Abstract:
An aerodynamic trailer including first and second side panels, the side panels each having a trapezoidal channel running along a substantial length thereof; an arcuate front panel extending substantially between front edges of the side panels; a top positioned above the front panel and the side panels, the top having a rearwardly sloping front section and two oppositely positioned outer fins running along outward portions thereof and a center fin running along a center thereof; a door positioned at rear edges of the side panels and the top; and at least one axle supporting at least two wheels. Other features of the trailer create aerodynamic benefits.

Description:
FIELD OF THE INVENTION 
     The embodiments of the present invention relate to an aerodynamic trailer designed to (i) eliminate a conventional interior trailer frame structure, (ii) improve over-road fuel efficiency by reducing aerodynamic drag and (iii) improve handling and safety by reducing the effects of crosswinds and turbulence created by ground effects and passing, or being passed by, other vehicles on the road. 
     BACKGROUND 
     Conventional trailers are constructed with an interior frame which provides the necessary support for the outer skin of the trailer. Moreover, such trailers are normally rectangular in shape to accommodate the desired load (e.g., automobiles) to be transported therein. 
     It would be advantageous, to develop a trailer with additional interior space by utilizing an exterior frame in lieu of a conventional interior frame. Beneficially, the trailer should be designed with aerodynamic features causing the trailer to ride smoother while resisting cross-winds for overall better handling of the trailer and vehicle pulling the same while improving fuel-efficiency for the vehicle pulling the same. 
     SUMMARY 
     Accordingly, one embodiment of the present invention is an aerodynamic trailer including first and second side panels each having aa longitudinal channel running along a substantial length thereof; an arcuate front panel extending substantially between front sections of said side panels; a top positioned above said front panel and said side panels, said top having a rearwardly sloping front section, two oppositely positioned outer fins running along outward portions thereof and a center fin running along a center thereof; a rear door positioned proximate to rear portions of said side panels and said top; and at least one axle supporting at least two wheels 
     The channels running along said side panels create rigidity along the side panels while the arcuate front panel being formed of a single piece of curved metal has a natural curved rigidity such that the trailer is structurally strengthened without an interior frame structure. In one embodiment, the side panels are each fabricated of a single piece of aluminum with the channels being created using a press brake machine or similar machine. 
     The unique aerodynamic design of the trailer reduces aerodynamic drag and the structural “exoskeletal” fins help reduce effects of crosswinds. In another embodiment, the entire undersurface and wheel axles are covered to further reduce drag and turbulence created by air moving beneath the trailer. 
     Other variations, embodiments and features of the present invention will become evident from the following detailed description, drawings and claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates an upper perspective front view of a trailer according to the embodiments of the present invention; 
         FIG. 2  illustrates a side and rear perspective view of the trailer according to the embodiments of the present invention; 
         FIGS. 3A and 3B  illustrate side views of the trailer according to the embodiments of the present invention; 
         FIG. 4  illustrates a front view of the trailer according to the embodiments of the present invention; 
         FIG. 5  illustrates a rear view of the trailer according to the embodiments of the present invention; 
         FIGS. 6A through 6C  illustrate various interior views of the trailer according to the embodiments of the present invention; 
         FIG. 7  illustrates a structural undercarriage frame according to the embodiments of the preset invention; 
         FIG. 8  illustrates a smoothly surfaced underside of the trailer according to the embodiments of the present invention; 
         FIG. 9  illustrates a side panel being stamped with a structural channel according to the embodiments of the present invention; 
         FIG. 10  illustrates a structural side panel according to the embodiments of the present invention; 
         FIG. 11  illustrates a front panel being formed according to the embodiments of the present invention; and 
         FIG. 12  illustrates a cross-sectional view of the roof/top connection to the trailer body according to the embodiments of the preset invention. 
     
    
    
     DETAILED DESCRIPTION 
     For the purposes of promoting an understanding of the principles in accordance with the embodiments of the present invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Any alterations and further modifications of the inventive feature illustrated herein, and any additional applications of the principles of the invention as illustrated herein, which would normally occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the invention claimed. 
