFIG. 5, the cross-braces62a-emay span varying widths (e.g., that increase from the front of the trailer10to the rear of the trailer10, as shown inFIG. 5) so that each of the cross-braces62a-espans from one skirt wall60to the opposite skirt wall60. As a result, the more forward cross-braces62b-eare successively shorter in width than one another and the most rearward cross-brace62a. Accordingly, in such applications, the brace system56does not run parallel to the side walls14, but rather is angled to correspond to the angle of the skirt system52.

Illustratively, each first example cross-brace62may include one or more truss members or beams with various cross-sections that offer suitable column compression and buckling strength. As shown inFIGS. 6 and 7, the first example cross-brace62may include first and second vertical posts70a, bat first and second ends96,98, and first and second truss beams72a, bcrisscrossed between the two vertical posts70a, b. More specifically, the first truss beam72ais coupled to an upper portion of the first vertical post70aat the first end96and to a lower portion of the second vertical post70bat the second end98. Similarly the second truss beam72bis coupled to a lower portion of the first vertical post70aat the first end96and to an upper portion of the second vertical post70bat the second end98. As a result, the truss beams72are oriented diagonally opposite from each other to form an X-shape. Herein, “upper portion” may generally refer to any portion along an upper half of a respective vertical post70a,band “lower portion” may generally refer to any portion along a lower half of the vertical post70a, b.

As shown inFIGS. 6-9, each of the first and second vertical posts70a, bis provided in the form of a member having a generally C-shaped cross-sectional profile with a closed face74, first and second closed sides76a, b, and an open face78. Each side face76a, bmay also include outer flanges80. Furthermore, the first and second vertical posts70a, bmay be oriented opposite each other at the first and second ends96,98of the cross-brace62. More specifically, the first vertical post70aincludes an open face78that faces rearward (e.g., toward the rear wheel assembly22), and the second vertical post70bincludes an open face78that faces forward (e.g., toward the landing gear24). Illustratively, the first and second truss beams72a, bare coupled to the open faces78at the respective lower portions of the first and second vertical posts70a, b. Similarly, the first and second truss beams72a, bare coupled to the respective closed faces74at the upper portion of the first and second vertical posts70a, b. Additionally, as shown inFIG. 6, at the lower portion of each vertical post70, the inwardly-facing first side faces76amay be shorter than the outwardly-facing second side faces76bto receive the diagonally oriented first and second truss beams72a, b. Furthermore, bottom edges79of the closed faces74may be angled from the outwardly-facing second side faces76bto the inwardly-facing first side faces76ato align with the respective first and second truss beams72a, b, as shown inFIGS. 6-8.

In some embodiments, as shown inFIGS. 6-9, the first and/or second truss beams72a, bmay be provided as a rectilinear enclosed beam provided in the form of a box. For example, as shown inFIG. 9, the first and/or second truss beams72a, bare defined by a sidewall forming a C-shaped channel82with a plate84coupled over an open face of the C-shaped channel82, thus creating a box-shaped channel with four solid faces. In some embodiments, the plate84may be stich welded to the C-shaped channel82. Alternatively, in some embodiments, the box-shaped the first and/or second truss beams72a, bmay be formed as a one-piece extruded component.

The first and second truss beams72a, bmay be coupled to the lower and upper portions of the first and second vertical posts70a, b, for example, via a welded coupling. However, other coupling mechanisms may be contemplated within the scope of this disclosure, such as bolts or fasteners. Furthermore, the first and second truss beams72a, bmay be loaded in compression, then welded together at an intersection point90to provide further structural integrity to the cross-brace62. In other embodiments, however, the first and second truss beams72a, bmay be pinned, bolted, bonded, hinged, or otherwise coupled together at the intersection point90.

Other configurations of truss beams in addition to those illustrated and described herein may be contemplated within the scope of this disclosure. Furthermore, the first example cross-braces62described herein may include material that is substantially rigid, but lightweight. For example, the first example cross-braces62may include any suitable material such as, but not limited to, metallic extrusions (such as extruded aluminum), roll formed high-strength aluminum alloy or high-strength steel, fiber reinforced polymeric matrix pultrusions, galvanized steel sheet stampings, combinations thereof, or any other suitable material or materials. Generally, such a suitable material may include suitable strength and light-weight features, and be conducive to form strong connections via welding, riveting, bolting, bonding or other methods. For example, the first example cross-braces62may also or alternatively include compression molded composite laminates and/or foam cores structures, such as compression-molded, fiberglass-reinforced plastic.

To couple the cross-braces62along a width of the trailer10, each cross-brace62may be coupled directly to a respective cross member40of the floor assembly26. For example, in some embodiments, a cross-brace62may be coupled to a cross member40using first and second brackets64a, b, as shown inFIGS. 6-9. More specifically, in one embodiment, the first and second brackets64a, bmay be welded to the cross member40(e.g., adjacent each end96,98), and the cross-brace62may be bolted to the first and second brackets64a, bvia respective bolted connections with the first and second vertical postings, each of the bolted connections including a bolt66and nut68(or connected via another suitable coupling). It should be noted that, while first and second brackets64a, bare shown inFIGS. 6-7, it is within scope of this disclosure to include additional brackets64or weld points along the cross member40.

The welded connection between the brackets64and the cross member40may help distribute vertical and horizontal loads from the cross-braces62to the floor assembly26. In some embodiments, each bracket64may be welded to a single surface of a respective cross member40. More specifically, as shown inFIGS. 6-9, each bracket64may be welded to an underside or bottom surface160of a lower flange162of a respective cross member40. This single undersurface connection can simplify installation, for example, compared to mechanisms that connect to multiple surfaces of the cross member40(e.g., above the lower flange162) or that require bolting through the cross member40, especially in retrofit applications. For example, welding can be performed from a top side of the bracket64to the underside160of the lower flange162.

In some embodiments, welding can be performed as a sub-assembly process during manufacturing of the floor assembly26. More specifically, a respective cross member40may be flipped over to weld the bracket64to the underside160of the lower flange162, and then the cross member40may be flipped back and assembled into the floor assembly26. Once the floor assembly26is assembled, vertical legs70can be coupled to the brackets64, as further described below. Accordingly, the brace system56may be manufactured when the floor assembly26is being manufactured (e.g., as part of an OEM process). Alternatively, in some embodiments, the brace system56may be retrofitted onto an existing floor assembly26. In either manner, welding the brackets64to the cross members40(and then coupling the vertical legs to the brackets64) may be an easier process than directly welding or coupling the first and second vertical posts70a, bto the cross members40. However, direct couplings between the first and second vertical posts70a, band the cross members40may also be contemplated in some embodiments.

