Abstract:
Presented is an improved panel and connector sidewall construction. While maintaining the benefits of standard structural panel designs, the post connector construction also achieves many benefits of traditional sheet and post designs, including simplified replacement of damaged interior panels. The design also allows for simplified replacement of the outer panels of the container while simultaneously providing an aerodynamic surface without protruding rivets. The sidewall construction also achieves the important objective of providing smooth trailer walls with minimal recesses, protrusions and snag points.

Description:
CROSS REFERENCE TO COPENDING APPLICATION 
       [0001]    This application claims the benefit of U.S. patent application Ser. No. 13/049,106 entitled “Container Sidewall Connector” by March Roush that was filed Mar. 16, 2011 the contents of which are herein incorporated by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates generally to a sidewall construction for a cargo container, and more particularly to a thin structural panel and post connector sidewall construction. 
       BACKGROUND OF THE INVENTION 
       [0003]    Designers of cargo containers have long faced many related challenges in the design of container sidewalls. First, the structural integrity of the overall container depends on the rigidity and strength of the sidewalls. Second, the sidewalls are optimally light in weight to reduce the transportation costs for the overall container. 
         [0004]    Third, government regulations or industry standards often limit the exterior dimensions of cargo containers. Thus, to maximize the capacity of the container, designers seek to minimize the width of the sidewalls without compromising the structural integrity of the container. 
         [0005]    Fourth, because cargo containers are repeatedly loaded and unloaded, the interior walls of the container must be resistant to the repeated impact of vehicles and implements used to load and unload the container. Containers must optimally be free of protrusions and snag points that could impede loading and unloading. Fifth, means for securing and dividing cargo within a container are often desirable, and may be provided by incorporating logistics slots in the sidewalls of the container. Sixth, even resilient sidewalls may become damaged with extended use and require replacement or repair, Seventh, installing bolts or rivets commonly used in assembling sidewalls increases the container construction time, sidewall thickness, and the cost of the container. Eighth, various thicknesses of panels are used in container construction based on the desired characteristics of the container. Connectors between panels must be adaptable to these various thicknesses. Other considerations, including the cost and availability of the sidewall components and the ease of manufacturing, are also important. 
         [0006]    These challenges are particularly acute in the design and construction of sidewalls for over-the-road trailers. Structural integrity for trailers is of course essential to the safe transportation of goods and materials on public highways. This structural integrity has conventionally been provided by either a “sheet and post” or a structural panel sidewall construction. 
         [0007]    In sheet and post sidewall construction, vertical posts are used to provide the primary structural integrity for the trailer. Such posts are typically formed by bending or roll forming galvanized steel or extruding aluminum into non-linear shapes, thus providing rigidity and strength for the post. Relatively thin and easily replaceable sidewall sheets, typically made of plywood or plastic, are attached to the vertical posts in the interior of the trailer and a protective outer skin is attached to the exterior of the trailer. A protective metal, wood, or plastic liner may also be provided at the base of the interior sidewall to protect the sheets and posts from being damaged or pierced by vehicles loading and unloading the trailer. This sheet and post design offers certain advantages, including high structural strength attributable to the vertical posts, lower cost and ease of manufacturing, among others. Also, although the thin interior sheets are susceptible to damage, these sheets are relatively inexpensive and easy to replace. Conventional sheet and post designs, however, suffer from a key disadvantage, namely, the thickness of the posts required to provide structural integrity for the trailer. 
         [0008]    Structural panel sidewalls have also been used in the construction of over-the-road trailers to address many of the challenges related to cargo containers. In particular, because of the strength and rigidity of the structural panels, sidewall thickness can generally be reduced as compared to conventional sheet and post designs. The structural panels are typically joined at their edges with vertical splicer plates on the inside and outside of the trailer, as shown in U.S. Pat. No. 4,904,017 ( FIG. 9 ) issued to Ehrlich, U.S. Pat. No. 5,860,693 ( FIG. 2 ) issued to Ehrlich and U.S. Pat. No. 6,450,564 ( FIG. 3 ) and U.S. Pat. No. 6,578,902 ( FIGS. 4 and 5 ) issued to Sill. The structural panels may also be joined with vertical posts on the inside and outside of the trailer, as disclosed in the applicant&#39;s U.S. Pat. No. 7,152,912 and incorporated herein by reference. These vertical posts are typically provided with logistics slots for securing and dividing cargo within the trailer. 