     The components described herein may be fabricated of various materials including metals, alloys, composites, fiberglass, polymers and the like. The components may be fabricated using machining, stamping, molding, additive techniques and the like. In one embodiment, aluminum and fiberglass are used to fabricate a large majority of the trailer. 
     Now referring to  FIGS. 1 through 3B , the embodiments of the present invention relate to an aerodynamic trailer  100 . The trailer  100  includes broadly a first side panel  110 , second side panel  120 , front panel  130 , top  140 , rear door  150 , wheels  160 - 1  through  160 - 4  and main frame, the internal undercarriage  170 . In one embodiment, each side panel  110 ,  120  is fabricated of a single piece of material (e.g., aluminum). As shown in  FIG. 8 , bends  115 - 1 ,  115 - 2 ,  125 - 1  and  125 - 2  are formed into each panel  110 ,  120 , respectively, to provide structural rigidity along lengths thereof. The bends  115 - 1 ,  115 - 2 ,  125 - 1  and  125 - 2  form trapezoidal channels  116 ,  126 , respectively. The trapezoidal channels  116 ,  126 , resist flexing along horizontal axes of the side panels  110 ,  120  such that an interior frame is not necessary to support said side panels  110 ,  120 . 
     As shown best in  FIG. 4 , in one embodiment, the front panel  130  is a single piece of aluminum bent into an arcuate shape as shown in  FIG. 11 . The arcuate shape is a natural stable shape which resists flexing while further providing an aerodynamic front surface. While a vehicle towing the trailer  100  tends to block air flow from the front surface of the trailer  100 , such is not always true. Accordingly, when air flow does reach the front surface of the trailer  100 , the arcuate front panel  130  directs said air flow around the front surface with limited drag. A conventional trailer&#39;s flat front surface creates maximum drag and turbulence when said flat front surface encounters air flow. 
     The front panel  130  incorporates two doors  131 ,  132  providing access to a front, internal portion of the trailer  100 . In one embodiment, the doors  131 ,  132  are formed by cutting out a section of the front panel  130  so a hinged arrangement may be used to re-attach the cutout sections to the front panel  130 . Locking handles  136 ,  137  maintain the doors  131 ,  132  in closed positions and provide means for opening the same. 
       FIGS. 2, 5A and 5B  show a rear, drop-down door or tailgate  150 . The rear, drop-down door  150  permanently and rotatably attaches to the undercarriage  170  enabling the rear, drop-down door  150  to swing open in a downward direction. In one embodiment, a rod and spring arrangement provides resistance to the weight of the door for easily controlled rotation of the rear, drop-down door  150 . A guard  152 , or rear apron, protects the rod and spring arrangement. Other rotation systems (e.g., spring-biased hinges) may be used as well. A pair of handle locks  171 ,  172  provides a mechanism for opening and securing the rear, drop-down door  150  in a closed position. A plurality of bumpers  173 - 175  provides a buffer for resting the rear, drop-down door  150  against the ground when in an open position. The bumpers  173 - 175  also serve to prevent damage to the rear, drop-down door  150  when in the open position. A rear vertical frame member  180  attaches to the undercarriage  170  (best seen in  FIG. 7 ) and frames the rear, drop-down door  150  and provides a structure for attachment of the pair of handle locks  171 ,  172 . In an open position, the rear, drop-down door  150  acts as a ramp to load vehicles or other cargo to be transported within said trailer  100 . 
     The undercarriage  170  is a sandwiched frame lattice which is configured to support the components of the trailer  100 . The frame lattice extends forward to a trailer hitch  175 . An adjustable height front wheel member  177  provides a mechanism for manually moving the trailer  100  and raising or lowering the front end of the trailer  100  onto a tow vehicle hitch. 
       FIGS. 1-5  show the top  140  of the trailer  100  in position upon the vertical frame member  180 , front panel  130  and side panels  110 ,  120 . Attachment of the top  140  is accomplished using a combination of fasteners and adhesives (e.g., two part epoxy) for bonding aluminum to fiberglass. In one embodiment, the adhesive may be supplemented with fasteners such as rivets  131  or nut and bolt combinations which attach the top  140  to an upper frame member  132  circumscribing an upper edge of said side panels  110 ,  120  and front panel  130 . The adhesive forms a secure bond and permits the two different materials to expand and contract at their own rates without impacting the other. In one embodiment, as shown in  FIG. 12 , the lower edge of the top  140  includes a flange comprising a horizontal section  146  and vertical section  148  which rests on the upper frame member  132  extending around the upper edge of the side panels  110 ,  120  and front panel  130 .  FIG. 12  shows the position of the adhesive. The upper frame member  132  connects to the rear vertical frame  180  proximate to the rear, drop-down door  150 . 
