Abstract:
In some embodiments, a decking system may include one or more of the following features: (a) a plurality of deck panels operably coupled to and supported by rails extending parallel to the deck panels, (b) a plurality of rail legs coupled to the rails at one end of the rail leg and extending the rails up off of a base coupled to the rail leg at a second end of the rail leg, (c) a plurality of cross rails positioned perpendicular to the deck panels and rails, the cross rails coupled to the rails and supporting angle bars welded to the deck panels, (d) a plurality of angled support members coupled to the base and to the rail legs, (e) a floor coupler attached to the rail leg for providing attachment to the base, (f) a decking coupler attached to the rail leg for providing attachment to the rail, and (g) a ladder slat coupled to the rail having slots to receive cross rails.

Description:
FIELD OF THE INVENTION 
     Embodiments of the present invention generally relate to transport systems. Particularly, embodiments of the present invention relate to facilitating transport of vehicles. More particularly, embodiments of the present invention relate to decking systems used for shipping vehicles in freight containers of all types. 
     BACKGROUND 
     Shipping is the physical process of transporting goods and cargo. Virtually every product ever made, bought, or sold has been affected by shipping. Despite the many variables in shipped products and locations, there are only three basic types of shipments: land, air, and sea. 
     Land or ground shipping can be either by train or by truck. Trucking is easily the most popular form of shipping. Even with air and sea shipments, ground transportation is still required to take the product from its origin to the airport or seaport and then to its destination. Ground transportation is typically more affordable than air shipments, but more expensive than shipping by sea. Trucks are also much faster than ships and rail but slower than planes. Many trucks will take freight directly from the shipper to its destination in what is known as a door to door shipment. Vans and trucks of all sizes make deliveries to sea ports and air ports where freight is moved in bulk also. 
     Manufacturers of vehicles, such as ATVs and golf carts, need a way to economically ship finished units from their factories to distributors and dealers throughout the country and oversees. Shipping these vehicles throughout the country can be done with semi-trailers. A semi-trailer is a trailer without a front axle. A large proportion of its weight is supported either by a road tractor or by a detachable front axle assembly known as a dolly or by the tail of another trailer. A semi-trailer is normally equipped with legs which can be lowered to support it when it is uncoupled. A road tractor coupled to a semi-trailer is often called a semi-trailer truck or semi. Though most road trailers meet this definition, the term is most often applied to heavy trailers appropriate for use in such a rig. 
     A typical trailer for an 18-wheel semi-tractor trailer is 8 ft. 6 in. wide, 53 ft. long and from floor to ceiling is about 9 ft. 2 in. in height. In shipping ATVs without crating, they can be placed two abreast in a semi-trailer and, given the length of the ATVs, however, only a limited number can be loaded onto the floor of the semi-trailer. If ATVs could be stacked two high within the semi-trailer, the hauling capacity can be doubled. 
     While it is recognized a semi-trailer could be especially constructed with an intermediate deck between the floor and ceiling of the semi-trailer, this application would be limited to being used on box trailers and not to curtain siders (a curtain sider is similar to a box trailer except the sides are movable curtains made of reinforced fabric coated with a waterproof coating). Thus only half of a curtain side semi-trailer can be used when transporting vehicles. Further, intermodal freight containers have no catch mechanisms mounted to the side of the containers for mounting an intermediate deck between the floor and the ceiling. 
     When shipping vehicles such as ATVs and golf carts, the vehicles are often crated up and placed in containers made of wood. However, the utilization of crates becomes problematic when shipping vehicles overseas. Due to the International Plant Protection Convention (abbreviated IPPC), most crates shipped across national borders must be made of materials are incapable of being a carrier of invasive species of insects and plant diseases. The standards for these pallets are specified in ISPM 15. 
     Crates made of raw, untreated wood are not compliant with ISPM 15. To be compliant the crates must be treated by either of the following under the supervision of an approved agency. (1) Heat treatment: The wood must be heated to achieve a minimum core temperature of 56° C. for at least 30 minutes. Crates treated via this method bear the initials HT near the IPPC logo. (2) Chemical fumigation: The wood must be fumigated with methyl bromide. Crates treated via this method bear the initials MB near the IPPC logo. Making creates IPPC compliant can be very expensive and purchasing these crates to ship commodities can be very expensive. Crates made of non-wood materials such as steel, aluminum, plastic, or engineered wood products, such as plywood, oriented strand board, or cardboard do not need IPPC approval. However, these crates are equally expensive. 
