Note: Descriptions are shown in the official language in which they were submitted.
CA 02604282 2007-09-26
COMPOSITE PANEL FOR A TRAILER WALL
FIELD OF THE INVENTION
The present invention generally relates to walls for trailers. More
specifically, the present
invention relates to walls for trailers being formed of a plurality of
composite panels having
sections of the core members of the composite panels removed or not provided
in order to
provide vertically extending voids along the height of the composite panels.
BACKGROUND OF THE INVENTION
The use of composite panels, namely those have inner and outer thin metal
skins and a
continuous core material provided therebetween, have become widely used in the
formation of
trailer walls because they are strong and lightweight. Both of these
properties are important in
the formation of trailer walls. The walls must be strong enough to prevent or
substantially inhibit
damage to the goods being shipped or stored within the trailer. The walls must
also be
lightweight because trailers including their payload are subjected to weight
restrictions when
traveling, such that the lighter the weight of the trailer is, the heavier the
weight of the payload
can be. Obviously, the larger the payload, the better.
Thus, it is desirable to provide composite panels for trailer walls that are
even more
lightweight, such that the payload to be shipped by the trailer can be even
larger, but without
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compromising the strength and structural integrity of the trailer walls. The
present invention
provides such a composite panel for a trailer wall.
It is further desirable for a trailer wall to provide a vent path from an
interior of the trailer
to an exterior of the trailer such that fluid build-up, namely moisture build-
up within the trailer,
can vent out of the trailer. The present invention provides such a trailer
wall.
SUMMARY OF THE INVENTION
Briefly, and in accordance with the foregoing, the invention provides a
composite panel
for use in a trailer wall. The composite panel has inner and outer metal skins
with each skin
having a top end and a bottom end. The composite panel also has core material
positioned
between and secured to the inner and outer skins. The core material has a
predetermined height
extending from a top end of the core material to a bottom end of the core
material. The core
material defmes or includes a plurality of voids. Each void extends generally
vertically along the
height of the core material such that each void is open to the top end of at
least the inner skin and
the bottom end of at least the outer skin.
In a preferred embodiment of the invention, at a plurality of points in a
cross-section
taken along the height of the core material, the core material is secured to
both the inner and
outer skins. In an alternative embodiment of the invention, at any point in a
cross-section taken
along the height of the core material, the core material is secured to at
least one of the inner and
outer skins.
The composite panel of the invention allows provides for a composite panel
that is lighter
in weight than prior art composite panels. The composite panel of the
invention also provides for
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a vent path from an interior of the trailer to an exterior of the trailer when
the top end of the core
material of the composite panel is separated from the top rail of the trailer
and when the bottom
end of the core material of the composite panel is separated from the bottom
rail of the trailer.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the invention which are believed to be novel are described in
detail
hereinbelow. The organization and manner of the structure and operation of the
invention,
together with further objects and advantages thereof, may best be understood
by reference to the
following description taken in connection with the accompanying drawings
wherein like
reference numerals identify like elements in which:
FIG. 1 is a perspective view of a trailer which incorporates a wall having
panels formed
in accordance with features of the present invention;
FIG. 2 is a partial perspective of the wall of FIG. 1;
FIG. 3 is a cross-sectional view of the wall panel shown in FIG. 2 and
illustrating the
voids provided in the wall panel;
FIG. 4 is a cross-sectional view of a first alternative embodiment of the wall
panel and
illustrating the configuration of the voids provided in the first alternative
embodiment of the wall
panel;
FIG. 5 is a cross-sectional view of a second alternative embodiment of the
wall panel and
illustrating the configuration of the voids provided in the second alternative
embodiment of the
wall panel;
FIG. 6 is a cross-sectional view of a wall of the trailer, showing the top and
bottom rails
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and a portion of the floor structure;
FIG. 6A is an enlargement of a portion of the cross-sectional view of the wall
of the
trailer taken from within the Circle 6A of FIG. 6; and
FIG. 6B is an enlargement of a portion of the cross-sectional view of the wall
of the
trailer taken from within the Circle 6B of FIG. 6.
DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS
While this invention may be susceptible to embodiment in different forms,
there is shown
in the drawings and will be described herein in detail, specific embodiments
with the
understanding that the present disclosure is to be considered an
exemplification of the principles
of the invention, and is not intended to limit the invention to that as
illustrated.
