CA2264311C

CA2264311C - Composite joint configuration

Info

Publication number: CA2264311C
Application number: CA002264311A
Authority: CA
Inventors: Rodney P. Ehrlich
Original assignee: Wabash National LP
Current assignee: Wabash National LP
Priority date: 1996-09-12
Filing date: 1997-09-10
Publication date: 2006-10-31
Anticipated expiration: 2017-09-10
Also published as: EP0925218A4; EP0925218A1; US5860693A; AU4260997A; CA2264311A1; WO1998010974A1

Abstract

A sidewall (24) of a trailer (20) is formed from at least two composite pane ls (42) joined together by a novel joining configuration. Each panel is formed from inner (48) and outer (50) thin metal skins and a plastic core (46) sandwiched between the skins. In some embodiments, one or two ends of the panels are of reduced thickness and eith er inserted into an adjoining panel end, or joined together via a splicing plate (152). In other embodiments, an insert member (452) is used to join the adjoining plates.

Description

ï»¿1015W0 98ll0974CA 02264311 1999-02-24PCT/US97/15917MP E JO CONFIGURATIONPH TNThis invention is generally directed to a novelsidewall for a trailer body. More particularly, theinvention relates to joined composite panels for trailerbodies, wherein each composite panel includes a plasticcore member sandwiched between thin metal skins andjoined together by novel joints.Trailers of the general type disclosed hereininclude a variety of types of sidewalls. A typical well-known construction is a panelâtype trailer which includesaluminum side posts. Generally, it is desirable to havea relatively thin trailer sidewall so that the totalinside dimensions of the trailer body can be increased to.carry the optimum amount of cargo. In addition, it isï»¿10152025W0 98/ 10974CA 02264311 1999-02-24PCT/US97/1591 7desirable to have a trailer sidewall which islightweight.QBQEEEELJï¬Eljï¬Eï¬ï¬ï¬DLÂ£ELIHE_lNEEHIlQNA general object of the present invention is toprovide a novel joint configuration for joining a pair ofcomposite panels together in a trailer sidewall, whereina plurality of such joined panels may be used to form thetrailer sidewall.An object of the present invention is to provide anovel sidewall for use in a trailer body, which sidewallis simple in design and economical to manufacture whileat the same time providing maximum interior space in thetrailer body.Another object of the present invention is toprovide a novel sidewall having a plurality of joinedcomposite panels, wherein each composite panel includes aplastic core member sandwiched between thin metal skins.These and other objects and features of the presentinvention will become more apparent from a reading of thefollowing descriptions.Briefly, and in accordance with the foregoing, thepresent invention discloses a sidewall of a trailer whichis formed from at least two composite panels joinedtogether by a novel joining configuration. Each panel isformed from inner and outer thin metal skins and aplastic core sandwiched between the skins. In severalï»¿101520CA 02264311 2005-11-1763632-1480embodiments, at least one of the skins has at least oneend coined to as to compress the core between the skinsto define a coined end section. A logistics plate and asplicing member are used to join the panels together andare secured thereto by rivets. The logistics plateand/or the splicing member sit against the coined endsections. In other embodiments, a logistics plate memberis secured by rivets to the panels for joining.themtogether. The splicing member is eliminated and instead,the outer skin of at least one panel is extended to liebehind the logistics plate. In yet other embodiments,one end of each panel has a thickness which is less thanthe other end of the panel. The skins at the greaterthickness end of the panel freely project beyond an endsof the core member. The lesser thickness end is insertedbetween the skins of the other panel at the greaterthickness end and secured thereto by rivets. To form thelesser thickness, the end of the panel may be coined orthe panel may taper from one end to the other end. Aninsert member, made of hard plastic or metal, may be usedâbetween the skins where the rivet is inserted in any ofthe embodiments to substantially prevent compression ofthe panels.ï»¿1015202530CA 02264311 2005-11-1763632-1480According to one aspect of the present invention,there is provided a sidewall for use in a trailer bodycomprising: at least a pair of panels having opposite ends,each said panel comprising an inner metal skin, an outermetal skin and a plastic core member sandwiched between saidinner skin and said outer skin, at least one of said innerand outer skins having at least one end being coined so asto compress said core member between said inner and outerskins and to define a coined end section of said skin, andjoining means for joining said panels together along saidcoined end section.According to another aspect of the presentinvention, there is provided a sidewall for use in a trailerbody comprising: a plurality of panels having first andsecond opposite ends, each said panel comprising an innerskin, an outer skin and a core member sandwiched betweensaid inner skin and said outer skin, said inner and outerskins at said first end of each said panel are coined so asto compress said core member between said inner and outerskins at said first end of each said panel such that saidfirst end of each said panel has a thickness which is lessthan said second end of each said panel, said first end ofone of said panels being inserted between said skins ofanother of said panels and secured to said skins at saidsecond end of said another of said panels.According to still another aspect of the presentinvention, there is provided a plurality of panels adaptedfor use in a sidewall of a trailer body comprising: eachsaid panel having first and second opposite ends andcomprising an inner skin, an outer skin and a core member3aï»¿lOCA 02264311 2005-11-1763632-1480sandwiched between said inner skin and said outer skin, saidinner and outer skins at said