     Further, crates can take up a lot of space in the container used to ship commodities overseas. Containerization is a system of intermodal freight transport using standard ISO containers (known as shipping containers or isotainers) loaded and sealed intact onto container ships, railroad cars, planes, and trucks. Containers have similar dimensions to the tractor trailer discussed above. 
     It would be desirable to provide a decking system readily installed and taken down by a single workman and which is relatively compact, allowing storage at the front of a trailer or container when not in use. It would be further desirable to eliminate the need for crates to ship vehicles such as ATVs and golf carts. It would be desirable to reduce the cost of shipping vehicles such as ATVs and golf carts. It would be desirable to eliminate the need to comply with regulations surrounding the use of crates in shipping materials. 
     SUMMARY OF THE INVENTION 
     In some embodiments, a decking system may include one or more of the following features: (a) a plurality of deck panels operably coupled to and supported by rails extending parallel to the deck panels, (b) a plurality of rail legs coupled to the rails at one end of the rail leg and extending the rails up off of a base coupled to the rail leg at a second end of the rail leg, (c) a plurality of cross rails positioned perpendicular to the deck panels and rails, the cross rails coupled to the rails and supporting angle bars welded to the deck panels, (d) a plurality of angled support members coupled to the base and to the rail legs, (e) a floor coupler attached to the rail leg for providing attachment to the base, (f) a decking coupler attached to the rail leg for providing attachment to the rail, and (g) a ladder slat coupled to the rail having slots to receive cross rails. 
     In some embodiments, a decking system for vehicles may include one or more of the following features: (a) a rail leg having a floor coupler and a decking coupler; the floor coupler capable of being coupled to a base of a shipping container, (b) a rail coupled to the decking coupler, (c) a first cross rail coupled to the rail, the cross rail being perpendicular to the rail, (d) a deck panel supported by the first cross rail and a second cross rail coupled to the rail, (e) angle bars welded to the deck panel, the angle bars being supported by the first cross rail and the second cross rail, and (f) a third cross rail extending between the rail and a second rail approximately half way down the deck panel to be received by a channel in the deck panel. 
     In some embodiments, a decking system for shipping ATVs may include one or more of the following features: (a) a left deck panel, a center deck panel, and a right deck panel, (b) a first cross rail supporting a front of the left, the center, and the right deck panels, (c) a second cross rail supporting a middle of the left, the center, and the right deck panels, (d) a third cross rail supporting a rear of the left, the center, and the right deck panels, (e) a first rail coupled to a left end of the first, the second, and the third cross rail, (f) a second rail coupled to a right end of the first, the second, and the third cross rail, (g) a rail leg coupled to a front, middle and rear of the first and second rails, (h) angle bars welded to the deck panels, the angle bars resting upon the first and third cross rails for the deck panels support, (i) a channel located in a midportion of the deck panels for accepting the second rail within the channel, (j) a ladder slat within a slat slot on the rails, (k) a claw catch located on the right and the left ends or the cross rails for insertion into a slot on the ladder slat, and (l) a rail slot on the rails for coupling the rails to the rail legs. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
         FIG. 1  shows a curtain sider trailer in an embodiment of the present invention; 
         FIG. 2  shows a shipping container in an embodiment of the present invention; 
         FIG. 3  shows all isometric view of a decking system for a shipping container in an embodiment of the present invention; 
         FIG. 4  shows a front or rear end view of a decking system for a shipping container in an embodiment of the present invention; 
         FIG. 5  shows a front view of connection between decking couplers, rails, and cross rails in an embodiment of the present invention; 
         FIG. 6  shows a side view of a connection between rails and cross rails in an embodiment of the present invention; 
         FIG. 7  shows a side view of a deck panel in an embodiment of the present invention; 
         FIG. 8  shows a front view of a decking system with loaded ATVs in an embodiment of the present invention; 
         FIG. 9  shows an isometric view of a decking system for a curtain sider trailer in an embodiment of the present invention. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The following discussion is presented to enable a person skilled in the art to make and use the present teachings. Various modifications to the illustrated embodiments will be readily apparent to those skilled in the art, and the generic principles herein may be applied to other embodiments and applications without departing from the present teachings. Thus, the present teachings are not intended to be limited to embodiments shown, but are to be accorded the widest scope consistent with the principles and features disclosed herein. The following detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. The figures, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of the present teachings. Skilled artisans will recognize the examples provided herein have many useful alternatives and fall within the scope of the present teachings. While embodiments of the invention discussed below are discussed in detail with respect to the shipping of vehicles such as ATVs and golf carts, it is fully contemplated the invention could be extended to most any vehicle or commodity without departing from the spirit of the invention. 