As illustrated in FIG. 1, a trailer 20 includes a body 22 formed from a pair
of rectangular
sidewalls 24, a front wall 26, rear frame and doors 28, a roof structure 30,
and a floor structure
32. The rear of the floor structure 32 is supported by a conventional rear
undercarriage assembly
34 and the front of the floor structure 32 has a landing gear 36 secured
thereunder. The floor
structure 32 and a lower portion of each sidewall 24 are secured to a
respective bottom rail 38
which extends the length of the trailer 20. The bottom rails 38 are preferably
formed of
aluminum, which may be extruded. The roof structure 30 and an upper portion of
each sidewall
24 are secured to a respective top rail 40 which extends the length of the
trailer 20. The top rails
40 are preferably formed of aluminum, which may be extruded. The trailer 20
can be connected
to a tractor 42 by conventional means, such as a fifth wheel assembly.
The sidewalls 24 are identical, and, as such, only one of the sidewalls 24 is
described.
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The sidewall 24 is formed from a plurality of composite panels 46 which are
joined together at
joints 48.
As best shown in FIG. 2, each composite panel 46 includes a core member 50
sandwiched
between an inner thin skin 52a and an outer thin skin 52b and bonded thereto
by a suitable
known adhesive or other like means. The inner skin 52a and the outer skin 52b
may be formed
of metal, preferably aluminum or steel, and can range in thickness (such as
0.013 to 0.026 for
steel skins and 0.050 inches for aluminum skins) or may be a thin composite
material and can
range in thickness (such as 0.026). It is to be understood that other
thicknesses may be used as
required by the application. Typically, each composite panel 46 is four feet
in width, but can be
longer or shorter depending on the application. At least two panels 46 are
joined together to
form the sidewall 24 of the body 22. The inner and outer skins 52a, 52b have
top ends 54a, 54b
and bottom ends 55a, 55b. In a preferred embodiment, as best illustrated in
FIG. 6, the top ends
54a, 54b are planar and the bottom ends 55a, 55b are planar.
Each core member 50 is made of some type of compressible non-metal material,
preferably thermoplastic, such as polypropylene or high density polyethylene.
Because
composite panels 46 are used, the weight of the trailer construction is
reduced over trailers
having metal sidewalls. The core member 50 has a height defined between a top
end 56 thereof
and a bottom end 58 thereof. In a preferred embodiment, the top end 56 of the
core member 50
is planar with the top ends 54a, 54b of the skins 52a, 52b, as best
illustrated in FIG. 6A, but may
be offset from one or both of the top ends 54a, 54b of the skins 52a, 52b.
Likewise, in a
preferred embodiment, the bottom end 58 of the core member 50 is planar with
the bottom ends
55a, 55b of the skins 52a, 52b, as best illustrated in FIG. 6B, but may be
offset from one or both
CA 02604282 2007-09-26
of the bottom ends 55a, 55b of the skins 52a, 52b.
The weight of the core member 50 is further reduced because a plurality of
sections of the
core member 50 have been removed or are not provided in the original
construction of the panel
46. Therefore, the core member 50 defines or includes a plurality of
vertically extending voids
56 which are preferably provided along the height of the core member 50 from
the top end 56
thereof to the bottom end 58 thereof, and thus the pane146, but may extend
along only a
substantial portion of the height of the panel 46, for instance when an end
56, 58 of the core
member 50 is offset from the ends 54a, 54b, 55a, 55b of the skins 52a, 52b.
The void 56 is
preferably continuous along its height and is open to at least one of the top
ends 54a, 54b of the
skins 52a, 52b and to at least one of the bottom ends 55a, 55b of the skins
52a, 52b. This reduces
the weight of the pane146, and thus the sidewall 24, without sacrificing
important structural
integrity.
As shown in FIGS. 2 and 3, in a preferred embodiment, the voids 56 extend the
full
distance between the skins 52a, 52b, such that the core member 50 is
discontinuous along the
length of the pane146. Preferably each void 56 is approximately 0.5 inches in
length (in the
direction from the front of the trailer 20 to the rear of the trailer 20), and
the discontinuous
sections of the core member 50 between adjacent voids 56 are approximately 1.5
inches in
length. Therefore, the voids 56 are formed generally two inches on center. The
voids 56 may
have straight sides as shown, may be curved or may take other forms. Thus, as
best illustrated in
FIG. 3, in a cross-section taken along the height of the core member 50, the
core member 50 is
secured to both the inner and outer skins 52a, 52b, but in a cross-section
taken along the height of
the void 56, the core member 50 is not secured to either the inner or outer
skins 52a, 52b.
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As shown in FIGS. 4 and 5, the core member 50 may define or include other
vertically
extending voids 56a, 56b of differing configurations. As shown, these voids
56a, 56b are
hemispherical, but may take other shapes.