first end of each said panelare coined so as to compress said core member between saidinner and outer skins at said first end of each said panelsuch that said first end of each said panel has a thicknesswhich is less than said second end of each said panel, saidfirst end of one of said panels being inserted between saidskins of another of said panels and secured to said skins atsaid second end of said another of said panels.BRIEF DESCRIPTION OF THE DRAWINGSThe organization and manner of the structure andoperation of the invention, together with further objects3bï»¿10152025CA 02264311 1999-02-24W0 98/10974 PCTIUS97l15917and advantages thereof, may best be understood byreference to the following description, taken inconnection with the accompanying drawings, wherein likereference numerals identify like elements in which:FIGURE 1 is a perspective view of a trailer having aplurality of joined panels forming the sidewalls of thetrailer which incorporates the features of the invention,with the trailer connected to a tractor;FIGURE 2 is a perspective view of a pair of joinedpanels used in forming a sidewall of the trailer shown inFIGURE 1 which incorporates the features of a firstembodiment of the invention;FIGURE 3 is a perspective view of a pair of joinedpanels used in forming a sidewall of the trailer shown inFIGURE 1 which incorporates the features of a secondembodiment of the invention;FIGURE 4 is a perspective view of a pair of joinedpanels used in forming a sidewall of the trailer shown inFIGURE 1 which incorporates the features of a thirdembodiment of the invention;FIGURE 5 is a perspective View of a pair of joinedpanels used in forming a sidewall of the trailer shown inFIGURE 1 which incorporates the features of a fourthembodiment of the invention;FIGURE 6 is a cross-sectional view of the joinedpanels shown in FIGURE 5 along line 6-6;FIGURE 7 is a cross-sectional view of a pair ofjoined panels used in forming a sidewall of the trailershown in FIGURE 1 which incorporates the features of aï»¿l0152025CA 02264311 1999-02-24W0 98/10974 PCT/US97/15917fifth embodiment of the invention;FIGURE 8 is a perspective view of a pair of joinedpanels used in forming a sidewall of the trailer shown inFIGURE 1 which incorporates the features of a sixthembodiment of the invention;FIGURE 9 is a crossâsectional view of the joinedpanels shown in FIGURE 8 along line 9-9;FIGURE 10 is a crossâsectional view of a panel usedin forming a sidewall of the trailer shown in FIGURE 1which incorporates the features of a seventh embodimentof the invention;FIGURE 11 is a crossâsectional View of a pair ofpanels shown in FIGURE 10 joined together, for use informing a sidewall of the trailer shown in FIGURE 1 whichincorporates the features of the seventh embodiment ofthe invention;FIGURE 12 is a crossâsectional View of a panel usedin forming a sidewall of the trailer shown in FIGURE 1which incorporates the features of a eighth embodiment ofthe invention; andFIGURE 13 is a crossâsectional view of a pair ofpanels shown in FIGURE 12 joined together, for use informing a sidewall of the trailer shown in FIGURE 1 whichincorporates the features of the eighth embodiment of theinvention.ï»¿10152025CA 02264311 1999-02-24W0 93/ 10974 PCT/US97/159l7REF D DI ENWhile the invention may be susceptible to embodimentin different forms, there is shown in the drawings, andherein will be described in detail, specific embodimentswith the understanding that the present disclosure is tobe considered an exemplification of the principles of theinvention, and is not intended to limit the invention tothat as illustrated and described herein.Turning now to the drawings, a trailer 20constructed in accordance with the present invention isshown in FIGURE 1 connected to a tractor 21 byconventional means, such as a fifth wheel assembly. Thetrailer 20 includes a body 22 formed from a pair ofrectangular sidewalls 24, a front wall 26, rear doors 28,a top panel or roof 30 and a floor 32. The floor 32 issupported by a conventional rear undercarriage assembly34 and has a landing gear 36 secured thereunder. The toppanel 30 and an upper portion of the sidewalls 22 aresecured to a top rail 38 and the floor 32 and lowerportion of the sidewalls 22 are secured to a bottom rail40.Each sidewall 22 includes a plurality of verticalupstanding composite side panels 42 joined together by anovel joint configuration 44. Each composite side panel42 includes a plastic core member 46 sandwiched betweenan inner thin metal skin 48 and an outer thin metal skin50 and bonded thereto by a suitable known adhesive orother like means. One advantage the composite panel 42ï»¿10152025W0 98/ 10974CA 02264311 1999-02-24PCT/US97/15917used in the present invention is that it can be coined orstepped down easily by applying pressure to the area tobe coined or stepped down, whereas in the prior artaluminum sidewalls, the aluminum sidewall could not beeasily coined.The inner skin 48 and the outer skin 50 arepreferably approximately 0.026 inches thick. The skins48, 50 are preferably made of aluminum; galvanized, fullhardened steel, such as AISI Grade E full hard steelbecause of its cost effectiveness, or the like.Preferably, the outer skin 50 is made of ASTM G90galvanized steel and the inner skin 48 is made of ASTMG60 galvanized steel. Aluminum may be used, but it maybe too soft for some purposes and strength and punchresistance are sacrificed, however, aluminum islightweight. Typically, each panel 42 is four feet inwidth, but can be longer or shorter depending on theapplication. At least two panels 42a, 42b are joinedtogether by the novel joint configuration 44 to form thesidewall 24 of the trailer body 22.Each core member 46 is made of some type ofcompressible nonâmetal material, preferablythermoplastic, such as polypropylene or high densitypolyethylene. These materials are relatively inexpensiveas compared to aluminum found in prior trailer wallconstructions. In addition, because a composite panel 42is used, the weight of the trailer construction isreduced over trailers