Patent Publication Number: US-11046160-B2

Title: Rigid cover for dump trailer tank

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     U.S. patent application Ser. No. 15/358,396 filed Nov. 22, 2016, published as US 2018-0141420 A1, now U.S. Pat. No. 10,086,683. 
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT 
     Not Applicable. 
     FIELD OF THE DISCLOSURE 
     The present disclosure relates generally to large truck trailer covers. More specifically, the present disclosure relates to a rigid cover for dump trailers, enabling enhanced trailer capacity with easy loading and unloading capability. 
     DISCUSSION OF RELATED ART 
     For many years, dump trailers have been the best choice for transporting a large volume of goods across long distances. Transporting goods using trailers is profitable only if it is possible to transport large volumes which can be rapidly loaded and unloaded. Generally trailers of the same nature have a similar loading capacity and it becomes the transporter&#39;s responsibility to increase the load-bearing capacity utilizing an alternate means. Normally a trailer does not have an installed covering for protecting the loaded goods from the weather or loss of some of the load during transport. These drawbacks can have a negative impact on the profitable transportation of goods using trailers. 
     Conventional methods utilize tarpaulin to cover the loaded area of the trailers to protect the loaded goods. Using tarpaulin covers can cause a delay in the unloading of the goods. Attaching tarpaulin covers in the proper orientation can also require a considerable amount of manpower. In addition to this, tarpaulin covers do not allow for increasing the load capacity. Other conventional methods include the use of pneumatic trailers, which provide a sealed tank that provides increased storage capacity and protects the goods from the outside environment and weather. The drawback to pneumatic trailers is that they are more expensive to purchase and operate given the additional cost and weight associated with the pneumatic system. Also, the unloading time for a typical pneumatic trailer may be as much as twenty minutes as opposed to the twenty seconds or so that it takes to unload a conventional belly dump trailer. Therefore, there is a need for a rigid cover for belly dump trailer which enables the trailer to increase the loading capacity without sacrificing unload times. Such a needed cover would facilitate the loading and unloading of a trailer in a shorter period of time with less manpower. This cover would need to be cost effective and relatively easy to install. Moreover, such a needed cover would provide top load ports for the fast loading and unloading with less loss of cargo. The present embodiment overcomes prior art shortcomings by accomplishing these critical objectives. 
     SUMMARY OF THE DISCLOSURE 
     To overcome the limitations found in the prior art, and to minimize other limitations that will be apparent upon the reading of the specification, the present invention is a rigid cover for a dump trailer used to transport bulk material. The dump trailer has a traditional storage region with an open top onto which the rigid cover may be configured as described in these embodiments of the present invention. 
     The rigid cover includes a plurality of cover side walls, a cover top, one or more ports and a plurality of cover fasteners. The plurality of cover side walls includes a top wall perimeter and a bottom wall perimeter and is configured along the bottom wall perimeter to correspond in shape with the open top of the trailer tank. The plurality of side walls is designed such that it may include a first side wall, a second side wall, a front side wall and a rear side wall, that flares outward away from the center of the rigid cover with respect to the plurality of side walls at the bottom wall perimeter to allow for increased bulk material storage capacity. 
     The cover top is connected to the plurality of cover side walls along the top wall perimeter. The cover top may be higher at a center region than at side regions adjacent to the plurality of cover side walls to allow for increased bulk material storage capacity. Each of the ports in the top cover may include a port lid which may, for example, be implemented as a removable port lid, sliding port lid, or a hinged port lid. 
     In some embodiment of the present invention, at least one of the cover top and the plurality of cover side walls includes an interior brace to reinforce structural integrity. Such an interior brace may be implemented as an interior rib flange along an interior of the cover top or an interior rib flange along an interior of the plurality of cover side walls. In other embodiments, an interior brace may be implemented an interior support beam across an interior of the cover top or across an interior of the plurality of cover side walls and connected to two of the plurality of cover side walls. Still further, in some embodiments, an interior brace to reinforce structural integrity may include an vertical support beam connected to the interior support beam and the cover top. And, in other embodiments, an interior brace to reinforce structural integrity may be implemented as an interior support beam across an interior of the plurality of cover side walls and connected to at least one of the plurality of cover side walls and the cover top. 
