Patent Description:
Utility trailers such as box trailers are used to transport cargo. Box trailers can typically be coupled to a car. Box trailers are made by welding a metal sheet floor to a metal frame. The metal frame extends upwardly from the floor and provides support for the walls of the box trailer.

A problem with metal frames is that they require extensive welding to manufacture the frame and to attach the floor and walls to the frame.

Another problem with welded frames is that the dimensions of a trailer cannot be easily changed if the frame is pre-welded.

A further problem with steel metal frames is that this adds significant weight to the trailer.

Prior art documents <CIT>, <CIT>, <CIT>, <CIT>, <CIT> and <CIT> disclose various modular trailers. A drawback to these trailers is that the tongue assemblies are attached to subframes or other parts of the trailers instead of to sidewall members, adding additional weight and/or additional production steps to the trailers.

It is an object of the present invention to overcome or at least alleviate one or more of the above mentioned problems with trailers and/or provide the consumer with a useful or commercial choice.

In one aspect, the present invention broadly resides in a trailer having.

The floor members are preferably made from extruded aluminium. Preferably, each of the floor members is connected to an adjacent floor member along a lengthwise edge. Preferably each end of each floor member is attached to one of the side wall members. More preferably, a first end of each floor member is attached to a first one of the side wall members and a second end of each floor member is attached to a second one of the side wall members.

Each of the floor members is preferably connected to an adjacent floor member by an interference fit. In one embodiment, each floor member has a hook portion on each longitudinal side. The hook portion is adapted to connect to a hook portion of an adjacent floor member. In another embodiment, each floor member has a tongue portion or prong portion on one side and a groove portion or hook portion on the opposed side to attach to adjacent floor members. In one embodiment, each of the floor members is additionally glued to an adjacent floor member.

Each floor member preferably has a substantially flat upper surface. Each floor member preferably has a support portion extending downwardly from the upper surface. In one embodiment, each floor member has a substantially hollow rectangular cross section.

In another embodiment, the floor members are attached to a base sheet. The base sheet is preferably made of aluminium. The floor members are preferably glued to the base sheet. The floor members and the base sheet preferably define the floor.

In one embodiment each floor member has an upper surface and an opposed lower surface. Preferably each floor member has a first connection portion and a second connection portion. Preferably, the first connection portion is adapted to connect to a second connection portion of an adjacent floor member. Preferably the second connection portion is adapted to connect to a first connection portion of an adjacent floor member. Preferably the first connection portion and the second connection portion are located adjacent the lower surface. Preferably, the first connection portion is adapted to rotatably connect to a second connection portion of an adjacent floor member. Preferably the second connection portion is adapted to rotatably connect to a first connection portion of an adjacent floor member. Preferably the first connection portion is a male portion. Preferably the second connection portion is a female portion. Preferably each floor member has a third connection portion and a fourth connection portion. Preferably, the third connection portion is adapted to connect to a fourth connection portion of an adjacent floor member. Preferably the fourth connection portion is adapted to connect to a third connection portion of an adjacent floor member. Preferably the third connection portion and the fourth connection portion are located adjacent the upper surface. Preferably the third connection portion includes a ramp portion. Preferably the fourth connection portion includes a ramp portion. Preferably, the first connection portion of each floor member is adapted to connect to a second connection portion of an adjacent floor member. Preferably, when the first connection portion of the floor member is connected to a second connection portion of an adjacent floor member, the floor member is rotatable relative to the adjacent floor member between a first position and a secured position. Preferably in the secured position, the third connection portion of the floor member engages with a fourth connection portion of an adjacent floor member. In an alternate embodiment, the first and second connection portions are located adjacent the upper surface and the third and fourth connection portions are located adjacent the lower surface.

The side wall members are preferably glued to the floor. More preferably the side wall members are glued to end portions of the floor members which define the floor. The side wall members are preferably made from extruded aluminium. Each side wall member preferably has a channel which receives the floor. Each side wall member preferably has a wall portion extending upwardly from the channel. The wall portion preferably has a substantially hollow rectangular cross section. Each side wall member preferably includes an indent or a lip in the channel to define a glue track. The glue track is preferably located on a lower portion of the channel. The glue track preferably retains glue as the floor is glued into the channel of each side wall member.

