Abstract: A cargo transport rear frame includes a pair of posts, an upper cross member, and a rear bolster. The posts are spaced in a width direction, and extend in a height direction. The upper cross member extends along the width between the posts. The rear bolster extends between lower ends of the posts such that the rear bolster is spaced below the upper cross member. The posts, the upper cross member, and the rear bolster bound the rear cargo opening. The rear bolster has a first side facing in a forward direction, and the rear bolster has a second side facing in a rearward direction to be exposed to a rear side of the cargo transport rear frame. The rear bolster comprises a sheet metal stamping including a base surface and a relief embossed in the rearward direction from the base surface to form a loading dock engagement feature.

Abstract: A trailer includes a front section having a first floor with an upper surface at a fixed vertical level approximately between three and six feet above a street level, a middle section, and a rear section having a second floor with an upper surface at the fixed vertical level. A horizontally-oriented platform is disposed in the middle section. A lifting mechanism is coupled to the platform and selectively raises and lowers the platform between a lower position of one to two feet above street level, otherwise known as curb-level, and an upper position of approximately between three and seven feet above street level.

Abstract: A vehicle cargo structure includes a reinforcement panel, an upright strut member having an upper end, a front wall structure having an attachment bracket fixed to an outboard upper end of the front wall structure and a bracket. The bracket is fixedly attached to a forward portion of the reinforcement panel and the upper end of the upright strut member. The bracket is further secured to the attachment bracket of the front wall structure via mechanical fasteners.

Abstract: A vehicle includes a divisible trunk defining an enclosure for storing a first object and a second object, a camera to capture first and second images of the first and second objects prior to being placed into the divisible trunk and a processor to execute a machine-vision module to process first and second image data to identify the first and second objects. The vehicle includes a trunk divider to divide the trunk into first and second trunk compartments and an actuator to displace the trunk divider from an inoperative position to an operative position. The processor outputs a divider signal to the actuator to displace the divider to divide the trunk into the first and second trunk compartments. The processor outputs a thermal control signal to a thermal controller to control first and second temperatures of the first and second trunk compartments by setting first and second setpoint temperatures.

Abstract: A vehicle body assembly includes a frame having a forward frame part defining a passenger cabin and a rear frame part defining a load carrying bed. A separate rear fender is removably fastened to the rear frame part, wherein a gap is provided between the forward frame part and the rear fender. A separate rear fender fairing is mounted to an inside surface of the rear fender. The rear fender fairing includes a seal located in the gap and sealingly engaging both the forward frame part and the rear fender.

Abstract: A transport container is provided including a frame including a front frame and a rear frame, each including two vertical corner posts interconnected by lower and upper crossmembers. The frame also includes a set of lower rails and a set of upper rails extending between the front and rear frames defining upper and lower longitudinal corner edges of the container. The transport container also includes a body comprising a plurality of container walls defining a cargo receiving space, each of the container walls being supported by the frame. The plurality of container walls includes a bottom, first and second longitudinal walls, and first and second end walls. The first longitudinal wall and the second longitudinal wall are flared, such that distance between the first longitudinal wall the second longitudinal wall is widest proximate to an opening disposed at the first end wall.

Abstract: A side-by-side vehicle includes a vehicle body frame; a driving power unit supported by the vehicle body frame; and a cargo carrier which is disposed above the driving power unit and has a loading space. The cargo carrier includes a bottom wall defining a bottom surface of the loading space. The bottom wall includes a center bottom wall portion, a rear bottom wall portion provided rearward of the center bottom wall portion and configured to be higher than the center bottom wall portion, and a protruding wall portion protruding upward from a rear end of the center bottom wall portion and connected to a front end of the rear bottom wall portion. The protruding wall portion is provided with a drain hole through which a space formed above the center bottom wall portion is in communication with a space formed under the rear bottom wall portion.

Abstract: Two-piece rail assemblies for truck trailers are provided. The two piece rail assemblies may include: a first rail configured with a first straight edge, and a second rail configured with a second straight edge coupled to the first straight edge of the first rail and configured with a curved edge to receive a cambered roof panel.