         [0009]    Structural panels are often composite panels made of a core plastic material and an outer skin of aluminum or steel. The metal skin of the panels is resistant to damage when the cargo is loaded and unloaded, and because of the strength and rigidity of the composite panels, trailer sidewall thickness can generally be reduced as compared to sheet and post designs. Although lighter in weight than solid aluminum panels, composite panels are typically more expensive than the materials used in conventional sheet and post designs. Additionally, structural panel sidewalls are difficult and expensive to replace if a single panel becomes damaged. 
         [0010]    The use of rivets to connect structural panels to posts or plates often increases the thickness of the sidewall, and also increases the number of snag points inside the container. Additionally, the use of rivets increases the number of parts used in constructing the container which can increase the cost and time to manufacture a cargo container. 
         [0011]    Some of the advantages of a rivetless cargo container sidewall that combines the thin cross-section of structural panel sidewalls with the easily replaceable interior panels of a sheet and post configuration have been recognized. 
         [0012]    U.S. Pat. No. 5,584,527 issued to Sitter discloses a “plate-type” trailer with a rivetless and boltless sidewall construction. This configuration includes corrugated panels and “seam extrusion members” that connect the corrugated panels. The corrugation of the paneling in the &#39;527 patent decreases the total available space inside the trailer, and the connectors make panel replacement difficult. Thus, the need remains for a rivetless and boltless sidewall construction that allows for easy replacement of damaged panels. 
         [0013]    U.S. Pat. No. 5,403,062 issued to Sjostedt discloses a “panel joint” trailer with a rivetless and boltless sidewall construction. This configuration includes modular panels with integral protrusions, tapered end sections, and adhesive to join the tapered end section of one panel to the integral protrusion section of another panel. The panels disclosed by the &#39;062 patent are highly interconnected, and therefore not easily replaceable. 
         [0014]    U.S. Pat. Nos. 5,860,693, 6,220,651, 6,412,854, 6,986,546, and 7,069,702 issued to Ehrlich disclose a structural panel joint configuration. This configuration includes a pair of panels and two metal plates connected by rivets. However, the panels are not easily replaceable due to the use of rivets. 
         [0015]    Accordingly, an object of the present invention is to provide a sidewall construction for a cargo container that is lightweight yet rigid and strong. 
         [0016]    A further object of the present invention is to provide a cargo container with thin sidewalls to maximize the capacity of the container. 
         [0017]    Another object of the present invention is to provide a sidewall construction that does not require the use of bolts or rivets. 
         [0018]    Yet another object of the present invention is to provide a cargo container with interior walls resistant to the impact of vehicles and implements used to load and unload the container, and to provide a cargo container with minimal protrusions and snag points that could impede the loading or unloading of the container. 
         [0019]    An additional object of the present invention is to provide a cargo container sidewall with panels that can be easily removed and replaced in the event they become damaged. 
         [0020]    A still further object of the present invention is to provide a cargo container with interior logistics slots in the container sidewalls for securing cargo. 
         [0021]    Finally, an object of the present invention is to provide a cargo container sidewall configuration that that is economical to manufacture and refined in appearance. 
       SUMMARY OF THE INVENTION 
       [0022]    An improved panel and connector sidewall construction is presented. While maintaining the benefits of standard structural panel designs, the post connector construction also achieves many benefits of traditional sheet and post designs, including simplified replacement of damaged interior panels. The design also allows for simplified replacement of the outer panels of the container while simultaneously providing an aerodynamic surface without protruding rivets. The sidewall construction also achieves the important objective of providing smooth trailer walls with minimal recesses, protrusions and snag points. 
         [0023]    The composite panel container sidewall construction provides additional interior logistics slots in the sidewalls of the container for securing cargo loaded into the container. These additional interior logistics slots are provided by a vertical support that is seated in the post to avoid creating snag points on the interior of the trailer. The sidewall construction also achieves the benefits of conventional composite panel designs, including the recognized benefit of thin container sidewalls that provide an overall interior trailer width of at least 101 inches. 