     Rather than using internal bracing, structural integrity of the side walls or cover top may be reinforced using surface corrugation. 
     The cover fasteners are mounted along the bottom wall perimeter and are configured to secure the plurality of cover side walls to the trailer tank so that the traditional storage region of the trailer tank is augmented with an expanded storage region that allows storage of more bulk material than could otherwise be stored in the trailer tank alone. The cover fasteners may include a fastener hinge mounted to the trailer tank along a top edge of the trailer tank, a fastening bar operatively connected to the hinge to swing upward toward the plurality of side walls and a fastener cradle mounted to the plurality of side walls along the bottom wall perimeter. Of course, one of skill in the art would understand that this cover fastener may be reversed whereby the fastener hinge is mounted to the side walls and the fastening bar connected to the hinge to swing downward to the top edge of the trailer tank to rest inside the fastener cradle mounted to the top edge of the trailer tank. The fastener cradle may have two cradle guides spaced apart to receive the fastening bar between the two cradle guides when the fastening bar rotates into the fastener cradle. The cover fasteners may include a fastening cap threaded onto the distal end of the fastening bar that secures the fastening bar in the cradle by rotating the fastening cap until the fastening cap tightens down on the cradle guides. The fastening cap may have a movable handle that provides additional leverage to an operator turning the fastening cap. The cover fasteners may also include a fastening plate mounted to the plurality of side walls along the bottom wall perimeter which includes at least one fastening plate hole, a bolt configured to pass through the fastening plate hole in the mounting plate and a tank mounting hole in a tank mounting plate configured along a top edge of the trailer tank and a nut configured to secure the bolt in the fastening plate and in the tank mounting plate of the trailer tank. The rigid cover for the dump trailer tank may also include one or more alignment projections extending downward from the bottom wall perimeter at the corners formed from the plurality of side walls. The alignment projections hold the rigid cover in place on the trailer tank while an operator secures the rigid cover to the trailer tank with the cover fasteners. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Elements in the figures have not necessarily been drawn to scale in order to enhance their clarity and improve understanding of these various elements and embodiments of the invention. Furthermore, elements that are known to be common and well understood to those in the industry are not depicted in order to provide a clear view of the various embodiments of the invention, thus the drawings are generalized in form in the interest of clarity and conciseness. 
         FIG. 1  is a perspective view of a rigid cover mounted over a traditional storage region of a dump trailer tank according to embodiments of the present invention; 
         FIG. 2  is a perspective view of the rigid cover for a dump trailer tank according to embodiments of the present invention; 
         FIG. 3  is a side view of the rigid cover mounted over the traditional storage region of a dump trailer tank according to embodiments of the present invention; 
         FIG. 4  is a perspective view of a cover fastener of the rigid cover for a dump trailer tank according to embodiments of the present invention; 
         FIG. 5  is a schematic diagram of the rigid cover showing three eighteen inch ports in the cover top of a rigid cover for a dump trailer tank in accordance with embodiments of the present invention; 
         FIG. 6  is a schematic diagram of the rigid cover showing two thirty inch ports in the cover top of a rigid cover for a dump trailer tank in accordance with embodiments of the present invention; 
         FIG. 7  is a front view of the rigid cover mounted over the traditional storage region of a dump trailer tank showing the cover side walls flare outwards according to embodiments of the present invention; 
         FIGS. 8A-F  are schematic diagrams showing different interior braces for reinforcing the structural integrity of the rigid cover according to embodiments of the present invention; 
         FIG. 9  is a perspective view of the rigid cover of  FIG. 2  for a dump trailer tank according to embodiments of the present invention having surface corrugation; 
         FIGS. 10A-C  are schematic diagrams showing different surface corrugation patterns for reinforcing the structural integrity of the rigid cover of  FIG. 9  according to embodiments of the present invention; 
         FIG. 11  is a perspective view of the rigid cover of  FIG. 2  for a dump trailer tank according to embodiments of the present invention having surface corrugation; and 
         FIGS. 12A-B  are enlarged views of the different surface corrugation patterns for reinforcing the structural integrity of the rigid cover of  FIG. 11  according to embodiments of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     In the following discussion that addresses a number of embodiments and applications of the present invention, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustrating specific embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and changes may be made without departing from the scope of the present invention. 