having aluminum sidewalls.Attention is now directed to the various embodimentsï»¿10152025W0 98/10974CA 02264311 1999-02-24PCT/U S97/ 1591 7of the novel joint configuration 44 used in forming thetrailer sidewalls 24 as shown in FIGURES 2-13. A firstembodiment of the joint configuration 144 is shown inFIGURE 2. A second embodiment of the joint configuration244 is shown in FIGURE 3; a third embodiment of the jointconfiguration 344 is shown in FIGURE 4; a fourthembodiment of the joint configuration 444 is shown inFIGURES 5 and 6; a fifth embodiment of the jointconfiguration 544 is shown in FIGURE 7; a sixthembodiment of the joint configuration 644 is shown inFIGURES 8 and 9; a seventh embodiment of the jointconfiguration 744 is shown in FIGURE 10; and a eighthembodiment of the joint configuration 144 is shown inFIGURE 13. Like elements are denoted with like referencenumerals with the first embodiment being in the onehundreds, the second embodiment being in the twohundreds, the third embodiment being in the threehundreds, the fourth embodiment being in the fourhundreds, the fifth embodiment being in the fivehundreds, the sixth embodiment being in the six hundreds,the seventh embodiment being in the seven hundreds andthe eighth embodiment being in the eight hundreds. Asshown in the drawings, only a portion of two joinedpanels 142a, 142b; 242a, 242b; 342a, 342b; 442a, 442b;542a, 542b; 642a, 642b; 742a, 742b; 842a, 842b are shown.It is to be understood that a plurality of panels may beused to form each sidewall 124, 224, 324, 424, 524, 624,724, 824. In addition, the novel joint 144, 24, 344,444, 544, 644, 744, 844 is only shown between one end ofï»¿10152025W0 98ll0974CA 02264311 1999-02-24PCT/US97ll59l7the two panels 142a, l42b; 242a, 242b; 342a, 342b; 442a,442b; 542a, 542b; 642a, 642b; 742a, 742b; 842a, 8421:. Itis to be understood that a like joint is provided betweeneach adjacent end of each panel used to form the trailersidewall.Directing attention to the first embodiment of thenovel joint configuration 144 shown in FIGURE 2, firstand second composite panels 142a, 142b are shown and arejoined together by a logistics plate 152 on the inside ofthe trailer 20 which extends along the entire height ofthe panels 142a, l42b and by a splicing member 154 on theoutside of the trailer 20 which extends along the entireheight of the panels 142a, 142b. The ends 156a, l56b ofthe panels 142a, 142b are spaced apart from each otherwhen joined by the logistics plate 152 and the splicingmember 154 such that an air pocket 158 is formed betweenthe logistics plate 152 and the splicing member 154.Each end of the inner skins 148a, 148b of each panel142a, 142b have an end section 160a, 160b (only one ofwhich is shown on each panel 142a, 142b) which is coinedor stepped down with an intermediate section 161a, l61bof each panel 142a, 142b remaining planar. The outerskin 150a, 150b of the panels 142a, 142b is not coinedand remains planar. When the end section 160a, 160b ofeach inner skin 148a, 148b is coined, the core member146a, 146b is squeezed or compressed between the innerand outer skins 148a, 150a; 148b, 150b and the coremember 146a, 146b may slightly extrude outwardly from theends of the skins 148a, 150a; 148b, 150b and into the airï»¿10152025W0 98/10974CA 02264311 1999-02-24PCT/US97/15917pocket 158 formed between the panels 142a, l42b.The logistics plate 152 is a flat member having aninner surface and an outer surface and which has aplurality of spaced openings or slots 162 therethroughalong an intermediate portion of the logistics plate 152.The slots 162 provide a means for which equipment can beengaged, for example by a clip, to the sidewall 24 of thetrailer 20. The logistics plate 152 is preferably formedfrom a heavier and stronger material than the materialthat is used for the skins 148a, 150a; 148b, l50b toprovide the sidewall with strength and rigidity. Whenthe logistics plate 152 is joined with the inner skins148a, 148b of the panels 142a, 142b, the outer surface ofthe logistics plate 152 sits against the inner surfacesof the inner end sections 160a, 160b such that the innersurface of the logistics plate 152 is flush with theinner surfaces of the intermediate sections 161a, 161b ofthe inner skins 148a, 148b to provide a co-planar surfacealong the length of the sidewall 24 in the interior ofthe trailer 20. Because the ends of the logistics plate152 are flush with the intermediate sections 161a, 161bof the inner skins 148a, 148b, snagging of cargo on theedges of the logistics plate 152 is substantiallyprevented. The logistics plate 152 bridges the gapbetween the panels 142a, 142b such that the slots 162align with the air pocket 158 so that clips can beengaged with the slots 162.The splicing member 154, which is like a post, isattached to the outer surface of the outer skins 150a,10ï»¿10152025W0 98l10974CA 02264311 1999-02-24PCT/US97l159l7150b and extends to clear the top and bottom rails 38, 40of the trailer 20. The splicing member 154 has flat endportions 164 which lie against the outer surfaces of theouter skins 150a, 150b and an intermediate portion 166which bulges outwardly from the end portions 164. Whenthe splicing member 154 is joined with the outer surfacesof the outer skins 150a, 150b of the panels 142a, 142b,the inner surfaces of the end portions 164 lie againstthe planar outer skins 150a, 150b and the intermediateportion 166 bulges outwardly from the sidewall. Thesplicing member 154 bridges the gap formed between thepanels 142a, 142b such that the bulging intermediateportion 166 aligns with the air pocket 158. Because thebulge is provided on the outside of the trailer 20, asmooth inner surface is provided within the trailer 20.This allows for more width within the inside of thetrailer 20 to load freight therein.The logistics plate 152 and splicing member 154 areattached to the first and second panels 142a, 142b bysuitable means, such as rivets 168, which extend throughthe logistics plate 152, the respective coined sections160a, 160b of the panels 142a, 142b and the end