U.S. patent application number 11/609204 was filed with the patent office on 2007-04-12 for collapsible cargo trailer and method of distribution.
Invention is credited to Scott T. Chapman, Kevin F. Owens, Perry L. Stow, Ronald E. Williams.
Application Number | 20070080508 11/609204 |
Document ID | / |
Family ID | 34890473 |
Filed Date | 2007-04-12 |
United States Patent
Application |
20070080508 |
Kind Code |
A1 |
Owens; Kevin F. ; et
al. |
April 12, 2007 |
COLLAPSIBLE CARGO TRAILER AND METHOD OF DISTRIBUTION
Abstract
A cargo trailer having a frame assembly with pivotally mounted
wall structures or frames. The frame assembly can be collapsed into
a compact shipping configuration wherein the wall structures are
positioned substantially parallel with the floor structure of the
trailer. Various parts of the cargo trailer can also be stowed in
the collapsed frame assembly for shipment of the frame assembly and
stored parts. After shipment of the cargo trailer, the wall
structures are pivoted into their upright positions and the final
assembly of the cargo trailer is completed. Exterior panels may be
shipped together in a compact stack with the frame to the final
assembly location where the panels are attached to the cargo
trailer.
Inventors: |
Owens; Kevin F.; (Elkhart,
IN) ; Chapman; Scott T.; (Bristol, IN) ;
Williams; Ronald E.; (Granger, IN) ; Stow; Perry
L.; (South Bend, IN) |
Correspondence
Address: |
BOTKIN & HALL, LLP
105 E. JEFFERSON BLVD.
SUITE 400
SOUTH BEND
IN
46601
US
|
Family ID: |
34890473 |
Appl. No.: |
11/609204 |
Filed: |
December 11, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10990931 |
Nov 17, 2004 |
7150466 |
|
|
11609204 |
Dec 11, 2006 |
|
|
|
60544631 |
Feb 13, 2004 |
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Current U.S.
Class: |
280/1 ;
280/656 |
Current CPC
Class: |
B62D 63/061 20130101;
B62D 63/062 20130101 |
Class at
Publication: |
280/001 ;
280/656 |
International
Class: |
B62B 15/00 20060101
B62B015/00 |
Claims
1. A method of distributing a cargo trailer, said method
comprising: pivotally attaching a plurality of frames to a floor
structure to thereby provide a frame assembly; placing the frame
assembly in a shipping configuration at a first location wherein
the plurality of frames are disposed proximate and substantially
parallel to the floor structure; shipping the frame assembly from
the first location to a second location with the frame assembly in
the shipping configuration; and completing assembly of the cargo
trailer at the second location including pivoting the plurality of
frames into an upright position substantially perpendicular to the
floor structure and securing the frames in the upright
position.
2. The method of claim 1 wherein said step of completing assembly
of the cargo trailer at the second location includes attaching an
axle assembly to the frame assembly.
3. The method of claim 2 wherein, during said step of shipping the
frame assembly, the axle assembly is stowed within the frame
assembly while the frame assembly is in the shipping
configuration.
4. The method of claim 3 wherein a hitch structure is stowed within
the frame assembly during the step of shipping the frame assembly
in the shipping configuration and said step of completing assembly
of the cargo trailer at the second location includes attaching the
hitch structure to the frame assembly.
5. The method of claim 1 wherein said step of completing assembly
of the cargo trailer at the second location includes attaching a
plurality of panels to the plurality of frames to thereby define an
exterior surface of the cargo trailer.
6. The method of claim 5 further comprising securing the plurality
of panels together in a stack and shipping the stacked panels to
the second location.
7. The method of claim 1 wherein a plurality of frame assemblies
are shipped from the first location to the second location and
assembly is completed for a corresponding plurality of cargo
trailers at the second location; and wherein said step of shipping
the frame assembly from the first location to the second location
includes stacking the plurality of frame assemblies, one upon the
other, while the frame assemblies are in the shipping
configuration.