As shown inFIGS. 6-9, the bracket64can extend downwardly from the lower flange162and can be substantially C-shaped (e.g., having two solid sides164, a closed face166, and an open face168). As shown inFIGS. 8-9, the bracket64can be sized to surround the closed face74and at least a portion of each side face76of a vertical post70. Accordingly, first and second brackets64a, bcan be welded to the cross member40in a manner that matches an orientation of the respective first and second vertical posts70a, b. More specifically, as shown inFIGS. 6 and 7, the first and second brackets64a, brespectively at the first and second ends96,98, like the first and second vertical posts70a, b, may be mirror images of one another. Thus, the first and second brackets64a, bcan be sized and positioned to receive a vertical post70so that the closed face74of the vertical post70extends into the open end168of the bracket64until it abuts the closed face166of the bracket64. In other words, the first and second brackets64a, band the first and second vertical posts70a, bare respectively offset from one another along the cross member40. The first truss beam72ais thus offset from the second truss beam72bto engage the lower portion of the open face78of the first vertical post70a, to engage the second truss beam72bat the intersection point90, and to engage the upper portion of the closed face74of the second vertical post70b. Further, the second truss beam72bis thus offset from the first truss beam72ato engage the lower portion of the open face78of the second vertical post70b, to engage the first truss beam72aat the intersection point90, and to engage the upper portion of the closed face74of the first vertical post70a.

Illustratively, the first and second vertical posts70a, bcan be respectively coupled to the first and second brackets64a, bby engaging the closed face74with the open face168. For example, the first and second brackets64a, band the first and second vertical posts70a, bcan each define mating apertures that align when the first and second vertical posts70a, bare respectively received by the first and second brackets64a, b. Illustratively, the first and second brackets64a, band the first and second vertical posts70a, bcan be respectively coupled together via bolts66routed through the mating apertures and nuts68securing the bolts66in place. This single sheer connection (i.e., the single vertical-surface contact point) between the first and second brackets64a, band the first and second vertical posts70a, bmakes aligning the mating apertures easier (e.g., as compared to couplings with multiple sheer connections) and also permits use of the bolt66to force components with variation into a correct position, thus permitting larger tolerances for aligning mating apertures and simplifying installation.

In some embodiments, each cross-brace62may be coupled to a respective cross member40through other coupling methods, such as welding, bolting, fasteners, and/or other suitable couplings. Alternatively, in some embodiments, one or more cross members40may be replaced with an integrated member that serves as both a cross member and a cross-brace. Furthermore, while the floor assemblies26are described and illustrated herein as including cross members40, it is within the scope of this disclosure to couple the cross-braces62to floor assemblies26of trailers without cross members40. In other words, while the cross-braces62are described and illustrated herein as being coupled to or integral with cross members40, it is within the scope of this disclosure to couple the cross-braces62to any part of the floor assembly26using, for example, fasteners, adhesives, or other suitable coupling methods.

Additionally, in some embodiments, one or more cross-braces62may be further coupled to the skirt walls60. For example, the cross-braces62and the skirt walls60may be coupled together via self-tapping bolts, rivets, or another suitable connector (not shown). The skirt walls60may thus be coupled to the support system54(such as the vertical posts70), and/or to the floor assembly26, and/or may be spaced apart from the support system54in some embodiments.

Accordingly, the cross-braces62, via the first and second truss beams72a, b, may provide sufficient strength and support between the skirt walls60to help reduce the chances of vehicle underride during a side impact collision. Furthermore, due to the interlocking first and second truss beams72a, b, the cross-braces62may operate to absorb some of the force and energy of any impact thereto to potentially decrease any forces on the passengers within an automobile that impacts the trailer10. The cross-braces62may also compress, deflect, or collapse slightly under impact (i.e., under lateral forces) to further absorb such forces.

Referring now to the cable system58, as best seen inFIGS. 3-5, the cable system58may include one or more cables112that traverse the intervals between adjacent cross-braces62. In one example, the cable112may be routed through the cross-braces62in tension to form the support system54having connected cross-braces62across a length of the trailer10. In another example, the cable112may be coupled to adjacent cross-braces62across a length of the trailer10in tension to form the support system54having connected cross-braces62. Illustratively, the cable112may be routed through or coupled to the cross-braces62near the lower portion of each vertical post70. As a result, the cable112may further assist to limit movement of the cross-braces62and maintain the vertical posts70in a substantially vertical orientation with respect to the floor assembly26. However, in other embodiments, the cable112may be routed or coupled at any location along the height of the vertical posts70.

According to the first example, in some embodiments, as shown inFIGS. 6-8, the first and second vertical posts70a, bof the cross-braces62may include an aperture(s) or a channel114, and the cable112may be routed through the apertures114in tension to form the support system54of connected cross-braces62. Illustratively, the apertures114may be positioned near the lower portion of the first and second vertical posts70a, b. As a result, the apertures114may also extend through the first and second truss beams72a, bpositioned at the lower portion of the vertical post70. Furthermore, one or more washers170may be positioned on the first and second vertical posts70a, band/or the first and second truss beams72a, badjacent each aperture114. Additionally, in some embodiments, collars (not shown) may be added on either side of each vertical post70to limit lateral sliding movement of the cable112relative to the first and second vertical posts70a, b. In this manner, if one or more of the first and second vertical posts70a, bfails upon an impact, the collar may help transfer load to adjacent vertical posts70rather than allowing the cable112to be pulled inwardly by the force of the impact.

Referring toFIGS. 10-13, a first example cable support subassembly200aincludes a first example cable clamp180connected to a second example cross-brace262in a first orientation210. Similarly, referring toFIGS. 14-17a second example support subassembly200bincludes the first example cable clamp180connected to the second example cross-brace262in a second orientation220.