     Various inventive features are described below that can each be used independently of one another or in combination with other features. However, any single inventive feature may not address any of the problems discussed above or only address one of the problems discussed above. Further, one or more of the problems discussed above may not be fully addressed by any of the features described below. The invention will now be described with reference to the accompanying drawing which does not limit the scope and the ambit of the invention. 
     As used herein, the singular forms “a”, “an” and “the” include plural referents unless the context clearly dictates otherwise. “And” as used herein is interchangeably used with “or” unless expressly stated otherwise. All embodiments of any aspect of the invention can be used in combination, unless the context clearly dictates otherwise. 
     Unless the context clearly requires otherwise, throughout the description and the claims, the words ‘comprise’, ‘comprising’, and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to”. Words using the singular or plural number also include the plural and singular number, respectively. Additionally, the words “herein,” “wherein”, “whereas”, “above,” and “below” and words of similar import, when used in this application, shall refer to this application as a whole and not to any particular portions of the application. 
     The description of embodiments of the disclosure is not intended to be exhaustive or to limit the disclosure to the precise form disclosed. While the specific embodiments of, and examples for, the disclosure are described herein for illustrative purposes, various equivalent modifications are possible within the scope of the disclosure, as those skilled in the relevant art will recognize. 
       FIG. 1  is a perspective view of a rigid cover  10  mounted over a traditional storage region of a bottom dump trailer tank  12  according to embodiments of the present invention. The rigid cover  10  includes a plurality of cover side walls  14 , a cover top  16 , one or more ports  18  (See  FIG. 2 ) and a plurality of cover fasteners  20 . The cover side walls  14  of  FIG. 1  are substantially vertical structures that permit the rigid cover  10  to extend the traditional storage region of a bottom dump trailer tank  12  according to embodiments of the present invention by augmenting the traditional storage region of the trailer tank  12  with an expanded storage region  13  that allows storage of more bulk material than could otherwise be stored in the trailer tank  12  alone. The cover side walls  14  of  FIG. 1  may be construction using a variety of materials as will be known to those of skill in the art including, for example, but not limited to metal, alloys, wood, certain rigid plastics or rubber, or some combination thereof. 
     The plurality of cover side walls  14  of  FIG. 1  includes a top wall perimeter  22  and a bottom wall perimeter  24  and is configured along the bottom wall perimeter  24  to correspond in shape with the open top of the trailer tank  12 . The plurality of cover side walls  14  is designed such that it includes a front side wall  26 , a rear side wall  28  (See  FIG. 5 ), a first side wall  30  and a second side wall  32  (See  FIG. 5 ). In the example of  FIG. 1 , the front side wall  30  is the wall of the cover side walls  14  that faces the front of the trailer where the trailer hitches to a truck. The rear side wall  28  (See  FIG. 5 ) described herein is the wall of the cover side walls  14  that faces the opposite direction of the front side wall  26  away from where the trailer hitches to a truck. The first side wall  30  and second side wall  32  (See  FIG. 5 ) described in these embodiments are the walls of the cover side walls  14  that face laterally away from the sides of the trailer. Although the rigid cover  10  of  FIG. 1  is implemented as a cover for a bottom dump trailer, rigid covers according to embodiments of the present invention would be beneficial for use with rear dump trailers such as, for example, the trailer mounted on the back of a dump truck. 