portions164 of the splicing member 154. The splicing member 154seals the junction between the panels 142a, l42b on theexterior of the trailer 20 so as to seal the interiorfrom moisture.Attention is now directed to the second embodimentof the novel joint configuration 244 shown in FIGURE 3.In this embodiment, first and second composite panels11ï»¿1O152025WO 98/10974CA 02264311 1999-02-24PCT/US97/15917242a, 242b are joined together by a logistics plate 252on the inside of the trailer 20 which extends along theentire height of the panels 242a, 242b and by a splicingmember 254 on the outside of the trailer 20 which extendsalong the entire height of the panels 242a, 242b. Theends 256a, 256b of the panels 242a, 242b are spaced apartfrom each other to provide a gap therebetween when joinedby the logistics plate 252 and the splicing member 254such that an air pocket 258 is formed between thelogistics plate 252 and the splicing member 254.Each end of the outer skins 250a, 250b of each panel242a, 242b have an end section 263a, 263b (only one ofwhich is shown on each panel 242a, 242b) which is coinedor stepped down with an intermediate section 265a, 265bof each panel 242a, 242b remaining planar. The innerskin 248a, 248b of the panels 242a, 242b is not coinedand remains planar. When the end section 263a, 263b ofeach outer skin 250a, 250b is coined, the core member246a, 246b is squeezed or compressed between the skins248a, 250a; 248b, 250b and the core member 246a, 246b mayslightly extrude outwardly from the ends 256a, 256b ofthe panels 242a, 242b and into the air pocket 258.The logistics plate 252 acts like a post and has endportions 270 which are flat and an intermediate portion272 which bulges inwardly from the end portions 270. Thebulging intermediate portion 272 has a plurality ofspaced openings or slots 274 therethrough. The slots 274provide a means for which equipment can be engaged, forexample by a clip, to the trailer sidewall. The12ï»¿10152025WO 98110974CA 02264311 1999-02-24PCTlUS97ll59l7logistics plate 252 is preferably formed from a heavierand stronger material than the material that is used forthe skins 248a, 250a, 248b, 250b to provide the sidewall24 with strength and rigidity. When the logistics plate252 is joined with the inner skins 248a, 248b of thepanels 242a, 242b, the outer surface of the end portions270 sits against the inner surface of the inner skins248a, 248b such that the intermediate portion 272 bulgesto the inside of the trailer 20. The logistics plate 252bridges the gap formed between the panels 242a, 242b suchthat the bulging intermediate portion 272 which has theslots 274 therethrough aligns with the gap.The splicing member 254 is flat and extends to clearthe top and bottom rails 38, 40 of the trailer 20. Whenthe splicing member is joined with the outer skins 250a,250b of the panels 242a, 242b, the inner surface of thesplicing member 254 sits against the coined end sections263a, 263b such that the outer surface of the splicingmember 254 is flush with the outer surface of therespective intermediate sections 265a, 265b of the outerskins 250a, 250b to provide a coâplanar surface along thelength of the sidewall 24 on the outside of the trailer20. The splicing member 254 bridges the gap formedbetween the panels 242a, 242b.The logistics plate 252 and the splicing member 254are attached to the respective first and second panels242a, 242b by suitable means, such as rivets 268, throughthe end portions 270 of the logistics plate 252, therespective coined sections 263a, 263b of the panels 242a,13ï»¿10152025W0 98/10974CA 02264311 1999-02-24PCT/US97ll59l7242b and the splicing member 254. The splicing member254 seals the junction between the panels 242a, 242b onthe exterior of the trailer 20 so as to seal the interiorfrom moisture.Directing attention to the third embodiment of thenovel joint configuration 344 shown in FIGURE 4, firstand second composite panels 342a, 342b are joinedtogether by a logistics plate 352 on the inside of thetrailer 20 which extends along the entire height of thepanels 342a, 342b and by a splicing member 354 on theoutside of the trailer 20 which extends along the entireheight of the panels 342a, 342b. The ends 356a, 356b ofthe panels 342a, 342b are spaced apart from each other toprovide a gap therebetween when joined by the logisticsplate 352 and the splicing member 354 such that an airpocket 358 is formed between the logistics plate 352 andthe splicing member 354.Each end of the inner skins 348a, 348b of each panel342a, 342b has an end section 360a, 360b (only one ofwhich is shown on each panel 342a, 342b) which is coinedor stepped down with an intermediate section 361a, 361bof each panel 342a, 342b remaining planar. Each end ofthe outer skins 350a, 350b of each panel 342a, 342b havean end section 363a, 363b (only one of which is shown oneach panel 342a, 342b) which is coined or stepped downwith an intermediate section 365a, 365b of each panel342a, 342b remaining planar. When the end sections 360a,363a; 360b, 363b are coined, the respective core members346a, 346b are squeezed or compressed between the skins14ï»¿10152025W0 98/10974CA 02264311 1999-02-24PCT/U S97] 1 591 7348a, 348b; 350a, 350b and may slightly extrude outwardlyfrom the ends 356a, 356b of the panels 342a, 342b andinto the air pocket 358.The logistics plate 352 and the splicing member 354are identical in construction to the second embodiment ofthe logistics plate 252 and the splicing member 254 shownand described with respect to FIGURE 3. Therefore, thespecifics of the construction of the logistics plate 352and the splicing member 354 are not repeated herein andinstead, the reference numerals are denoted with likenumerals and are shown in the drawings.When the logistics plate 354 is joined with theinner skins 348a, 348b of the panels 342a, 342b, theouter surfaces of the flat end portions 370 sit againstthe inner surfaces of the respective coined end sections360a, 360b such that the inner surfaces of the endportions 370 are flush with the inner surfaces of