Referring particularly now toFIG. 11, a second example cross-brace262includes a first vertical post270a, a second vertical post (not shown), and first and second truss beams272a, b. Referring toFIGS. 10-17, it should be understood that the second example cross-brace262is a variation on, and thus structurally similar to, the first example cross brace62ofFIGS. 6-9. It should also be understood that the second example cross-brace262is designed to connect to the cross member40in the same manner as the first example cross-brace62ofFIGS. 6-9.

Referring still toFIGS. 10-17, like the first example cross-brace62ofFIGS. 6-9, the first and second truss beams272a, bof the second example cross-brace262diagonally cross one another and are connected to the first vertical post270aand to the second vertical post. The first vertical post270ais generally C-shaped, having a closed face274, first and second closed sides276a, b, and an open face278. Each side face276a, bmay also include outer flanges280. Like the first and second vertical posts70a, bofFIGS. 6-9, the first vertical post270aand the second vertical post are arranged opposite one another at a first end296and a second end (not shown) of the cross-brace262. The second vertical post is generally identical to the first vertical post270a. Thus, the first vertical post270aand the second vertical post are mirror images of one another.

Referring again toFIGS. 10-17, the first and second truss beams272a, bare coupled to the first vertical post270aand the second vertical post in the same manner as the first and second truss beams72a, bofFIGS. 6-9are coupled to the first and second vertical posts70a, bofFIGS. 6-9. Additionally, as shown inFIG. 12, at the lower portion of the first vertical post270a, the inwardly-facing first side face276ais shorter than the outwardly-facing second side face276bto receive the diagonal second truss beam272b. The second vertical post similarly receives the diagonal first truss beam272a(seeFIG. 6). In contrast with the first example cross-brace62ofFIGS. 6-9, the first vertical post270aincludes a lobe279that extends downwardly beyond the second truss beam272b, as shown inFIGS. 11-13. Similarly, the second vertical post also includes a lobe that extends downwardly beyond the first truss beam272a(not shown).

Like in the first example cross-brace ofFIGS. 6-9, in some embodiments, as shown inFIGS. 10-17, the first and/or second truss beams272a, bmay be box-shaped. For example, as shown inFIGS. 11, 12, 15, and 16the first and/or second truss beams272a, bmay include a C-shaped channel282with a plate284coupled over an open face of the C-shaped channel282, thus creating a box-shaped channel with four solid faces. In some embodiments, the plate284may be stich welded to the C-shaped channel282. Alternatively, in some embodiments, the box-shaped the first and/or second truss beams272a, bmay be formed as a one-piece extruded component.

Referring toFIGS. 10-17, the first and second truss beams272a, bmay be coupled to the lower and upper portions of the first vertical post270aand the second vertical post, for example, via a welded coupling. However, other coupling mechanisms may be contemplated within the scope of this disclosure, such as bolts or fasteners. Furthermore, the first and second truss beams272a, bmay be loaded in compression, then welded together to provide further structural integrity to the second example cross-brace262. In other embodiments, however, the first and second truss beams272a, bmay be pinned, bolted, bonded, hinged, or otherwise coupled together.

Still referring toFIGS. 10-17, it should be understood that the first vertical post270a, the second vertical post, and the first and second truss beams272a, bdo not define apertures through which the cable112is routed, in contrast with the first example cross brace62ofFIGS. 6-9that defines the cable-routing apertures114. Instead, according to a second example, in some embodiments, as shown inFIGS. 10-17, the cable112may be coupled to the cross-braces262via a first example cable clamp180to form the support system54of connected second example cross-braces262. Illustratively, the first example cable clamps180may be coupled to the first vertical post270aand to the second vertical post, and the cable112may be routed through the cable clamps180to couple the cable112to the cross-brace262. In the example ofFIGS. 10-13, the first example cable clamps180are be coupled to the first vertical post270aand to the second vertical post in a first orientation210to extend downwardly from the cross brace262. In the example ofFIGS. 14-17, the first example cable clamps180are be coupled to the first vertical post270aand to the second vertical post in a second orientation220to extend outwardly from the cross brace262. Alternatively, the cable clamps180may be coupled to the first and second truss beams272a, bto couple the cable112to the cross-brace262.

Referring toFIGS. 10-21, each first example cable clamp180may include a bracket182and a rope clip184including a U-bolt186, nuts188, and a saddle190. Referring more specifically toFIGS. 11, 12, 14, and 16, the saddle190defines an aperture190a(e.g., a trough). The cable112may be secured between the U-bolt186and the saddle190by routing the U-bolt186through the aperture190aof the saddle190. With reference toFIGS. 10, 17, and 21, the cable112may thus be coupled to the bracket182via the U-bolt186and the nuts188. More specifically, the bracket182may define apertures (not shown), the U-bolt186may be routed through the apertures from one side of the bracket182, and the nuts188may be threaded or otherwise secured to the U-bolt186from the other side of the bracket182. As shown inFIGS. 10, 11, 13-15, 17-19, and21, the saddle190is engaged with the bracket182. In some embodiments, the saddle190may be welded or otherwise coupled to a surface192of the bracket182. In other embodiments, the saddle190may be separate from the bracket182, and the nuts188may be tightened against the U-bolt186until the saddle190abuts the surface192of the bracket182. In some embodiments, the saddle190may be omitted. In such embodiments, the cable112may be captured between the U-bolt186and the surface192.

It should be understood that as the nuts188are tightened, the U-bolt186draws the cable112toward the surface192until the cable112contacts the saddle190and/or the surface192. Thus, in some embodiments, the cable112may be relatively freely slidably engaged with the rope clip184. Once the cable112is in contact with the saddle190and/or the surface192, further tightening of the nuts188increasingly compresses the cable112between the U-bolt186and the surface192. Thus, in some embodiments, the cable112may be restrictively slidably engaged with the rope clip184. In further embodiments, the nuts188may be tightened until the cable112is fixed relative to the rope184. In other words, the rope clip184is adjustable to frictionally damp lateral sliding movement of the cable112relative to the rope clip184. Thus, the rope clip184adjustably impedes sliding movement of the cable112relative to the structures to which the rope clip184is directly and indirectly attached (e.g., the cross brace262, the bracket182, etc.).