8. The method of claim 7 further comprising: shipping a plurality
of panels to the second location; and attaching the plurality of
panels to the plurality of frame assemblies to thereby complete the
assembly of a plurality of cargo trailers at the second location.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional of U.S. patent application
Ser. No. 10/990,931, filed Nov. 17, 2004, which claims priority to
U.S. provisional application Ser. No. 60/544,631, filed Feb. 13,
2004, the disclosures of which are hereby incorporated by
reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to cargo trailers and, more
particularly, to a cargo trailer having a structure which is
adapted for efficient shipping of the trailer.
[0004] 2. Description of the Related Art
[0005] A variety of cargo trailers are known in the art.
Commercially available cargo trailers include cargo trailers having
one or two axles which support a generally rectilinear enclosure
with a tongue extending from one end. A hitch is located on the end
of the tongue and is engageable with a ball located on a tow
vehicle such as a pick-up truck or automobile. The cargo trailer
also typically includes at least one door that controls access to
the interior of the cargo trailer. The potential uses of such cargo
trailers are innumerable and such trailers are often used by small
businesses. For example, construction contractors and landscapers
often use such cargo trailer to transport equipment and materials
between job sites.
[0006] Although known cargo trailers are effective for their
intended purposes, the process used to manufacture and distribute
such trailers is not without inefficiencies. For example, after
completing the manufacture of the trailer, the trailer must be
transported from the manufacturing location to a dealer location
where the trailer is sold to the end user. The transporting of the
assembled trailers to the dealer location must be accomplished by
either towing individual trailers or otherwise transporting a small
number of trailers.
[0007] The transport of the completed trailers between the
manufacturing location and the dealer location is a source of
significant expense in the ultimate cost of the trailer and a
reduction in this expense is desirable.
SUMMARY OF THE INVENTION
[0008] The present invention provides a cargo trailer that has a
frame which can be collapsed so that several frames can be stacked
for shipment from the location of manufacture to the location of
sale. The assembly of the cargo trailer is easily completed at the
shipping destination point. By shipping the cargo trailers in a
partially assembled and collapsed condition, the cargo trailers can
be more efficiently shipped and shipping costs reduced.
[0009] The invention comprises, in one form thereof, a cargo
trailer that includes a frame assembly having a substantially
planar floor structure with a substantially rectangular
configuration defining two lateral edges and two longitudinal side
edges. The frame assembly also includes an end frame pivotally
secured to the floor structure proximate one of the lateral edges
and first and second side frames. Each of the side frames are
pivotally secured to the floor structure proximate a respective one
of the longitudinal side edges. The frame assembly has a shipping
configuration and an assembled configuration wherein, when the
frame assembly is in the shipping configuration, the end frame, the
first side frame and the second side frame are all disposed
proximate and substantially parallel to the floor structure. When
the frame assembly is in its assembled configuration, the end
frame, the first side frame and the second side frame are all
disposed substantially perpendicular to the floor structure and
define an enclosed cargo space above the floor structure. The cargo
trailer further includes an axle assembly attachable to the frame
assembly when the frame assembly is in the assembled configuration,
a hitch structure attachable to the frame assembly when the frame
assembly is in the assembled configuration, and a plurality of
panel members which are attachable to the end frame, the first side
frame and the second side frame.
[0010] The invention comprises, in another form thereof, a cargo
trailer kit. The cargo trailer kit includes a frame assembly having
a substantially planar floor structure with a substantially
rectangular configuration defining two lateral edges and two
longitudinal side edges and a plurality of wall structures
pivotally secured to the floor structure proximate a respective one
of the edges. The frame assembly has a shipping configuration and
an assembled configuration. When the frame assembly is in the
shipping configuration, the plurality of wall structures are all
disposed proximate and substantially parallel to the floor
structure. The frame assembly defines two opposed and cooperating
stacking surfaces when in the shipping configuration whereby the
frame assembly is stackable upon on a similar frame assembly. When
the frame assembly is in the assembled configuration, the plurality
of wall structures are all disposed substantially perpendicular to
said floor structure to define an enclosed cargo space above the
floor structure. The cargo trailer kit further includes an axle
assembly and a hitch structure both of which are attachable to the
frame assembly when the frame assembly is in the assembled
configuration.