The axle assembly preferably includes one or more axles. Each axle preferably has at least one wheel attached thereto. The axle assembly preferably includes one or more suspension assemblies to suspend the one or more axles relative to the side wall member. The axle assembly is preferably bolted to the side walls. In one embodiment, the axle assembly is glued to the side wall members. In another embodiment, the axle assembly is additionally attached to the side wall members by brackets which are glued to the side wall members and glued to the axle assembly. In one embodiment, the side wall members include one or more glue tracks on an external surface. The glue tracks preferably retain glue as the brackets are glued to the side wall members.

The tongue assembly is preferably glued to the side wall members. In one embodiment, the tongue assembly is bolted to the side wall members. In another embodiment a bracket attaches each side wall member to the tongue assembly. Each bracket is preferably glued to a side wall member and to the tongue assembly. The tongue assembly preferably includes two draw bar portions which attach the tongue assembly to the side walls. The draw bar portions are preferably glued to the side wall members. Each draw bar portion preferably includes an indent portion or two opposed lips to define a glue track. The glue track preferably retains glues as the draw bar portions are glued to the side wall members. The indent portion or two opposed lips are preferably located on an upper side of the respective draw bar portion. The tongue assembly preferably includes a coupling to couple the trailer to a vehicle. The coupling is preferably a tow hitch receiver. In one embodiment, the tongue assembly includes a dolly wheel.

The trailer preferably includes a front wall member attached to the floor. The front wall member is preferably attached to a front side of the floor. The front wall member is preferably glued to a front side of the floor. The front wall member is preferably attached to the side wall members. In one embodiment, the front wall member is attached to the side wall members by brackets. Preferably each bracket is glued to one of the side wall members and the front wall member. The front wall member preferably has a channel which receives the floor. Each front wall member preferably includes an indent or a lip in the channel to define a glue track. The glue track is preferably located on a lower portion of the channel. The glue track preferably retains glue as the floor is glued into the channel of the front wall member. The front wall member preferably has a wall portion extending upwardly from the channel. The wall portion preferably has a substantially hollow rectangular cross section. Preferably the front wall member is made from the same aluminium extrusion as the side wall members. The front wall member is preferably attached to the tongue assembly. More preferably the front wall member is glued to the tongue assembly.

The trailer preferably includes a rear wall member attached to the floor. The rear wall member is preferably attached to a rear end of the floor. The rear wall member is preferably glued to a rear end of the floor. The rear wall member is preferably attached to the side wall members. In one embodiment, the rear wall member is attached to the side wall members by brackets. Preferably each bracket is glued to one of the side wall members and the rear wall member. The rear wall member preferably has a channel which receives the floor. Each rear wall member preferably includes an indent or a lip in the channel to define a glue track. The glue track is preferably located on a lower portion of the channel. The glue track preferably retains glue as the floor is glued into the channel of the rear wall member. The rear wall member preferably has a wall portion extending downwardly from the channel. In one embodiment, the wall portion extends upwardly from the channel. The wall portion preferably has a substantially hollow rectangular cross section. Preferably the rear wall member is made from the same aluminium extrusion as the side wall members.

The trailer preferably includes a fender on each side of the trailer to at least partially cover one or more wheels on each side of the trailer. Each fender is preferably attached to a side wall member. In one embodiment, each fender is glued to a side wall member. In one embodiment, each fender is bolted to a side wall member. An advantage of bolting a fender to a side wall member is that in the event of a fender being damaged, the fender can be easily replaced.