Abstract: A communication vehicle system or platform that provides for the integration of multiple audio, visual, telecommunications, thermal, radiological, chemical and biological data detection and/or communication devices. The communication vehicle can be configured for providing mobile communications and surveillance in an environment in which the surrounding communications and/or power infrastructure has been damaged or is non-existent. For example, the vehicle can be deployed to the scene of a disaster or emergency. Accordingly, the mobility of the preferred communication vehicle can enhance and extend the reach of any emergency operations center. Other possible applications include law enforcement surveillance; tactical military command and control; weather and storm chasing; homeland security search and rescue; forward deployment monitoring, news agencies and border patrol.

Abstract: The present invention relates to a container assembly comprising a container, and a load bearing exoskeleton for the container, the exoskeleton comprising a space frame construction. Also disclosed are a vehicle trailer, a rail wagon, and dump body for a dump truck comprising the container assembly.

Abstract: A pickup truck box assembly includes a pair of longitudinal frame rails, an extruded cross-member, and a truck bed. The cross-member has a uniform longitudinal cross-section assembled perpendicular to the rails and defines a rectilinear profile with a front flange extending from a cross-member upper portion on a front side and a rear flange extending from the upper portion on a rear side. The truck bed is secured on top of the flanges and the cross-member upper portion. The cross-member may include a first end adjacent a first wheel well defined by the truck bed and a second end adjacent a second wheel well defined by the truck bed such that the cross-member spans between the wheel wells. The ends may be spaced from their respective wheel wells a distance selected to provide space for a truck box inner panel.

Abstract: A vehicle includes a frame having a pair of longitudinal rails and a box. The box includes a bed supported by the rails and a pair of opposing sidewalls connected to the bed outboard of the rails. A pair of braces provide additional support between the bed and the frame rails. Each may be attached between respective rails and a bottom portion of the bed outboard the rails.

Abstract: The invention is a vehicle for ground transportation that is an aerodynamic shell attached to wheels. The aerodynamic shell is shaped according to airship technology and is elevated such that air flow around the shell is like air flow would be for that shell in flight. The elevation is accomplished with attached structure and attached wheels. Wheels at each side of the vehicle are arranged in wheel trains that are filled in and streamlined to form secondary aerodynamic units, with space between wheels used for equipment. The invention requires changing the position of the engine from its usual place that is low and at the front of the vehicle to a very different position that is high and at the rear of the vehicle.

Abstract: A collapsible truck trailer comprises an upper container that houses, and is slidably engaged with, a primary container via a lifting mechanism and vertical guide rails. The lifting mechanism changes trailer between a collapsed configuration wherein the upper container completely houses the primary container, and an extended configuration wherein the upper container is completely above the primary container. The vertical guide rails comprise a vertical c-channel fixed to the upper container that is slidably engaged with a complementary vertical rail fixed to the primary container. The lifting mechanism includes a series of intersecting lift arms driving by a motor and actuator. An automatically adjusting wind guard covers the front side of the upper container to reduce wind drag. The wind guard has a base portion connected to the truck roof and a flat portion having a terminal end that rests upon the upper container.

Abstract: A travel trailer configured to be coupled to and towed by a vehicle is provided. The travel trailer has a compartment that is attached to a chassis which includes a front end and a rear end. A plurality of wheels are attached to the chassis adjacent the rear end, and a hitch assembly is attached to the chassis adjacent the front end. The compartment at the front end of the chassis forms first and second corners. A recess, directed inwardly toward the interior of the compartment, is located at each corner of the compartment. Cavities formed by each recess may receive a portion of the vehicle while the vehicle is engaged in a turn.

Abstract: A composite structure (10) includes a first outer skin (12); a second outer skin (14); and a core (16) sandwiched between the first outer skin (12) and the second outer skin (14). The core (16) includes a plurality of spaced apart ridges (18) between the first outer skin (12) and the second outer skin (14), each of the spaced apart ridges (18) extending from one end (20) of the composite structure (10) to an opposite end (22); and a plurality of connecting elements (24) between the first outer skin (12) and the second outer skin (14) configured to intersect with the ridges (18) to form open channels (26) within the core (16).

Abstract: A travel trailer has a trailer body, including a front cap. The cap defines a recess in the front portion thereof. A recess cover is pivotally secured to said front cap for covering said recess. The cover is movable between a closed position, in which said recess is covered, and an open position, in which said recess is accessible. One or more liquid propane tanks are provided in the recess. The liquid propane tanks are covered when the recess cover is in the closed position and accessible when said recess cover is in the open position.

