Abstract:
A trailer having a double wall extruded panel nose construction. A trailer wall construction for use as part of a trailer assembly includes a curved front wall including at least one curved panel having spaced apart inner and outer shells. Another trailer wall construction includes a series of elongated panels joined to each other along respective adjacent edges, each of the panels being curved and having spaced apart inner and outer shells. The joined panels form a curved wall of the trailer assembly.

Description:
BACKGROUND 
       [0001]    The present invention relates generally to wheeled vehicle construction and, in an embodiment described herein, more particularly provides a trailer having a double wall extruded panel nose construction. 
         [0002]    It is very beneficial to be able to reduce the tare weight of a trailer used commercially to haul loads. For example, bridge laws and other regulations limit the gross weight of over-the-road vehicles. Thus, if the tare weight can be reduced, the weight of cargo can be increased, thereby resulting in more efficient and economical hauling operations. 
         [0003]    Where a trailer is used to haul loose material, such as dirt, garbage, etc., it would be beneficial to provide a trailer wall construction which minimizes or eliminates square corners between the walls. This would prevent the loose material from being retained in the corners when the trailer load is dumped. Particularly in very cold conditions, damp material is prone to freezing and sticking in the front of conventional trailers. 
         [0004]    Since fuel costs reduce profit margins in the material transfer industry, aerodynamic trailer designs would be very beneficial. 
         [0005]    Another important consideration in trailer construction is aesthetics. It would be beneficial to be able to provide a trailer wall construction which is aesthetically pleasing, both at the time it is manufactured and after it has been in use. 
         [0006]    Unfortunately, typical trailer wall construction methods have been unable to adequately satisfy the needs for reduced weight, minimized square corners between walls, reduced freezing of materials, improved aerodynamics and improved aesthetics. Thus, it will be appreciated that a need exists for improved trailer wall construction. 
       SUMMARY 
       [0007]    In carrying out the principles of the present invention, a trailer wall construction is provided which solves at least one problem in the art. One example is described below in which a trailer assembly includes a curved wall made up of curved extruded hollow panels. Another example is described below in which the panels are uniquely joined to each other, and to other walls in the trailer assembly. 
         [0008]    In one aspect of the invention, a trailer wall construction for use as part of a trailer assembly is provided. The trailer wall construction includes a curved front wall including at least one curved panel having spaced apart inner and outer shells. 
         [0009]    In another aspect of the invention, a trailer wall construction for use in a trailer assembly includes a series of elongated panels joined to each other along respective adjacent edges. Each of the panels is curved and has spaced apart inner and outer shells. The joined panels form a curved wall of the trailer assembly. 
         [0010]    These and other features, advantages, benefits and objects of the present invention will become apparent to one of ordinary skill in the art upon careful consideration of the detailed description of representative embodiments of the invention hereinbelow and the accompanying drawings, in which similar elements are indicated in the various figures using the same reference numbers. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]      FIG. 1  is an isometric view of a trailer assembly embodying principles of the present invention; 
           [0012]      FIG. 2  is an enlarged scale top plan view of a nose portion of the trailer assembly of  FIG. 1 ; 
           [0013]      FIG. 3  is a further enlarged scale top plan view of an extruded panel section of the trailer nose portion; 
           [0014]      FIG. 4  is a further enlarged scale top plan view of an engagement portion of the extruded panel section; and 
           [0015]      FIG. 5  is a top plan view of another engagement portion of the extruded panel section. 
       
    
    
     DETAILED DESCRIPTION 
       [0016]    It is to be understood that the various embodiments of the present invention described herein may be utilized in various orientations, such as inclined, inverted, horizontal, vertical, etc., and in various configurations, without departing from the principles of the present invention. The embodiments are described merely as examples of useful applications of the principles of the invention, which is not limited to any specific details of these embodiments. 
         [0017]    In the following description of the representative embodiments of the invention, directional terms, such as “above”, “below”, “upper”, “lower”, etc., are used for convenience in referring to the accompanying drawings. 
