COMPOSITE FLOOR STRUCTURE WITH EMBEDDED ANCHOR POINT CONNECTOR AND METHOD FOR MANUFACTURING THE SAME

Abstract

A cargo vehicle is described that has a composite floor assembly with at least one recessed anchor point connector. The recessed connector can be used to securely attach other vehicle components to the composite floor assembly, such as a coupler assembly with a latch bolt.

Description

COMPOSITE FLOOR STRUCTURE WITH EMBEDDED ANCHOR POINT CONNECTOR AND METHOD FOR MANUFACTURING THE SAME Field of Invention This description generally refers to floor structures and methods for manufacturing them. More specifically, this description refers to composite floor structures with embedded anchor point connectors for use in cargo vehicles and methods for manufacturing them. Background of the Invention Cargo vehicles are used in the transportation industry to transport many different types of cargo. Cargo vehicles can be constructed using composite materials, which can lead to an absence or reduction in metal and wood materials and associated advantages, including simplified construction, thermal efficiency, reduced water intrusion and corrosion, and improved fuel efficiency through weight reduction, for example. However, it is desirable to reinforce connections between the composite materials and other vehicle components. For example, it is desirable to reinforce a connection between a composite floor assembly and a cargo vehicle coupler assembly. Summary of the Invention A cargo vehicle is described that has a Ref. 334230 Composite floor assembly with at least one recessed anchor point connector. The recessed connector can be used to securely attach other vehicle components to the composite floor assembly, such as a coupler assembly with a latch bolt. In accordance with an illustrative embodiment of the present description, a cargo body is provided that includes a composite floor assembly, a plurality of connectors embedded in the composite floor assembly, and a coupler assembly attached to the plurality of connectors using a plurality of mechanical fasteners, the coupler assembly including a latch bolt extending from the composite floor assembly to couple the cargo body to a vehicle. In accordance with another illustrative embodiment of the present description, a vehicle load body is provided that includes a composite floor assembly comprising a plurality of beams, the plurality of beams including a beam subgroup, and a plurality of connectors embedded in the beam subgroup. In accordance with yet another illustrative embodiment of the present description, a method is provided for manufacturing a composite floor assembly with at least one embedded connector. The method includes placing at least one connector in an outer cover, inserting an extensible core material within the outer cover, expanding the core material around the at least one connector in the outer cover to form a composite beam with the at least one connector embedded therein, and arranging the composite beam with a plurality of additional composite beams to form a composite floor assembly. Additional features and advantages of the present invention will become evident to those skilled in the art after consideration of the following detailed description of the illustrative embodiments that exemplify the best way to carry out the invention as currently perceived. Brief Description of the Figures The above aspects and many of the desired advantages of this invention will be more easily appreciated as it is better understood by reference to the following detailed description when taken in conjunction with the accompanying figures. Figure 1 is a top perspective view of an illustrative semi-trailer of the present description that includes a composite floor assembly; Figure 2 is a bottom perspective view of a front end of the composite floor assembly of Figure 1; Zfrficnn / 77Π7 / Β / YILI Figure 3 is a cross-sectional view of the composite floor assembly of Figure 2; Figure 4 is a partially exploded top perspective view of the composite floor assembly of Figure 2; Figure 5 is a perspective view of composite beams with embedded connectors used to form the composite floor assembly of Figure 4; Figure 6 is an end view of one of the composite beams in Figure 5; Figure 7 is a flow chart of an illustrative method for manufacturing the composite floor assembly described herein; Figure 8 is a bottom perspective view, assembled from a coupler assembly attached to the composite floor assembly of Figure 2; Figure 9 is a bottom perspective, exploded view of the coupler assembly and composite floor assembly of Figure 8; Figure 10 is a bottom plan view of the coupler assembly of Figure 8; and Figure 11 is a top plan view of the coupler assembly of Figure 8. The corresponding reference characters indicate corresponding parts across the various Zfrficnn / 77P7 / B / YILI views. Although the