       FIG. 2  is a perspective view of the rigid cover  10  for a bottom dump trailer tank  12  according to embodiments of the present invention. The cover top  16  is connected to the plurality of cover side walls  14  along the top wall perimeter  22 . The cover top  16  is higher at a center region than at side regions adjacent to the plurality of cover side walls  14  to allow for increased bulk material storage capacity and helps to load as much as into the trailer because if the top was flat then the material would fill up to the hole in a conical fashion before filling into the area around the hole. The one or more ports  18  in the cover top  16  also include a port lid  34  which can be removable port lid, a sliding port lid or a hinged port lid. A removable port lid according to some embodiments of the present invention is a lid used to open and close the port by detaching and reattaching the lid from and on to, respectively, the port. When attached, the removable port lid may be secured using a variety of latches or clamps, such as, for example only, pull-action latch clamps. A sliding port lid according to some embodiments of the present invention is a lid used to open and close the port by sliding away from and on to, respectively, the port. A hinged port lid according to some embodiments of the present invention is a lid used to open and close the port by rotating down on to and away from, respectively, the port. 
       FIG. 3  is a side view of the rigid cover  10  mounted over a traditional storage region of the bottom dump trailer tank  12  according to embodiments of the present invention. The rigid cover  10  for the bottom dump trailer tank  12  further includes one or more alignment projections  36  extending downward from the bottom wall perimeter  24  at corners formed from the plurality of cover side walls  14 . The alignment projections  36  of  FIG. 3  hold the rigid cover  10  in place on the trailer tank  12  while an operator secures the rigid cover  10  to the trailer tank  12  with the plurality of cover fasteners  20 . The alignment projections  36  of  FIG. 3  are useful because these projections  36  not only keep the rigid cover  10  from sliding off of the trailer tank  12 , but such projections  36  also help ensure that the cover fasteners are aligned properly for engagement when the rigid cover  10  is lowered onto the trailer tank  12 . To assist with raising and lowering the rigid cover  10 , the rigid cover  10  in the example of  FIG. 3  includes lifting rings  17 . The lifting rings  17  of  FIG. 3  may be welded to the plurality of side walls  14  or connected using heavy-duty hinges. 
       FIGS. 1-3  each utilize two different types of cover fasteners  20 . In the middle of the first side wall  30  (See  FIG. 3 ), the cover fastener  20  consists of two plates mounted together with a bolt-nut combination in the manner described herein according to embodiments of the present invention. That is, the middle cover fastener  20  (See  FIG. 1 ) includes a fastening plate  38  mounted to the plurality of cover side walls along the bottom wall perimeter  24  which includes at least one fastening plate hole (not shown), a bolt  46  configured to pass through the fastening plate hole (not shown) in the mounting plate  38  and a tank mounting hole (not shown) in a tank mounting plate  44  configured along a top edge of the trailer tank  12  and a nut  42  configured to secure the bolt in the fastening plate  38  and the tank mounting plate  44  on the trailer tank  12 . 
     The second type of cover fastener  20  used in  FIGS. 1-3  is a quick connect fastener according to embodiments of the present invention. A quick connect fastener as used in embodiments of the present invention allows an operator to engage and disengage a particular cover fastener without the use of tools other than the operator&#39;s hands. This second type of cover fastener  20  used in  FIGS. 1-3  is further described with reference to  FIG. 4 . 
