Abstract:
The sidewalls of a truck/trailer box are constructed from a plurality of panels ( 10, 12, 14 ) which are welded together where their vertical edges meet ( 82, 88, 90 ). The panels ( 10, 12, 14 ) are each extrusions and each includes thin side skins ( 24, 26  and  48, 50  and  56, 58 ) and thin webs ( 28, 52, 60 ). The top panel ( 10 ) may be formed to include an integral top rail ( 34 ). The bottom panel ( 14 ) may be formed to include one or two side rails ( 18, 18 ′ and  120 ). The regions that need to be welded are made thick enough to be welded. Other regions are too thin to be welded. The overall construction is lightweight and quite strong and facilitates construction of the truck/trailer box.

Description:
RELATED APPLICATIONS 
     This application is a divisional of my application Ser. No. 09/754,705, filed Jan. 4, 2001 now U.S. Pat. No. 6,425,626, and entitled “Truck/Trailer Box Construction”. 
    
    
     TECHNICAL FIELD 
     This invention relates to truck/trailer box constructions. More particularly, it relates to a sidewall construction for a truck/trailer box that is basically characterized by a plurality of horizontally elongated sidewall panels each composed of skins and webs that are too thin to be welded, and to a joint construction that permits the sidewall panels to be welded together where they join. 
     BACKGROUND OF THE INVENTION 
     There is a need for a way of constructing the sidewalls of truck/trailer boxes from materials that are very light weight but strong and rigid. There is also a need for such a truck/trailer box construction that permits sections of a sidewall to be welded together while still allowing for the use of very thin skins and webs that are themselves too thin to be welded. 
     There is also a need for a truck/trailer box sidewall construction that provides for the easy manufacture of both a top rail and a bottom rail for adding strength and rigidity to the tops and bottoms of the sidewalls. 
     The principal object of the present invention is to provide a truck/trailer sidewall construction that meets the above needs. Regarding the prior art, U.S. Pat. No. 5,052,741, granted Oct. 1, 1991, to Raynard Brown and Norval I. Lopshire discloses a truck box that is composed of a plurality of sidewall panels and an interlocking joint structure where edges of the panels meet. In the Background of the Invention portion of this patent, there is reference to the more common truck body sidewalls that are formed from plywood covered with an aluminum or plastic exterior surface. U.S. Pat. No. 5,791,726, granted Aug. 11, 1998, to Thomas N. Kaufman discloses a livestock trailer having sidewalls that are constructed from aluminum tubular members. The Background of the Invention section of this patent discloses and discusses several prior art trailers. 
     U.S. Pat. No. 4,785,929, granted Nov. 22, 1988, to Raymond K. Foster, and U.S. Pat. No. 5,096,356, granted Mar. 17, 1992, also to Raymond K. Foster disclose bottom constructions for truck/trailer boxes. The truck/trailer box sidewalls of the present invention are particularly adapted for use with the bottom constructions disclosed by these patents. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention includes providing a truck/trailer box sidewall construction that is characterized by a horizontally elongated bottom sidewall panel having a top edge, a bottom edge, inside and outside, vertical side skins, and a plurality of vertically spaced apart, horizontal webs interconnecting the side skins vertically between the top and bottom edges. The side skins and the webs together define a plurality of horizontally elongated inner spaces in said bottom sidewall panel. Each inner space is defined horizontally between the two side skins and vertically between the two webs. A horizontally elongated side rail may extend laterally outwardly from the inside skin of the sidewall at a location spaced above the bottom edge. The side rail has a bottom surface that forms a nook with a lower side surface of the inside side skin that extends downwardly from the bottom surface of the side rail. The top and bottom edges, the inside and outside vertical side skins, the horizontal webs and the side rail are all portions of a common extrusion. 