In one embodiment, the trailer includes one or more upper wall members. Preferably each upper wall member is attachable to a side wall member or an adjacent upper wall member. Preferably in this manner a side wall member and attached upper wall members define a side wall of the trailer which is higher than just a side wall member by itself. Preferably each upper wall member is attachable to a side wall member, a front wall member, a rear wall member or an adjacent upper wall member. In one embodiment, each upper wall member is adapted to attach to a panel. Preferably each upper wall member has a slot to receive the panel. Preferably in this manner a side wall member, an attached upper wall member and an attached panel define a side wall of the trailer. In another embodiment, each side wall member is adapted to attach to a panel. Preferably each side wall member has a slot to receive the panel. In another embodiment, each front wall member is adapted to attach to a panel. Preferably each front wall member has a slot to receive the panel. In another embodiment, each rear wall member is adapted to attach to a panel. Preferably each rear wall member has a slot to receive the panel.

The glue is preferably suitable for bonding metals. The glue is preferably a two part adhesive. The glue is preferably a Methacrylate adhesive. The glue when cured preferably has a tensile strength of at least <NUM> MPa. In one embodiment, the glue has a tensile strength of between <NUM> and <NUM> MPa. The glue preferably has a tensile modulus of between <NUM> to <NUM> MPa. In one embodiment, the glue is in the form of a double sided adhesive tape.

In another aspect, the present invention broadly resides in a trailer having.

In one embodiment, each axle assembly includes at least one stub axle. Preferably each axle assembly includes suspension means. Preferably each axle assembly includes at least one wheel. In one embodiment, each axle assembly includes two stub axles and two wheels.

In a further aspect, the present invention broadly resides in a trailer having.

The side wall members are preferably glued to the tongue assembly. The side wall members are preferably glued to the one or more axle assemblies.

The side wall members are preferably bolted to the tongue assembly. The side wall members are preferably bolted to the one or more axle assemblies.

In another aspect, the present invention broadly resides in a method of manufacturing a trailer, including the steps of.

Preferably the method further includes the step of attaching a front wall member to the floor. Preferably the step of attaching a front wall member to the floor includes receiving the floor in a channel of the front wall member. Preferably the step further includes gluing the floor into the channel of the front wall member.

Preferably the method further includes the step of attaching a rear wall member to the floor. Preferably the step of attaching a rear wall member to the floor includes receiving the floor in a channel of the rear wall member. Preferably the step further includes gluing the floor into the channel of the rear wall member.

Preferably the step of connecting a plurality of floor members together to define a floor of the trailer includes interconnecting hook portions or hook and prong portions of adjacent floor members. Preferably the step of connecting a plurality of floor members together to define a floor of the trailer includes gluing adjacent floor members together.

Preferably the step of attaching side wall members to opposed sides of the floor includes receiving the floor in a channel in each side wall member. Preferably the step further includes gluing the floor into each channel.

Preferably the step of attaching a tongue assembly to the side wall members includes gluing draw bar portions of the tongue assembly to the side wall members.

Preferably the method further includes the step of attaching the tongue assembly to the front wall member.

Preferably the step of an axle assembly to the side wall members includes bolting the axle assembly to the side wall members.

Preferably the method further includes the step of attaching at least one fender to each side wall member.

The features described with respect to one aspect also apply where applicable to all other aspects of the invention. Furthermore, different combinations of described features are herein described and claimed even when not expressly stated.

In order that the present invention can be more readily understood reference will now be made to the accompanying drawings which illustrate a preferred embodiment of the invention and wherein:.

With reference to <FIG>, there is shown a trailer <NUM> according to an embodiment of the present invention. The trailer <NUM> has a plurality of floor members <NUM> defining a floor <NUM>. The floor members <NUM> are aluminium extrusion. The floor <NUM> is glued to side wall members <NUM>,<NUM>. The floor <NUM> is also glued to front wall member <NUM> and rear wall member <NUM>. The wall members <NUM>,<NUM>,<NUM>,<NUM> are aluminium extrusion. Wall members <NUM>,<NUM>,<NUM>,<NUM> are the same type of extrusion, with rear wall member <NUM> installed upside down compared to wall members <NUM>,<NUM>,<NUM>.

Side wall members <NUM>,<NUM> are attached to the front wall member <NUM> by brackets <NUM>,<NUM>. Bracket <NUM> is glued to side wall member <NUM> and front wall member <NUM>. Bracket <NUM> is glued to side wall member <NUM> and front wall member <NUM>.