         [0024]    These and other advantages will become apparent as this specification is read in conjunction with the accompanying drawings and claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0025]      FIG. 1  is a perspective view of a sidewall with logistics slots, outer sheets and inner liners connecting to posts. 
           [0026]      FIG. 2  is a top view of a sidewall with logistics slots, outer sheets and inner liners connecting to posts. 
           [0027]      FIG. 3  is a top perspective view of a sidewall with logistics slots, outer sheets and inner liners connecting to posts. 
           [0028]      FIG. 4  is a top view of a post. 
           [0029]      FIG. 5  is an outer perspective view of a post. 
           [0030]      FIG. 6  is an inner perspective view of a post. 
           [0031]      FIG. 7  is a front view of a post. 
           [0032]      FIG. 8  is a rear view of a post. 
           [0033]      FIG. 9  is a top view of a second embodiment of a sidewall. 
           [0034]      FIG. 10  is a top view of a third embodiment of a sidewall. 
           [0035]      FIG. 11  is a top view of a fourth embodiment of a sidewall used for refrigerated trailers. 
           [0036]      FIG. 12  is a compressed top view of the second embodiment of the sidewall. 
           [0037]      FIG. 13  is a compressed top view of the third embodiment of the sidewall. 
           [0038]      FIG. 14  is a compressed top view of the fourth embodiment of the sidewall. 
           [0039]      FIG. 15  is a side view of a post with ratcheting grooves securing outer sheets. 
           [0040]      FIG. 16  is a side view of a post with ratcheting grooves securing outer sheets with flush rectangular edges. 
           [0041]      FIG. 17  is a side view of a post having ratcheting grooves securing interlocking outer sheets with flush rectangular edges. 
           [0042]      FIG. 18  is a side view of a post securing interlocking outer sheets with flush rectangular edges. 
           [0043]      FIG. 19  is a side view of a post having separate pockets individually securing outer sheets. 
           [0044]      FIG. 20  is a top view of a post having a logistic span. 
           [0045]      FIG. 21  is an upper perspective view of a post having a logistic span. 
           [0046]      FIG. 22  is a lower perspective view of a post having a logistic span. 
           [0047]      FIG. 23  is an upper perspective view of a post having a logistic span and a logistic slot in the logistic span. 
           [0048]      FIG. 24  is an interior view of liners and a post with logistic slots in a logistic span. 
           [0049]      FIG. 25  is a perspective view of a sidewall post with an interior wall horizontally bounded by two vertical edges and partitions extending to a geometric plane from the interior wall. 
           [0050]      FIG. 26  is a side view of a sidewall construction highlighting the distances between partitions. 
       
    
    
     DETAILED DESCRIPTION 
       [0051]    The sidewall construction may be used with any type of transportable cargo container and is particularly suited for applications requiring a large, lightweight container that is regularly loaded and unloaded by utility vehicles. The improved sidewall construction may be used with containers transported by road, rail, sea, or air. However, for descriptive purposes, the sidewall construction will be described in use with an over-the-road trailer. 
         [0052]      FIG. 1  shows a side perspective view of a sidewall  5  constructed from posts  10 , outer sheets  15  or exterior panels, inner liners  20  or removable panels and logistics panels  25 . The outer sheets  15  have inward protrusions  30  that are secured into pockets  35  in the posts. The logistic panels  25  include logistic slots  40  that may be used to secure cargo or tie downs to the sidewall of the trailer. The sidewall may be used in a cargo container having an interior for the storage and transport of cargo, a floor  54 , and the sidewall construction extending upwardly from the floor to bound a cargo storage space. 
         [0053]    The inner liners  20  are preferably constructed of recycled or virgin polyethylene, and thus are flexible and resilient upon impact. The flexibility of the liners  20  enables them to be bent slightly and inserted into the posts  10  after the posts are secured in place. However, the liners  20  may also be slid into place from the top of the posts  10 , or placed in position when the posts  10  are secured in place. Although resistant to damage, the liners  20  may be easily removed for replacement in the event that the liners do become damaged. 
