Abstract: A method of producing a composite core member along a production line is disclosed. The core member is designed to be used within a composite panel of a tractor trailer. The method comprises the steps of providing an intermediate core member comprising a reinforced material positioned on at least one end of the intermediate core member and producing at least two strips of reinforced material. The intermediate core member is inserted between the strips of reinforced material and the strips of reinforced material are coupled to a first side and a second side of the intermediate core member to form the core member.

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: 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: Apparatus and methods directed to a panel for use on a trailer. The panel includes a panel member core with a length that can have a first segment of thermoplastic foam extending the length and a second segment of thermoplastic foam extending the length adjacent the first segment. The first segment can have a first density and the second segment can have a second density. The first density can be greater than the second density. A sheet can extend over the first and second segments and can be laminated to the panel member core. The panel member can be formed through extrusion.

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: 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 method of producing a composite core member along a production line is disclosed. The core member is designed to be used within a composite panel of a tractor trailer. The method comprises the steps of providing an intermediate core member comprising a reinforced material positioned on at least one end of the intermediate core member and producing at least two strips of reinforced material. The intermediate core member is inserted between the strips of reinforced material and the strips of reinforced material are coupled to a first side and a second side of the intermediate core member to form the core member.

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 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: 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 conveyor system for loading a trailer is disclosed. The conveyor system includes a support frame adapted to couple to a floor of a trailer, a conveyance mechanism coupled to the support frame and configured to extend from a rear of the trailer toward a front of the trailer, and a conveyor rail arranged to extend between and interconnect the support frame and the conveyance mechanism.

Abstract: A conveyor system for loading a trailer is disclosed. The conveyor system comprises a spring hinge comprising a hinge butt portion configured to be coupled to a surface of a trailer and a hinge strap portion configured to be coupled to a bottom surface of the load deck panel. The spring hinge further includes a hinge pin coupling the hinge butt portion and the hinge strap portion, the hinge pin forming a pivot axis and a position-assist element positioned below a bottom surface of the load deck panel. The position-assist element is configured to assist in hinged movement of the load deck panel about the pivot axis between a closed position in which the load deck panel is substantially vertical and an open position in which the load deck panel is substantially horizontal.

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 nose gap reducer for reducing drag on a vehicle is disclosed. The nose gap reducer may be coupled to a vehicle such as a trailer of a semi-trailer truck for example. The trailer may be positioned between a tractor unit or between another trailer.

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: An aerodynamic rear drag reduction system is configured to be coupled to a frame assembly of a trailer including a rear frame and a rear swing door. The drag reduction system includes a top panel configured to be coupled to a top portion of the rear swing door to extend generally horizontally along a top portion of the rear frame of the trailer. The drag reduction system also includes a folding mechanism coupled to the top panel to move the top panel between a fully-deployed position wherein the top panel is configured to extend rearwardly generally away from the rear end of the trailer and a collapsed position wherein the top panel is configured to lie generally adjacent the rear swing door of the trailer. The folding mechanism is configured to be coupled to a door locking mechanism of the trailer.

Abstract: A device for reducing aerodynamic drag comprises a fairing structure configured to be attached to a vehicle surface. The fairing structure comprises a curved wall, a rounded edge, and a substantially flat wall. The substantially flat wall is connected to a mounting surface configured to be attached to the surface of the vehicle.

Abstract: A side skirt system for reducing drag on a trailer or other ground vehicle includes plurality of wall panels each configured to be coupled to one side of the trailer to extend generally below a storage container of the trailer at least partially along a length of the trailer. The wall panels are horizontally spaced-apart from each other.

Abstract: A trailer having a storage container, a landing gear assembly coupled to the storage container, and a rear wheel assembly coupled to the storage container includes a side skirt system for reducing drag on the trailer. The side skirt system includes a side skirt wall configured to be coupled to one side of the trailer to extend below one side wall of the trailer at least partially along a length of the trailer. A length of the side skirt wall along a top edge of the side skirt wall is approximately 48%-80% of a distance between the landing gear and forward-most position of the rear wheel assembly.

Abstract: A drag reduction system is configured to be coupled to a rear frame assembly of a trailer including a rear swing door and a rear frame. The drag reduction system includes a main wall panel configured to be coupled to a vertical member of the rear frame to extend generally rearwardly of the trailer at least partially along a height of the trailer. The main wall panel is pivotable relative to the rear frame between a deployed position wherein the inner surface of the wall panel is spaced-apart from the outer surface of the rear swing door, and a stowed position wherein the inner surface of the wall panel is adjacent to and engaged with the outer surface of the rear swing door.