     With reference to  FIGS. 1 and 2 , environments for application of embodiments of the present invention are shown.  FIG. 1  shows a curtain sider trailer  10  having a deck  12 , ceiling  14 , a first curtain side  16 , a second curtain side  18 , and a front end  20 . As discussed above, curtain sider trailer  10  could be utilized for land transport of commodities, such as ATVs and golf carts (vehicles), transported by tractor trailer trucks. Implementation of a decking system for a curtain sider trailer will be discussed in more detail below. 
       FIG. 2  shows a shipping container  30  having a base  32 , ceiling  34 , side walls  36  and  38 , and container openings  40  and  42 . Shipping container  30  can be used to ship commodities, such as vehicles, via land, air, or sea. Shipping container  30  can be carried on tractor trailer trucks, ships, or planes. Implementation of a decking system for a shipping container will be discussed in more detail below. 
     With reference to  FIG. 3 , an isometric view of a decking system for a shipping container in an embodiment of the present invention is shown. Shipping container decking system  50  can have a rail leg  52  having a floor coupler  54  and a decking coupler  56 , rail  58 , cross-rail  60 , one-wheel deck panel  62 , and two-wheel deck panel  64 . Overall decking system  50  is approximately 39′6″ long, 90″ wide, and 53″ high. Thus decking system  50  could fit well within a 53′, 48′, 45′, or 40′ shipping container without modification. Further, with modification, decking system  50  could be placed within a 20′ shipping container by simply reducing decking system  50  to half its size as will become more readily apparent with further discussion of embodiments of the present invention. While decking system  50  is referenced above with specific measurements, it is fully contemplated decking system  50  could have most any, realistic, measurements to fit most any shipping container without departing from the spirit of the invention. 
     With reference to  FIG. 4 , a front or rear end view of a decking system for a shipping container in an embodiment of the present invention is shown. Decking system  50  can be made from an aluminum-nickel-titanium alloy known in the art as aluminum-6005 T5. However, most any material of necessary strength could be used without departing from the spirit of the invention. Rail legs  52  support decking system  50  above base  32 . Rail leg  52  has a height of 52.37″ to lift decking system  50  off of base  32  to allow vehicles to be parked or stowed below decking system  50  in the area marked as  70 . Thus decking system  50  can have vehicles parked on decking system  50  and below decking system  50  thus filling up container  30 . 
     Rail legs  52  can have floor couplers  54  to secure rail legs  52  to base  32 . This could be performed by simply drilling holes into base  32  and securing floor couplers  54  to base  32  with bolts or screws or most any other fastening device. Floor couplers  54  are also secured to rail legs  52  as well. Floor couplers  54  and rail legs  52  can be one integral part, welded together, or can even be attached with a fastening device. Floor couplers provide vertical stability for rail legs  52  so rail legs  52  do not fall over or collapse. At the top of rail legs  52  are decking couplers  56 . Decking couplers  56  provide support for rail  58 , cross-rail  60 , one-wheel deck panel  62 , and two-wheel deck panel  64  and eventually vehicles  200 . As with floor couplers  54 , decking couplers  56  can be integral with rail legs  52 , welded to rail legs  52 , or attached with a fastening device. 
     With reference to  FIG. 5 , a front view of connection between decking couplers, rails, and cross rails in an embodiment of the present invention is shown. From this view, decking coupler  56  is coupled to rail  58  with a nut and bolt assembly  71 . During installation of decking system  50 , bolts are placed through apertures in decking coupler  56 . Rail  58  is then placed adjacent to decking coupler  56  so the bolt head of bolt assembly  71  is captured or slid into rail slot  72 . When the bolt heads are within rail slot  72 , rail  58  is slid along decking coupler  56  until rail  58  is in place. When in place, a nut is placed on screw threading of bolt assembly  71  and then tightened into place thus securing rail  58  to decking coupler  56 . This process is repeated for each decking coupler  56  and rail  58 . Decking couplers  56  could be spaced approximately 47.75″ apart to provide optimal strength and stability for vehicles  200  to be carried by decking system  50 . It is fully contemplated rail legs  52  and decking couplers  56  could be spaced most any distance apart without departing from the spirit of the invention. 