         [0018]    Representatively illustrated in  FIG. 1  is a trailer assembly  10  which embodies principles of the present invention. The trailer assembly  10  is representatively illustrated as being of the type known as a dump trailer, but it should be clearly understood that other types of trailers (such as box trailers, etc.) can incorporate principles of the invention. 
         [0019]    The trailer assembly  10  includes vertical side walls  12 ,  14  which are preferably constructed in a manner described in either of U.S. patent application Ser. Nos. 11/112,489 and 11/223,581, the entire disclosures of which are incorporated herein by this reference. A tailgate  16  and floor  18  (see  FIG. 2 ) may also be constructed using the techniques described in the incorporated patent applications. 
         [0020]    Preferably, the side walls  12 ,  14 , tailgate  16  and floor  18  are made up of joined hollow extruded panels  20 , each of which has spaced apart inner and outer shells with hollow cavities therebetween, as described in the incorporated patent applications. However, it should be clearly understood that other types of walls, panels, etc., may be used in keeping with the principles of the invention. 
         [0021]    A suspension system  22  supports a rear end of the trailer assembly  10  above a road surface. The suspension system  22  and associated undercarriage  24  may be similar to those described in U.S. patent application Ser. No. 11/176,037, the entire disclosure of which is incorporated herein by this reference. However, other types of suspension systems and undercarriages may be used in keeping with the principles of the invention. 
         [0022]    In one unique feature of the trailer assembly  10 , a nose portion  26  of the trailer assembly includes a generally vertical front wall  28  which has a curved shape. Preferably, the front wall  28  is made up of multiple curved panels  30 . In  FIG. 2 , the curved shape of the front wall  28  and each of the panels  30  can be clearly seen. 
         [0023]    Note that the front wall  28  in this example has a semicircular shape and extends in a circular arc between the side walls  12 ,  14 . Each of the panels  30  comprises a section of the circular arc, and the joined panels thereby make up the semicircular shape of the front wall  28 . However, it should be clearly understood that other curved shapes (such as oval, elliptical, etc.) may be used in keeping with the principles of the invention. 
         [0024]    Each of the panels  30  is elongated and extends in a vertical direction. Thus, joined edges between respective adjacent panels also extend in a vertical direction. However, it should be clearly understood that the panels  30  and respective adjacent edges could extend in other directions (such as horizontal or inclined, etc.), in keeping with the principles of the invention. 
         [0025]    As depicted in  FIGS. 1 &amp; 2 , the front wall  28  is made up of seven of the panels  30 . The panels  30  are preferably of equal width, therefore, each panel makes up approximately 25.7° of the 180° circular arc of the front wall  28 . However, any number of the panels  30  could be used, and it is not necessary for the panels to have equal widths, in keeping with the principles of the invention. 
         [0026]    Note that the panels  30  at each end of the front wall  28  are attached both to the floor  18  and to a respective one of the side walls  12 ,  14 . Vertical posts  32  facilitate the attachment between the panels  30  and the side walls  12 ,  14 . However, if the panels  20  in the side walls  12 ,  14  extend vertically, then the panels  20 ,  30  in the front and side walls  12 ,  14 ,  28  could be joined to each other along respective adjacent edges, without use of the posts  32 , if desired. 
         [0027]    Although in  FIGS. 1 &amp; 2  a top rail is not illustrated on the front wall  28  (similar to the top rails  34  on the side walls  12 ,  14 ), such a top rail could be provided, if desired. Furthermore, additional or alternate components, such as bottom rails, connectors, etc. suitable for use with hollow extruded panels (for example, the various components described in the incorporated patent applications) may be used, if desired. 
         [0028]    Referring additionally now to  FIG. 3 , an enlarged top view of one of the panels  30  is representatively illustrated, apart from the remainder of the trailer assembly  10 . In this view it may be seen that the panel  30  has a radius R which is preferably approximately one-half of the width W (see  FIG. 2 ) of the trailer assembly  10 , which is also the lateral width of the front wall  28 . For example, if the front wall  28  has a width W of 90 inches, then the radius R of each panel is preferably 45 inches, although as described above, other curvatures may be used in keeping with the principles of the invention. 
