Trailer, wall construction and manufacturing method

A trailer includes a bed with a floor structure and a superstructure mounted on the bed. The superstructure includes a wall construction of wall sections with interconnected tongue-and-groove edges and wall section ends. Corner posts include channels receiving the wall section ends for forming corners of the superstructure. A top rail forms a rim of the superstructure and receives the top-most wall sections. A rub rail connects the walls to the floor structure and receives the bottom-most wall sections. A method of manufacturing a trailer includes the steps of providing a bed with a floor structure and forming a superstructure from wall sections by interconnecting their tongue-and-groove edges. The trailer can be configured for a moving floor, a tipping mechanism or an ejector mechanism for discharging and/or loading materials and cargo in an interior.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to vehicle systems and methods for constructing vehicle walls, and in particular to the construction of trailers for transporting goods and materials. More specifically, the present invention relates to a wall construction comprising interconnected members and methods of constructing vehicle walls by interconnecting extruded members.

2. Description of the Related Art

Vehicles are commonly constructed with enclosed or partially-enclosed interior spaces for receiving cargo and passengers. For example, trailers are constructed in various configurations including flatbed (unenclosed), open-top, fully-enclosed and numerous variations, all according to their intended cargoes, occupancies and uses. The design criteria for enclosed vehicle construction can include strength, weather resistance, aerodynamics and light weight for fuel efficiency, long service life, aesthetics, adaptability to various configurations and economy of construction. Vehicles have previously been constructed using various materials, configurations and construction techniques in order to satisfy these and other design criteria.

A common trailer configuration uses a framework of interconnected, elongated steel or aluminum structural members, which are covered by a suitable skin, such as sheet metal, on the sides and/or top. A bed is constructed for mounting wheels and a trailer hitch, such as a king pin. A superstructure including walls can be mounted on the bed. Vertical ribs can be left exposed or covered for a smooth-side exterior. Extruded panels have also been used for constructing trailers. Examples are shown in U.S. Pat. Nos. 7,014,252; 7,100,972 and No. 7,152,909.

Heretofore there has not been available a trailer, wall construction and manufacturing method with the advantages and features of the present invention.

SUMMARY OF THE INVENTION

In the practice of an aspect of the present invention, a vehicle, such as a trailer, is constructed using multiple, extruded sections for forming walls. Each wall section includes a tongue and a groove adapted for interlocking with an adjacent section or sections. Corners are formed with corner posts adapted for receiving the ends of the sections forming the intersecting walls. Top rails form a rim around the top of the trailer superstructure. Rub rails are provided for interconnecting the walls and a trailer bed. A trailer door at a rear wall of the trailer can be added to enclose the interior cargo space. According to another aspect of the present invention, a wall is constructed using interconnected, extruded sections. According to still another aspect of the present invention, a trailer construction method includes the steps of interconnecting multiple, extruded sections to form a superstructure including walls, and mounting the superstructure on a trailer bed.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

I. Introduction and Environment

Certain terminology will be used in the following description for convenience in reference only and will not be limiting. For example, up, down, front, back, right and left refer to the invention as oriented in the view being referred to. The words “inwardly” and “outwardly” refer to directions toward and away from, respectively, the geometric center of the embodiment being described and designated parts thereof. Forwardly and rearwardly are generally in reference to the direction of travel, if appropriate. Said terminology will include the words specifically mentioned, derivatives thereof and words of similar meaning.

Referring toFIG. 1, the reference numeral2generally designates a trailer embodying an aspect of the invention. The trailer2generally includes a bed3mounting a superstructure5. The bed3mounts a wheel truck7and a king pin hitch9, and includes a floor structure18. The superstructure5includes sidewalls11, a front wall13and an optional rear door10in a rear wall34. Without limitation on the generality of useful trailer configurations embodying the present invention, the trailer2shown has an open-top configuration forming an interior12for receiving cargo. A cross brace8connects the sidewalls11at an upper rim15of the superstructure5. Alternatively, the superstructure5could be provided with a roof or a removable cover, such as a tarp, for fully-enclosing the interior12. A rollup-type door10is shown, but other types of doors could also be provided at the rear wall34and at other locations as required for accessing the interior12. The superstructure5is generally constructed with multiple, horizontal, interconnecting wall sections4and corner posts6at the wall intersections.

III. Wall Construction

As shown inFIGS. 4 and 4A, the wall sections4snap together through a top snap connection or groove20and a bottom snap connection or tongue22to form the walls11and13. Top rails14are connected to the top-most wall sections4and form the superstructure upper rim15. Rub rails16are connected to the bottom-most wall sections4and the floor structure18. The top rails14and the rub rails16are also connected to the corner posts6as shown inFIGS. 6 and 7. The superstructure5components can be welded, glued, or connected together with any suitable fastening technique, including press-fit and mechanical fasteners. For example and without limitation, the wall sections4can be secured together by a suitable adhesive, by welding or simply by snap-fitting together. Likewise and without limitation, the top and rub rails14,16and the corner posts6can be welded, glued or mechanically fastened (e.g., rivets, screws, bolts, etc.) together. Different fastening techniques can be used for different sets of components of the superstructure5, as appropriate for accommodating different dynamic stress and load conditions and other considerations.