     The front portion of the top  140  is arcuate sloping rearward to limit drag. As detailed above relative to the front panel  130 , a vehicle towing the trailer  100  tends to block air flow from the front surface of the top  140 , such is not always true (e.g., when a low profile automobile is towing the trailer). Accordingly, when air flow does reach the front surface of the trailer  100 , the arcuate top  140  directs said air flow over the front surface with limited drag. A conventional trailer&#39;s flat front surface creates maximum drag when said flat front surface encounters air flow. 
     One or more spars  147 , as best visible in  FIGS. 6A and 6B , provide an inner shielded routing for electrical wiring and also providing additional support and stability for the top  140 . Five struts  141 - 145  extending vertically between the undercarriage  170  and upper frame member  132  proximate to the front panel  130  serve to support the weight of the top  140  and/or maintain the arcuate shape of the front panel  130 . More or less than five struts may be used. Other interior features of the trailer  100  comprise wheel covers (inner fenders)  190 ,  191 , a floor  192  secured to the undercarriage  170  which is “sandwiched” to the frame  170  to increase structural rigidity, a shelf  193  and various tie-downs  194 . 
     The top  140  also incorporates a pair of outer fins  145 - 1 ,  145 - 2  and a center fin  147 . In one embodiment, the top  140 , including triangular sectioned outer fins  145 - 1 ,  145 - 2  and center fin  147 , is molded using fiberglass or similar composite material. Those skilled in the art will recognize that other fabrication techniques may be used to create the top  140 . The outer fins  145 - 1 ,  145 - 2  and center fin  147  provide longitudinal structure to the top  140  and also provide stability to the trailer  100  when being towed. More specifically, the outer fins  145 - 1 ,  145 - 2  and center fin  147  maintain the trailer  100  moving in a forward direction and resist swaying caused by turbulent air including cross-winds. In one embodiment, the center fin  147  has a triangular cross-section. The center portion  149  of the top  140  has a slight arcuate shape which helps smooth air flow between the center fin  147  and two outer fins  145 - 1 ,  145 - 2  as well as increasing structural rigidity of the roof  140  top. 
     Two fiberglass wheel guards  190 - 1 ,  190 - 2  protect the wheels/tires and are further configured to permit smooth air flow around the wheels which tend to create turbulence when in motion. In one embodiment, like the top  140 , the wheel guards (exterior fenders)  190 - 1 ,  190 - 2  are molded of fiberglass and may be adhered to the side panels  110 ,  120 , respectively, using an adhesive. In another embodiment, conical wheel covers  192  further reduce turbulence caused by tires turning and disrupting air flow.  FIG. 8  illustrates an underside of the trailer  100  including a substantially flat aluminum panel  200  connected to, and covering, the underside of the undercarriage  180  and wheel axles. Multiple flat members may be attached to the undercarriage  180  as well. Like other components of the trailer  100  described herein, the flat aluminum panel  200  reduces drag caused by air turbulence beneath the trailer  100  when in motion and increases the structural rigidity of the main frame  170 . Nerf bars  153  running along bottom portions of the trailer  100  provide style and certain functionality (e.g., additional structural integrity) to the trailer  100 . 
       FIG. 9  illustrates a side panel  110 ′ undergoing a press brake stamping process to form the trapezoidal channel section according to the embodiments of the present invention and  FIG. 10  illustrates a finished side panel  110 ′ and channel  116 ′ according to the embodiments of the present invention.  FIG. 11  illustrates a front panel  130 ′ undergoing a rolling process to create its arcuate shape according to the embodiments of the present invention. 
     Although the invention has been described in detail with reference to several embodiments, additional variations and modifications exist within the scope and spirit of the invention as described and defined in the following claims.