Abstract: A convertible cargo bed for a utility vehicle can be easily converted, without tools, between passenger-seating, cargo-storage, and cargo-loading configurations. The hinged cargo bed floor and tailgate convert to a folding seat assembly that can be latched and carry passengers when not hauling cargo. A seat cushion is secured to the seating surface of the hinged floor panel and is not cargo-facing when the bed is storing cargo. The fully-functioning tailgate secures cargo in the interior of the cargo bed and can be unlatched to provide an open-bed. The convertible cargo bed can be tilted to dump cargo.

Abstract: In a vehicle that features a luggage compartment with a cargo opening that can be closed, as well as an operating element that can be actuated in order to open the luggage compartment, an auxiliary function is provided for a function other than the function of opening the luggage compartment and assigned to the operating element while the cargo opening is open such that no additional operating elements.

Abstract: A thermal insulated composite wall panel for use in insulated trailers, containers and insulated compartments, including a first liner panel, a second liner panel having a layer of fibers and at least one structural polymer resin layer disposed coplanar to and bonded with the layer of fibers, thereby forming a laminate liner panel, and an insulated core layer disposed intermediate to and bonded with the first and the second liner panels. The layer of fibers is adjacent the insulated core layer and is lofted prior to being bonded to the insulated core layer.

Abstract: A logistics strip defining at least one opening therethrough may be bonded to an inner surface of a storage container side wall. At least one channel may be formed in the inner surface of the side wall. A bonding medium may be applied to an underside of the logistics strip along opposite sides thereof with the at least one opening positioned therebetween. The at least one opening may then be aligned over the at least one channel. The underside of the logistics strip may then be contacted with the inner surface of the side wall such that the bonding medium contacts and bonds to the inner surface of the side wall on both sides of the at least one channel.

Abstract: A travel trailer configured to be coupled to and towed by a vehicle is provided. The travel trailer has a compartment that is attached to a chassis which includes a front end and a rear end. A plurality of wheels are attached to the chassis adjacent the rear end, and a hitch assembly is attached to the chassis adjacent the front end. The compartment at the front end of the chassis forms first and second corners. A recess, directed inwardly toward the interior of the compartment, is located at each corner of the compartment. Cavities formed by each recess may receive a portion of the vehicle while the vehicle is engaged in a turn.

Abstract: A trailer mounted shooting bench with a storage container and a detachable target apparatus provides a portable shooting station which is placed in a safe shooting area, with the target apparatus detached from the shooting bench and placed in a selected location prior to the placement of the shooting bench at a selected shooting location. The trailer mounted shooting bench and storage container may also be used while hunting, with the target apparatus remaining attached or set aside. The shooting bench has a storage container built within and upon which the shooting platform is hingeably attached, the shooting bench having one or more seats available for a right handed or left handed shooter to sit while the shooting platform provides a flat level surface, including an arm rest, for a shooter to position themself while shooting at the target apparatus. The storage compartment provides transport storage for firearms, target accessories, ammunition, camping supplies.

Abstract: Various embodiments of an improved top rail for a container body, e.g. a truck body, are disclosed. In exemplary embodiments, a support structure is disposed at least partially within a channel of the top rail to provide increased strength to the top rail and to protect the top rail and container body from damage. Examples of support structures include support blocks, such as composite blocks, and support rails, such as metal rails. In an exemplary embodiment, a low-profile light source can be installed on the top rail and/or the support structure.

Abstract: A multifunctional inventive flatbed system is described for all-terrain vehicles (ATVs), and in particular light tactical all-terrain vehicles (LTATVs) for special operations units of the military, where the flatbed system is specially adapted for improved transport of patients in litters, personnel and cargo on such vehicles.

Abstract: A cargo bed of a utility vehicle includes an extruded wall panel with an integrally-formed track and an attachment assembly that can be positioned on the track and secured without the use of tools. The attachment assembly includes a first piece that is inserted into the track and a second piece that abuts an outer surface of the track. The attachment assembly also includes a clamping mechanism that draws the first and second pieces together to clamp a portion of the track between them. The attachment assembly may include a spring that biases the first and second pieces together, such that insertion of the first piece into the track includes a push-and-twist action to overcome the spring bias, properly insert the first piece through a slot, and locate the first piece within the track.