An assembled cable clamp180(that is, the U-bolt186, the saddle190, the cable112, and the bracket182, assembled together via the nuts188) may be coupled to the cross-brace262via the bracket182. More specifically, the bracket182may be welded or otherwise coupled to one or more of the first vertical post270a, the second vertical post, the first truss beam272a, and/or the second truss beam272b. Illustratively, the bracket182may be substantially C-shaped, as shown inFIGS. 10-21, with a longer side edge194and a shorter side edge196, and the longer side edge194may be welded to the vertical post70or the truss beam72. The C-shaped orientation and longer side edge194may provide sufficient surface area for a strong weld connection while still permitting access to the nuts188when the bracket182is coupled to the cross-brace62. It should also be noted that, in some embodiments, the C-shaped orientation ofFIG. 10-21may instead be L-shaped.

Looking atFIGS. 10-13, more specifically, the cable clamp180in the cable clamp bottom first orientation210ofFIGS. 10-13may be coupled to a closed face274of the first vertical post270a(e.g., opposite the second truss beam272b). An additional cable clamp180may be coupled to a closed end of the second vertical post (e.g., opposite the first truss beam272a) (not shown). The cable clamp180may be coupled to respective lower portions of the first vertical post270aand the second vertical post so that the surface192of the bracket182faces downward and the U-bolt186and the saddle190extend downward beneath the first vertical post270a(e.g., beneath the lobe279) and the second vertical post. As a result, the cable112may be routed underneath the first vertical post270aand the second vertical post, as shown inFIGS. 10-13. In some embodiments, as shown inFIG. 12, the lobe279of the first vertical post270amay include a carve-out198sized to accommodate the cable112. However, in other embodiments, the lobe279may not include a carve-out. Because the cable112is routed beneath the first vertical post270aand the second vertical post, and the cable clamp180does not extend laterally outside the first vertical post270aand the second vertical post (e.g., past a plane extending from the trailer sidewall14), the cable system58of this embodiment may not interfere with a skirt wall60that would extend downward from the sidewall14. Accordingly, in this embodiment, a skirt system52may be installed before or after the support system54is installed. An additional first example cable clamp may be coupled to the second vertical post in the same manner as the illustrated first example cable clamp180is connected to the first vertical post270ain the first orientation210.

As shown inFIGS. 14-17, more specifically, the cable clamp180of the cable clamp outboard second orientation220ofFIGS. 14-17may be coupled to the closed face274of the first vertical post270a(e.g., opposite the second truss beam272b). An additional cable clamp180may be coupled to a closed end of the second vertical post (e.g., opposite the first truss beam272a) (not shown). The cable clamp180may be coupled to respective lower portions of the first vertical post270aand the second vertical post so that the surface192of the bracket182faces outwardly and the U-bolt186and the saddle190extend outside the first vertical post270aand the second vertical post (e.g., outward past the respective outer side faces276bof the first vertical post270aand the second vertical post). As a result, the cable112may be routed outside the first vertical post270aand the second vertical post, as shown inFIGS. 14-17. An additional first example cable clamp may be coupled to the second vertical post in the same manner as the illustrated first example cable clamp180is connected to the first vertical post270ain the second orientation220.

Referring now toFIGS. 18-21, a third example cable support subassembly300includes the first example cable clamp180connected to a third example cross-brace362. The third example cross-brace362includes a first vertical post370a, a second vertical post (not shown), a first truss beam (not shown), and a second truss beam372b. It should be understood that the third example cross-brace362is a variation on, and thus structurally similar to, the first and second example cross braces62,262ofFIGS. 6-17. It should also be understood that the third example cross-brace362connects to the cross member40in the same manner as the first example cross-brace62ofFIGS. 6-9.

Referring still toFIGS. 18-21, like the first and second example cross braces62,262ofFIGS. 6-17, the first truss beam and the second truss beams372bof the third example cross-brace362diagonally cross one another and are connected to the first vertical post370aand to the second vertical post. The first vertical post370ais generally C-shaped, having a closed face374, first and second closed sides376a, b, and an open face378. Each side face376a, bmay also include outer flanges380. Like the first and second vertical posts70a, bofFIGS. 6-9, the first vertical post370aand the second vertical post are arranged opposite one another at a first end396and a second end (not shown) of the cross-brace362. The second vertical post is generally identical to the first vertical post370a. Thus, the first vertical post370aand the second vertical post are mirror images of one another.

As shown inFIGS. 18-21, the first truss beam and the second truss beam372bare coupled to the first vertical post370aand the second vertical post in the same manner as the first and second truss beams72a, bofFIGS. 6-9are coupled to the first and second vertical posts70a, bofFIGS. 6-9. The first truss beam is generally identical to the second truss beam372b. Thus, the first truss beam and the second truss beam372bare mirror images of one another. Additionally, as shown inFIG. 20, at the lower portion of the first vertical post370a, the inwardly-facing first side face376ais shorter than the outwardly-facing second side face376bto receive the diagonal second truss beam372b. The second vertical post similarly receives the diagonal first truss beam (seeFIG. 6).

Referring toFIGS. 18-21, in contrast with the first example cross-brace62ofFIGS. 6-9, the first vertical post370aincludes a lobe379that extends downwardly beyond the second truss beam372b, as shown inFIGS. 19-21. Similarly, the second vertical post also includes a lobe that extends downwardly beyond the first truss beam (not shown). Additionally in contrast with the first and second example cross-braces62,262ofFIGS. 6-17, a cutout is provided in the respective lower portions of the first vertical post370aand the second vertical post that defines a recess310sized to receive the cable112. More specifically, the recess310can be cut through the outer side face376b, a portion of the closed face374, and, in some embodiments, the respective first truss beam or second truss beam372b.

Like in the first and second example cross-braces62,262ofFIGS. 6-17, in some embodiments, as shown inFIGS. 18-21, the first truss beam and/or second truss beam372bmay be box-shaped. For example, as shown inFIGS. 19 and 20the second truss beam372bmay include a C-shaped channel382with a plate384coupled over an open face of the C-shaped channel382, thus creating a box-shaped channel with four solid faces. In some embodiments, the plate384may be stich welded to the C-shaped channel382. The first truss beam may be formed of a C-shaped panel and a plate in the same manner as the second truss beam372b. Alternatively, in some embodiments, the box-shaped the first truss beam and/or the second truss beam372bmay be formed as a one-piece extruded component.