       FIG. 4  is a perspective view of another type of the cover fasteners  20  of the rigid cover  10  for the bottom dump trailer tank  12  according to embodiments of the present invention. The plurality of cover fasteners  20  is mounted along the bottom wall perimeter  24  and is configured to secure the plurality of cover side walls  14  to the trailer tank  12  so that the traditional storage region of the trailer tank  12  is transformed into an expanded storage region that allows storage of more bulk material than could otherwise be stored in the trailer tank  12  alone. The cover fastener  20  of  FIG. 4  includes a fastener hinge  48  mounted to the trailer tank  12  along a top edge of the trailer tank  12 . The cover fastener  20  of  FIG. 4  also includes a fastening bar  50  operatively connected to the fastener hinge  48  to swing upward toward the plurality of side walls  14 . The cover fastener  20  of  FIG. 4  has a fastener cradle  52  mounted to the plurality of cover side walls  14  along the bottom wall perimeter  24 . The fastener cradle  52  has two cradle guides  54  spaced apart to receive the fastening bar  50  between the two cradle guides  54  when the fastening bar  50  rotates into the fastener cradle  52 . The cover fastener  20  of  FIG. 4  includes a fastening cap  56  threaded onto the distal end of the fastening bar  50  that secures the fastening bar  50  in the cradle  52  by rotating the fastening cap  56  until the fastening cap  56  tightens down on the cradle guides  54 . To facilitate tightening the fastening cap without the need for any tools, the fastening cap  56  of  FIG. 4  includes a movable handle  58  that provides additional leverage to an operator turning the fastening cap  56 . Of course, one of skill in the art would understand that the cover fastener  20  of  FIG. 4  is for example only and not for limitation. Other cover fasteners useful in embodiment of the present invention may be reversed whereby the fastener hinge is mounted to the side walls of the cover and the fastening bar connected to the hinge to swing downward to the top edge of the trailer tank to rest inside the fastener cradle mounted to the top edge of the trailer tank. 
     Those of skill in the art will recognize that although the embodiments of the present invention described herein utilize both of these previously described fastener types, such use in combination is for example and illustration only, not for limitation. Either of these fastener types or any other cover fastener as will occur to those of skill of the art may be useful in embodiments of the present invention. 
       FIGS. 5 and 6  are schematic diagrams of the rigid cover  10  showing three 18″ ports  18  and two 30″ ports  18  for loading and unloading the trailer tank  12  in accordance with the preferred embodiment of the present invention. Having more than one port  18  in the cover top  16  enables an operator to load more, as the material is filled to form an ant hill-like structure in the trailer tank  12  and multiple ports  18  allows loads of even more material to get multiple ant hill structures. One of skill in the art will recognize that the shape and diameter of the ports in the examples of  FIGS. 5 and 6  are for example only and not for limitation. Other shapes and sizes may be useful and the size of the port for any given embodiment may depend on a variety of factors as will occur to those of skill in the art including, but not limited to, the desired loading speed for a particular bulk material, the apparatus available to fill a trailer, the granularity of the bulk material, the overall shape of the rigid cover, and so on. Other embodiments of the port may be shaped in the form of a square, rectangle, ellipse or other shape, and there is no requirement that the lid be shaped in the same manner as the port opening—only that the port lid cover the port opening. 
     Although not shown, to keep out water or other materials from getting through the port when the lid is closed, the port may include a gasket around the edge of the lid so that the lid seals on the opening when closed. Alternatively, or in addition to, a gasket, a port according to embodiments of the present invention could include a flange around the opening that the port lid fits around to help prevent contaminants or other materials from getting through the port into the storage area. 
       FIG. 7  is a front view of the rigid cover  10  mounted over the traditional storage region of the bottom dump trailer tank  12  showing the cover side walls  14  flare outwards away from the center of the rigid cover with respect to the plurality of side walls at the bottom wall perimeter to allow for increased bulk material storage capacity according to embodiments of the present invention. 
     In many embodiments of the present invention, the side walls and cover top are made from three-sixteenth ( 3/16) inch thick steel. In other embodiments of the present invention, the side walls and cover top may be implemented using aluminum or some carbon fiber material. Thicker sheets may increase the weight load of the trailer top and thereby may limit the amount of cargo that can be carried because of the weight limits on the trailers and vehicle traveling on highways. Thinner sheets may decrease the overall structural integrity of the rigid cover. To increase the structural integrity of rigid cover, either or both of the cover top and the cover side walls may include an interior brace to reinforce structural integrity. The interior nature of the interior brace means that the brace is configured on the inside of the rigid cover in the expanded storage region  13  (See  FIGS. 1 and 8A -F). 
       FIGS. 8A-F  are schematic diagrams showing different interior braces for reinforcing the structural integrity of the rigid cover  10  according to embodiments of the present invention.  FIG. 8A  depicts interior braces as interior rib flanges  80  along the interior of the cover top  16  and along the interior of the plurality of cover side walls  14 . A flange according to embodiment of the present invention is an external or internal ridge, or rim, for strength, or attachment to another object. The interior rib flanges  80  of  FIG. 8A  are internal and may be made of the same types of materials as the cover top or side walls, although the materials may not be same in any given embodiment. 
