Leak proof roof and wall structure for enclosed trailer

Abstract

A leak proof roof and wall structure for use on trailers includes a roof sheet with an angular extension, a roof support beam receiving member, an elongated angular member, a rain lip member, and a formed coved piece. These components are joined together and attached to a side wall and a roof of a trailer. In operation, fluid drains from the roof across the formed coved piece and into an exterior channel where it drains off the trailer. Fluid that leaks between the roof and the formed coved piece may drain via gravity down the elongated angular member and into an interior channel where it is drained off the trailer. Fluid that leaks between the first partial H-channel and the elongated angular member drains through the J-channel of the elongated angular member to the front or rear and off of the trailer.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Ser. No. 60/472,372, filed May 21, 2003.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to structures that provide a leak proof enclosure. In particular, the present invention relates to a roof and wall structure that provides a leak proof enclosure in different types of trailers

2. Background of the Invention

Horse and livestock trailers are well known. Due to their diverse operating conditions, structural components in livestock trailers must be robust and able to withstand outdoor conditions, natural water exposure, and repeated washings with harsh detergents and acids. As further discussed below, one complication with such trailers is their tendency to leak during rain or while being washed. Water leakage can damage fixtures inside the trailers. Leakage of cleaning chemicals can cause property damage in addition to being harmful to animals and people inside the trailer.

A recent enhancement to livestock trailers, and especially horse trailers, involves the placement of living quarters within a portion of the trailer. These living quarters often include insulation, tiles and other decorative treatments to make the space more comfortable. However, these treatments are extremely sensitive to water and other fluids. A leaking roof can destroy portions of the living structure, requiring repair or replacement and/or can affect the health of the animals during transportation. Such repairs or replacements are undesirably costly and time consuming.

These specially constructed trailers are enclosed to provide shelter and protection to the interior of the trailer and to inhabitants when occupied. Consequently, the structure includes side walls, roofs, loading gates, doors and coupler assemblies. Heretofore trailer manufacturers have used a frame structure, which is enclosed by interlocking aluminum sheets. The trailer roofs are attached directly to the side walls with rivets, T-bolt fasteners, or other connectors along the seams between the roof and the side wall. Typically, the roof sheet is placed within a groove or shoulder that exists on the top of the side walls. The seam between the roof sheet and the side wall is then sealed with a sealant, such as caulk, gaskets, and/or adhesive tapes, to prevent water leakage into the trailer.

The seam between the roof sheet and the side wall sheets often provides a point for dirt, debris, and water to collect. When two pieces of material (e.g., wood, metal, or aluminum) are placed together, a slight vacuum forms along the seam between the two pieces of material. This slight vacuum tends to suck water and other liquids into the joint between the members via capillary action. As mentioned above, in order to prevent capillary action, most trailer manufacturers use caulks, gaskets, sealants, or other means to seal the joints. This additional sealing step increases labor and materials required for the trailer assembly. Unfortunately, the material employed to seal the roof-side wall seam eventually breaks down with use potentially resulting in leakage. Because the seam sits above the interior of the trailer, a leak along the roof side wall seam will allow water to seep into the interior of the trailer.

In addition to costly repairs, trailer manufacturers struggle with the high warranty costs for problems with leaking trailer roofs. These costs include the time and effort required to implement warranty programs, process warranty claims and actually replace damaged trailer parts.

Accordingly, there is a need for improved interlocking seams between the roof sheet and the side wall sheets that eliminates collection of dirt and debris. There also exists a need for an improved interlocking seam between the roof sheet and the side walls that eliminates leakage of water, acids, detergents and any other liquids to which the trailer may be subjected. There is still an additional need for some sort of mechanical seal between the roof sheet and the side walls.

BRIEF SUMMARY OF THE INVENTION

The present invention relates to a leak proof roof and wall structure for use in a trailer that provides a solution for the aforementioned problems. More specifically, the leak proof roof and wall structure of the present invention comprises an elongated angular member, a roof support beam receiving member, a roof sheet, and a formed coved piece for protecting the interior of trailers from fluid leakage.

Thus, in one aspect of the present invention, the elongated angle member has a first end and a second end, where the second end includes a horizontally extending piece. The horizontally extending piece includes a J-channel in cross-section integrally formed therewith. The present invention further comprises a side wall receiving member integrally formed at the first end of the elongated angular member for receiving a trailer side wall. The side wall member includes first and second walls. The first wall comprises a rain lip member having an exterior channel and an interior channel separated by a divide.