[0011] The invention comprises, in yet another form thereof, a
method of distributing a cargo trailer. The method includes
pivotally attaching a plurality of frames to a floor structure to
thereby provide a frame assembly, placing the frame assembly in a
shipping configuration at a first location wherein the plurality of
frames are disposed proximate and substantially parallel to the
floor structure, shipping the frame assembly from the first
location to a second location with the frame assembly in the
shipping configuration and completing assembly of the cargo trailer
at the second location including pivoting the plurality of frames
into an upright position substantially perpendicular to the floor
structure and securing the frames in the upright position.
[0012] An advantage of the present invention is that it provides a
cargo trailer that can be collapsed into a stackable and
space-saving configuration for shipment from a manufacturing
location to an assembly location positioned near the ultimate
distribution point of the trailer. This reduces the space required
for each trailer and allows the trailers to be stacked and shipped
together and, thus, can provide a significant reduction in shipping
costs. Once at the second location, e.g., a cargo trailer
dealership, the final assembly of the cargo trailer can be easily
accomplished.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The above mentioned and other features and objects of this
invention, and the manner of attaining them, will become more
apparent and the invention itself will be better understood by
reference to the following description of the invention taken in
conjunction with the accompanying drawings, wherein:
[0014] FIG. 1 is a view of a frame assembly in a shipping
configuration in accordance with the present invention;
[0015] FIG. 2 is a view of the frame assembly of FIG. 1 prior to
final assembly;
[0016] FIG. 3 is a view of the frame assembly of FIG. 1 during
final assembly;
[0017] FIG. 4 is a view of the frame assembly of FIG. 1 during
final assembly;
[0018] FIG. 5 is a view of the frame assembly of FIG. 1 during
final assembly;
[0019] FIG. 6 is a view of the frame assembly of FIG. 1 with an
axle and hitch attached thereto;
[0020] FIG. 7 is a partial cutaway view of an assembled cargo
trailer in accordance with the present invention;
[0021] FIG. 8A is a schematic exploded view of two frame assemblies
in a shipping configuration;
[0022] FIG. 8B is a schematic exploded view of two stacks of
panels; and
[0023] Corresponding reference characters indicate corresponding
parts throughout the several views. Although the exemplification
set out herein illustrates the invention in one form, the
embodiment disclosed below is not intended to be exhaustive or to
be construed as limiting the scope of the invention to the precise
form disclosed.
DETAILED DESCRIPTION OF THE INVENTION
[0024] A cargo trailer 20 in accordance with the present invention
is shown in FIG. 7. The cargo trailer includes a frame assembly 22
that can be collapsed to facilitate the shipping of cargo trailer
20 prior to the final assembly of cargo trailer 20.
[0025] Frame assembly 22 is best seen in FIGS. 1-5 and includes a
floor structure 24, an end frame 26, a first side frame 28, and a
second side frame 30. Each of these frames 26, 28 and 30, are wall
structures that include a plurality of structural members 32, 33
secured together in an open framework. Outer perimeter members 32
are braced by members 33. Structural members 32 and bracing members
33 are elongate square or box tube steel members that are secured
together by welding. Bolts or other suitable method may also be
used to secure members 32 together to form frames 26, 28, 30.
[0026] Floor structure 24 has a frame defined by structural steel
members 35. Axle brackets 36 and hitch reinforcement members 37 are
secured to structural members 35. Plywood sheeting (not shown) is
laid on top of frame members 35 to define the flat floor surface
for the assembled cargo trailer 20. As seen in FIGS. 1-6, the
illustrated floor structure 24 is substantially planar with a
rectangular configuration having two lateral edges 38 and two
longitudinal edges 40. Each of the frames 26, 28 and 30 are
pivotally secured to floor structure 24 with hinges 34. The frames
26, 28 and 30 are pivotally secured at different heights to permit
each of frames 26, 28, 30 to be pivoted downwards toward floor
structure 24 to define a collapsed shipping configuration (FIG. 2)
where each of the frames 26, 28, 30 are positioned substantially
parallel to floor structure 24.