Referring toFIGS. 18-21, the first truss beam and the second truss beam372bmay be coupled to the lower and upper portions of the first vertical post370aand the second vertical post, for example, via a welded coupling. However, other coupling mechanisms may be contemplated within the scope of this disclosure, such as bolts or fasteners. Furthermore, the first truss beam and the second truss beam372bmay be loaded in compression, then welded together to provide further structural integrity to the third example cross-brace362. In other embodiments, however, the first truss beam and the second truss beam372bmay be pinned, bolted, bonded, hinged, or otherwise coupled together.

Looking still atFIGS. 18-21, it should be understood that, like the second example cross-brace262ofFIGS. 10-17, the first vertical post370a, the second vertical post, the first truss beam, and the second truss beams372bdo not define apertures through which the cable112is routed, in contrast with the first example cross brace62ofFIGS. 6-9that defines the cable-routing apertures114. Instead, similar to the example ofFIGS. 10-17, in some embodiments, as shown inFIGS. 18-21, the cable112may be coupled to the cross-braces362via the first example cable clamps180to form the support system54of connected third example cross-braces362. Illustratively, the first example cable clamps180may be coupled to the first vertical post370aand to the second vertical post in a third orientation330inboard of the recess310. Further, the cable112may be routed through the cable clamps180and the recess310to couple the cable112to the cross-brace362.

Looking atFIGS. 18-21, more specifically, in the third orientation330, the cable clamp180may be coupled to the closed face374of the first vertical post370a(e.g., opposite the second truss beam372b). The cable clamp180may be coupled to a lower portion of the first vertical post370aso that the surface192of the bracket182faces outward, like the second orientation220ofFIGS. 14-17, but the coupling may be recessed inward so that the U-bolt186and the saddle190do not extend (or minimally extend) outward past an outer side face376bof the first vertical post370a. As a result, the cable112may be routed through the recess310along the outer side face376bof the vertical post370a, as shown inFIGS. 18-21. Because the cable112is recessed inwardly, and the cable clamp180does not extend (or minimally extends) outside the first vertical post370a(e.g., past a plane extending from the trailer sidewall14), the cable system58of this embodiment may not interfere with a skirt wall60that would extend downward from the sidewall14. Accordingly, in this embodiment, a skirt system52may be installed after the support system54is installed. An additional first example cable clamp may be coupled to the second vertical post and the first truss beam in the same manner as the illustrated first example cable clamp180is connected to the first vertical post370ain the third orientation330.

Referring now toFIGS. 22-25, a fourth example cable support subassembly400includes a second example cable clamp2180connected to a fourth example cross-brace462. The fourth example cross-brace462includes a first vertical post470a, a second vertical post (not shown), a first truss beam (not shown), and a second truss beam472b. It should be understood that the fourth example cross-brace462is a variation on, and thus structurally similar to, the first, second, and third example cross braces62,262,362ofFIGS. 6-21. It should also be understood that the fourth example cross-brace462connects to the cross member40in the same manner as the first example cross-brace62ofFIGS. 6-9.

Referring still toFIGS. 22-25, like the first, second, and third example cross braces62,262,362ofFIGS. 6-21, the first truss beam and the second truss beam472bof the fourth example cross-brace462diagonally cross one another and are connected to the first vertical post470aand to the second vertical post. The first vertical post470ais generally C-shaped, having a closed face474, first and second closed sides476a, b, and an open face478. Each side face476a, bmay also include outer flanges480. Like the first and second vertical posts70a, bofFIGS. 6-9, the first vertical post470aand the second vertical post are arranged opposite one another at a first end496and a second end (not shown) of the cross-brace462. The second vertical post is generally identical to the first vertical post470a. Thus, the first vertical post470aand the second vertical post are mirror images of one another.

Referring again toFIGS. 22-25, the first truss beam and the second truss beam472bofFIGS. 22-25are coupled to the first vertical post470aand the second vertical post in the same manner as the first and second truss beams72a, bofFIGS. 6-9are coupled to the first and second vertical posts70a, bofFIGS. 6-9. The first truss beam is generally identical to the second truss beam472b. Thus, the first truss beam and the second truss beam472bare mirror images of one another. Additionally, as shown inFIG. 24, at the lower portion of the first vertical post470a, the inwardly-facing first side face476ais shorter than the outwardly-facing second side face476bto receive the diagonal second truss beam472b. The second vertical post similarly receives the diagonal first truss beam (seeFIG. 6).

Referring toFIGS. 22-25, in contrast with the first, second, and third example cross-braces62,262,362ofFIGS. 6-21, the closed face474of the first vertical post470amay extend downwardly (e.g., past a bottom edge402of the side face476) to form a wing479as shown inFIGS. 22-25. Thus, the wing479extends downwardly beyond the second truss beam472b. Similarly, the second vertical post also includes a wing that extends downwardly beyond the first truss beam (not shown). Additionally in contrast with the first, second, and third example cross-braces62,262,362ofFIGS. 6-21, the respective wings479of the first vertical post470aand the second vertical post may define a recess404sized to permit the cable112to pass through.

Like in the first, second, and third example cross-braces62,262,362ofFIGS. 6-21, in some embodiments, as shown inFIGS. 22-25, the first truss beam and/or second truss beam472bmay be box-shaped. For example, as shown inFIGS. 23 and 24the second truss beam472bmay include a C-shaped channel482with a plate484coupled over an open face of the C-shaped channel482, thus creating a box-shaped channel with four solid faces. In some embodiments, the plate484may be stich welded to the C-shaped channel482. The first truss beam may be formed of a C-shaped panel and a plate in the same manner as the second truss beam472b. Alternatively, in some embodiments, the box-shaped the first truss beam and/or the second truss beam472bmay be formed as a one-piece extruded component.

Referring toFIGS. 22-25, the first truss beam and the second truss beam472bmay be coupled to the lower and upper portions of the first vertical post470aand the second vertical post, for example, via a welded coupling. However, other coupling mechanisms may be contemplated within the scope of this disclosure, such as bolts or fasteners. Furthermore, the first truss beam and the second truss beam472bmay be loaded in compression, then welded together to provide further structural integrity to the fourth example cross-brace462. In other embodiments, however, the first truss beam and the second truss beam472bmay be pinned, bolted, bonded, hinged, or otherwise coupled together.