In FIG. 4, pairs of voids 56a are formed adjacent to each other to form a
generally hour-
glass shape, with one void 56a being provided between the inner skin 52a and
the core member
50 and the other void 56a being provided between the outer skin 56b and the
core member 50.
The voids 56a in each pair may intersect each other, but are preferably
separate such that the core
member 50 continuously extends along a length of the composite panel 46, such
that the pair of
voids 56a are discontinuous between the skins 52a, 52b. Thus, in a plurality
of points in a cross-
section taken along the height of the core member 50, the core member 50 is
secured to both the
inner and outer skins 52a, 52b, but in a cross-section taken along the height
of the voids 56a, the
core member 50 is not secured to either the inner or outer skins 52a, 52b.
In FIG. 5, voids 56b are offset from each other and alternate between being
provided
between the inner skin 52a and the core member 50 and being provided between
the outer skin
52b and the core member 50. The core member 50 continuously extends along a
length of the
composite panel 46 such that the offset and alternating voids 56b are
discontinuous between the
skins 52a, 52b. Thus, at any point in a cross-section taken along the height
of the core member
50, the core member 50 is secured to at least one of the skins 52a, 52b. More
particularly, when
a cross-section is taken along the height of the core member 50 through the
void 56b provided
along the inner skin 52a, the core member 50 is secured to the outer skin 52b;
when a cross-
section is taken along the height of the core member 50 through the void 56b
provided along the
outer skin 52b, the core member 50 is secured to the inner skin 52a; when a
cross-section is taken
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along the height of the core member 50 and not through any of the voids 56b,
the core member
50 is secured to both the inner and outer skins 52a, 52b.
It is to be understood that the voids 56, 56a, 56b illustrated herein are
merely exemplary
and the voids may take other forms and shapes. Because the core member 50
defines or includes
the voids 56, 56a, 56b, in order to ensure the structural integrity of the
composite panel 46, the
core member 50 preferably is secured to both the inner and outer skins 52a,
52b when a cross-
section is taken from a plurality of points along the height of the composite
panel 46, as
illustrated in each of FIGS. 3-5. Alternatively, in order to ensure the
structural integrity of the
composite panel 46, the core member 50 is secured to at least one of the inner
and outer skins
52a, 52b when a cross-section is taken from any point along the height of the
composite panel 46,
as illustrated in FIG. 5.
The joint 48 connects the ends of the adjacent composite panels 46. The joint
48 shown
in FIG. 2 is exemplary, and it is to be understood that other joints can be
provided for joining the
panels 46.
As shown, the joint 48 includes an inner logistics member 62 and an outer
logistics cap
64, sometimes called a splicing member, both of which are known in the art.
The inner logistics
member 62 is provided on the inside of the trailer 20 and may extend along the
entire height of
the panels 46 or may terminate at its lower end at scuff plate 66. The outer
logistics cap 64 is
provided on the outside of the trailer 20 and may extend along the entire
height of the panels 46,
or may terminate at the bottom and top rails 38, 40. The ends of the panels 46
are spaced apart
from each other when joined by the joint 48 such that an air pocket 68 is
formed between the
inner logistics member 62 and the outer logistics cap 64.
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The inner logistics member 62 is preferably, as shown, a flat plate having a
plurality of
spaced apart openings or slots 70 therethrough along an intermediate portion
of the inner
logistics member 62. The slots 70 provide a means for which equipment can be
engaged, for
example by a clip or a hook, to the sidewall 24 of the trailer 20. The inner
logistics member 62
may be formed from a heavier and stronger material than the material that is
used for the inner
and outer skins 52a, 52b to provide the sidewall 24 with strength and
rigidity. The inner logistics
member 62 sits against the inner skins 52a of the adjacent panels 46. The
inner logistics member
62 bridges the gap between the panels 46 such that the slots 70 align with the
air pocket 68 so
that clips or hooks can be engaged with the slots 70.
The outer logistics cap 64, which is like a post, preferably sits against the
outer skins 52b
of the adjacent panels 46 and may extend under the bottom and top rails 38, 40
of the trailer 20,
or may terminate at the bottom and top rails 38, 40. The outer logistics cap
64 preferably has a
flat top portion (not shown), a flat bottom portion 72 and flat side portions
74, 76 which
preferably lie against the outer surfaces of the adjacent outer skins 52b, and
an intermediate
portion 78 which bulges outwardly from the top, bottom and side portions 72,
74, 76. When the
outer logistics cap 64 is joined with the outer skins 52b of the panels 46,
the inner surfaces of the
side portions 74, 76 lie against the planar outer skins 52b and the
intermediate portion 78 bulges
outwardly from the sidewall 24. The bulging intermediate portion 78 bridges
the air pocket 68
formed between the panels 46 and aligns with the air pocket 68. The bulging
intermediate
portion 78 provides for more space within the air pocket 68 to allow for the
attachment of
members, such as clips or hooks, to the slots 70 of the inner logistics member
62.