[0027] The pivot axes of frames 26, 28, 30 are vertically separated
by a distance that is at least as great as the thickness of the
frames to allow each of the frames to lie parallel to the floor
structure 24 in the shipping configuration shown in FIG. 2. Steel
structural members are attached and extend along the edges of floor
structure 26 to provide mounting locations for hinges 34. These
structural members have different sizes to position the pivot axes
defined by hinges 34 at different vertical heights for each of the
different frames 26, 28, 30.
[0028] In the illustrated embodiment, structural members 32 are
larger than members 33 and each of the frames 26, 28, 30 is formed
with perimeter members 32 having a common size. The vertical
distance separating the pivot axes defined by hinges 34 of each of
the frames 26, 28, 30 is substantially equivalent to this thickness
of perimeter members 32 to allow frames 26, 28, 30 to lie on top of
each other in the shipping configuration.
[0029] While FIG. 2 shows frame assembly 22 in its shipping
configuration without any other parts, FIG. 1 illustrates frame
assembly 22 in its shipping configuration with an axle assembly 42,
wheels 44, and hitch structure 46 all stowed within the frame
assembly 22. Dashed lines 48 generically represent additional cargo
trailer components that can be stored within frame assembly 22 in
its shipping configuration, such as roof beams 50. Strapping
material, cardboard, or other suitable shipping and packaging
materials are used to secure the stowed items within frame assembly
22 and secure frames 26, 28 and 30 in their shipping configuration
positions. The plywood sheeting used to form the floor surface of
cargo trailer 20 may also be installed on floor structure 24 prior
to stowing items in frame assembly 22 so that the stowed items can
rest on top of the plywood sheeting and thereby facilitate the
securement of the stowed items between the plywood sheeting and
bracing members 33.
[0030] After the stowed items and frame assembly 22 have been
secured in the shipping configuration (FIG. 1), the frame assembly
22 and stowed items can be easily shipped to another location for
final assembly of cargo trailer 20. Additional parts of cargo
trailer 20, such as exterior panel members, may be separately
shipped to the assembly location. To assemble cargo trailer, the
stowed items are first removed from frame assembly 22. End frame
26, which lies atop both side frames 28, 30 in the shipping
configuration, is then pivoted into an upright position as seen in
FIG. 3. Next, side frame 28 and then side frame 30 are pivoted into
upright positions as shown in FIG. 4 so that all three frames 26,
28, 30 are positioned perpendicular to floor structure 24. Side
frames 28, 30 are then each secured to end frame 26 with bolts or
by welding. To provide further stability to the assembled cargo
trailer frame, structural members 50 are attached to and extend
between first and second side frames 28, 30 at their upper edges
opposite floor structure 24 to thereby form roof beams as shown in
FIG. 5.
[0031] Brackets 43 on axle assembly 42 are then secured to brackets
36 using bolts to secure axle assembly 42 to frame assembly 22.
Axle assembly 42 utilizes a torsion bar suspension as is well known
to those having ordinary skill in the art. Wheels 50 are then
attached to axle assembly 42. In the illustrated embodiment, wheels
50 are shipped in a deflated condition to allow them to more easily
fit within frame assembly 22 in its shipping configuration.
[0032] Tongue or hitch structure 46 is then secured to frame
assembly 22 by welding or other suitable method. Members 37
reinforce frame assembly 22 at the location where hitch structure
46 is secured. Hitch structure 46 includes a conventional hitch 47
that mates with a ball located on a tow vehicle and a conventional
manually operated stand 45 that supports cargo trailer in a level
position when cargo trailer is not hitched to a vehicle. FIG. 6
illustrates frame assembly 22 in its assembled configuration after
attachment of axle assembly 42 and hitch structure 46 to frame
assembly 22 and prior to the attachment of the exterior panels.