Looking still atFIGS. 22-25, it should be understood that, like the second and third example cross-braces262,362ofFIGS. 10-21, the first vertical post470a, the second vertical post, the first truss beam, and the second truss beam472bdo not define apertures through which the cable112is routed, in contrast with the first example cross brace62ofFIGS. 6-9that defines the cable-routing apertures114. Instead, similar to the examples ofFIGS. 10-21, in some embodiments, as shown inFIGS. 22-25, the cable112may be coupled to the cross-braces462via second example cable clamps2180to form the support system54of connected fourth example cross-braces462. Illustratively, the second example cable clamps2180may be coupled to the first vertical post470aand to the second vertical post in a fourth orientation440below the first truss beam and the second truss beam472b. Further, the cable112may be routed through the cable clamps2180and the recess404to couple the cable112to the cross-brace362.

Referring toFIGS. 22-25, each second example cable clamp2180may include a bracket2182and the rope clip184. As discussed above, the rope clip184includes the U-bolt186, nuts188, and the saddle190to secure the cable112. More specifically, the bracket2182may define apertures (not shown), the U-bolt186may be routed through the apertures from one side of the bracket2182, and the nuts188may be threaded or otherwise secured to the U-bolt186from the other side of the bracket2182. In some embodiments, the saddle190may be welded or otherwise coupled to a surface2192of the bracket2182. In other embodiments, the saddle190may be separate from the bracket2182, and the nuts188may be tightened against the U-bolt186until the saddle190abuts the surface2192of the bracket2182. In some embodiments, the saddle190may be omitted. In such embodiments, the cable112may be secured between the U-bolt186and the surface2192.

An assembled cable clamp2180(that is, the U-bolt186, the saddle190, the cable112, and the bracket2182, assembled together via the nuts188) may be coupled to the cross-brace462via the bracket2182. More specifically, the bracket2182may be welded or otherwise coupled to the respective wings479of the first vertical post470aand the second vertical post. Illustratively, the bracket2182may be substantially L-shaped, as shown inFIGS. 22-25, with a longer side edge2194, a shorter side edge2196, and a vertical edge2198. The respective the longer side edges2194may be welded to the first truss beam and the second truss beam472b. The respective the vertical edges may be welded to the wings479. The L-shaped orientation, longer side edge2194, and vertical edge2198may provide sufficient surface area for a strong weld connection while still permitting access to the nuts188when the bracket2182is coupled to the cross-brace462. It should also be noted that, in some embodiments, the L-shaped orientation ofFIG. 22-25may instead be C-shaped.

Looking atFIGS. 22-25, more specifically, the cable clamp2180of the cable clamp recessed bottom fourth orientation440ofFIGS. 22-25may be coupled to the second truss beam472badjacent to a lower portion of the first vertical post470a. The cable clamp2180may be coupled to a lower surface of the second truss beam472band/or an inner surface of the wing479so that the surface2192of the bracket2182faces outward, like the second orientation220ofFIGS. 14-17, but the coupling may be recessed inward so that the U-bolt186and the saddle190do not extend (or minimally extend) outward past an outer side face476bof the first vertical post470a. As a result, the cable112may be routed through the recess404along the underside of the first vertical post470a, as shown inFIGS. 22-25. Because the cable112is recessed inward, and the cable clamp2180does not extend (or minimally extends) outside the first vertical post470a(e.g., past a plane extending from the trailer sidewall14), the cable system58of this embodiment may not interfere with a skirt wall60that would extend downward from the sidewall14. An additional second example cable clamp may be coupled to the second vertical post and the first truss beam in the same manner as the illustrated second example cable clamp2180is connected to the first vertical post470aand the second truss beam472bin the fourth orientation440. Additionally, in some embodiments, to accommodate for cable clamps2180underneath the first truss beam and the second truss beam472b, the first truss beam and the second truss beam472bmay be respectively coupled at higher positions along the second vertical post and the first vertical post470acompared to the embodiments ofFIGS. 10-21. As a result, the first truss beam and the second truss beam472bin this embodiment may be shorter than, and therefore weigh less than, the truss beams in the embodiments ofFIGS. 10-21.

Referring now toFIGS. 26-28, a fifth example support subassembly500includes a third example cable clamp3180connected to a fifth example cross-brace562. The fifth example cross-brace562includes a first vertical post570a, a second vertical post (not shown), a first truss beam (not shown), and a second truss beam572b. It should be understood that the fifth example cross-brace562is a variation on, and thus structurally similar to, the first, second, third, and fourth example cross braces62,262,362,462ofFIGS. 6-25. It should also be understood that the fifth example cross-brace562connects to the cross member40in the same manner as the first example cross-brace62ofFIGS. 6-9.

Referring still toFIGS. 26-28, like the first, second, third, and fourth example cross braces62,262,362,462ofFIGS. 6-25, the first truss beam and the second truss beam572bof the fifth example cross-brace562diagonally cross one another and are connected to the first vertical post570aand to the second vertical post. The first vertical post570ais generally C-shaped, having a closed face574, first and second closed sides576a, b, and an open face578. Each side face576a, bmay also include outer flanges580. Like the first and second vertical posts70a, bofFIGS. 6-9, the first vertical post570aand the second vertical post are arranged opposite one another at a first end596and a second end (not shown) of the cross-brace562. The second vertical post is generally identical to the first vertical post570a. Thus, the first vertical post570aand the second vertical post are mirror images of one another.

The first truss beam and the second truss beam572bare coupled to the first vertical post570aand the second vertical post in the same manner as the first and second truss beams72a, bofFIGS. 6-9are coupled to the first and second vertical posts70a, bofFIGS. 6-9. The first truss beam is generally identical to the second truss beam572b. Thus, the first truss beam and the second truss beam572bare mirror images of one another. Additionally, as shown inFIG. 27, at the lower portion of the first vertical post570a, the inwardly-facing first side face576ais shorter than the outwardly-facing second side face576bto receive the diagonal second truss beam572b. The second vertical post similarly receives the diagonal first truss beam (seeFIG. 6).

Referring toFIGS. 26-28, in contrast with the first, second, third, and fourth example cross-braces62,262,362,462ofFIGS. 6-25, the closed face574of the first vertical post570amay define a recess510sized to accommodate a third example cable clamp3180. The recess510is inboard of the outwardly-facing second side face576b. Thus, the recess510is inwardly-facing.