The roof support beam receiving member of the present invention receives a trailer roof operatively connected to the J-channel of the elongated angle member. The roof support beam receiving member has an upper and a lower wall. The upper wall includes an extension leg.

The roof sheet has a flat portion and an angular extension portion. The roof sheet is operatively connected to the extension leg.

The formed coved piece includes an upper roof end and a lower rain lip end. The upper roof end is operatively connected to the flat portion of the roof sheet. The interior channel of the first end of the rain lip member operatively receives the lower rain lip end of the formed coved piece.

In another embodiment of the present invention, the rain lip member further comprises the exterior channel and interior channel separated by a divide. In addition, the rain lip member has a first protrusion and second protrusion integrally joined to the first wall of the rain lip member. These protrusions bias the lower rain lip end of the formed coved piece against the divide to facilitate fluid drainage off the trailer

Another aspect of the present invention provides a method of manufacturing a leak proof roof and wall structure for use in a trailer. The method includes providing an elongated angular member having first and second ends with the second end having a horizontally extending piece, including a J-channel. A side wall receiving member is integrally formed at the first end of the elongated angular member for receiving a trailer side wall where the side wall member includes a rain lip member having an exterior channel and an interior channel and a second wall. A roof support beam receiving member receives a trailer roof that is operatively connected to the J-channel of the elongated angular member. A roof sheet with a flat portion and an angular extension portion is connected to the extension leg of the roof support beam receiving member. A formed coved piece having an upper roof end and a lower rain lip end is attached to the flat portion of the roof sheet and the lower rain lip end.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of the leak proof roof and wall structure of the present invention;

FIG. 2 is a cross-sectional view of the elongated angular member and rain lip member of the present invention;

FIG. 2A is an enlarged view of the rain lip member of the present invention;

FIG. 3 is an enlarged view of the roof support beam receiving member of the present invention; and

FIG. 4 is a detailed view formed coved piece of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The embodiment herein described is not intended to be exhaustive or to limit the invention to the precise form disclosed. Rather, it is employed to explain the principles of the invention and its application and practical use to enable those skilled in the art to follow its teachings. In this light, the invention is described below in the context of an enclosed trailer. One example of such a trailer is a horse trailer used to carry horses, and possibly including living quarters.

Referring now to FIG. 1, the leak proof roof and wall structure (10) of the present invention broadly includes a roof sheet (12) with an angular extension (14), a roof support beam receiving member (16), an elongated angular member (18), a rain lip member (20), and a formed coved piece (22). The leak proof roof and wall structure (10) is typically constructed from metal, such as aluminum, but the use of fiberglass, plastics, or any other synthetic materials are within the scope of the present invention. In one embodiment of the present invention, the formed coved piece (22) may be attached to the roof sheet (12) and the roof support beam receiving member (16) with a fastening means (28), such as a mechanical fastener, including rivets, bolts, screws, or the like, or a chemical fastener accomplished by chemical bonding between polymers or adhesion, and the like. A roof support beam (30) or any structural support known in the art may be used to support the roof sheet (12).

Referring now to FIG. 2, the elongated angular member (18) of the present invention includes a first end (19) and a second end (21) integrally attached by welding or the like, to an elongated angle piece (34). The first end includes a side wall receiving member (36) with a first wall (44) and a second wall (45). The first wall (44) includes a rain lip member (2). The second end (21) of the elongated angular member (18) depicted in FIG. 2 includes a J-channel in cross-section (32), and a horizontally extending piece (38). In one embodiment of the present invention, the J-channel (32) may be integrally joined to the horizontally extending piece (38) by attachment means, such as welding, extrusion, molding, chemical bonding between polymers or adhesion, and the like. The rounded lower channel (40) of the J-channel (32) is designed with sufficient depth to allow liquid to drain to the rear of the trailer.

The horizontally extending piece (38) may be integrally joined to the elongated angle member (18) by an attachment means, such as welding, extrusion, molding, chemical bonding between polymers or adhesion, and the like. The elongated angle piece (34) is designed with sufficient slope to allow drainage of fluids via gravity.

Referring again to FIG. 2, the elongated angle piece (34) may be integrally joined to the side wall receiving member (36) in the same fashion as those previously discussed. The side wall receiving member (36) is designed to rest along the top of the side wall (42) of the trailer. The elongated angular member (18) may be integrally joined to the rain lip member (20) by an attachment means, such as welding, extrusion, molding, chemical bonding between polymers or adhesion, and the like.

