Patent Publication Number: US-10308382-B2

Title: Method for applying an underlayment layer to trucking cargo

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims priority to and is a divisional of U.S. patent application Ser. No. 12/123,671 filed May 20, 2008, the contents of which are herein incorporated by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention generally relates to an apparatus and method for covering large containers and more particularly to the process of covering loaded trucks and rail cars with tarps or related coverings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a side view of an apparatus for applying an underlayment layer to trucking cargo, in accordance with an exemplary embodiment. 
         FIG. 2  is a perspective view of the roll of the underlayment layer of the exemplary embodiment of  FIG. 1 . 
         FIG. 3  is the side view of a vertical driving mechanism of the apparatus of  FIG. 2 . 
         FIG. 4  is a top view of a portion of the apparatus of the exemplary embodiment of  FIG. 1 , illustrating a horizontal driving mechanism. 
         FIG. 5  is a perspective view of the roll of underlayment layer with a driving motor and a cutting mechanism added to the exemplary embodiment of  FIG. 1 . 
         FIG. 6 ,  FIG. 8  and  FIG. 9  are side views of the apparatus of  FIG. 1  illustrating various steps involved in the method of applying an underlayment layer to the trucking cargo. 
         FIG. 7  is a top view of the apparatus of  FIG. 1  illustrating a step involved in the method of applying an underlayment layer to the trucking cargo. 
         FIG. 10  is a side view of an apparatus for applying an underlayment layer to a trucking cargo, in accordance with another exemplary embodiment. 
         FIG. 11  is a side view of an apparatus for applying an underlayment layer to a trucking cargo, in accordance with yet another exemplary embodiment. 
         FIG. 12  is a side view of the apparatus for applying an underlayment layer that also includes tarp application, in accordance with another exemplary embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Each embodiment of the present invention provides for an apparatus  10  and method for applying an underlayment layer  12  to a trucking cargo  22 . This can be done without requiring a person climb on the trailer  20  carrying the trucking cargo  22  or on top of the trucking cargo  22  to apply the underlayment layer  12  thereto. Such an arrangement may thus increase user safety related to the application of an underlayment layer  12  to trucking cargo  22 . The underlayment layer  12  acts as an additional barrier and hence protects the trucking cargo  22  from natural elements. A tarp or other protective member may alternatively be added on top of the underlayment layer  12  to further protect the trucking cargo  22  during transport. The underlayment layer  12  may be made of a suitable material, for example plastic or the like, for providing the necessary protection to the trucking cargo  22 . The term trucking cargo  22  used throughout the description refers to any load which is being transported by a heavy vehicle. 
     Reference will now be made in detail to the embodiments of the invention, examples of which are illustrated in the drawings. 
     Prior to being applied to the trucking cargo  22 , the underlayment layer  12  can be formed into a continuous roll  14  by being folded towards its center, once or a number of times. The underlayment layer  12 , without limitation, is 20 feet wide. It may be folded 4 times towards its center to make it 5 feet wide. However, it is to be understood that the underlayment layer  12  can be of a different size and folded any number of times as contemplated within the scope of the invention. The apparatus  10  includes roll  14  of the underlayment layer  12  thus formed and a rod  24 . The rod  24  is disposed through the roll  14  of underlayment layer  12 . According to one exemplary embodiment, as seen in  FIG. 1 , the roll  14  of the underlayment layer  12  may be supported by a frame  16 . 
     In accordance with certain exemplary embodiments, the roll  14  may be five feet wide and the rod  24  may be sixteen feet wide. Any number of rolls may be placed on the rod  24 . For example, two rolls  14  of dissimilar width can be placed onto the rod  24  so that the apparatus  10  can dispense underlayment layers  12  of different widths. The rolls  14  can be moved from side to side on the rod  24  as desired for proper alignment. In another arrangement, three rolls  14  can be used. The rolls  14  can be perforated or unperforated so that added functionality may be realized. Additional arrangements are possible in which one or more rods  24  can be used. Here, for example, three rods  24  can be present so that one rod  24  hangs from another. 