theintermediate sections 361a, 36lb of the inner skins 348a,348b and the intermediate portion 372 of the logisticsplate 352 bulges to the inside of the trailer 20. Theends 356a, 356b of the panels 342a, 342b are spaced apartfrom each other. Because the inner surfaces of the endportions 370 are flush with the inner surfaces of theintermediate sections 361a, 36lb of the skins 348a, 348b,snagging of cargo on the edges of the logistics plate 352is substantially prevented. The logistics plate 352bridges the gap formed between the panels 342a, 342b suchthat the bulging intermediate portion 372, which has theopenings or slots 372 therein, aligns with the air pocket15ï»¿10152025W0 98/ 10974CA 02264311 1999-02-24PCT/US97l159l7358.When the flat splicing member 354 is joined with theouter skins 350a, 350b of the panels 342a, 342b, theinner surface of the splicing member 354 sits against theouter surfaces of the coined end sections 363a, 363b suchthat the outer surface of the flat splicing member 354 isflush with the outer surfaces of the intermediatesections 365a, 365b of the outer skins 350a, 350b toprovide a co-planar surface along the length of thesidewall 24 on the outside of the trailer 20. Thesplicing member 354 bridges the gap formed between thepanels 342a, 342b.The logistics plate 352 and the splicing member 354are attached to the respective first and second panels342a, 342b by suitable means, such as rivets 368, throughthe end portions 370 of the logistics plate 352, thecoined portions of the panels 342a, 342b and the splicingmember 354. The splicing member 354 seals the junctionbetween the panels 342a, 342b on the exterior of thetrailer 20 so as to seal the interior from moisture.In the first, second and third embodiments of thenovel composite joint constructions 144, 244, 344, toengage the rivets 168, 268, 368 with the logistics plate152, 252, 353, the splicing member 154, 254, 354 and therespective first and second panels 142a, 142b; 242a,242b; 342a, 342b, each rivet 168, 268, 368 is engaged byusing the method and apparatus disclosed in co-pendingUnited States Patent Application Serial No. 08/620,999entitled âMethod Of Punching A Composite Plateâ, which is16ï»¿10152025CA 02264311 2005-11-1763632-1480commonly owned by the assignee herein.142b;Coining the ends of the panels 142a,242a, 242b; 342a, 342b, as describedherein, condenses the plastic coremember 146a, 146b; 246a, 246b; 346a, 346b sufficiently tosupport clamping force or pressure from the rivets 168,268, 368 without subsequent loosening. If desired, holescan be provided through the logistic panel 152, 252, 352and the splicing member 154, 254, 354 through which therivets 168, 268, 368 are engaged.In addition, in the first, second and thirdembodiments of the composite joint configurations 144,244, 344, it is envisioned that an insert, as discussedhereinbelow with respect to the fifth embodiment shown inFIGURE 7, can be provided in the construction of theseembodiments of the trailer sidewalls.Attention is now directed to the fourth embodimentof the novel joint configuration 444 shown in FIGURES 5and 6. In this embodiment, first and second compositepanels 442a, 442b are joined together by a logisticsplate 452 on the inside of the trailer 20 which extendsalong the entire height of the panels 442a, 442b and thesplicing member provided in the previous embodiments hasbeen eliminated.At one end of the first panel 442a, as shown inFIGURES 5 and 6, the outer skin 450a has a length that issubstantially longer than the length of the inner skin448a. The ends of the inner and outer skins 448a, 450afreely project beyond the end of the core member 446a so17ï»¿10152025W0 98/ 10974CA 02264311 1999-02-24PCT/US97/1591 7as to leave an open area between the inner and outerskins 448a, 450a at the ends of the first panel 442a. Atthe other end of the panel 442a (not shown), the innerand outer skins 448a, 448b freely project beyond the endof the core member 446a the same distance so as to leavean open area between the inner and outer skins 448a,450a.At one end of the second panel 442b, the inner andouter skins 448b, 450b are of the same length and freelyproject beyond the end of the core member 446b the sameamount so as to leave an open area between the inner andouter skins 448b, 450b. This structure is identical tothe end of panel 442a which is not shown. At theopposite end of the second panel 442b, the constructionis identical to the end of the first panel 442a shown inFIGURES 5 and 6.The logistics plate 452 is form by extruded orformed aluminum. The logistics plate 452 has flat endportions 470 with an intermediate portion 472 that bulgesinwardly therefrom. The end portions 470 areapproximately the same thickness as the thickness of thecore members 446a, 446b and each have a length which isapproximately equal to the distance between the end ofeach inner skin 448a, 448b to the respective core members446a, 446b. The bulging intermediate portion 472 has athickness which is substantially less than the thicknessof the end portions 470 and has a plurality of spacedopenings or slots 474 along the length thereof.To assemble the logistics plate 452 with the first18ï»¿10152025W0 98/ 10974CA 02264311 1999-02-24PCT/US97/15917and second panels 442a, 442b, the end portions 470 of thelogistics plate 452 are inserted between the inner andouter skins 448a, 450a; 448b, 45Gb of the first andsecond panels 442a, 442b such that the ends of the endportions 470 generally abut against the ends of the coremembers 446a, 446b. The ends of the inner skins 448a,448b sit adjacent to the junction between the respectiveend portions 470 and the bulging intermediate portion 472of the logistics plate 452. The outer skin 450a of thefirst panel 442a extends behind the logistics plate 452and lies against the outer skin 450b of the second panel442b. The outer skin 450a may lie against outer skin450b on the inside thereof or the outside thereof. Anair pocket 458 is formed between the bulging intermediateportion 472 of the logistics plate 452 and the outer skin450a of the