figures represent embodiments of various features and components in accordance with the present description, the figures are not necessarily to scale and certain features may be exaggerated for the purpose of illustrating and explaining the present description. The examples set forth herein illustrate one embodiment of the invention, and such examples shall not be construed as limiting the scope of the invention in any way. Detailed Description of the Invention For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the figures, which are described below. The embodiments described below are not intended to be exhaustive or to limit the invention to the precise form described in the following detailed description. Rather, the embodiments are chosen and described in such a way that other people skilled in the art may benefit from their teachings. It is understood that no limitation of the scope of the invention is intended herein. The invention includes any further alterations and modifications to the illustrative devices and methods described and any further applications of the principles of the invention that would normally occur to a person skilled in the art to whom the invention relates. 1. Semi-trailer When referring initially to Figure 1, a semi-trailer 100 is shown for supporting and transporting cargo. The illustrative trailer 100 extends along a longitudinal axis A from a front end 102 to a rear end 104. The illustrative trailer 100 includes a cargo body 110 with a floor assembly 112, a roof 114, a right side wall 116R, a left side wall 116L, a front wall or overhang 118, and a rear door assembly 120 having a rear frame 122 and a door (not shown) for accessing the cargo body 110. Moving from the front end 102 to the rear end 104, the trailer 100 also includes a coupler assembly 130 (Figure 8) configured to couple the cargo body 110 to a powered tractor or other vehicle (not shown), a landing gear assembly 132 configured to support the cargo body 110 on the ground, a fuel tank assembly 134, and a skid rail assembly (not shown) configured to couple the cargo body 110 to a rear wheel assembly (not shown). The front end 102 of the cargo body 110 can be supported on the tractor (not shown) via the coupler assembly 130 in a transport condition or on the landing gear assembly 132 in a stationary condition, and the rear end 104 of the cargo body 110 can be supported on the wheel assembly. Zfrficnn / 77Π7 / Β / ΥΙΛΙ (not shown). In the embodiment illustrated in Figure 1, the cargo body 110 of the trailer 100 is enclosed. The cargo body 110 may be refrigerated and / or insulated for transporting temperature-sensitive cargo. Although the concepts in this description are related to a refrigerated trailer 100, they are understood to be equally applicable to other vehicles in general, and more specifically to conventional trailers (e.g., dry cargo trailers, flatbed trailers, commercial trailers, small personal trailers) and / or box or van semi-trailers, and the like. Accordingly, those skilled in the art will appreciate that the present invention can be implemented in a number of different applications and embodiments and is not specifically limited in its application to the particular embodiments illustrated herein. The 100 trailer may have several features in common with the vehicles shown and described in International Publication No. WO 2016 / 137974 and U.S. Publication No. 2017 / 0240217, the descriptions of which are expressly incorporated herein by reference in their entirety. 2. Composite Materials The cargo body 110 of trailer 100 may be constructed, at least in part, of composite materials. For example, the assembly of floor 112, roof 114, right side wall 116R, left side wall 116L, and / or projection 118 of the load-bearing body 110 may be constructed of composite materials. As such, the assembly of floor 112, roof 114, right side wall 116R, left side wall 116L, and / or projection 118 of the load-bearing body 110 may be referred to herein as composite structures. Composite materials are generally formed by combining two or more different constituents that remain separate and distinct in the final composite material. Illustrative composite materials for use in the composite cargo body 110 include fiber-reinforced plastics (FRPs), for example, carbon fiber-reinforced plastics (CRPs). Each composite structure may be a single unit component, which may be formed from a plurality of constituents or layers permanently bonded together. Other elements of the cargo body 110 may be constructed of non-composite materials (for example, metals). For example, the rear door assembly 120 of the cargo body 110 may be constructed of metallic materials. The composite construction of the 110 load-bearing body can offer certain advantages. First, because the Zfrficnn / 77P7 / E / YILI Composite structures may lack structural metal components; the