     According to another aspect of the invention, the truck/trailer sidewall further comprises a horizontally elongated top sidewall panel and a plurality of horizontally elongated intermediate sidewall panels. The intermediate sidewall panels are positioned vertically between the top sidewall panel and the bottom sidewall panel. The top sidewall panel has a top portion, a bottom edge, inside and outside vertical side skins, and a plurality of vertically spaced apart horizontal webs interconnecting the vertical side skins. The intermediate sidewall panels have top and bottom edges, inside and outside vertical side skins, and a plurality of vertically spaced apart horizontal webs interconnecting the vertical side skins. The bottom edge of the top sidewall panel is connected to the top edge of an adjacent intermediate wall panel that is below it. The top edge of the bottom wall panel is connected to the bottom edge of an adjacent intermediate sidewall panel that is above it. All other intermediate wall panels are connected to edges of the wall panel that is above it and the wall panel that is below it. When the top sidewall panel, the bottom sidewall panel and the intermediate sidewall panels are all connected together, the outside vertical side skins of all of said panels are substantially coplanar and the inside vertical side skins of all of said wall panels are substantially coplanar. 
     A further aspect of the invention is to provide a side rail that is integral with the inside side skin of the bottom sidewall panel. This sidewall projects laterally from the inside, vertical side skin. 
     The present invention also includes providing a truck/trailer box sidewall construction that comprises a horizontally elongated top sidewall panel having a top portion, a bottom edge, inside and outside, vertical side skins, and a plurality of vertically spaced apart, horizontal webs interconnecting the side skins vertically between the top portion and the bottom edge. The side skins and webs together define a plurality of horizontally elongated inner spaces in said top sidewall panel. Each said inner space is defined horizontally between the two side skins and vertically between two webs. The top portion of the top sidewall panel includes a top rail extending longitudinally of the top sidewall panel. The top edge rail is wider than the top sidewall panel and includes a vertical outside skin, a vertical inside skin, a top skin and a bottom skin, and at least one web extending between the side skins and dividing the top rail into inner spaces. The top rail and the bottom edge of the top sidewall panel, and the inside and outside vertical side skins, and the top and bottom skins of the top rail, and the horizontal webs in the top sidewall panel, and in the top rail, are all portions of a common extrusion. 
     The present invention further includes providing a truck/trailer box sidewall construction that is characterized by a lower, horizontally elongated, first sidewall panel and an upper, horizontally elongated second sidewall panel. The first sidewall panel has a top edge, vertical inside and outside side skins, and vertically spaced apart horizontal webs interconnecting the side skins vertically below the top edge and horizontally between the two side skins. The second sidewall panel has a lower edge, vertical inside and outside side skins, and horizontal webs interconnecting the side skins together vertically above the bottom edge and horizontally between the two side skins. The inside and outside skins of the first and second sidewall panels are too thin to be welded. One of the top and bottom edges includes a longitudinal groove and the other includes a longitudinal tongue that extends into the groove when the top and bottom edges are in contact. The first sidewall panel has corner regions that extend diagonally between the side skins and the top edge of the first wall section. The second sidewall panel has corner regions that extend diagonally between the side skins of the second sidewall section and the bottom edge of the second sidewall section. The corner regions together form horizontally extending weld recesses where the corner regions of the first sidewall panel adjoin the corner regions of the second sidewall panel when the top and bottom edges are in contact. The corner regions of the first and second sidewall panels are thick enough at the weld recesses to permit the placement of weld beads in the weld recesses. Weld beads are placed in the weld recesses and serve to weld the upper edge of the first sidewall panel to the lower edge of the second sidewall panel. 
     Other objects, advantages and features of the invention will become apparent from the description of the best mode set forth below, from the drawings, from the claims and from the principles that are embodied in the specific structures that are illustrated and described. 