     Frame  16  may be a free standing structure positioned on the ground  38 . The free standing structure  16 , without limitation, may comprise of a plurality of vertical support members  90  attached to a top rectangular frame  92 . The free standing structure  16  may optionally be provided with wheels or other rotating elements, below the vertical support members  90  to make it portable. 
       FIG. 2  illustrates a perspective view of the roll  14  of the underlayment layer  12  loaded on rod  24 . The roll  14  may be suspended from the top rectangular frame  92  by a pair of straps  64  and  66 , or a pair of cables or the like. A pair of drums  60  and  62  may be located on opposite ends of the rod  24 . The drums  60  and  62  can be supported by the pair of straps  64  and  66 . The straps  64  and  66  may be flexible in nature. The roll  14  can be configured to be moved vertically with respect to the ground  38  such that the roll  14  of the underlayment layer  12  can move closer to and farther from the ground  38 . The vertical bidirectional movement of the roll  14  in the vertical direction  32  is achieved by the use of a vertical driving mechanism  28 . 
     Referring to  FIG. 3 , which illustrates a side view of the vertical driving mechanism  28 , the strap  64  extends around a first directional roller  68 , drum  60  and a second directional roller  70 . A take-up roller  72  can be used to wrap the strap  64  around thereon. The take-up roller  72  can be rotated clockwise or counter-clockwise by the use of a vertical driving motor  44  (illustrated in  FIG. 4 ). As the take-up roller  72  is rotated, strap  64  winds around take-up roller  72  and hence the drum  60  is elevated. Rotating the take-up roller  72  in the opposite direction causes the strap  64  to unwind therefrom and thus lowering of the drum  60 . In a similar manner, drum  62  can be raised and lowered as the take-up roller  72  rotates. 
     Referring to  FIG. 4 , the strap  66 , which extends around the directional rollers  74  and  76 , winds around the take-up roller  72  as it is rotated by the vertical driving motor  44 . Thus, as the take-up roller  72  is rotated by the vertical driving motor  44 , the drums  60  and  62  are raised or lowered. This causes the roll  14  to be moved vertically with respect to the free standing structure  16  so that the roll  14  moves closer to and farther from the ground  38 . 
     Although described as being capable of being moved in the vertical direction  32 , it is to be understood that other exemplary embodiments are possible in which the roll  14  does not move in the vertical direction  32 . For example, the roll  14  may be located a particular height from the ground, and the leading edge  48  can be grasped so as to dispense the underlayment layer  12  from roll  14 . 
     When the frame  16  is a free standing structure, the roll  14  can be configured to move horizontally with respect to the free standing structure  16 . As illustrated in  FIG. 4 , a horizontal driving mechanism  30  may be employed to achieve the horizontal movement of roll  14 . Racks  78  may be present on the top rectangular frame  92  of the free standing structure  16 . The racks  78  may be fixedly or removably attached upon the top rectangular frame  92  by means of bolts or other fastening elements. The racks  78  extend along the length of the top rectangular frame  92 . The horizontal driving mechanism  30  has a pair of pinions  80  which complement the racks  78  and are capable of meshing therewith. The pinions  80  can be driven by horizontal driving motors  46 . The pinions  80  may be fixedly or removably attached to a pair of platforms  86  and  88  by means of bolts or other fastening elements. The platforms  86  and  88  support the take-up roller  72  thereon. As the pinions  80  are driven by the horizontal driving motors  46 , the pinions  80  move along the lengths of the racks  78 . The movement of the pinions  80  causes the platforms  86  and  88  to move horizontally along the racks  78  in the horizontal direction  34 . Hence, the take-up roller  72  and the roll  14 , along with the directional rollers  68 ,  70 ,  74  and  76  may move horizontally along racks  78 . 
       FIG. 5  illustrates an exemplary embodiment in which rod  24  is driven by means of a motor  26 . This rotation results in the winding and unwinding of the underlayment layer  12  depending upon the direction of rotation of the rod  24 . Thus, simultaneous operation of the motor  26  and the horizontal driving motor  46  are possible to result in dispensing of the underlayment layer  12  roll  14  while roll  14  moves horizontally along the racks  78 . After a desired length of the underlayment layer  12  is dispensed from the roll  14 , the underlayment layer  12  may be cut at a desired position by means of a cutting mechanism  42 . The cutting mechanism  42  may be an automatic cutting mechanism in accordance with one exemplary embodiment. The cutting mechanism  42  may employ any suitable means capable of cutting the underlayment layer  12 . In other arrangements, a cutting mechanism  42  need not be present. For example, a utility knife or the like could be used in order to cut the underlayment layer  12 . However, it is to be understood that in alternate embodiments the underlayment layer  12  may have perforations  56  defined at predetermined lengths to facilitate easy tearing or cutting of the underlayment layer  12  without the need of a cutting mechanism  42 . 