The flat top portion and the flat bottom portion 72 of the outer logistics cap
64 facilitate
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connection of the panels 46 and prevent the entry of moisture into the
interior of the trailer 20
through the air pocket 68. The upper end of the flat top portion may butt
against the top rail 40,
or the upper end of the flat top portion may sit underneath a portion of the
top rail 40. The lower
end of the flat bottom portion 72 may butt against the bottom rail 38, or the
lower end of the flat
bottom portion 72 may sit underneath a portion of the bottom rail 38.
The inner logistics member 62 and the outer logistics cap 64 are attached to
the panels 46
by suitable means, such as rivets 80 as shown, and/or adhesives (not shown).
The rivets 80
extend through the inner logistics member 62, the respective end sections of
the adjacent panels
46 and the side portions 74, 76 of the outer logistics cap 64 and/or the scuff
plate 66. The rivets
80 extend through the core member 50 of the panels 46. There is sufficient
uninterrupted core
member 50 between the voids 56, 56a, 56b to accommodate the rivets 80. The
panels 46 and the
scuff plate 66 are attached together by suitable means, such as rivets 82 as
shown, and/or
adhesives (not shown). The rivets 82 extend through the panels 46 and the
scuff plate 66. The
rivets 82 extend through the core member 50 of the panels 46. There is
sufficient uninterrupted
core member 50 between the voids 56, 56a, 56b, 56c to accommodate the rivets
82.
If desired, each end of the inner skins 52a of each panel 46 may have a side
end section
which is coined or stepped down with an intermediate section of each panel 46
remaining planar.
The inner logistics member 62 may then be seated against the side end section
so that the inner
surface of the sidewall 24 is flush.
As best illustrated in FIGS. 6 and 6B, the base rail 38 is preferably formed
of a vertical
wall 84 having a generally horizontal flange 86 extending perpendicularly
therefrom to an
exterior of the trailer 20 and a generally horizontal flange 88 extending
perpendicularly therefrom
CA 02604282 2007-09-26
toward the interior of the trailer 20. The horizontal flanges 86, 88 divide
the wall into an upper
wall portion 90 and a lower wall portion 92. The floor structure 32 is
attached to the flange 88
and the lower wall portion 92 in a conventional manner. The upper wall portion
90 sits against
an inner surface of the inner skins 52a of the panels 46, proximate to the
bottom ends 55a
thereof. The scuff plate 66 may overlap the upper wall portion 90 on the
interior or exterior side
thereof, may terminate at the upper end of the upper wall portion 90, or may
be integrally formed
with the upper wall portion 90. In a preferred embodiment, the bottom ends
55a, 55b, 58 of the
skins 52a, 52b and the core member 50 are preferably slightly spaced from the
horizontal flange
86 such that a small gap 94 is provided therebetween.
As best illustrated in FIGS. 6 and 6A, the top rail 40 preferably has an L-
shaped wall
having a vertical wall portion 96 which sits against an outer surface of the
outer skins 52b of the
panels 46, proximate to the top ends 54b thereof, and a horizontal wall
portion 98 which is
attached to the roof structure 30. In a preferred embodiment, the top ends
54a, 54b, 56 of the
skins 52a, 52b and the core member 50 are preferably spaced from the
horizontal wall portion 98
such that a gap 100 is provided therebetween.
As a result of this construction, a vent path is provided in the sidewall 24
of the trailer 20.
Fluids, typically moisture build-up in the trailer 20, can flow through from
the interior of the
trailer 20, into the gap 100, through the voids 56, 56a, 56b in the sidewall
24, and out the gap 94
to the exterior of the trailer 20.
It is to be understood that while the present invention is described with
respect to the
trailer sidewalls 24, the panels 46 could be used in the formation of the
front wall 26, the rear
doors 28, or a rear wall if rear doors are not provided.
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While preferred embodiments of the invention are shown and described, it is
envisioned
that those skilled in the art may devise various modifications without
departing from the spirit
and scope of the foregoing description, the attached drawings and the appended
claims.
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