Abstract: A travel trailer has a trailer body, including a front cap. The cap defines a recess in the front portion thereof. A recess cover is pivotally secured to said front cap for covering said recess. The cover is movable between a closed position, in which said recess is covered, and an open position, in which said recess is accessible. One or more liquid propane tanks are provided in the recess. The liquid propane tanks are covered when the recess cover is in the closed position and accessible when said recess cover is in the open position.

Abstract: An inner top corner connector for a container body includes an angled fitting of elastic material. An inner roof sheet connecting portion of the angled fitting has a first end portion bending toward the inner roof sheet and includes an outer seal blade inclining toward the inner roof sheet and the first end portion of the inner roof sheet connecting portion. An inner side panel connecting portion of the angled fitting is provided with a connecting plate for connecting to a top end portion of the inner side panel of the container body. The connecting plate is provided with a guide blade. An inserting groove is defined by the guide blade, the inner side panel connecting portion and a part of the connecting plate, wherein an angle of the angled fitting defined by the inner roof sheet connection portion and the inner side panel connecting portion is 95°-105°.

Abstract: A vehicle body includes structure that defines a first surface, a second surface, a third surface, and an opening between the first and third surfaces. The first surface and the second surface at least partially define lateral boundaries of a vehicle cargo area. The third surface at least partially defines a compartment separate from the cargo area. A first fastening element is mounted with respect to a flexible member. A second fastening element is mounted with respect to the second wall and is releasably engageable with the first fastening element. The flexible member is selectively movable through the opening from a stowed configuration to a deployed configuration. In the stowed configuration, the flexible member is substantially entirely outside the cargo area. In the deployed configuration, the flexible member extends sufficiently across the cargo area such that the first fastening element is engaged with the second fastening element.

Abstract: A convertible cargo bed for a utility vehicle can be easily converted, without tools, between passenger-seating, cargo-storage, and cargo-loading configurations. The hinged cargo bed floor and tailgate convert to a folding seat assembly that can be latched and carry passengers when not hauling cargo. A seat cushion is secured to the seating surface of the hinged floor panel and is not cargo-facing when the bed is storing cargo. The fully-functioning tailgate secures cargo in the interior of the cargo bed and can be unlatched to provide an open-bed. The convertible cargo bed can be tilted to dump cargo.

Abstract: A box truck for supplying sufficient electrical power and compressed air flow to enable spray foam contractors to use specialized equipment to foam insulate buildings. Such a truck has the necessary generator and air compressor systems mounted within the chassis of the vehicle and said systems do not take up valuable cargo space within the truck box, while utilizing components present in normal box truck designs to assist in their operation. The generator system is hydraulically powered and utilizes a PTO (Power Take-Off) mechanism to use power from the truck power train to drive the hydraulic system. The air compressor is a screw type compression system and is belt driven off the truck engine.

Abstract: Various embodiments of an improved top rail for a container body, e.g. a truck body, are disclosed. In exemplary embodiments, a support structure is disposed at least partially within a channel of the top rail to provide increased strength to the top rail and to protect the top rail and container body from damage. Examples of support structures include support blocks, such as composite blocks, and support rails, such as metal rails. In an exemplary embodiment, a low-profile light source can be installed on the top rail and/or the support structure.

Abstract: An illumination device is installed in a box body of a toolbox of a construction machine, and is protected by a protective cover. Water that flows into the box body through a weep hole formed in a lid is received by the protective cover and is guided to a water drain hole formed in a bottom plate of the box body. Then, the water is drained to the outside of the box body.

Abstract: A travel trailer configured to be coupled to and towed by a vehicle is provided. The travel trailer has a compartment that is attached to a chassis which includes a front end and a rear end. A plurality of wheels are attached to the chassis adjacent the rear end, and a hitch assembly is attached to the chassis adjacent the front end. The compartment at the front end of the chassis forms first and second corners. A recess, directed inwardly toward the interior of the compartment, is located at each corner of the compartment. Cavities formed by each recess may receive a portion of the vehicle while the vehicle is engaged in a turn.

Abstract: A cover made of an elastomer material to act as protection for a steel hopper of very heavy-duty trucks and train cars. The cover protects the metallic hopper or cars from shocks from boulders and material of varied granulometry, in addition to providing protection against abrasion, unloading and corrosion. Fastening elements prevent the cover from loosing as a result of the dragging generated by the unloading of materials from the hopper. The protection provided by the cover increases equipment availability and decreases stopping time during repairs.