Referring now to FIG. 2A, the rain lip member (20) of the present invention includes a first wall (44) with a first protrusion (46) a second protrusion (48) and a second wall (45). The rain lip member (20) includes an exterior channel (50) and an interior channel (52) separated by a divide (53). Referring to FIG. 3, the roof support beam receiving member (16) depicted in FIG. 1 has an upper wall (54) and an extension leg (60) that are integrally joined to a vertically extended piece (56). The vertically extended piece (56) is then integrally joined to a lower wall (58). These components may be integrally joined via welding, extrusion, molding, chemical bonding between polymers or adhesion, and the like. The dimensions of these components are selected so that the roof support beam receiving member (16) are interlocked with the roof support beam (30) as depicted in FIG. 1.

Referring now to FIG. 4, the formed coved piece (22) has an upper roof end (62), a lower rain lip end (64) and a coved middle (66). The formed coved piece (22) is typically all one piece constructed from metals, such as aluminum, or plastics, or any other synthetic material. The dimensions of the formed coved piece (22) are selected so that it spans from the roof sheet (12) to the rain lip member (20) as depicted in FIG. 1.

In operation, the leak proof roof and wall structure (10) of the present invention is designed to prevent fluid leakage into the cargo spaces of trailers and other movable vehicles. Such vehicles include livestock trailers (e.g., horse and cattle trailers), recreational trailers (e.g., motor cycles, snowmobiles, etc.) and the like. Referring to FIG. 1, the roof support beam receiving member (16) is placed vertically adjacent to the J-channel (32). The roof support beam receiving member (16) attaches to the second end (21) of the elongated angular member (18) via rivets, bolts, screws, chemical bonding between polymers or adhesion, and the like. In another embodiment of the present invention, rivets, bolts or screws are used to fasten these parts together wherein the rivet, bolt or screw is driven through the upper portion of the first wall (44) of the J-channel (32) and the vertically extended piece of the (56) of the roof support beam receiving member (16). In this manner, the roof support beam receiving member (16) fixedly attaches to the elongated angular member (18).

Referring to FIG. 1, the roof support beam receiving member (16) is fitted onto the roof support beam (30). The angular extension (14) of the roof sheet (12) horizontally extends over and past the extension leg (60) of the roof support beam receiving member and the horizontally extending piece (38) of the elongated angular member (18), such that fluid entering the seam of the formed coved piece (22) and the roof sheet (12) may be diverted via gravity down the elongated angle piece (34) of the elongated angular member (18) and into the exterior channel (50) and/or the interior channel (52) of the rain lip member (20). A first sealing means (24), such as epoxy, adhesive tape, and caulk, and the like may be used between the roof sheet (12) and the roof support beam (30). A second sealing means (26), such as epoxy, adhesive tape, and caulk, and the like may be used between the extension leg (60) of the roof support beam receiving member (16) and the roof sheet (12).

Referring to FIG. 1, the side wall receiving member (36) of the elongated angular member (18) may be fitted along the top of the trailer side wall (42). The rain lip member (20) may be attached to the side wall (42) of the trailer via rivets, bolts, screws, chemical bonding between polymers or adhesion, and the like. The rivet, bolt or screw is driven through the first wall (44) into the side wall (42) of the trailer between the first protrusion (46) and the second protrusion (48).

Referring to FIG. 1, the lower rain lip end (64) of the formed coved piece (22) is placed in the interior channel (52) of the rain lip member (20) such that it is flush with the first protrusion (46) and the second protrusion (48). The first protrusion (46) and second protrusion (48) bias the lower rain lip end (64) of the formed coved piece (22) against the divide (53) to encourage liquid to drain into the exterior channel (50). The formed coved piece (22) provides additional tension to bias the lower rain lip end (64) against the divide (53) because of the bend in the formed coved piece (22). The upper roof end (62) of the formed coved piece (22) then overlays the roof sheet (12) such that the coved middle (66) covers the elongated angle piece (34) of the elongated angular member (18). The upper roof end (62) of the formed coved piece (22) may be attached to the roof sheet (12) and the extension leg (60) of the roof support beam receiving member (16) via rivets, bolts, screws, chemical bonding between polymers or adhesion, and the like. A rivet, bolt or screw is driven through the upper roof end (62) of the formed coved piece (22), the roof sheet (12), the second sealing means (26) and the extension leg (60) of the roof support beam receiving member (16).