    
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING 
     Like reference numerals are used to designate like parts throughout the several views of the drawing, and: 
     FIG. 1 is an end elevational view of a first extrusion that forms a top wall panel section of a trailer sidewall; 
     FIG. 2 is an end elevational view of a second extrusion that forms an intermediate wall panel section of the trailer sidewall; 
     FIG. 3 is an end elevational view of a third extrusion that forms a bottom wall panel section of a trailer sidewall; 
     FIG. 4 is an enlarged scale end elevational view showing the top edge portion of a lower wall panel spaced form a bottom edge portion of an adjacent upper wall panel; 
     FIG. 5 is a view like FIG. 4, but showing the two edge portions of the wall panels together and further showing welds connecting the wall panel sections together where they meet; 
     FIG. 6 is an enlarged scale fragmentary view of the lower portion of FIG. 3, showing an end portion of a transverse beam that extends cross the full width of the trailer and connects to the lower regions of the bottom sidewall panel sections of the trailer; 
     FIG. 7 is a view like FIG. 6, showing a reciprocating slat conveyor installed on the transverse beams, and further showing a relationship between an outside conveyor slat and the side rail that is a part of the extrusion that forms the bottom sidewall panel sections of the trailer sidewall; 
     FIG. 8 is an end elevational view of a modified top sidewall panel showing a top rail extrusion that is separate from the extrusion that forms the top sidewall panel; and 
     FIG. 9 is a view like FIG. 6, but showing a modified construction of the side rail, and showing the bottom sidewall panel section further including a bottom flange that is vertically spaced from the side rail, so as to define an elongated channel in which an end portion of a cross frame member, or a trailer floor section is received. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     FIG. 2 of the aforementioned U.S. Pat. No. 5,096,354 shows a reciprocating slat conveyor forming a floor in a material receiving compartment of a trailer box (TB). The trailer box (TB)is shown to have a pair of sidewalls ( 14 ,  16 ), a forward wall ( 18 ), a rear wall ( 20 ) and a floor or bottom ( 10 ). The rear wall ( 20 )is formed of a door or a pair of doors. The floor ( 10 ) is shown to include transverse beams ( 36 ) on which the conveyor components rest. In FIGS. 2,  3  and  6 , the illustrated transverse beams are I-beams ( 36 ). The construction of the sidewalls is not disclosed and does not matter in that patent. 
     FIGS. 1-3 show components for making the sidewalls of a trailer box or similar container or compartment. Element  10  shown in FIG. 1 is a top panel section for a sidewall. Element  12  shown in FIG. 2 is an intermediate panel section. Element  14  shown in FIG. 3 is a bottom panel section. A typical sidewall is formed by one top panel section  10 , three intermediate panel sections  12  and one bottom panel section  14 . The second sidewall can be formed by the same panel sections  10 ,  12 ,  14 . However, the top panel section  10  and the bottom panel section  14  would have to be turned end to end so that the top rail on top panel section  10  is projecting inwardly and the side rail  18  on bottom panel section  14  is directed inwardly. Because of the sidewall construction, it is only necessary to show one top panel section  10 , one intermediate panel section  12  and one bottom panel section  14 . When the two sidewalls are assembled, each is a mirror image of the other. 
     Top panel section  10  includes a top edge  20  that forms a part of the bottom or base of the top rail  16 . It further includes a bottom edge  22 , a pair of laterally spaced apart side skins  24 ,  26  and a plurality of horizontal webs  28 . The top rail  16  includes an outside skin  30 , a top skin  32 , an inside skin  34 , and a bottom skin  36  and one or two webs  38 . All portions of the top panel section  10  are horizontally elongated, preferably for the full length of the trailer. The top edge  20 , a substantial portion of the bottom edge  22 , skins  32 ,  36  and the webs  28 ,  38  all extend horizontally. The side skins  24 ,  26 ,  30 ,  34  extend vertically. As clearly shown by FIG. 1, outside skins  24 ,  20  are different sections of a continuous single skin that extends from the bottom edge  22  up to the top skin  32 . Inside skin  34  is offset outwardly from inside skin  36 . Webs  28  and edge walls  20 ,  22  divide the space that is laterally between the side skins  24 ,  26  into horizontally elongated spaces  40 . Webs  38  define the space that is laterally between skins  30 ,  32  into three spaces  42 . Spaces  40 ,  42  are horizontally elongated spaces. As previously described, the top panel section  10  is a one-piece extrusion. It is preferably formed from a metal that is predominately aluminum. 
     The intermediate panel section  12  is also a one-piece extrusion. It has an upper edge wall  44 , a lower edge wall  46 , an outside skin  48 , an inside skin  50  and a plurality of webs  52 . Webs  52  divide the space that is laterally between skins  48 ,  50  into smaller spaces  54 . Side skins  48 ,  50  are parallel to each other in separate vertical planes. The webs  52  are parallel to each other in separate horizontal planes. 