composite 110 load body may have a reduced heat loss coefficient (Ua) and improved thermal efficiency. Also, the composite 110 load body can operate to minimize blowing agent outgassing, minimize air loss, and minimize water intrusion. Additionally, the composite 110 load body may be lighter in weight than a typical metal load body, which can improve fuel efficiency. Furthermore, the composite 110 load body may have fewer metal structures than a typical load body, which can make the composite 110 load body less susceptible to corrosion. Also, the composite 110 load body may include fewer parts than a typical metal load body, which can simplify construction, reduce inventory, and reduce manufacturing variation.Furthermore, the Composite Load Body 110 may be suitable for use with sensitive cargo, including food products, because the composite materials are inert, preventing reaction with the cargo and other materials, and are easy to clean and maintain, ensuring proper hygiene. As a result, the Composite Load Body 110 can be classified as food-grade equipment. Zfrficnn / 77Π7 / Β / YΙΛΙ The composite structures described herein may contain one or more structural supports or preforms. The preform may have a structural core that has been covered with an outer fabric layer or cover. An illustrative preform 216L is further described below and shown in Figure 6 and includes a core 250 and outer covers 252, 254. The outer cover may be stitched or otherwise attached to the underlying core and / or any surrounding layer. The core may be extruded, pultruded, or otherwise formed into a desired shape and cut to a desired length. In one illustrative embodiment, the core is a polyurethane foam or other foam material, and the outer cover is a nonwoven spun polyester material, a fiberglass fabric, or other suitable material.Advantageously, in addition to its structural effect, the foam core can have an insulating effect in certain applications, including refrigerated truck transport. Illustrative preforms include PRISMA® preforms supplied by Compsys, Inc. of Melbourne, Florida. Both the core and outer shell of the preform can be selected to suit the needs of the particular application. For example, in areas of the final structure that require more strength and / or insulation, a low-density foam can be replaced with a high-density foam or a rigid plastic block. Zfrficnn / 77Π7 / Β / YΙΛΙ Individual preforms can also be sized, shaped, and arranged to suit the needs of a particular application. For example, in areas of the final structure requiring less strength, the preforms can be relatively large, with the foam cores spanning relatively long distances before reaching the surrounding outer shells. Conversely, in areas of the final structure requiring more strength, the preforms can be relatively small, with the foam cores spanning relatively short distances before reaching the surrounding outer shells. In other words, the preforms can be formed as relatively wide panels in areas of the final structure requiring less strength and as relatively narrow support beams in areas of the final structure requiring more strength. The composite structures described herein may also contain one or more reinforcing materials or layers around the preforms. Each reinforcing layer may contain reinforcing fibers and may be impregnated and / or coated with a resin, as further discussed in Section 3 below. Suitable fibers include carbon fibers, glass fibers, cellulose, or polymers, for example. The fibers may be in a fabric form, which may be mat, woven, nonwoven, or uncut, for example. Illustrative reinforcing layers include cut fiber fabrics, such as cut yarn mats (CSM), and continuous fiber fabrics, such as 0° / 90° fiberglass fabrics, +45° / -45° fiberglass fabrics, +60° / -60° fiberglass fabrics, 0° warp unidirectional fiberglass fabrics, and other stitched fiber fabrics, for example.Such fabrics are commercially available from Vectorply Corporation of Phenix City, Alabama. Illustrative fabrics include E-LM 1810 fiberglass fabric with 0° unidirectional fibers, E-LTM 3610 fiberglass fabric with 0° / 90° fibers, and E-LTM 2408 fiberglass fabric with 0° / 90° fibers, for example. According to an illustrative embodiment of the present description, a plurality of different reinforcing layers can be stacked together and used in combination. For example, a staple fiber fabric can be placed adjacent to a continuous fiber fabric. In this stacked arrangement, the staple fibers can help support and hold the adjacent continuous fibers in place, especially around corners or other transitions. Also, the staple fibers can serve as a web to resist column-type loads in compression, while the adjacent continuous fibers can resist flange-type loads in compression. Adjacent reinforcing layers can be sewn or otherwise joined together to simplify fabrication, ensure proper placement, and prevent shifting and / or bunching. 