The leak proof roof and wall structure (10) depicted in FIG. 1 allows the diversion of fluid from the roof sheet (12) over the formed coved piece (22) and into the exterior channel (50) where it drains away from the trailer via the front or rear termination point of the exterior channel (50). If fluid leaks between the formed coved piece (22) and the roof sheet (12), it flows down the elongated angle piece (34) of the elongated angular member (18) and into the interior channel (52) of the rain lip member (20) where it drains off the trailer via the front or rear termination point of the interior channel (52). Finally, if fluid is unable to escape via the rain lip member (20) or for some reason enters the seam between the elongated angular member (18) and the roof support beam receiving member (16), it drains into the rounded lower channel (40) of the J-channel (32) where it drains away from the trailer via the front or rear termination point of the rounded lower channel (40).

All of the foregoing components may be constructed of metal, such as aluminum, or plastic or any other synthetic material. Furthermore, they may be extruded, molded, or integrally joined, via welding, soldering, chemical bonding between polymers or adhesion, or any technique known in the art.

As described above, the present invention provides for a leak proof roof and wall structure (10) to prevent fluid leakage into trailers and other movable vehicles. While reference has been made to a horse trailer, this attachment structure would be equally applicable to any other enclosure. Examples include motor homes, campers, over the road trucks, sports trailers, specialized trailers (e.g., race cars, etc.), temporary buildings, and any other enclosed structure.

The invention has herein been described in its preferred embodiments to provide those skilled in the art with the information needed to apply the novel principles and to construct and use the embodiments of the examples as required. However, it is to be understood that the invention can be carried out by specifically different devices and that various modifications can be accomplished without departing from the scope of the invention itself, which is set out in the following claims:

Claims

1. A leak proof roof and wall structure for use in a trailer comprising:

(a) an elongated angular member having first and second ends, said second end comprising a horizontally extending piece, said horizontally extending piece including a J-channel integrally formed therewith;

(b) a side wall receiving member integrally formed at said first end of said elongated angular member for receiving a trailer side wall, said side wall member including first and second walls, said first wall comprising a rain lip member having an exterior channel and an interior channel;

(c) a roof support beam receiving member for receiving a trailer roof said member operatively connected to said J-channel, said roof support beam receiving member having an upper and a lower wall, said upper wall including an extension leg;

(d) a roof sheet having a flat portion and an angular extension portion, said roof sheet operatively connected to said extension leg; and

(e) a formed coved piece having an upper roof end and a lower rain lip end, said upper roof end operatively connected to said flat portion of said roof sheet and said lower rain lip end operatively received by said interior channel.

2. The leak proof roof and wall structure of claim 1, further comprising a divide separating said interior channel and said exterior channel.

3. The leak proof roof and wall structure of claim 1, further comprising a first protrusion and a second protrusion integrally joined to said first wall.

4. The leak proof roof and wall structure of claim 3, wherein said first protrusion and said second protrusion on said rain lip member biases said lower rain lip end of said formed coved piece against said divide providing direct fluid flow into said exterior channel.

5. The leak proof roof and wall structure of claim 1, further comprising first sealing means positioned between said extension leg of said roof support beam receiving member and said flat portion of said roof sheet.

6. The leak proof roof and wall structure of claim 5, wherein said first sealing means comprises any of epoxy, adhesive tape or caulk.

7. The leak proof roof and wall structure of claim 1, further comprising second sealing means positioned between said formed coved piece a roof support beam.

8. The leak proof roof and wall structure of claim 7, wherein said second sealing means comprises any of epoxy, adhesive tape or caulk.

9. The leak proof roof and wall structure of claim 1, wherein said angular extension portion extends over and past said horizontally extending piece and said extension leg.

10. The leak proof roof and wall structure of claim 1, wherein said side wall receiving member is attached to said trailer side wall by mechanical means.

11. The leak proof roof and wall structure of claim 10, wherein said mechanical means includes any of rivets, bolts and screws.

12. The leak proof roof and wall structure of claim 1, wherein said side wall receiving member is attached to said trailer side wall by chemical means, including chemical bonding or adhesion.

13. The leak proof roof and wall structure of claim 1, wherein said J-channel is joined to said roof support beam receiving member by mechanical means.

14. The leak proof roof and wall structure of claim 13, wherein said mechanical means includes any of rivets, bolts or screws.

15. The leak proof roof and wall structure of claim 1, wherein said J-channel is joined to said roof support beam receiving members by chemical means, including chemical bonding or adhesion.

16. The leak proof roof and wall structure of claim 1, wherein said formed coved piece is joined to said roof sheet and said extension leg by mechanical means.