first panel 442a. The slots 472 align withthe air pocket 458 so that clips or the like can beattached thereto for attaching equipment to the logisticsplate 452. Rivets 468 are engaged through the respectiveinner skins 448a, 448b, the respective end portions 470of the logistics plate 452, the respective outer skins450a, 450b and the extension of the outer skin 450a.The extension of the first panel outer skin 450aeliminates the need for the separate splicing member asused in the first, second and third embodiments. Theouter skin 450a is very thin, however, and, as such, doesnot provide as much reinforcement as the splicing memberprovides. The extension of the first panel outer skin450a seals the junction between the panels 542a, 542b on19ï»¿10152025CA 02264311 1999-02-24WO 98/10974 PCT/US97/15917the exterior of the trailer 20 so as to seal the interiorfrom moisture.Directing attention to the fifth embodiment of thenovel joint configuration 544 shown in FIGURE 7, thisembodiment is the same as the joint configuration 444shown in the fourth embodiment except that the flat endportions 570 of the logistics plate 552 are not the samethickness as the core members 546a, 546b. Instead, theflat end portions 570 and the bulging intermediateportion 572 of the logistics plate 552 are of asubstantially uniform thickness.To fill the space between the respective endportions 570 of the logistics plate 552 and thean insert 576 isrespective outer skins 550a, 550b,provided in each such space. Each insert 576 is made ofhigh density plastic or metal and completely fills thespace between the outer skin 550a, 550b and the endportion 570 of the logistics plate 552. The rivets 568are engaged through the respective inner skins 548a,548b, the respective end portions 570 of the logisticsplate 532, the respective inserts 576 and the respectiveWhen the rivets 568 are insertedouter skins 550a, 550b.through the panels 542a, 542b, the insert 576substantially prevents compression of the panels 542a,542b, which can occur during the insertion of a rivetbecause the core member 546a, 546b is made of acompressible material.Alternatively, the logistics plate 552 could beattached to the inner surface of the inner skins 548a,20ï»¿10152025W0 98/ 10974CA 02264311 1999-02-24PCT/US97/1591 7548b with the respective inserts 576 completely fillingthe space between the skins 548a, 550a; 548b, 550b. Inaddition, the logistics plate 552 could be attached tothe inner surface of the inner skins 548a, 548b, theinsert 576 eliminated, and the core member 546a, 546bused to completely fill the space between the skins 548a,550a; 548a, 550a.Directing attention to the sixth embodiment of thenovel joint configuration 644 shown in FIGURES 8 and 9,first and second composite panels 642a, 642b are joinedtogether by a logistics plate 652 on the inside of thetrailer 20 which extends along the entire height of thepanels 642a, 642b and, like the fourth and fifthembodiments, the splicing member provided in the previousembodiments has been eliminated.At each end of the first panel 642a, the outer skin650a has a length that is substantially longer than thelength of the inner skin 648a. The ends of the inner andouter skins 648a, 650a freely project beyond the end ofthe core member 646a so as to leave an open area betweenthe inner and outer skins 648a, 650a at each end of thefirst panel 642a.The second panel 642b is similarly constructed tothe first panel 642a. At each end of the second panel642b, the outer skin 650b has a length that issubstantially longer than the length of the inner skin648b. The ends of the inner and outer skins 648b, 650bfreely project beyond the end of the core member 646b soas to leave an open area between the inner and outer21ï»¿10152025W0 98ll0974CA 02264311 1999-02-24PCT/U S97/ 15917skins 648b, 650b at each end of the second panel 642b.The logistics plate 652 is identical in constructionto that described with respect to the fourth embodiment.Thus, a repetition of the construction of the logisticsplate 652 is not repeated herein.To assemble the logistics plate 652 with the firstand second panels 642a, 642b, the flat end portions 670of the logistics plate 652 are inserted between the innerand outer skins 648a, 650a; 648b, 650b of the first andsecond panels 642a, 642b such that the ends of the endportions 670 generally abut against the ends of the coremembers 646a, 646b. The ends of the inner skins 648a,648b sit adjacent to the junction between the respectiveend portions 670 and the bulging intermediate portion 672of the logistics plate 652. The outer skin 650b of thesecond panel 642b extends behind the logistics plate 652and lays against the outer skin 650a of the first panel642a. The outer skin 650a of the first panel 642aextends behind the logistics plate 652 and lies againstthe outer skin 650b of the second panel 642b. The outerskin 650a may lie against outer skin 650b on the insideor the outside of outer skin 650b. An air pocket 658 isformed between the bulging intermediate portion 672 ofthe logistics plate 652 and the outer skin 650a of thefirst panel 642a. The openings or slots 672 align withthe air pocket 658 so that clips or the like can beattached thereto for attaching equipment to the logisticsplate 652. Rivets 668 are engaged through the respectiveinner skins 648a, 648b, the respective end portions 67022ï»¿10152025WO 98110974CA 02264311 1999-02-24PCT/US97/15917of the logistics plate 652 and the respective outer skins650a, 650b and the extensions of the outer skins 650a,650b.Because the outer skin 650a of the first panel 642aoverlays the outer skin 650b of the second panel 642b, abend 678 is provided in the outer skin 650a of the firstpanel 642a so that the outer skins 650a, 650b lie againsteach other. This forms a double thickness behind theintermediate portion 672 of the logistics plate 652 toprovide more strength and rigidity than when a singlethickness is used, such as that shown in the fourth andfifth embodiments. The extension of the outer skins650a, 650b of the first and second panels 642a, 