     With reference to  FIG. 6 , a side view of a connection between rails and cross rails in an embodiment of the present invention is shown. During installation of decking system  50 , a ladder slat  74  is slid down slat slot  76  ( FIG. 5 ) and held in place with attachment mechanisms, such as screws  78 . Ladder slats  74  are used to support cross rails  60 . Claw like catches  80  on the ends of cross rails  60  are placed into slots  82  located on ladder slat  74 . A four sided stable structure is now created consisting of base  32 , rail legs  52 , and cross rails  60 . Cross rails  60  are spaced every 47.75″ to provide adequate support for decking system  50 . 
     With reference to  FIG. 7 , a side view of a deck panel in an embodiment of the present invention is shown. A one wheel deck panel  62  is shown in  FIG. 7 , however, for purposes of this discussion a one wheel deck panel  62  and a two wheel deck panel  64  are essentially equivalent except for two wheel deck panel  64  is approximately twice as wide as one wheel deck panel  62  to provide support for two wheels instead of one as shown in  FIG. 8 . Deck panels  62  and  64  can be made of Welded aluminum-6061, however, deck panels  62  and  64  can be made of most any resilient material without departing from the spirit of the invention. 
     Each of deck panels  62  and  64  has a side rail  126 , which may be extruded bars of I cross-section or, alternatively, can be extruded tubes of rectangular cross-section. Angle bars  125  and  127  are welded to the opposed ends of each of panels  62  and  64  for engaging cross rails  60 . Extending between rails  125  and  127  and welded thereto is aluminum decking members  128 . Without limitation, each of decking members  128  may be approximately 9″ in width with adjacent decking members  128  spaced apart by about 3″ along the length of rails  126 . By spacing decking members  128  in the manner described, the overall weight of each decking system is reduced without compromise of its structural integrity and load bearing ability for the load contemplated. 
     Transversely extending channel  130  defines a notch inset into rails  126  at their approximate midsections to allow them to engage cross rails  60  at a location to prevent shifting of deck panels  62  and  64  due to any sudden acceleration or deceleration during shipping. Once deck panels  62  and  64  are installed so as to run the full length of the shipping container  30 , ATVs  200  may now be loaded ( FIG. 8 ). To facilitate the loading operation, the system of the present invention includes a ramp assembly used to allow ATVs  200  to be driven from ground level and up a ramp to either the floor level of the trailer or to the elevated deck. A suitable ramp for placing ATVs  200  on decking system  50  can be found in U.S. Pat. No. 6,524,055, issued to Overbye, titled Semi-Trailer Loading Ramp for Transporting ATVs herein incorporated by reference in its entirety. 
     With reference to  FIG. 9 , an isometric view of a decking system for a curtain sider trailer in an embodiment of the present invention is shown. Similar to decking system  50 , decking system  300  can be used with curtain sider trailer  10  as discussed above. Decking system  300  can have rail legs  302  supported by angled support members  310 . Rail legs  302  can be connected to rails  304  in a manner similar to the discussion above. Rails  304  have, located between rails  304 , one wheel  306  and two wheel deck panels  308  replacing cross rails  60  in the embodiment of decking system  50 . Deck panels  306  and  308  could be secured directly to rails  304  to prevent movement of deck panels  306  or  308  during transportation. During loading of sider trailer  10  with vehicles  200 , a ramp system as discussed above would be placed at the side of trailer  10  where vehicles  200  could be loaded. This could be done by loading a bottom vehicle first and then loading a top vehicle or vise versa. In this embodiment, vehicles  200  would be transported perpendicular to the length of trailer  10  in contrast to decking system  50 . Nevertheless, no modification of any parts of decking system  50  is required. Decking system  300  could be implemented using elements of decking system  50 . Thus, only one decking system could be manufactured and sold regardless of the environment it would be used within. 
     Thus, embodiments of the MODULAR VEHICLE TRANSPORT are disclosed. One skilled in the art will appreciate the present teachings can be practiced with embodiments other than those disclosed. The disclosed embodiments are presented for purposes of illustration and not limitation, and the present teachings are limited only by the claims follow.