         [0029]    In this enlarged view of the panel  30 , the construction of the panel may also be seen more clearly. The panel  30  is preferably constructed with an inner shell  36  spaced apart from an outer shell  38 , with multiple webs  40  connecting the shells to each other. 
         [0030]    The webs  40  separate multiple internal hollow cavities  42 . It is not necessary for the cavities  42  to be hollow, since they could instead be filled with substances, such as foam, plastics, etc. to further strengthen the panel  30 . 
         [0031]    Although the inner shell  36  is depicted in  FIG. 3  as having approximately the same thickness as the outer shell  38 , these shells could have different thicknesses, if desired. For example, the inner shell  36  could be made thicker to provide increased wear resistance, puncture resistance and strength. 
         [0032]    An engagement portion  44  is formed on a side edge of the panel  30 , and a complementarily shaped engagement portion  46  is formed on an opposite side edge. These engagement portions  44 ,  46  are constructed to facilitate convenient and durable joining of the respective adjacent edges of the panels  30  in the front wall  28 . 
         [0033]    An enlarged scale view of the engagement portion  44  is representatively illustrated in  FIG. 4 . In this view it may be seen that the engagement portion  44  includes a recess  48  which is laterally inclined at an angle A relative to an axis of curvature  52  of the panel  30 . 
         [0034]    An enlarged scale view of the engagement portion  46  is representatively illustrated in  FIG. 5 . In this view it may be seen that the engagement portion  46  includes a projection  50  which is laterally inclined at the same angle A relative to the axis of curvature  52  of the panel  30 . 
         [0035]    The recess  48  and projection  50  are complementarily shaped so that, when the engagement portions  44 ,  46  of adjacent panels  30  are engaged with each other, the respective adjacent edges of the panels may be readily and securely joined. The inclined angles A of the projections  50  and recesses  48  facilitate assembly of the panels  30  in the semicircular shape of the front wall  28 . However, it should be clearly understood that other types of engagement portions (such as those described in the incorporated patent applications) may be used in keeping with the principles of the invention. 
         [0036]    At each of the attachments between adjacent edges of the panels  30 , the panels are preferably welded to each other along their respective edges. However, it should be clearly understood that other attachment methods may be used instead of, or in addition to, welding. For example, adhesive bonding, mechanical fasteners, or any other type of attachment method or combination of attachment methods may be used, as well as any of the methods described in the incorporated patent applications. 
         [0037]    Preferably, the edges of the panels  30  are attached by welding along inner seams between the adjacent edges. Chamfers  54  formed on the engagement portions  44 ,  46  facilitate the welding along the inner seams. The edges of the panels  30  could also (or alternatively) be attached by welding along outer seams between the adjacent edges. Chamfers similar to the chamfers  54  shown in  FIGS. 4 &amp; 5  could be provided on the engagement portions  44 ,  46  to facilitate this welding along the outer seams. 
         [0038]    It may now be fully appreciated that the trailer wall construction described above provides several benefits. For example, the use of square corners between the front wall  28  and the side walls  12 ,  14  is eliminated. The construction of the front wall  28  is aesthetically pleasing, and the spaced apart inner and outer shells  36 ,  38  ensure that it is less likely that material or items carried in the trailer assembly  10  will puncture or deform the exterior of the front wall. The hollow cavities  42  with supporting webs  40  in each of the panels  30  provide enhanced strength while also providing a light weight construction. The cavities  42  also provide insulation, thereby helping to prevent material carried in the trailer assembly  10  from freezing. Furthermore, the curved shape of the front wall  28  and its smooth joining to the side walls  12 ,  14  without square corners improves the aerodynamics of the trailer assembly  10 . 
         [0039]    Of course, a person skilled in the art would, upon a careful consideration of the above description of representative embodiments of the invention, readily appreciate that many modifications, additions, substitutions, deletions, and other changes may be made to these specific embodiments, and such changes are within the scope of the principles of the present invention. Accordingly, the foregoing detailed description is to be clearly understood as being given by way of illustration and example only, the spirit and scope of the present invention being limited solely by the appended claims and their equivalents.