642beliminates the need for the separate splicing member asshown in the previous embodiments. If desired, inserts,like those provided in the fifth embodiment, may beprovided. The extensions of the outer skins 650a, 650bseal the junction between the panels 642a, 642b on theexterior of the trailer 20 so as to seal the interiorfrom moisture.In the fourth, fifth and sixth embodiments of thenovel composite joint configurations 444, 544, 644, therivets 468, 568, 668 are engaged by using the method andapparatus disclosed in coâpending United States PatentApplication Serial No. 08/620,999, which disclosure hasbeen herein incorporated by reference. If desired, holescan be provided through the logistic panel 452, 552, 652and the panels 442a, 442b; 542a, 542b; 642a, 642b.Attention is now directed to the seventh embodiment23ï»¿10152025W0 98/10974CA 02264311 1999-02-24PCT/US97/1591 7of the novel joint configuration 744, shown in FIGURE 11,which has first and second composite panels 742a, 742b.One of the panels 742b is shown in FIGURE 10. It is tobe understood that the other panels used to construct thetrailer sidewall are identical in construction. At oneend of the panel 742b, as shown in FIGURE 10, the innerand outer skins 748b, 750b are longer than its associatedcore member 746b so as to freely project beyond the endof the core member 74Gb. At the opposite end of thepanel 742b, the inner and outer skins 748b, 750b arestepped down or coined so as to provide an end portion780b which has a thickness that is less than thethickness of the remainder of the panel 742b. The edgeof the core member 746b is generally flush with the endof the coined end portion 780b of the panel 742b,however, when the skins 748b, 750b are coined, some corematerial may extrude outwardly therefrom.As shown in FIGURE 11, to connect the panels 742a,742b together to form a sidewall 24 of the trailer 20,the coined end portion 780b of one panel 742b is insertedbetween the freely projecting inner and outer skins 748a,750a of the adjacent panel 742a. When interconnectedtogether, the outer surface of the inner skin 748b ofpanel 742b lies against the inner surface of the innerskin 748a of panel 742a and the outer surface of theouter skin 750b of panel 742b lies against the innersurface of the outer skin 750a of panel 742a. When thepanels 742a, 742b are joined together, because of thecoined end portion 780b, the inner surfaces and outer24ï»¿10152025W0 98l10974CA 02264311 1999-02-24PCT/US97/15917surfaces of the panels 742a, 742b are smooth and flushalong the length thereof on the inside and outside of thetrailer 20. An insert, like that disclosed in the fifthembodiment, may replace the core material between theskins in the coined end portion 780b, if desired. Rivets768 are engaged through the freely projecting ends of theinner and outer skins 748a, 750a and the coined endportion 780b.Attention is now directed to the eighth embodimentof the novel joint configuration 844, shown in FIGURE 13,which has first and second composite panels 842a, 842b.One of the panels 842a is shown in FIGURE 12. It is tobe understood that the other panels used to construct thetrailer sidewall 24 are identical in construction. Ateach end of the panel 842a, as shown in FIGURE 12, theinner and outer skins 848a, 850a are longer than itsassociated core member 846a so as to freely projectbeyond the ends of the core member 846a. The panel 842btapers from one end to the other end such that thedistance D1 between the inner and outer skins 848b, 850bat one end is greater than the distance D2 between theinner and outer skins 848b, 850b at the other end. Thus,the core member 846b tapers from one end of the panel842b to the other end of the panel 842b.As shown in this embodiment, an insert 876, like theinsert 576 in the fifth embodiment, is provided betweenthe freely projecting skins 848b, 850b at the end of thepanel 842b which has the lesser thickness. The insert876 completely fills the space between the inner and25ï»¿10152025CA 02264311 2005-11-1763632-1480outer skins 848b, 850b and is made of high densityplastic, metal or the like. When the rivets 868 areinserted through the panels 842a, 842b, the insert_876substantially prevents compression of the panels 842a,842b, which can occur during the insertion of a rivetbecause the core member 846a, 84Gb is made of acompressible material. Alternatively,_the insert 876could be eliminated and the core member 846b extended tofill the space.To connect the panels together to form a sidewall 24the trailer 20, the smaller end of one panel 842b isinserted into the larger end of the adjacent panel 842a.When interconnected together, the outer surface of the-inner skin 848b of panel 842b lies against the innersurface of the inner skin 848a of panel 842a and theouter surface of outer skin 850b of panel 842b liesagainst the inner surface of the outer skin 850a of panel842a. I 1 5In the seventh and eighth embodiments of the noveljoint configuration 744, 844, each rivet 768, 868 isengaged with the panels by using the method and apparatusdisclosed in co-pending United States Patent ApplicationSerial No. 08/620,999. During thispunching process, the core material mayextrude and fill any gaps between the end ofthe panel and the core member of the otherpanel. If desired, holes can be provided through theskins of the one panel and the reduced portion of theother panel through which the rivets are engaged.26ï»¿10CA 02264311 1999-02-24WO 98110974 PCTlUS97l15917While preferred embodiments of the present inventionare shown and described, it is envisioned that thoseskilled in the art may devise various modifications ofthe present invention without departing from the spiritand scope of the appended claims. For example, in any ofthe embodiments which uses a logistics plate, theinlogistics plate may be flat or bulge inwardly. Also,any of the embodiments which uses a splicing member, thesplicing member may be flat or bulge outwardly. Aninsert could be provided in any of the embodiments oreliminated in the embodiments where it is shown.27