[0033] Separate panels 52 are attached to each of end frame 26 and
side frames 28, 30. FIG. 7 illustrates one of the panels 52 in a
partial cutaway view. As can be seen in FIG. 7, each of the panels
52 has a laminated structure that includes a half-inch plywood
substrate 54 and an exterior layer 56 of 0.003 inch aluminum
sheeting. Alternative panel members having a different construction
may also be employed with the present invention. Panels 52 are
attached to frame members 32 with threaded fasteners or by other
suitable means. A panel 58 having a construction similar to panels
52 is attached to structural members 50 and the upper edges of
frames 26, 28, 30 to form a roof structure that closes the top of
cargo space 21 defined by panels 52 and floor structure 24. Panels
52 and 58 not only enclose cargo space 21 but also enhance the
structural rigidity of cargo trailer 20. The exterior panels also
include a door panel 64 having a hinged door 66 that provides
access to cargo space 21. When installed, door panel 64 extends
along a lateral edge 38 of trailer 20 opposite end frame 26 to form
the rear end of cargo trailer 20. Opposite ends of door panel 64
are attached to side frames 28, 30. A door panel 64 is
schematically illustrated in FIG. 8B.
[0034] Additionally, aluminum corner molding 60 is attached at the
joints between panels 52, 58, 64. The vertically extending moldings
60 extend below the lower end of panels 52 and also cover the
corners of aluminum skirting 62 mounted to floor structure 24 below
panels 52. Fender wells 61 are attached to panels 52 and floor
structure 24 over wheels 50 as shown in the fully assembled cargo
trailer 20 depicted in FIG. 7.
[0035] The ability to collapse frame assembly 22 into a compact
shipping configuration allows several of the frame assemblies 22 to
be stacked together when they are in their shipping configuration.
A stack of panels 68 that contains each of the panels 52, 58, 64
necessary to complete the assembly of a cargo trailer 20 can also
be secured together in a stack 68 for shipment. This allows for the
efficient shipping of a kit of parts from a manufacturing and/or
preliminary assembly location to a second location where the final
assembly of cargo trailer 20 takes place. If desirable, the stack
of panels 68 could be shipped to the final assembly location from a
location that is different than the location from which frame
assembly 22 is shipped.
[0036] Moreover, the compact nature of the frame assemblies 22 in
their shipping configuration and of panel stacks 68 allows such
frame assemblies 22 to be stacked together and for panel stacks 68
to be stacked together in a single truck trailer or shipping
container. To facilitate the stacking of panel stacks 68 and frame
assemblies 22 it may be necessary to wrap such assemblies in
various packaging materials to protect the cargo trailer parts
during shipment. It may also be necessary to use spacing objects to
provide frame assemblies 22 with opposed and cooperating stacking
surfaces 70 that provide for the level stacking of the frame
assemblies 22. In the schematic illustration of FIG. 8A wooden
blocks 23 are secured with strapping 25 to ensure the stability of
the stacked assemblies 22. Similar spacing objects might be used
with panel stacks 68. It would also be possible for a number of
such collapsed trailers to be placed on a pallet and/or placed in a
shipping container for the efficient overseas shipping of the
trailers.
[0037] To take full advantage of the shipping efficiencies afforded
by the present invention it will generally be desirable for the
final assembly of the cargo trailers 20 to take place near the
point of sale or final delivery of the cargo trailer. Thus, a
single tractor-trailer could haul several cargo trailers 20 in
their shipping configuration from a manufacturing site to a
dealership or other retail sales location where the final assembly
of the cargo trailers takes place thereby significantly reducing
the cost of shipping.
[0038] While this invention has been described as having an
exemplary design, the present invention may be further modified
within the spirit and scope of this disclosure. This application is
therefore intended to cover any variations, uses, or adaptations of
the invention using its general principles.
* * * * *