A tongue assembly <NUM> is attached to the side wall members <NUM>,<NUM> and the front wall member <NUM>. The tongue assembly has two draw bars <NUM>,<NUM>. Draw bar <NUM> is glued to the side wall member <NUM> and front wall member <NUM>. Draw bar <NUM> is glued to the side wall member <NUM> and front wall member <NUM>. The draw bars <NUM>,<NUM> are aluminium extrusion. In one embodiment (not shown) the draw bars are further attached to the side wall members by brackets which are glued to the corresponding draw bars and side wall members. The tongue assembly also includes a coupling in the form of a tow hitch receiver <NUM>.

An axle assembly <NUM> is attached to the side wall members <NUM>,<NUM>. In this embodiment, the axle assembly <NUM> is bolted to the side wall members <NUM>,<NUM>. The axle assembly <NUM> includes suspension <NUM>, axles <NUM> and wheels <NUM>.

Fenders <NUM> and <NUM> are bolted to sidewalls <NUM> and <NUM> respectively and partially cover the wheels <NUM>.

<FIG> is a sectioned view of the trailer <NUM> showing where the lower portions of the side wall members <NUM>,<NUM> are glued to the draw bars <NUM>,<NUM> of the tongue assembly <NUM>. <FIG> also shows where the front wall member <NUM> is glued to the draw bars <NUM>,<NUM>. <FIG> also shows the axle assembly <NUM> in some more detail. Side wall members <NUM>,<NUM> are also further attached to front wall member <NUM> by gusset members 24a,26a.

With reference to <FIG>, there is shown a detailed cross section of the trailer <NUM>. The side wall member <NUM> has a channel <NUM> which receives the floor members <NUM> of the floor <NUM>. The channel also receives a sheet <NUM> which is glued to the floor members <NUM> and is also part of the floor <NUM>. The floor <NUM> is glued into the channel <NUM>. The side wall member <NUM> has a wall portion <NUM> which extends upwardly from the channel <NUM>.

With reference to <FIG>, there is shown a detailed sectioned side view of the trailer <NUM>. The floor members <NUM> are attached to adjacent floor members <NUM> and are also glued to the aluminium sheet <NUM> to define the floor <NUM>.

<FIG> shows a detailed sectioned side view of the trailer <NUM>. The rear wall <NUM> is made of the same extrusion as the other wall members <NUM>,<NUM>,<NUM>. The rear wall member <NUM> is attached to the floor <NUM> in an upside down manner compared to the other wall members <NUM>,<NUM>,<NUM>.

With reference to <FIG>, there is shown a cross section view of the side wall member <NUM>. The channel <NUM> includes lips <NUM> and <NUM> which define glue tracks 64a and 66a. The glue tracks 64a and 66a are used to retain glue as the side wall member <NUM> is glued to the floor (not shown). The side wall member <NUM> also has lips <NUM> which define glue tracks 68a. Glue tracks 68a are used to retain glue as brackets (not shown) are glued onto the side wall member <NUM>. The side wall member <NUM> also has glue tracks 62a on upper sides and a top portion of the side wall member <NUM>. Glue tracks 62a are used to retain glue as accessories (not shown) are glued to the top of the side wall member <NUM>, for example wall extensions (not shown) which are used if the trailer is used as a horse float.

With reference to <FIG>, there is shown a cross section view of the draw bar <NUM>. The draw bar has lips 32a which define glue track 32b. The glue track 32b is used to retain glue as the side wall member <NUM> (not shown) and the front wall member <NUM> (not shown) are glued to the draw bar <NUM>.

With reference to <FIG>, there is shown a cross section view of a floor member <NUM>. The floor member <NUM> has a substantially flat upper surface <NUM>. A support portion <NUM> extends downwardly from the upper surface <NUM>. When defining a floor (not shown) the support portion <NUM> is glued to the aluminium sheet <NUM> (not shown). The floor member <NUM> has a tongue portion <NUM> and a groove portion <NUM> so that adjacent floor members can be connected.

