Abstract: A cargo vehicle is disclosed having a composite floor assembly with at least one embedded or laminated hardpoint connector. The composite floor assembly may comprise a plurality of transverse beams, wherein a subset of the plurality of transverse beams includes at least one embedded hardpoint connector. The composite floor assembly may comprise a plurality of transverse beams, wherein at least one hardpoint connector is laminated across a subset of the plurality of transverse beams. The embedded or laminated connector may be used to securely and removably couple other vehicle components to the composite floor assembly, such as a landing gear assembly and/or a slide rail assembly.

Abstract: A method of producing a core for a composite panel along a continuous production line is disclosed. The method includes the steps of providing a thermoplastic sheet of material onto the production line and vacuum forming the thermoplastic sheet of material into alternating pairs of matching shapes, providing the thermoplastic sheet of material with alternating pairs of matching shapes onto upper and lower conveyor belts that are operating at lower speeds than the production line causing the pairs of matching shapes to bunch up and form a honeycomb structure, and cutting the honeycomb structure into discrete sections with spaces therebetween. A plurality of reinforced plastic bands with gaps therebetween are provided and the honeycomb structure is aligned with the gaps. The plurality of reinforced plastic bands and the honeycomb structure are secured together.

Abstract: A cargo vehicle configured to support cargo includes a frame assembly with at least one rail member defining a portion of an outer perimeter of the trailer. The cargo vehicle also includes a composite member adjacent to the frame assembly and a mounting member removably coupled to the at least one rail member and permanently coupled to the composite member.

Abstract: Embodiments of the invention provide a skylight assembly for an enclosure having an enclosure panel with an opening. The skylight assembly includes a lens, a gasket, and a nut. The lens includes an annular lens flange and a lens stem extending axially away from the annular lens flange. The gasket is receivable around the threaded lens stem and is adapted to be seated on the lens flange. The nut includes an annular nut flange and nut stem extending axially away from the nut flange. The nut stem is configured to engage the lens stem to secure the skylight assembly to the enclosure panel and compress the gasket against the enclosure panel.

Abstract: A floor securing apparatus comprises a riser slot formed in a floor riser, extending from a top surface toward a bottom surface of the floor riser. The floor riser is configured to support a floor sheet. The apparatus further includes a key including a locking head and at least one anchor tab, where the key is slidable into the riser slot and configured to engage a portion of the floor sheet when slid into the riser slot to prevent vertical movement of the floor sheet relative to the floor riser.

Abstract: A composite structure of a cargo body and a method of making the same are disclosed. The composite structure includes at least one electrical grid embedded within fiber-reinforced polymer (FRP) layers. The embedded electrical grid includes a plurality of conductive fibers and a plurality of insulating fibers integrated into a polymer matrix of the FRP layers. The embedded electrical grid may be used for power distribution, structural strengthening and stiffness, and/or puncture detection.

Abstract: Some embodiments provide a core member for a composite panel that includes a hollow cell network structure, such as a honeycomb arrangement for example, and reinforced plastic strips positioned on a portion of the continuous honeycomb structure. The honeycomb structure and the solid plastic strips may be fastened together using heat and/or pressure applications. Additionally, the method for the production of the core member is provided.

Abstract: A shipping trailer wall panel includes a first partially hollow section, a second partially hollow section, and a reinforcing section. The first partially hollow section includes a first plurality of cell walls. The second partially hollow section is interlockingly connected to the first partially hollow section. The second partially hollow section includes a second plurality of cell walls. The reinforcing section is connected to one or more of the first partially hollow section and the second partially hollow section.

Abstract: A vehicle is disclosed having a composite cargo body. A floor of the cargo body is constructed of a first composite material. A roof, a right sidewall, a left sidewall, and a nose of the cargo body are constructed of a second composite material different from the first composite material. Various components of the composite cargo body are bonded together with an adhesive. Mechanical fasteners also may be used to join other components of composite cargo body.

Abstract: An aerodynamic drag reduction system includes a side panel configured to be coupled to a rear swing door to extend generally vertically at least partially along a height of a trailer and a top panel configured to be coupled to the rear swing door to extend generally horizontally at least partially along a width of the trailer. The drag system includes a cable system configured to connect the side and top panels to prevent upward movement of the top panel beyond its generally horizontal position. The cable system includes a first cable with a first end coupled to an inner surface of the side panel, and a second cable and a third cable each with a first end coupled to a bottom surface of the top panel. A second end of each of the first cable, the second cable, and the third cable is coupled together at a juncture.

Abstract: A side underride system configured to be coupled to a trailer is provided. The side underride system includes a support system, including a brace system and a cable, configured to be positioned below the trailer to provide side underride protection. The brace system includes a plurality of cross-braces that each extend across a width of the trailer and are spaced apart at intervals along a length of the trailer. The cable is configured to extend across the intervals between the cross-braces.

Abstract: A side underride system configured to be coupled to a trailer is disclosed. The side underride system comprises a support system configured to be positioned below the trailer to provide side underride protection. The support system includes a cable system and a brace system. The cable system is configured to couple to the trailer. The brace system includes a plurality of cross-braces that each extend at least partially across a width of the trailer, are spaced apart at intervals along a length of the trailer, and are configured to capture the cable system.

Abstract: A cargo vehicle is disclosed having a composite floor assembly with at least one embedded hardpoint connector. The embedded connector may be used to securely couple other vehicle components to the composite floor assembly, such as a coupler assembly with a king pin.

Abstract: A method of making a vehicle coupler assembly comprises the steps of assembling together a coupler assembly, the coupler assembly comprising a coupler grid plate and a kingpin coupled together with the coupler grid plate and extending below a bottom surface of the coupler grid plate and after assembling together the coupler grid and the kingpin, applying a coating to at least a portion of the coupler assembly.

Abstract: A rear impact guard configured to be coupled to a rear end of a vehicle comprises a bumper support member, a support base, and a horizontal bumper. The bumper support member is configured to be coupled to the rear end of the vehicle. The support base is configured to be coupled to the rear end of the vehicle, configured to be positioned adjacent to a sidewall of the vehicle and below a floor assembly of the vehicle, and is in contact with the bumper support member and extends further forward toward a front of the vehicle than the bumper support member. The horizontal bumper is mounted at a lower end of the bumper support member.

Abstract: Embodiments of the invention provide a header for enclosing a counterbalance assembly for use with an overhead door assembly. The header comprises a top surface, a rear surface coupled to a rear end of the top surface, a bottom surface coupled to a bottom end of the rear surface, and at least one reinforcement member disposed rearward of the counterbalance assembly and forward of the rear surface. The at least one reinforcement member provides necessary reinforcement to the header while allowing for a vertical height of the header to be minimized.

Abstract: A composite floor structure having a plurality of transverse beams. Each transverse beam may include a preform core having a plurality of side surfaces and two end surfaces, and at least one reinforcing layer formed around each of the side surfaces of the preform core.

Abstract: A counterbalance assembly for use with an overhead door assembly of a trailer, for example, includes a first counterbalance mechanism having a first adjustment mechanism for adjusting a tension force of the first counterbalance mechanism and a second counterbalance mechanism having a second adjustment mechanism for adjusting a tension force of the second counterbalance mechanism. The first and second counterbalance mechanisms are spaced-apart from each other.