     Referring back to  FIG. 1 , a trailer  20  loaded with a trucking cargo  22  is driven by a cab  18  and positioned beneath the free standing structure  16 . The rod  24  carrying the roll  14  of underlayment layer  12  is supported by the free standing structure  16 . The trailer  20  is stationed on the ground  38  such that the roll  14  is positioned proximate to the front  52  of the trailer  20 . As the vertical driving mechanism  28  ( FIG. 2  and  FIG. 3 ) is energized, the roll  14  is lowered to allow an operator to reach the roll  14 . As illustrated in  FIG. 6  and  FIG. 7 , the roll  14  is lowered to a level which allows the operator to be able to pull a leading edge  48  of the underlayment layer  12  and secure it to the trailer  20 . The leading edge  48  can be secured at a position proximate to a front  52  of the trailer  20 . The operator may be personnel or any automated mechanism configured to secure the leading edge  48  proximate to the front  52  of the trailer  20 . 
     The leading edge  48  may be secured to the trailer  20  by various means. For example, the underlayment layer  12  can be tied at the sides of the trailer  20 . Additionally or alternatively, adhesives may be used to effect such an attachment. The underlayment layer  12  can be wide enough to accommodate the entire width  96  of the trucking cargo  22 . As soon as the operator pulls the leading edge  48  of the underlayment layer  12 , the rod  24  is rotated by the motor  26  (seen in  FIG. 5 ), causing the underlayment layer  12  to be dispensed from the roll  14 . 
     After the leading edge  48  of the underlayment layer  12  is secured to the trailer  20 , the horizontal driving mechanism  30  is activated. Activation of the horizontal driving mechanism results in the movement of roll  14  in a horizontal plane parallel to the ground  38  along the length of the free standing structure  16  (as illustrated in  FIG. 4 ). The roll  14  moves along racks  78  from a position proximate to the front  52  towards the back  54  of trailer  20 . Also, the roll  14  is raised to a sufficient height to ensure that the horizontal movement of the roll  14  is not hindered by the trucking cargo  22 . 
     While the roll  14  moves in a horizontal plane, the underlayment layer  12  is unfolded from the roll  14  so that the trucking cargo  22  positioned underneath may be draped with the underlayment layer  12 . Referring to  FIG. 8 , the dispensed length of the underlayment layer  12  is sufficient to drape the entire length  40  of the trucking cargo  22 . However, it is to be understood that other arrangements are possible in which the underlayment layer  12  is not positioned over the entire length  40  of trucking cargo  22 . Thereafter, the underlayment layer  12  is cut at a desired position, by the use of the cutting mechanism  42  illustrated in  FIG. 5 . 
     As illustrated in  FIG. 9 , after the underlayment layer  12  is detached from the roll  14 , the trailing edge  50  of the underlayment layer  12  is secured to the back  54  of the trailer  20 . The trailing edge  50  of the underlayment layer  12  may either be tied at the back  54  of the trailer  20  or secured using tape or other conventional adhesives capable of holding the underlayment layer  12  in place. The trucking cargo  22  may be fully covered by the underlayment layer  12 . 
     The motors  26 ,  44  and  46  may be gear motors of 1½ HP. Motors of various types and powers may be used in other embodiments depending upon the weight and requirement of the underlayment layer  12 . The vertical driving mechanism  28  and the horizontal driving mechanism  30  may be operated by an electric drive system, a hydraulic drive system, a pneumatic drive system or any other type of drive system. 