As shown inFIG. 5, each corner post6includes a pair of wall channels26which receive ends17of the wall sections4. The corner post6is capped with a corner cap28which sits atop the top rail14and seals off the corner post6(FIG. 6). The corner post6includes a radiused, outer wall21and an inner wall23extending at an angle of approximately 45° between the wall channels26, which are oriented at an angle of approximately 90° with respect to each other for forming a right-angle corner with a side wall11at the front or rear of the trailer2.

As shown inFIG. 4, the wall sections4can be interlocked using their tongue-and-groove configurations to create the walls11and13. Each wall section4includes a first or inner wall face30and a second or outer wall face32, although these orientations could be reversed. Each wall section also includes multiple (e.g., two) internal spacers24extending between the faces30,32and defining multiple, enclosed, longitudinally-extending hollow compartments25. The wall section grooves20are located at a first or upper wall section edge27and are shown with upwardly-open orientations. The tongues22are located at a second or lower wall section edge29and are shown depending downwardly, although these orientations could be reversed. The top snap connection groove20is formed by a first upper extension31of the inner wall face30and by a second upper extension33of the outer wall face32. The first upper extension31includes a double thickness of material forming a ridge38protruding inwardly into the groove20. A groove base35extends between the extensions31,33and provides a lower closure for the groove20and an upper closure for the upper wall section compartment25.

The tongue22is recessed from the wall section faces30,32and has a cross-sectional configuration corresponding to the groove20with a lip37forming a channel39for receiving the ridge38of a respective tongue22in a snap-together, retained relationship (FIG.4A) with the wall section faces30,32generally flush. The wall section tongues22and grooves20can be dimensioned for secure, snapped-together interconnections whereby entire walls11,13can be constructed with or without additional fastening means. Other tongue-and-groove or interconnecting wall section configurations can be used.

As shown inFIG. 4B, each top rail14includes: a first or outer face52; a second or inner face54; a top rail spacer56connecting the faces52,54; a top panel58; an upper beveled face60; and a lower beveled face62. Upper and lower top rail hollow chambers64,66are formed above and below the spacer56respectively. The lower top rail chamber66is downwardly-open through a passage68between the outer face52and the lower beveled face62. The lower chamber66receives the top-most wall section4, which extends partly into the lower chamber66. The top rails14intersect at their ends with the corner posts6, as shown inFIG. 6.

As shown inFIG. 4C, each rub rail16includes an upper portion70with a beveled face72extending between the lower-most wall section4and the floor18. A horizontal face74overlies the floor18. A channel-shaped lower portion76includes an inner face78located adjacent to an edge of the floor18, a bottom spacer80and an outer lip82. The lower portion forms an upwardly-open channel84, which receives the tongue22. The rub rail16securely mounts the walls11,13on the floor structure18by mechanical fasteners, welding, adhesive, etc.

The floor structure18includes multiple crossbeams19extending transversely with respect to the trailer bed3and each having a configuration as shown inFIG. 8with a front leg44extending downwardly and rearwardly from a deck46for improved aerodynamics because the streamlined slope of the leg44offers less wind resistance than a vertical leg. A crossbeam base48is generally horizontal and a rear leg50extends generally vertically and connects to the floor deck46. The flooring for the trailer2can be of any type or variety. A solid floor deck46can be placed atop the crossbeams19, as shown inFIG. 8.

V. Construction and Operation.

The trailer2can be alternatively configured for various tasks. For example, moving floors have slats driven by hydraulics for conveying material along their surfaces to facilitate loading and unloading operations. Such moving floors are available from Keith Mfg. Co. of Madras, Oreg. under its trademark Walking Floor®. Ejectors are also available for installing in trailer interiors and include hydraulic rams for forcibly ejecting the trailer contents. A dump trailer configuration accommodates tipping the superstructure5and the floor18at an incline to discharge the contents. Such alternative constructions and discharge schemes accommodate certain types of operations, particularly those involving bulk materials such as grain, gravel, refuse, scrap metal, etc. The floor18and the crossbeams19can be configured in multiple ways and only a basic configuration is shown in the drawings.

The trailer2can be efficiently constructed using the components discussed above. For example, the wall sections4tend to snap and/or glue together relatively quickly to form the walls11,13. The wall sections4, the corner posts6and the rails14,16can be extruded in various configurations and dimensions from aluminum or some other suitable material. Moreover, the components and the construction method of the present invention accommodate scaling whereby trailers of various sizes and configurations can be constructed using stock components.

In operation, the wall sections enhance the aerodynamic properties of the trailer2by providing a relatively smooth outer surface, thus avoiding wind resistance problems and drag associated with vertical external ribbing. The double-wall construction of the wall sections4also tends to be relatively strong and lightweight, further enhancing the favorable performance characteristics of the trailer2. The inner wall faces30tend to absorb cargo impact forces whereby dents are confined to the interior, leaving the exterior with an unblemished, smooth appearance even after relatively rugged use.

It is to be understood that while certain embodiments and/or aspects of the invention have been shown and described, the invention is not limited thereto and encompasses various other embodiments and aspects.