Abstract: Embodiments of the present disclosure include a composite panel and a method of manufacturing the composite panel. The composite panel includes first and second fiber reinforced plastic (FRP) layers. The composite panel also includes a core layer disposed between the first and second FRP layers. The core layer includes one of: a honeycomb material and a foam material. The composite panel further includes an exterior layer disposed on a surface of the first FRP layer opposite the core layer and an interior layer disposed on a surface of the second FRP layer opposite the core layer. The layers are cured together in one processing step.

Abstract: A convertible and configurable cargo system for integration with pick up bed (or truck chassis): a bed rail assembly, support joists, jacks, and cargo deck. The cargo assembly frame consists of longitudinal supports and transverse joists. It has attachable wheels for rolling cargo in and out of the truck bed. With trailer tongue attachment it also serves as a utility trailer. The cargo deck is comprised of removable panels that are installed on the support joists that also may provide channels for carrying water away from the truck bed below. The removable panels are further covered with an elastomeric material to provide weather protection. For the removal of items in the bed of the truck, the panels have lift up doors with waterproof seals.

Abstract: A livestock trailer providing a dual level livestock loading entrance with a first loading area at a level for loading and unloading livestock or other animals at a dock height and a built-in chute within a second loading area at a level for ground loading and unloading livestock at or near ground level, the trailer further providing a combination interior wall and floor panel with a central rotating mechanism providing either an interior wall separating the first and second loading areas or lying securely flat over the recessed floor in the second ground loading area to prevent access to the recessed floor of the ground loading area during loading and unloading in the first loading area and also providing a ramp in the recessed floor of the second loading area, the ramp being adjustable at a front end to be raised or lowered, the raised position utilized during the loading and unloading operation forming a ramp between the principle trailer floor and the recessed floor of the second loading area, and a lower

Abstract: A sidewall assembly for a trailer or van having a plurality of composite panels interconnected along the length of the trailer. The composite panels have a polyurethane core sandwiched between inner and outer metal panels in bonded relationship. The composite panels are affixed to a respective hat-shaped inner side post between adjacent vertical ends of the composite panels. A plurality of vertically arranged rivets affixes the composite panel to inner post and to an outer sidepost.

Abstract: A logistics strip defining at least one opening therethrough may be bonded to an inner surface of a storage container side wall. At least one channel may be formed in the inner surface of the side wall. A bonding medium may be applied to an underside of the logistics strip along opposite sides thereof with the at least one opening positioned therebetween. The at least one opening may then be aligned over the at least one channel. The underside of the logistics strip may then be contacted with the inner surface of the side wall such that the bonding medium contacts and bonds to the inner surface of the side wall on both sides of the at least one channel.

Abstract: A pick-up style utility vehicle according to the present invention has a front seat, a rear seat, a cargo bed expandable forward, and a screen shield arranged at the front end of the cargo bed. The cargo bed is position changeable between an expanded state and a non-expanded state. A winding device for the screen shield is provided on a front panel. The screen shield is made of a net material having flexibility, for example. One end of the screen shield is windably supported by the winding device. The other end of the screen shield has an engaging portion. A first engaged portion for a non-expanded position and a second engaged portion for an expanded position are provided in the cabin frame.

Abstract: The present invention relates to a pick-up style utility vehicle having a front seat, a rear seat, and a cargo bed in this order from front, and a screen shield partitioning the cargo bed and a riding space in front of the cargo bed. The cargo bed is changeable between an expanded state and a non-expanded state. The screen shield is shiftable between an expanded position corresponding to the expanded state of the cargo bed and a non-expanded position corresponding to the non-expanded state of the cargo bed. Screen shield fixing means are provided to fix the screen shield in each of the expanded position and the non-expanded position. The screen shield fixing means have pin insertion holes of the screen shield, pin insertion holes at the upper ends of side panels, and pins provided so as to be separated from the screen shield and a front panel.

Abstract: A pick-up style utility vehicle according to the present invention has a front seat, a rear seat, a cargo bed expandable in a front direction, and a screen shield arranged at a front end of the cargo bed. The cargo bed has at least a stationary bottom plate, right and left stationary side panels, a front panel, expandable side panels, and an expandable bottom plate and can be changed between an expanded state in which the cargo bed is expanded in a front direction to a rear portion riding space and a non-expanded state not occupying the space. Each of the expandable side panels and the screen shield are supported by a vehicle body configuring portion so as to be integrally shifted between an expanded position and a non-expanded position.