With reference to <FIG>, there is shown a cross section view of a floor member <NUM> according to another embodiment of the invention. The floor member <NUM> has a substantially flat upper surface <NUM> and a lower surface <NUM>. The floor member <NUM> also has female portions <NUM> and <NUM> and male portions 96a and 98a. The female portions <NUM>,<NUM> engage with male portions (not shown) of an adjacent floor member (not shown). The male portions 96a,98a engage with female portions (not shown) of another adjacent floor member (not shown). In this manner, a plurality of floor members <NUM> can be connected to define a floor.

With reference to <FIG>, there is shown a cross section view of a floor member <NUM> (looking from an end in the lengthwise direction of the floor member) according to a further embodiment of the invention. The floor member <NUM> has a substantially flat upper surface <NUM> and a lower surface <NUM>. The upper surface <NUM> is spaced from the lower surface by support walls <NUM>,<NUM>. The floor member <NUM> also has a female portion <NUM> and a male portion <NUM>. The female portion <NUM> is adapted to engage with a male portion (not shown) of an adjacent floor member (not shown). The male portion <NUM> is adapted to engage with a female portion (not shown) of another adjacent floor member (not shown). The male portion <NUM> has a sheath portion <NUM>. The male portion <NUM> is adapted to engage with a female portion (not shown) of another adjacent floor member at an angle as can be seen from <FIG> due to the sheath portion <NUM>.

The floor member <NUM> has a first ramp portion <NUM> and a second ramp portion <NUM>. The first ramp portion <NUM> is adapted to engage with a second ramp portion of an adjacent floor member (not shown). The second ramp portion <NUM> is adapted to engage with a first ramp portion of another adjacent floor member (not shown).

In use, the male portion <NUM> connects with a female portion (not shown) of another adjacent floor member at an angle, the floor member <NUM> is then rotated relative to the adjacent floor member to a secured position so that the second ramp portion <NUM> engages with a first ramp portion of the adjacent floor member (not shown) to secure the floor members together. In this manner, a plurality of floor members <NUM> can be connected to define a floor.

An advantage of the preferred embodiment of the trailer includes the ability to manufacture a trailer with no or minimal welding. Another advantage of the preferred embodiment of the trailer includes a lighter construction compared to a welded frame or steel framed trailer. A further advantage of the preferred embodiment of the trailer includes the ability to easily change the dimensions of the trailer by changing the length and/or number of floor members. An additional advantage of the preferred embodiment of the trailer includes faster assembly and reduced costs due to no or minimal welding. A further advantage of the preferred embodiment of the trailer being made from aluminium is that it does not require painting or galvanisation as is typically required for steel framed trailers.

Claim 1:
A trailer (<NUM>) having
a plurality of elongate floor members (<NUM>), each of the floor members (<NUM>) connected to an adjacent floor member (<NUM>) to define a floor (<NUM>) of the trailer (<NUM>);
side wall members (<NUM>,<NUM>) attached to opposed sides of the floor (<NUM>);
an axle assembly (<NUM>) attached to the side wall members (<NUM>,<NUM>); and
characterised in that the trailer (<NUM>) further includes
a tongue assembly (<NUM>) attached to the side wall members (<NUM>,<NUM>),
wherein each side wall member (<NUM>,<NUM>) has a channel (<NUM>) which receives the floor (<NUM>), and wherein each side wall member (<NUM>,<NUM>) has a wall portion (<NUM>) extending upwardly from the channel (<NUM>);
wherein each of the floor members (<NUM>) has a first connection portion, a second connection portion, a third connection portion and a fourth connection portion, wherein the first connection portion is rotationally connected to a second connection portion of an adjacent floor member (<NUM>), the floor member (<NUM>) rotated relative to the adjacent floor member (<NUM>) from a first position in which the third connection portion is separate from a fourth connection portion of the adjacent floor member (<NUM>) to a secured position in which the third connection portion is secured to the fourth connection portion of the adjacent floor member (<NUM>).