         [0054]    As shown in  FIG. 2 , the liner  20  is held securely in place because the inner surface  45  of the liner  20  is pressed against a lateral protrusion  50  of the post  10 . The outer surface  55  of the liner  20  is pressed against inward protrusions  60  of the posts  10 . Because the liner  20  is held securely in place by the novel configuration of the post  10 , rivets or screws are not needed to attach the liner to the post. Thus, unlike conventional sheet and post designs, potential protrusions and snag points are eliminated. 
         [0055]    The logistic panels  25  have lateral wings  65  that seat in the logistics seat  70  of the post  10 . The logistic panels  25  are preferably made of a rigid material such as metal so they are slid into place from the top of the posts  10 , or placed in position when the posts are secured in place. However, flexible logistic panels may be bent into position in a manner similar to the liners. Since flexible logistic panels may not be appropriate for securing cargo to the sidewall, the flexible panels are preferably used when logistic slots are not needed. Alternatively, a sidewall may be constructed with a mix of lightweight plastic logistic panels and rigid metal logistic panels when a full compliment of tie down locations is not needed and the weight of the sidewall is to minimized. 
         [0056]      FIGS. 3 through 8  show views of a post  10 . The post  10  has a pocket  75  for receiving and securing inward protrusions of the outer sheets. Inside of the pocket  75  there are multiple ridges  80  that act to mechanically secure the outer sheets to the post. Adhesive may also be used to secure the outer sheets to the pocket. Laterally extending from the pocket are a first wall  85  and a second wall  90  that run adjacent to the outer sheets. In the illustrated example of  FIGS. 3 and 4 , the walls ( 85  and  90 ) extend to the inward protrusions  60  of the post. However, the walls may extend beyond the inward protrusions, such as shown in  FIGS. 9 ,  10 ,  12  and  13 . Small outward protrusions  95  extend from the walls toward the outer sheets. Adhesive may be placed between the small outward protrusions to help secure the post to the outer sheets. A lateral protrusion  50  extends away from the pocket  75  towards one of the inward protrusions  60  and is structured to press against and secure the inner surface of a liner. 
         [0057]    Extending inward from the second wall  90  between an inward protrusion  60  and the pocket is an inward projection  100  that forms part of the logistics seat  70 . A lateral protrusion  50  also extends away from the inward projection  100 . Both lateral protrusions  50  act to secure the inner surface of a liner. 
         [0058]      FIGS. 9 and 12  illustrate a second embodiment of a sheet and post side wall. In the sidewall shown in  FIGS. 9 and 12 , the post has a combined logistics seat  105  that acts as both the logistics seat for the logistics panel and the lateral protrusion for securing the inner liner. Also, the post has rounded inward protrusions  110  and wall extensions  115 . The larger rounded protrusions may help to prevent the liner from cracking or breaking if the sidewall is impacted from within the cargo container. The wall extensions  115  provide additional surface area for adhesively securing the outer sheets to the post.  FIGS. 10 and 13  illustrate the third embodiment of the sidewall with rounded inward protrusions  110  but lacking the combined lateral protrusion and logistics seat. 
         [0059]      FIGS. 11 and 14  illustrate an embodiment of a sidewall construction where insulation  120  has been applied between the outer sheets and the inner liner. The insulated sidewall construction is particularly well suited for refrigerated trailers. 
         [0060]      FIG. 15  illustrates an example of a pocket that has ratcheting grooves  125  that facilitate easy entry of the outer sheets into the pocket while also securely holding the sheets in the pocket.  FIG. 16  shows outer sheets with rectangular edges  130 . The rectangular edges provide a smooth aerodynamic outer surface for a trailer.  FIG. 17  shows sheets with interlocking features  135  that not only secure the outer sheets to the post, but also to themselves.  FIG. 18  shows another combination of sheets with rectangular edges  130  and interlocking features  135  without the ratcheting grooves of  FIGS. 15 through 17 . 
         [0061]      FIG. 19  illustrates an alternate embodiment of a post having dual pockets  140  that separately receive outer sheets. The first wall  85  and the second wall  90  of the post are separated by a center wall  145 . The center wall  145  extends beyond the first and second walls so that the outer surface of the sidewall construction is relatively smooth. 