Abstract: The present invention is a pick-up style utility vehicle including a front seat, a rear seat and a cargo bed in order from the front side to the rear side, and a screen for partitioning the cargo bed and ride space on the front side of the cargo bed, in which the cargo bed has at least a stationary bottom plate and an expansion bottom plate, and is changeable between an expanded state where the cargo bed is expanded forward to the ride space and a non-expanded state where the cargo bed does not occupy the ride space, and the expansion bottom plate is pivotable on a horizontal shaft in the right and left direction relative to the stationary bottom plate and the screen.

Abstract: Devices, systems, and methods for connecting a rail bogie to a bimodal hauling vehicle and converting the vehicle for use over either a railway or roadway are disclosed. An illustrative system for connecting a rail bogie to a bimodal hauling vehicle includes a receiver unit coupled to the vehicle. A king pin and bogie locking mechanism on the receiver unit can be used to releasably secure the rail bogie to the receiver unit during transitioning of the vehicle from a highway mode of operation to a railway mode of operation. The bogie locking mechanism can include a number of lock jaw members and a lock jaw actuator, which can be engaged to actuate the lock jaw members between an unlocked position and a locked position about a number of locking pins on the rail bogie frame.

Abstract: The invention generally concerns a semi-trailer to be trailed by a tractor. The semi-trailer comprises a wheeled deck having two lateral sides, proximate and distal longitudinal end sides. The semi-trailer also comprises two wall structures so pivotably mounted to the deck along a respective lateral side thereof as to be movable between an upright position, where the semi-trailer is in a dry-box configuration, and a lay down position wherein the semi-trailer is in a flatbed configuration. The two pivotable wall structures allow the semi-trailer to be moved between the dry-box configuration and the flatbed configuration.

Abstract: In an all terrain vehicle, a radiator is disposed forward of a front panel in a longitudinal direction of the vehicle. The radiator is also disposed in a transverse center of the vehicle. A fan is configured to blow air from the front to an area behind the radiator. An engine unit is disposed rearward of the front panel. A cargo bed is disposed rearward of a seat. An exhaust device is disposed under the cargo bed. The exhaust device is disposed in the transverse center of the vehicle. A communication path is positioned in the transverse center of the vehicle. The communication path connects a space positioned behind the radiator and a space that the exhaust device is disposed. The communication path at least partially overlaps with the fan in a front view of the vehicle.

Abstract: An off-road vehicle has a frame, at least four wheels, each including a tire, a seat, a steering assembly, an engine, and a cargo box (28, 50) pivotally mounted to the frame rearwardly of the seat. The cargo box includes a cargo box body (52) having a front wall (54), a pair of side walls (56) extending from the front wall, a first floor (58) connected to a lower end of the front and the pair of side walls, and an at least partially opened rear side. A second floor (72) is supported inside the cargo box body above the first floor. At least one tailgate (68) selectively closes the at least partially opened rear side.

Abstract: A modular assembly structured to assume either a shipping container configuration or a building unit configuration including a frame comprising a plurality of support members and defining both a part of the building unit configuration and shipping unit configuration. A plurality of frame panels are movably connected to the frame and disposable in either a closed position or an opened position so as to respectively and at least partially define either the shipping unit configuration or the building unit configuration. The plurality of unit panels are movably connected to the frame and disposable outwardly therefrom to collectively define end wall portions and ceiling portions of the building unit configuration wherein the unit panels may be stored within the interior of the frame. An erection assembly is selectively disposable in an assembled position exteriorly of the frame and supported thereon so as to facilitate the assembly of at least some of the frame panels and/or unit panels.

Abstract: An improved truck bed toolbox lid and a method of producing the same. The truck bed toolbox lid includes an outer metallic sheet layer comprising a generally rectangular top sheet member, a longitudinal front edge member, two lateral edge members and a longitudinal rear edge member. A metallic liner sheet member is disposed inside the top sheet member in edge contact abutment with beveled inside edges of the front and rear longitudinal edge members and the lateral edge members to create an internal cavity in which the liner is by stitch welding. One or more injection ports are provided through the liner sheet member through which a self-expanding and self-curing, relatively high-density, foam is injected. The stitch welded edge contacts leave non-welded, gas permeable junctions along the wedged cavity periphery at a funneled apex of the edge contacted boundary which facilitate expansion of the foam toward the outermost edges of the cavity.