     A second embodiment of the apparatus is explained hereinafter. The second embodiment is similar to the first embodiment described hereinabove except that the present embodiment facilitates applying the underlayment layer  12  to the trucking cargo  22  when the horizontal drive mechanism  30  is not present or is inoperative. The present embodiment utilizes the horizontal movement of the trailer  20  with respect to the free standing structure  16  to completely cover the trucking cargo  22 . This eliminates the need for the horizontal movement of the rod  24  and the horizontal driving mechanism  30  used in the first embodiment. As in the first embodiment, the vertical driving mechanism  28  ensures the smooth lifting or lowering of the roll  14  closer to and farther from the ground  38 . The trailer  20  may be parked directly below the free standing structure  16 . In this regard, the roll  14  is positioned proximate to the front  52  of the trailer  20 . The roll  14  may be lowered to allow the operator to pull the leading edge  48  of the underlayment layer  12 . The proximity of the roll  14  to the front  52  of the trailer  20  enables the operator to conveniently secure the leading edge  48  of the underlayment layer  12  thereto. Thereafter, the roll  14  can be raised above the height of the trucking cargo  22 . 
     As illustrated in  FIG. 10 , the trailer  20  is then driven forward in the horizontal direction  34 . The roll  14  is raised to a sufficient height which allows the trucking cargo  22  to be driven beneath the free standing structure  16 , without hitting the roll  14 . As the trailer  20  moves forward in the horizontal direction  34 , the leading edge  48  of the underlayment layer  12  is pulled and the underlayment layer  12  is further dispensed from the roll  14  over the trucking cargo  22 . The trucking cargo  22  driven beneath the free standing structure  16  is draped by the dispensed underlayment layer  12 . The underlayment layer  12  is wide enough to accommodate the width  96  of the trucking cargo  22 . The speed of the trailer  20 , and hence of the trucking cargo  22 , should be controlled to ensure uniform and smooth draping of the trucking cargo  22 . It may be contemplated that in certain situations alternative methods of covering the trucking cargo  22  could be used. For example, in accordance with one alternative embodiment, the horizontal movement of the trucking cargo  22  may be utilized in conjunction with the horizontal movement of the roll  14  used in the first embodiment. 
     A third embodiment of the apparatus  10  is illustrated in  FIG. 11 . In this exemplary embodiment, the roll  14  of underlayment layer  12  is supported by the frame  16 . Frame  16  may be attached to a ceiling  36 . The trucking cargo  22  to be covered is parked directly beneath frame  16 . The rod  24  carrying the roll  14  is then rotated to unwind the underlayment layer  12  from the roll  14 . A sufficient length of the underlayment layer  12  is unfolded and dispensed from the roll  14 , such that the operator is able to reach the leading edge  48  of the underlayment layer  12 . As the roll  14  mounted on the frame  16  is situated more proximate to the front  52  of the trailer  20 , the operator conveniently secures the leading edge  48  of underlayment layer  12  thereto. 
     As in the second embodiment, the trucking cargo  22  is driven horizontally relative to the frame  16  in the horizontal direction  34  depicted in  FIG. 11 . As the trailer  20  moves forward in the horizontal direction  34 , the leading edge  48  of the underlayment layer  12  is pulled and the underlayment layer  12  is further dispensed from the roll  14  over the trucking cargo  22 . The trucking cargo  22  being driven beneath the frame  16  is draped by the dispensed underlayment layer  12  which is wide enough to accommodate the width  96  of the trucking cargo  22 . The speed of the trailer  20  and hence of the trucking cargo  22  should be controlled to ensure uniform and smooth draping of the trucking cargo  22 . 
     The roll  14  may be motorized so that it can rotate in order to dispense the underlayment layer  12 . Alternatively, the roll  14  need not arranged so that it is automatically driven. Instead, the roll  14  can rotate freely on rod  24  or another mechanism due to forces being applied to the underlayment layer  12 . In this regard, the underlayment layer  12  can be pulled from the roll  14  without automatically rotating the roll  14 . Other embodiments are possible in which the underlayment layer  12  is dispensed from the roll  14  through both a combination of pulling of underlayment layer  12  and a rotation of the roll  14 . 