     Bottom panel section  14  is also a continuous single piece extrusion. It is formed of outside and inside skins  56 ,  58  that are in separate, parallel vertical planes. The space between the skins  56 ,  58  is divided into smaller spaces by horizontal webs  60 . Webs  60  divide the larger space into smaller spaces or cells  62 . Bottom panel section  14  includes a top edge wall  66  and a bottom edge wall  70 . It also includes the aforementioned side rail  18 . In this embodiment, the side rail  18  has an inner wall  72  that includes the inside skin  58  plus some additional thickness. It also includes a top wall  74 , an inside wall  76 , and a bottom wall  78 . Walls  74 ,  76 ,  78  are substantially equal in thickness. Wall  72  has a thickness that is substantially the sum of the thickness of walls  76  and the skin  58 . 
     Near the bottom of the bottom panel section  14 , the outside skin  56  includes a recess  80 . Because the bottom panel section  14  is formed by extrusion, it is easy to provide the recess  80  and the side rail  18  to the rest of the extrusion. The recess  80  extends the full length of the bottom panel section  14 . A conspicuity tape is received within the recess  80 . 
     The sidewall panel sections  10 ,  12 ,  14  are connected together by weld beads  82 , one on each side of the sidewall. By way of example, the thickness dimension T for the top panel section  10 , below the top rail  16 , the entire intermediate panel section  12 , and the bottom panel section  14 , except at the side rail  18  and at the recess  80  may be substantially about 1½ inches. The skins  24 ,  26 ,  30 ,  48 ,  50 ,  56 ,  58  and webs  28 ,  52 ,  60  may be substantially about 0.09 inches thick. The center-to-center dimension between adjacent webs  28 ,  52 ,  60  may be substantially about 1.763 inches. An important dimension is the thickness Z in the region of the welds  82 . In the example, this thickness is substantially about 0.188 inches. The weld recess width W is substantially about 0.250 inches. The weld recess depth D is substantially about 0.125 inches. 
     In preferred construction, the lower edge walls  22 ,  46  are formed to include a longitudinally extending groove  84 . The top edges  44 ,  68  are provided with a complementary longitudinally extending tongue  86 . As shown by FIG. 5, the tongue  86  makes a loose fit with the groove  84 . In the given example, the tongue width may be substantially about 0.1875 inches. The groove width may be substantially about 0.25 inches. The tongue length may be about 0.1825 inches. The groove depth may be substantially about 0.2475 inches. During assembly, two panel sections to be joined are brought together. The tongue  86  on one is inserted into the groove  84  in the other. Then, the side planes of the two panel sections are put into substantial coplanar alignment and the weld beads  82  are placed within the weld recess W, D. The tongue and groove components facilitate the welding process. If they were not present when the panels were welded together, the panels would expand and contract and become “wavy” down the length of the side. This would make it impossible to weld properly. It would be possible to “tack” weld every twelve inches on one side, but this would be impractical. The invention includes any type of tongue and groove system that holds the panels parallel to each other for welding purposes. For example, a two tongue and two groove system could be used. 
     At each joint, the diagonal corner regions  88 ,  90  provide both structural reinforcement and width and depth for the weld beads W. A weld bead  82  that is substantially triangular in cross section, substantially about 0.250 inches wide, and substantially about 0.125 inches deep is made possible because of the thickness of the material in regions  88 ,  90 . The corner regions  88 ,  90  and the weld beads  82  together form outwardly widening flanges that, together with the wall sections  22 ,  44  provide a reinforcing beam section at the location of each joint. This beam section extends the full length of the joint and its parts  22 ,  44 ,  82 ,  88 ,  90  in effect form I-beam like longitudinal stiffening and strengthening ribs at each joint location. 
     The panels  10 ,  12 ,  14  that make up a sidewall are laid flat on a jig. They are clamped and then tack welded about every four feet on the underneath side. They are no tack welds on the top. Then, all panels are welded the full length of the wall, simultaneously. The wall forming panel assembly is then flipped over to position its welded side facing downwardly. The wall structure is then clamped down and the new “up” side is welded the full length, simultaneously. 
     In the stated example, the width of top rail  16  may be substantially about 3.5 inches. The depth dimension, from the top of skin  32  to the bottom of skin  36  may measure substantially about 9.149 inches. The width dimension of skins  32 ,  34 ,  36  may be substantially about 0.1495 inches. 