       FIG. 8B  depicts interior braces as an interior support beam  81  across the interior of the cover side walls  14 . A beam according to embodiment of the present invention may be tubular or solid or some composite of a solid with pockets of air or other medium lighter in weight than the solid forming the beam. The interior support beam  81  of  FIG. 8B  is connected to two of the cover side walls  14 .  FIG. 8C  depicts interior braces as an interior support beam  81  across the interior of the cover side walls  14  and as vertical support beam  82  connected to the interior support beam  81  and the cover top  16 .  FIG. 8D  depicts interior braces as interior support beams  83 , 84  across the interior of the cover side walls  14 . The interior support beams  83 , 84  connect to opposite cover side walls  14 .  FIG. 8E  depicts interior braces as interior support beams  85 , 86  across the interior of the cover side walls  14 . Each of the interior support beams  85 , 86  connect to a cover side wall  14  and the cover top  16 . The interior support beams  85 , 86  may connect together to form an ‘X’ shape or may not touch or be connected together at all.  FIG. 8F  depicts interior braces as an interior support beam  87  across an interior of the cover top  16 . One of skill in the art will understand that placement of in interior brace according to embodiments of the present invention on either side of a port may be advantageous so as not to block the bulk material being loaded into the trailer via that port. 
       FIG. 9  is a perspective view of the rigid cover  10  of  FIG. 2  for a bottom dump trailer tank according to embodiments of the present invention with some surface corrugation. Surface corrugation according to embodiments of the present invention means that the surface of a material is shaped into alternate areas of ridges and valleys. Surface corrugation according to embodiments of the present invention may be formed from crimping sheet material, stamping sheet material or various other mechanisms as will occur to those of skill in the art. 
       FIGS. 10A-C  are schematic diagrams showing different surface corrugation patterns  91 , 92 , 93  for reinforcing the structural integrity of the rigid cover of  FIG. 9  according to embodiments of the present invention. The surface corrugation pattern  91  of  FIG. 10A  is implemented as a sine wave. The surface corrugation pattern  92  of  FIG. 10B  is implemented as a trapezoid wave. The surface corrugation pattern  93  of  FIG. 10C  is implemented as a triangle wave. 
       FIG. 11  is a perspective view of the rigid cover  10  of  FIG. 2  for a bottom dump trailer tank according to embodiments of the present invention having other types of surface corrugation.  FIGS. 12A-B  are enlarged views of the different surface corrugation patterns for reinforcing the structural integrity of the rigid cover  10  of  FIG. 11  according to embodiments of the present invention. The surface corrugation pattern depicted in  FIG. 12A  is implemented as a series of hemispherical bumps along the surface of the cover side wall  30 . The surface corrugation pattern depicted in  FIG. 12B  is implemented as a series of elliptical bumps in perpendicular orientation along portions of the surface of the cover top  16 . 
     The surface of the material used to form the cover side walls and cover top according to the embodiments of the present invention may be painted or galvanized to reduce corrosion caused by rust and increase the longevity of the rigid cover when the cover is made from metal. Of course when the rigid cover is implemented using other materials, such as for example a carbon fiber material, one of skill in the art would recognize certain techniques available to increase the life span of the rigid cover. 
     The claimed subject matter has been provided here with reference to one or more features or embodiments. Those skilled in the art will recognize and appreciate that, despite the detailed nature of the exemplary embodiments provided here; changes and modifications may be applied to said embodiments without limiting or departing from the generally intended scope. These and various other adaptations and combinations of the embodiments provided here are within the scope of the disclosed subject matter as defined by the claims and their full set of equivalents. 
     The foregoing description of the preferred embodiment of the present invention has been presented for the purpose of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teachings. It is intended that the scope of the present invention not be limited by this detailed description, but by the claims and the equivalents to the claims appended hereto.