Claims

CLAIMS:

1. A sidewall for use in a trailer body comprising:
at least a pair of panels having opposite ends, each said panel comprising an inner metal skin, an outer metal skin and a plastic core member sandwiched between said inner skin and said outer skin, at least one of said inner and outer skins having at least one end being coined so as to compress said core member between said inner and outer skins and to define a coined end section of said skin, and joining means for joining said panels together along said coined end section.

2. A sidewall as defined in claim 1, wherein said joining means comprises a logistics plate member attached against said inner skins of said panels and a splicing member attached against said outer skins of said panels.

3. A sidewall as defined in claim 2, wherein at least one end of said inner skins of said panels is coined to define inner coined end sections and said logistics plate sits against said inner coined end sections.

4. A sidewall as defined in claim 3, wherein said logistics plate is flat and has a plurality of apertures therethrough, said logistics plate sitting against said inner coined end sections to define a surface which is flush with an inner surface of said inner skins.

5. A sidewall as defined in claim 3, wherein said logistics plate has generally flat end portions and an intermediate portion between said end portions which bulges outwardly from said flat end portions, said bulging intermediate portion having a plurality of apertures therethrough, said end portions sitting against said inner coined end sections to define a surface which is flush with an inner surface of said inner skins with said intermediate portion bulging outwardly from said flush surface.

6. A sidewall as defined in claim 3, wherein the ends of said outer skins of said panels are coined to define outer coined end sections and said splicing member sits against said outer coined end sections.

7. A sidewall as defined in claim 2, wherein at least one end of said outer skins of said panels is coined to define outer coined end sections and said splicing member sits against said outer coined end sections.

8. A sidewall as defined in claim 7, wherein said splicing member is flat such that a flush outer surface is provided.

9. A sidewall as defined in claim 1, wherein one end of said panels is coined to compress said core member therebetween and to define a coined end section and the opposite end of said panels has inner outer and skins which project beyond an end of said core member, said coined end section of one of said panels being inserted between said projecting skins of another one of said panels, and said joining means comprises at least one rivet through said projecting skins and said coined end section.

10. A sidewall for use in a trailer body comprising:
a plurality of panels having first and second opposite ends, each said panel comprising an inner skin, an outer skin and a core member sandwiched between said inner skin and said outer skin, said inner and outer skins at said first end of each said panel are coined so as to compress said core member between said inner and outer skins at said first end of each said panel such that said first end of each said panel has a thickness which is less than said second end of each said panel, said first end of one of said panels being inserted between said skins of another of said panels and secured to said skins at said second end of said another of said panels.

11. A sidewall as defined in claim 10, wherein said inner and outer skins at said first end of each said panel project beyond an end of said core member and further including an insert member placed between said skins at said first end of each said panel.

12. A sidewall as defined in claim 11, wherein said insert member is formed from hard plastic or metal.

13. A plurality of panels adapted for use in a sidewall of a trailer body comprising:
each said panel having opposite ends and comprising an inner metal skin, an outer metal skin and a plastic core member sandwiched between said inner skin and said outer skin, at least one of said inner and outer skins having at least one end being coined to as to compress said core member between said inner and outer skins and to define a coined end section of said skin, and joining means for joining said panels together along said coined end section.

14. A plurality of panels as defined in claim 13, wherein said joining means comprises a logistics plate member attached against said inner skins of said panels and a splicing member attached against said outer skins of said panels.

15. A plurality of panels as defined in claim 14, wherein at least one end of said inner skins of said panels is coined to define inner coined end sections and said logistics plate sits against said inner coined end sections.

16. A plurality of panels as defined in claim 15, wherein said logistics plate is flat and has a plurality of apertures therethrough, said logistics plate sitting against said inner coined end sections to define a surface which is flush with an inner surface of said inner skins.

17. A plurality of panels as defined in claim 15, wherein said logistics plate has generally flat end portions and an intermediate portion between said end portions which bulges outwardly from said flat end portions, said bulging intermediate portion having a plurality of apertures therethrough, said end portions sitting against said inner coined end sections to define a surface which is flush with an inner surface of said inner skins with said intermediate portion bulging outwardly from said flush surface.

18. A plurality of panels as defined in claim 15, wherein the ends of said outer skins of said panels are coined to define outer coined end sections and said splicing member sits against said outer coined end sections.

19. A plurality of panels as defined in claim 14, wherein at least one end of said outer skins of said panels is coined to define outer coined end sections and said splicing member sits against said outer coined end sections.

20. A plurality of panels as defined in claim 19, wherein said splicing member is flat such that a flush outer surface is provided.

21. A plurality of panels as defined in claim 13, wherein one end of said panels is coined to compress said core member therebetween and to define a coined end section and the opposite end of said panels has inner outer and skins which project beyond an end of said core member, said coined end section of one of said panels being inserted between said projecting skins of another one of said panels, and said joining means comprises at least one rivet through said projecting skins and said coined end section.

22. A plurality of panels adapted for use in a sidewall of a trailer body comprising:
each said panel having first and second opposite ends and comprising an inner skin, an outer skin and a core member sandwiched between said inner skin and said outer skin, said inner and outer skins at said first end of each said panel are coined so as to compress said core member between said inner and outer skins at said first end of each said panel such that said first end of each said panel has a thickness which is less than said second end of each said panel, said first end of one of said panels being inserted between said skins of another of said panels and secured to said skins at said second end of said another of said panels.

23. A plurality of panels as defined in claim 22, wherein said inner and outer skins at said first end of each said panel project beyond an end of said core member and further including an insert member placed between said skins at said first end of each said panel.

24. A plurality of panels as defined in claim 23, wherein said insert member is formed from hard plastic or metal.