     Referring to FIGS. 6 and 7, in the given example, the width and height outside dimensions of the side rail  18  may be substantially about 1.75 inches. Side rail  18  includes a bottom surface  92  that is substantially perpendicular to the side surface  94  of the bottom panel section  14 . The bottom surface  92  and the side surface  94  together form a substantially right angle “nook” in which end portions  96  of transverse frame beams  98  are received. In a manner known per se, the transverse beams  98  are parallel to each other and are spaced apart longitudinally of the trailer. In accordance with an aspect of the present invention, the end portions  96  of the beams  98  are welded to the side rail  18  and the lower portion of the bottom panel section  14  that depends downwardly from the side rail  18 . In the given example, the height dimensions H of the beams  98  is substantially about 5.25 inches. The flanged width a is substantially about 2 inches. The flange and web thicknesses b, c, is substantially about 0.25 inches. In the given example, the dimension d between the lower surface of the lower flange of beam  98  and the lower surface  70  of bottom panel section  14  is substantially about 0.25 inches. To a certain extent, the inside and outside skins of the first and second sidewall panels are too thin to be welded. They can be welded across the ribs but suffer stress cracking when welded along the ribs. 
     FIG. 7 shows a reciprocating slat conveyor mounted on the floor beams  98 . Longitudinal guide a support beams  100  are welded to the top flanges of the beams  98 . See also, for example, FIG. 11 of U.S. Pat. No. 4,785,929. Self-lubricated plastic bearings  102  are positioned on the beams  100 . Elongated conveyor slats  104  are positioned on the bearings  102 . The floor slats  104  are reciprocated lengthwise of the beams  100 . For example, they are all moved in unison from the front to the rear of the truck/trailer box. They are then stopped and are retracted, one third at a time. That is, slats  1 ,  4 ,  7 , etc. are retracted while the remaining slats remain stationary. Then, slats  2 ,  5 ,  8 , etc. are retracted while the others slats are stationary. Then, slats  3 ,  6 ,  9 , etc. are retracted while the other slats are stationary. Then, the cycle is repeated. 
     The conveyor slats  104  carry seal members  106 . The inside seal members  106  make a sliding sealing contact with an opposing side portion of an adjacent conveyor slat  104 . On the two sides of the conveyor, the seal strips  106  make sliding sealing contact with a surface  108  that is the inside vertical face of the side rail  18 . In the system shown by FIG. 7, the floor slat  104  that is adjacent the side rail  18  at the opposite side of the truck/trailer box includes two seal strips  106 . The inside seal strip  106  contacts a confronting surface of the next conveyor slat  104  that is to its inside. The outside seal strip  106  makes sealing contact with a side rail  18  that is like side rail  18  shown in FIG. 7, but projecting inwardly from the bottom sidewall panel  14  that is on the opposite side of the truck/trailer box. 
     As shown by FIG. 7, the skin portion  94  is thicker than the skin portions  56 ,  58 . It is thick enough to allow the end portion of beams  98  to be welded to the skin portions  94 . The side rail  104  is also made thick enough so that it can welded to the top flanges of the transverse beams  98 . 
     FIG. 8 shows an alternate construction of the top panel  10 ′. Panel  10 ′ includes outer and inner skins  24 ′,  26 ′ and webs  28 ′. In this embodiment, the top rail  16 ′ is a separate extrusion from the remainder of the top panel  10 ′. It is formed to include a downwardly opening longitudinal channel  110  formed by and between side members  112 ,  114 . The upper edge portion of the top panel  10 ′ fits in the channel  110  and is welded to the flanges  112 ,  114  at  116 ,  118 . 
     FIG. 9 shows a modified construction of the bottom panel  14 ′. It has vertically spaced apart upper and lower side rails  18 ′,  120 . The side rails  18 ′,  120  and wall portion  122  together form inwardly opening longitudinal channels  12  in which end portions of the floor beams  98  are received. The floor beams  98  may be welded to the side rails  18 ′,  120  at  126 ,  128 . 
     Other floor constructions are within the scope of the present invention. For example, the floor structure may itself be formed by a plurality of joined together panels or extrusions, for example. Other floor constructions could be used as well. 
     The illustrated embodiments are only examples of the present invention and, therefore, are non-limitive. It is to be understood that many changes in the particular structure, materials and features of the invention may be made without departing from the spirit and scope of the invention. Therefore, it is my intention that my patent rights not be limited by the particular embodiments illustrated and described herein, but rather determined by the following claims, interpreted according to accepted doctrines of claim interpretation, including use of the doctrine of equivalents and reversal of parts.