Note: Descriptions are shown in the official language in which they were submitted.
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TRAILER LINER PANEL
FIELD OF THE INVENTION
[0001] The present invention provides a cargo vehicle liner panel and more
particularly a lightweight metal skinned dry van trailer liner panel.
BACKGROUND OF THE INVENTION
[0002] Currently most sheet and post dry van trailers use plywood as an
inexpensive
material for the inside wall lining. Plywood however needs to be replaced
frequently
because of its relatively low impact and gouge resistance. Although the
initial cost of
plywood is low, continuous replacement of the plywood will drive up servicing
expenses
making long term use an expensive method. Also, since plywood is pre-disposed
to moisture
pickup and rotting, it may be unsuitable for transportation of consumer goods
or foods.
[0003] There are some commercial alternatives available, for example Bulitex
and
SSL, however these alternatives are costly, heavy, or they may not have good
gouge or
abrasion resistance.
[0004] It is therefore desirable to provide a lightweight liner panel that has
good
impact resistance, good abrasion and gouge resistance, is easy to install and
has a low
manufacturing cost.
SUMMARY OF THE INVENTION
[0005] In one aspect, the present invention provides a lightweight metal
skinned liner
panel.
[0006] In another aspect, the present invention provides a lightweight metal
skinned
liner panel having a thickness of less than 0.2 inches.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The present invention will now be described in further detail with
reference to
the accompanying drawings in which:
[0008] Figure 1 illustrates a sectional side view of one embodiment of the
liner panel
of the present invention;
[0009] Figure 2 is a top view of a series of liner panels, in accordance with
the
present invention, joined together;
[0010] Figure 3 is a side view of the liner panels of Figure 2
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0011] The present invention provides a lightweight liner panel indicated
generally at
numeral 10 in Figure 1.
[0012] The liner panel 10 includes a first metal skin layer 12 and a second
metal skin
layer 14 having a core layer 16 disposed between them.
[0013] The particular choice of metal for metal skin layers 12 and 14 used in
liner
panel 10 is not particularly restricted. First metal skin layer 12 and second
metal skin layer
14 may be the same or different. Non-limiting examples of suitable metal skin
layers for use
in the present liner panel include aluminum, cold rolled steel, galvanized
steel, tin-coated
steel and stainless steel. In a preferred embodiment of the present liner
panel, one or both of
first metal skin layer 12 and second metal skin layer 14 comprise pre-painted,
galvanized,
high yield strength steel.
[0014] Preferably, first metal skin layer 12 and second metal skin layer 14
have the
same or different thicknesses and the thickness of each is at least 0.010
inches. More
preferably, first metal skin layer 12 and second metal skin layer 14 have the
same or different
thicknesses and the thickness of each is in the range of from about 0.010
inches to about
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0.015 inches. Most preferably, first metal skin layer 12 and second metal skin
layer 14 have a
thickness of 0.012 inches each.
[0015] In one embodiment the core layer 16 may be formed from one or more
layers
of plastic. The thickness of the final liner panel being equal to or less than
0.2 inches. The
plastic may be of any suitable type that may be formed into a thin sheet.
Preferably the
plastic is chosen from polyethylene resin or polypropylene resin.
[0016] In an alternative embodiment the core layer 16 may be formed from an
extruded composite core of resin and natural fiber. The thickness of the final
liner panel
being equal to or less than 0.2 inches. More preferably the thickness of the
final liner panel is
equal to or less than 0.1 inches. Most preferably the thickness of the final
liner panel is equal
to or less than 0.06 inches.
[0017] In one embodiment the resin in the extruded composite core layer is
polyethylene or polypropylene and the fiber is wood flour or other natural
fiber such as rice
husk.
[0018] In an alternative embodiment the core layer 16 may be formed from three
layered resin coated paper sheets. However, varying numbers of sheets may be
used
depending on the thickness. The thickness of the final liner panel being equal
to or less than
0.2 inches. More preferably the thickness of the final liner panel is equal to
or less than 0.1
inches. Most preferably the thickness of the final liner panel is equal to or
less than 0.06
inches.
[0019] In one embodiment the paper sheets are of saturating kraft paper
extrusion
coated with polyethylene resin.
[0020] The liner panel of the present invention provides a liner with the
desired
mechanical and physical properties of a traditional trailer liner, including
impact resistance,
abrasion and gouge resistance, moisture damage resistance while being low cost
to
manufacture and being of an appropriate thickness to be used as a liner.
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[0021] The liner panel of the present invention may include first and second
adhesive
layers 18, 20. The first adhesive layer 18 may be disposed between the core
layer 16 and the
first metal skin layer 12. The second adhesive layer 20 may be disposed
between the core
layer 16 and the second metal skin layer 14. The adhesive that may be used can
be any
adhesive that is compatible with the metal skins and the material used to form
the core layer.
It will be understood that the inclusion of an adhesive layer is optional and
that the liner
panel may not require an adhesive layer, for example if the core layer is
formed from paper
that includes a resin that acts as an adhesive to the metal skins.
[0022] The liner panel of the present invention has increased stiffiiess,
increased
gouge and abrasion resistance, good impact resistance, is light weight
(approx. 1.2 lbs/sq. ft.)
and allows for conventional installation. The liner panel of the present
invention is also
resistant to mold and mildew growth and will not sag or creep like plywood or
other plastic
panels.
[0023] The current industry standard for gouge resistance is measured using
plywood. The liner panel of the present invention has improved gouge
resistance compared
to the industry standard and provides good stiffness at 0.060".
[0024] The liner panel of the present invention may be sheared or cut and then
fastened in place without any requirement for specific tooling providing a
liner panel that
may be easily installed. The liner panel of the present invention may be used
instead of
plywood or other alternatives, as an interior liner for the walls, doors,
scuff plate, front
bulkhead or roof of a cargo vehicle.
[0025] The increased stiffness of the liner panel of the present invention
with a lower
overall thickness allows for the elimination of a spacer material that is used
in conjunction
with liner panels acts as an additional stiffener between the outer aluminum
skin of the
vehicle and the liner panel.
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[0026] The liner panel of the present invention is formed by methods known in
the art
and includes the batch press method, the roll coater method, continuous
lamination method
or method of direct extrusion between or onto metal skins.
[0027] The following provides an example of the properties of a liner panel
produced
according to the present invention. The panel included 0.012" steel skins. The
flexural
stiffness of the panel, based on a 1"x6" sample, was 80 lbs/inch, the tensile
modulus was
13.0 x106 psi. The tensile strength of the panel was 49 x106 psi and the
nominal weight of the
panel was 1.2 lbs/ft2. The total thickness of the panel was 0.055 inches.
[0028] While this invention has been described with reference to illustrative
embodiments and examples, the description is not intended to be construed in a
limiting
sense. Thus, various modifications of the illustrative embodiments, as well as
other
embodiments of the invention, will be apparent to persons skilled in the art
upon reference to
this description. It is therefore contemplated that the appended claims will
cover any such
modifications or embodiments. Further, all of the claims are hereby
incorporated by
reference into the description of the preferred embodiments.