         [0062]      FIGS. 20 through 23  illustrate an alternate embodiment of a container side wall constructed from outer sheets  15 , inner liners  20 , and a post. The inner surfaces  45  of the liners are pressed against two later protrusions  50  on the post while the outer surfaces  55  of the liners  20  are pressed against inward protrusions  60  on the post. A logistics span  51  or interior wall extends between the two lateral protrusions  50  of the post of  FIG. 20 . 
         [0063]    The post includes a pocket  75  with ridges  80  adapted to secure the outer sheets  15  in the pocket  75 . A first wall  85  and a shortened second wall  91  run adjacent to the outer sheets  15  or outer panels and include small outward protrusions  95  that extend from the walls toward the outer sheets. Adhesive may be placed between the small outward protrusions to help secure the post to the outer sheets. An outward span protrusion  52  or first partition extends outwards from the logistics span  51  or interior wall towards the outer sheets  15 . A third wall  92  is secured to the outermost portion of the span protrusion and runs adjacent to the outer sheets  15 . In the illustrated example, the inward protrusions  60  of the post include inner bulbous areas  61  and outer bulbous areas between a thin span  63 . The bulbous areas ( 61  and  62 ) present larger surface areas for the inner and outer sheets ( 15  and  20 ) to contact. The larger surface area spreads out the forces exerted by the post on the sheets and decreases the likelihood that a post would damage a sheet. The thin span  63  between the bulbous regions reduces the amount of material needed to construct the post and also reduces the weight of the post.  FIG. 23  shows a logistic slot  53  in the logistic span  51 , and  FIG. 24  illustrates multiple logistic slots  53  in a single logistic span  51 . The sidewall construction shown in  FIG. 24  is part of a cargo container and extends up from the floor  54 . The sidewall bounds an interior storage space. 
         [0064]      FIG. 25  shows a sidewall construction with an interior wall  200  extending between and horizontally bounded by a first vertical edge  205  and a second vertical edge  210 . The vertical edges extend upwardly from the floor of the cargo container. A first partition  215 , a second partition  220 , and a third partition  225  extend perpendicularly from the interior wall  200  to a geometric plane  230 . A first wall  235  extends from the first partition  215  away from the second partition  220  and parallel to the interior wall  200 . A second wall  240  extends from the second partition  220  towards the first partition and parallel to the interior wall  200 . A third wall  245  extends from the third partition  225  away from the second partition  220  and parallel to the interior wall  200 . A fourth partition  250  extends perpendicularly inwardly from the first wall  235  and a fifth partition  255  extends perpendicularly inward from the third partition. The first, second and third partitions are all distant from both the first vertical edge  205  and the second vertical edge  210  of the interior wall  200 . 
         [0065]      FIG. 26  illustrates a sidewall with a first partition  215  separated from a second partition  220  by a first distance  260 . The third partition  225  is separated from the second by a second distance  265 , and the second distance  265  is substantially smaller than the first distance  260 . The first partition  215  is separated from the fourth partition  250  by a third distance  270  and the third partition  225  is separated from the fifth partition  255  by a fourth distance  275 . The third distance  270  and the fourth distance  275  are substantially equal. In the illustrated example, a first outer panel  280  is adhesively bound to both the first wall  235  and the second wall  240 , while a second outer panel  285  is adhesively bound to the third wall  245 . Each of the first and second outer panels includes a portion located and secured between the second partition  220  and the third partition  225 . Removable panels are secured in the sidewall by the fourth and fifth partitions exerting inward forces  290  on the removable panels while the interior wall is exerting outward forces  295  upon the removable panels. 
         [0066]    The materials used in the side wall construction may include, but are not limited to, wood, metals, carbon fibers, and polymers. The individual components may be of a uniform or variant composition. A protective coating may be added to any material to protect it from road spray and general corrosion. 
         [0067]    The inventors contemplate several alterations and improvements to the disclosed invention. Other alterations, variations, and combinations are possible that fall within the scope of the present invention. Although the preferred embodiment of the present invention has been described, those skilled in the art will recognize other modifications that may be made that would nonetheless fall within the scope of the present invention.