17. The leak proof roof and wall structure of claim 16, wherein said mechanical means includes any of rivets, bolts or screws.

18. The leak proof roof and wall structure of claim 1, wherein said formed coved piece is joined to said roof sheet and said extension leg by chemical means, including chemical bonding or adhesion.

19. A method of manufacturing a leak proof roof and wall structure for use in a trailer comprising:

(a) providing an elongated angular member having first and second ends, said second end comprising a horizontally extending piece, said horizontally extending piece including a J-channel integrally formed therewith;

(b) providing a side wall receiving member integrally formed at said first end of said elongated angular member for receiving a trailer side wall, said side wall member including first and second walls, said first wall comprising a rain lip member having an exterior channel and an interior channel;

(c) supplying a roof support beam receiving member for receiving a trailer roof operatively connected to said J-channel, said roof support beam receiving member having an upper and a lower wall, said upper wall including an extension leg;

(d) joining a roof sheet having a flat portion and an angular extension portion to said extension leg; and

(e) further joining a formed coved piece having an upper roof end and a lower rain lip end to said flat portion of said roof sheet and said lower rain lip end.

20. The method of claim 19, further comprising providing a first protrusion and a second protrusion on said rain lip member biasing said lower rain lip end of said formed coved piece against a divide providing direct fluid flow into said exterior channel.

21. The method of claim 19, further comprising positioning first sealing means between said extension leg of said roof support beam receiving member and said flat portion of said roof sheet.

22. The method of claim 19, further comprising applying second sealing means between said roof sheet and a roof support beam.

23. The method of claim 19, further comprising attaching said side wall receiving member to said trailer side wall by mechanical means.

24. The method of claim 23, wherein said mechanical means includes any of rivets, bolts or screws.

25. The method of claim 19, further comprising attaching said side wall receiving member to said trailer side wall by chemical means, including chemical bonding or adhesion.

26. The method of claim 19, further comprising attaching said J-channel to said roof support beam receiving member by mechanical means.

27. The method of claim 26, wherein said mechanical means includes any of rivets, bolts or screws.

28. The method of claim 19, further comprising attaching said J-channel to said roof support beam receiving member by chemical means, including chemical bonding or adhesion.

29. The method of claim 19, further comprising attaching said formed coved piece to said roof sheet and said extension leg by mechanical means.

30. The method of claim 29, wherein said mechanical means includes any of rivets, bolts or screws.

31. The method of claim 19, further comprising attaching said formed coved piece to said roof sheet and said extension leg by chemical means, including chemical bonding or adhesion.

32. A leak proof roof and wall structure for use in a trailer comprising:

(a) elongated angular member means for diverting fluid from a roof line, said angular member means having first and second ends, said second end comprising a horizontally extending piece, said horizontally extending piece including a J-channel integrally formed therewith;

(b) a side wall receiving member means for receiving a side wall, said side wall receiving member means integrally formed at said first end of said elongated angular member means for receiving a trailer side wall, said side wall member means including a first wall and a second wall, said first wall including a rain lip member means for diverting fluid, said rain lip member means having an exterior channel and an interior channel;

(c) a roof support beam receiving member means for receiving a trailer roof, said roof support beam receiving member means operatively connected to said J-channel, said roof support beam receiving member means having an upper wall and a lower wall, said upper wall including an extension leg;

(d) a roof sheet having a flat portion and an angular extension portion, said roof sheet operatively connected to said extension leg; and

(e) formed coved piece means for protecting a trailer interior from leaks, said formed coved piece means having an upper roof end and a lower rain lip end, said upper roof end operatively connected to said flat portion of said roof sheet and said lower rain lip end operatively received by said interior channel.

33. The leak proof roof and wall structure of claim 32, further comprising a divide means for direct fluid flow into said exterior channel, said divide means situated between said exterior channel and said interior channel.

34. The leak proof roof and wall structure of claim 32, further comprising a first protrusion means and a second protrusion, said first and second protrusion means for outwardly biasing said formed coved piece means against said divide means, said first and second protrusion means integrally joined to said first wall.

35. The leak proof roof and wall structure of claim 32, further comprising first sealing means for sealing, said first sealing means positioned between said extension leg of said roof support beam receiving member means and said flat portion of said roof sheet.

36. The leak proof roof and wall structure of claim 32, further comprising second sealing means for sealing, said second sealing means applied between said roof sheet and a roof support beam.

37. The leak proof roof and wall structure of claim 32, wherein said angular extension portion extends over and past said horizontally extending piece and said extension leg.