Like in the first, second, third, and fourth example cross-braces62,262,362,462ofFIGS. 6-25, in some embodiments, as shown inFIGS. 22-25, the first truss beam and/or second truss beam572bmay be box-shaped. For example, as shown inFIG. 27, the second truss beam572bmay include a C-shaped channel582with a plate584coupled over an open face of the C-shaped channel582, thus creating a box-shaped channel with four solid faces. In some embodiments, the plate584may be stitch welded to the C-shaped channel582. The first truss beam may be formed of a C-shaped panel and a plate in the same manner as the second truss beam572b. Alternatively, in some embodiments, the box-shaped the first truss beam and/or the second truss beam572bmay be formed as a one-piece extruded component.

Referring toFIGS. 26-28, the first truss beam and the second truss beam572bmay be coupled to the lower and upper portions of the first vertical post570aand the second vertical post, for example, via a welded coupling. However, other coupling mechanisms may be contemplated within the scope of this disclosure, such as bolts or fasteners. Furthermore, the first truss beam and the second truss beam572bmay be loaded in compression, then welded together to provide further structural integrity to the fifth example cross-brace562. In other embodiments, however, the first truss beam and the second truss beam572bmay be pinned, bolted, bonded, hinged, or otherwise coupled together.

Looking still atFIGS. 26-28, it should be understood that, like the second, third, and fourth example cross-braces262,362,462ofFIGS. 10-25, the first vertical post570a, the second vertical post, the first truss beam, and the second truss beam572bdo not define apertures through which the cable112is routed, in contrast with the first example cross brace62ofFIGS. 6-9that defines the cable-routing apertures114. Instead, similar to the examples ofFIGS. 10-25, in some embodiments, as shown inFIGS. 26-28, the cable112may be coupled to the cross-braces562via third example cable clamps3180to form the support system54of connected fifth example cross-braces562. Illustratively, the third example cable clamps3180may be coupled to the first truss beam and to the second truss beam572bin a fifth orientation550below the first vertical post570aand the second vertical post. Further, the cable112may be routed through the cable clamps3180to couple the cable112to the cross-brace562.

Referring toFIGS. 26-28, each third example cable clamp180may include a bracket3182and the rope clip184. The bracket3182includes first side plate3182a, a second side plate3182b, a bridge3182c, and a connecting plate3182d. As discussed above, the rope clip184includes the U-bolt186, nuts188, and the saddle190to secure the cable112.

Looking still atFIGS. 26-28, the first and second side plates3182a, bare generally triangular and opposing mirror images of one another. The first and second side plates3182a, binclude stiffening flanges3198. The bridge3182cis generally concave and connects the first and second side plates3182a, bto one another. Thus, the assembled first and side plates3182a, band the bridge3182care generally C-shaped. The first and second side plates3182a, bextend upwardly from the bridge3182c. The connecting plate3182dis connected to the first and second side plates3182a, band to the bridge3182c. The connecting plate3182dextends inwardly from the bridge3182cbetween the first and second side plates3182a, b. In some embodiments, the first and second side plates3182a, b, the bridge3182c, and the connecting plate3182dare variously connected to one another via welding.

Referring again toFIGS. 26-28, the bridge3182cmay define apertures (not shown), the U-bolt186may be routed through the apertures from one side of the bridge3182c, and the nuts188may be threaded or otherwise secured to the U-bolt186from the other side of the bridge3182c. The connecting plate3182dis disposed between the apertures. In some embodiments, the saddle190may be welded or otherwise coupled to a surface3192of the bridge3182c. In other embodiments, the saddle190may be separate from the bridge3182c, and the nuts188may be tightened against the U-bolt186until the saddle190abuts the surface3192of the bridge3182c. In some embodiments, the saddle190may be omitted. In such embodiments, the cable112may be secured between the U-bolt186and the surface3192.

An assembled cable clamp3180(that is, the U-bolt186, the saddle190, the cable112, and the bracket3182, assembled together via the nuts188) may be coupled to the cross-brace562via the bracket3182. More specifically, inner surfaces3194a, bof the first and second side plates3182a, band an upper edge3196of the bridge3182cmay be welded or otherwise coupled to the first truss beam and the second truss beam572b. Thus, the first and second side plates3182a, band the bridge3182care partially disposed in the recess510and extend downwardly from the second truss beam572band the first vertical post570a. The C-shaped orientation, inner surfaces3194a, b, and upper edge3196may provide sufficient surface area for a strong weld connection while still permitting access to the nuts188when the bracket3182is coupled to the cross-brace562.

Looking atFIGS. 26-28, more specifically, the cable clamp3180of the cable clamp recessed bottom fourth orientation550ofFIGS. 26-28may be coupled to the second truss beam572badjacent to a lower portion of the first vertical post570aso that the surface3192of the bridge3182cfaces outwardly, like the second orientation220ofFIGS. 14-17, but the coupling may be recessed inward so that the U-bolt186and the saddle190do not extend (or minimally extend) outward past an outer side face576bof the first vertical post570a. As a result, the cable112may be routed along the underside of the second truss beam572b, as shown inFIGS. 26-28. Because the cable112is recessed inward, and the cable clamp3180does not extend (or minimally extends) outside the first vertical post570a(e.g., past a plane extending from the trailer sidewall14), the cable system58of this embodiment may not interfere with a skirt wall60that would extend downward from the sidewall14. An additional third example cable clamp may be coupled to the second vertical post and the first truss beam in the same manner as the illustrated third example cable clamp3180is connected to the first vertical post570aand the second truss beam572bin the fifth orientation550.

The embodiments shown inFIGS. 10-28allow the cable system58to be completely assembled before being installed within the brace system56. For example, in embodiments where the cable112is routed through apertures114of the cross-braces62, the cable system assembly may only take place after installation of the brace system56. On the other hand, in the embodiments ofFIGS. 10-28, the cable system58and the brace system56may be independent components of the support system54capable of being separately assembled and/or disassembled. As a result, either system58,56may be removed for repair or replacement without the need to disassemble the complete support system54.