       FIG. 12  illustrates an alternative exemplary embodiment of the apparatus  10 . Here, a roll  14  is positioned at the front portion of the frame  16  and extends in the longitudinal direction from the vertical support member  90  so that the vehicle first encounters the roll  14  before the trucking cargo  22  is positioned between the vertical support members  90 . The underlayment layer  12  can be attached to the trailer  20  and/or trucking cargo  22  and the trailer  20  can be moved from left to right in  FIG. 12  so that the underlayment layer  12  is rolled from the rod  24  and applied to the trucking cargo  22  in the longitudinal direction from the front to the back of the trucking cargo  22 . 
     The roll  14  may be arranged so that it can move vertically with respect to the ground but not horizontally with respect to the ground. This arrangement allows the leading edge  48  of the underlayment layer  12  to be placed into proper position for attachment. The roll  14  may spin freely on the rod  24  so that the underlayment layer  12  can be pulled therefrom without having to be motor driven. 
     The arrangement in  FIG. 12  also includes a tarp application member  100  that is supported by the frame  16 . The tarp application member  100  can be used to apply a tarp  102  to the trucking cargo  22  after the underlayment layer  12  is applied to the trucking cargo  22 . In this regard, the tarp application member  100  has a tarp support frame  104  that may engage the vertical support members  90  and be moveable therewith. An independent motor may be used to move the tarp support frame  104  vertically, or a motor used in connection with the roll  14  may be employed. The tarp application member  100  includes a number of straps  106  that are stretched between the tarp support frame  104  in order to support the tarp  102  which is generally unfolded. The trucking cargo  22  can be located under the tarp  102 , and the tarp support frame  104  can be lowered so that the tarp  102  is placed on top of the trucking cargo  22 . The straps  106  may be removed and the tarp  102  can be secured to the trucking cargo  22 . Alternatively, the straps  106  may be used to effect attachment of the tarp  102  to the trucking cargo  22 . The vehicle and trucking cargo  22  may thus move through the frame  16  until the underlayment layer  12  is properly applied, and the vehicle and trucking cargo  22  may be reversed back into the frame  16  so that the tarp  102  can be applied. 
     The underlayment layer  12  may be made out of a variety of materials in accordance with certain exemplary embodiments. For example, the underlayment layer  12  may be made out of plastic in accordance with certain embodiments. The underlayment layer  12  can be placed on the trucking cargo  22  in order to provide protection during transport. The underlayment layer  12  may be paced on the trucking cargo  22  in order to function as a moisture resistance layer. The underlayment layer  12  may made of a flexible material and may be waterproof in accordance with certain exemplary embodiments. A tarp, such as a canvas tarp, can be placed on top of the underlayment layer  12  to further protect the trucking cargo  22 . In accordance with other exemplary embodiments, a tarp is not placed on top of the underlayment layer. 
     The underlayment layer  12  may be applied to the trucking cargo  22  in the longitudinal direction so as to cover the trucking cargo  22 . As used herein, including in the claims, the term “longitudinal direction” refers to the direction from the front of the vehicle to the back of the vehicle or from the back of the vehicle to the front of the vehicle. The longitudinal direction may thus be from the front of the trailer  52  to the back of the trailer  54 . The longitudinal direction of the trucking cargo  22  is likewise the same in that it may also extend from the front of the trailer  52  to the back of the trailer  54 , or from the back of the trailer  54  to the front of the trailer  52 . The term, “transverse direction” refers to the direction from the side of the vehicle/trucking cargo  22  to the opposite side of the vehicle/trucking cargo  22 . For example, the transverse direction may be from the left side of the trucking cargo  22  or trailer  20  to the right side of the trucking cargo  22  or trailer  20 . 
     Various modifications to the above mentioned embodiments are possible. For example, with respect to the first embodiment, it may be inconvenient to start applying the underlayment layer  12  by securing the leading edge  48  proximate to the front  52  of the trailer  20 . The leading edge  48  can instead be secured at the back  54  of the trailer  20 . In order to apply the underlayment layer  12  over the entire trucking cargo  22 , the roll  14  may then be moved towards the front  52  of the trailer  20 , over the free standing structure  16 . Similarly, in the second and third embodiments, the leading edge  48  may be secured proximate to the back  54  of the trailer  20  and the trucking cargo  22  may then be moved backwards in the horizontal direction  34 . While the embodiments of the present invention have been described, it is to be understood that the claimed invention is not to be limited in scope to the aforementioned and described embodiments.