Referring toFIGS. 10-21, the first example cable clamps180can be coupled to or mounted on the vertical posts or the truss beams of the second and third example cross braces262,362in a variety of orientations, such as the first orientation210that routes the cable112under the first vertical post270a(as shown inFIGS. 10-13), the second orientation that routes the cable112outside the first vertical post270a(as shown inFIGS. 14-17), or the third orientation330that routes the cable112through the recess310on an outside of the third vertical post370(as shown inFIGS. 18-21). Additionally, the second example cable clamp2180can be coupled to the fourth example cross brace462in the fourth orientation440that routes the cable112through the recess404at a bottom of the vertical post470a(as shown inFIGS. 22-25). Further, the third example cable clamp3180can be coupled to the fifth example cross brace562in the fifth orientation550that routes the cable112below the second truss beam572band inboard of the outwardly-facing second side face576b(as shown inFIGS. 26-28). The differences in these orientations may affect weight, cost, strength, aerodynamics, ease of fabrication and assembly, installation sequence, and/or component access. Because each of these orientations uses a single cable clamp (e.g., first, second, or third example cable clamps180,2180,3180) per vertical post, the resulting cross-brace assemblies are lighter than other designs that require multiple clamping mechanisms. As a result, these orientations may provide a low-weight, low-cost solution for a cable system58that may be compatible with new brace systems56or to retrofit older systems.

Referring back toFIGS. 3-5, the cable system58may span a length of the trailer10. In some embodiments, the cable system58may span substantially the entire length of the brace system56and/or the skirt system52. For example, as shown inFIGS. 3-5, the cable112may span from the landing gear24to the floor assembly26adjacent the rear wheel assembly22. Furthermore, as the cable112is routed through or coupled to the cross-braces62, the cable system58may follow the angled profile of the brace system56, as shown inFIG. 5. Illustratively, this angled or curved profile of the brace system56and the cable system58may permit a positioning of the skirt system52that is more efficient than a skirt system mounted parallel to the side walls14of the trailer10. The cable flexibility allows the cable system58to be routed in different orientations or angles while still being stiff enough to transfer loads to adjoining cross-braces62. It is also contemplated within the scope of this disclosure to include a cable system58that spans shorter or longer lengths than the brace system56or the skirt system52. For example, the cable system58may span from the landing gear24to the rear impact guard, or may be routed across a width of the trailer10through the rear impact guard, the landing gear24, or other mounting brackets to generally form a continuous cable loop around the trailer10. It should be appreciated that the cable system58may be used in conjunction with any of the above described example cross-braces62,262,362,462,562and cable clamp180,2180,3180assemblies.

Looking atFIGS. 3 and 4, the cable112may be permanently or removably anchored to the landing gear24, the floor assembly26, and/or other components of the trailer10. In other words, the cable112may be directly anchored to the trailer10. For example, as shown inFIGS. 3 and 4, the cable system58may include an anchor point116at the landing gear24and an anchor point130(seeFIG. 3) on the floor assembly26adjacent the rear wheel assembly22. As shown inFIG. 29, the anchor point116may include a bracket118, a bolt120, and an eye nut122. The bracket118may be welded to the landing gear24and include an aperture (not shown) to receive the bolt120therethrough. Further, as shown inFIG. 29, the eye nut122may be threaded onto the bolt120after the bolt is routed through the aperture. The cable112may be routed through the eye nut122and then doubled onto itself for increased strength at the anchor point116.

As shown inFIG. 29, one or more clamps126may wrap around the doubled-up portion of the cable112to secure the cable112at the anchor point116. Additionally, in some embodiments, as shown inFIG. 29, the anchor point116may include a curved sleeve or track128to reduce stress on the cable112where it routes through the eye nut122and to potentially reduce twisting of the cable112at the point where it is routed through the eye nut122. In some embodiments, the cable112may be previously wrapped through the forged eye nut122and crimped with the clamps126on either end to form a preset length (e.g., as a pre-clamped assembly). Upon installation, the cable112may be tensioned at the landing gear24by tightening the bolt120and eye nut122arrangement.

In some embodiments, the cable112may include one or more steel cables and may be approximately ½ inch to ¾ inch in diameter. In one specific embodiment, the cable112may be approximately ⅝ inch in diameter. Of course, it is within the scope of this disclosure to include any number of cables of any diameter made from other suitable materials including composite rope, composite fibers, and other suitable high strength, low stretch materials, and having other suitable diameters. Further, the cable112may be covered in ballistic nylon or canvas. Any of the cable concepts, or any other concepts, disclosed in U.S. Provisional Application Ser. No. 62/487,743, filed on Apr. 20, 2017, and entitled Side Underride Guard, may also be utilized with the embodiments described herein. Furthermore, any of the concepts disclosed in U.S. Provisional Application Ser. No. 62/487,775, filed on Apr. 20, 2017, U.S. Provisional Application Ser. No. 62/557,977, filed on Sep. 13, 2017, and U.S. Pat. No. 8,162,384 may be utilized with the embodiments described herein. The disclosure of such applications are hereby incorporated by reference in their entirety.

As described above, a trailer10may be provided with a side underride system50including a skirt system52with skirt walls60and a support system54with any number of cross-braces62and a cable system58between the skirt walls60. Any one of the support systems54described above may be retrofit with existing skirt systems, may be added with new skirt systems, or may completely replace existing skirt systems. The above-described side underride system50may provide dual functions of potentially improving aerodynamic efficiency (i.e., via the skirt system) and providing side underride protection (i.e., via the skirt system and the support system) without presenting operational limitations, such as difficult or costly installation, limiting access to the underside of the floor assembly26, or adding considerable weight to the trailer10. Alternatively, the above-described side underride system50may solely provide side underride protection (i.e., via the support system, without a skirt system) without presenting such operational limitations. Such side underride protection may reduce the risk of passenger vehicle underride in the event of a side impact collision, and may reduce the risk of pedestrians, bicyclists, or motorcyclists from falling or sliding under the trailer10, for example, between the landing gear24and the rear wheel assembly22.

While the invention has been illustrated and described in detail in the foregoing drawings and description, the same is to be considered as illustrative and not restrictive in character, it being understood that only illustrative embodiments thereof have been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected. For example, any of the features or functions of any of the embodiments disclosed herein may be incorporated into any of the other embodiments disclosed herein.