3. Composite Molding Process The composite structures described herein can be formed by a molding process, as further discussed below. An illustrative molding process may involve manufacturing one or more preforms. This step may involve providing a mold in a desired shape, covering the mold's interior surfaces with the outer cover material (e.g., fiberglass cloth), and injecting or otherwise introducing the core material (e.g., foam) into the mold. The core material may be allowed to expand within the mold and penetrate interstices of the surrounding outer cover material. Once solidified and / or cured, the preform can be removed from the mold. In certain embodiments, and as further discussed below, other elements (e.g., embedded connectors) may also be placed within the mold and molded integrally with the preform. Next, the illustrative molding process may involve fabricating the final composite structure of the preforms. This step may involve cutting the preforms to Zfrficnn / 77Π7 / Β / YILI size, arrange the preforms and reinforcing layers together in a mold that resembles the final shape, moisten the materials with at least one resin and a catalyst to impregnate and / or coat the materials, and cure the materials to form a single, integral, laminated composite structure. After curing, the preforms can be removed from the mold, which may be an open or closed mold. In certain embodiments, and as further discussed below, other elements (e.g., exterior panels) may also be placed inside the mold and molded integrally with the final composite structure. The resin used to construct the composite structure may be a typical thermoset resin, a co-curing resin containing a plurality of individual co-curing resins that can be selectively distributed throughout the composite structure during the molding process, or a combination thereof. Such co-curing resins comprise one or more elastomer components, such as a urethane, co-cured with one or more resin components, such as a vinyl ester, epoxy, or unsaturated polyester components. Illustrative co-curing resins are described in U.S. Patent No. 9,371,468 and U.S. Publication No. 2016 / 0263873, the descriptions of which are incorporated herein by reference in their entirety. As used herein, co-curing refers to the fractions involved in curing the elastomer components that occur essentially concurrently with the reactions involved in curing the one or more resin components.In certain configurations, areas of the composite structure that will be susceptible to high stress can receive a resin with a relatively higher polyurethane content for strength, while other areas of the composite structure that provide bulk and section modulus can receive a lower-cost, rigid polyester-based resin, such as an isophthalic polyester resin. Additional information regarding the construction of composite structures is described in the following published patents and patent applications, each of which is incorporated herein by reference in its entirety: U.S. Patent Nos. 5,429,066, 5,664,518, 5,800,749, 5,830,308, 5,897,818, 5,908,591, 6,004,492, 6,013,213, 6,206,669, 6,496,190, 6,497,190, 6,543,469, 6,723,273, 6,755,998, 6,869,561, 6,911,252, and 8,474,871, and U.S. Publication No. 2014 / 0262011. 4. Composite Floor Assembly The front end 102 of floor assembly 112 is shown in more detail in Figures 2-6. The illustrative floor assembly 112 includes an interior surface 200 (Figure 2) that faces downward toward the floor when in use. The illustrative floor assembly 112 also includes a top surface or platform 202 (Figure 4) that faces upward when in use to support loads or other objects. The illustrative floor assembly 112 has a generally rectangular outer perimeter 204 with a width W, a length L, and a height H, although this shape may vary, and an interior portion 206. As discussed in Sections 2 and 3 above, the floor assembly 112 may be a composite structure that is constructed, at least in part, of composite materials. As shown in Figures 4 and 5, the outer perimeter 204 of the illustrative floor assembly 112 includes an outer composite skirt 210 and a plurality of composite beams, specifically: a front crossbeam 212; a right front longitudinal beam 214R; a left front longitudinal beam 214L; a right rear longitudinal beam 216R; and a left rear longitudinal beam 216L. The front crossbeam 212 extends in a direction perpendicular to the longitudinal axis A, while the longitudinal beams 214R, 214L, 216R, and 216L extend in a direction parallel to the longitudinal axis A. The individual composite beams 212, 214R, 214L, 216R, and 216L can be constructed in accordance with Sections 2 and 3 above. Zfrficnn / 77Π7 / Β / YΙΛΙ As shown in Figures 2 and 3, the interior portion 206 of the illustrative floor assembly 112 includes a plurality of composite beams, specifically: a first plurality of crossbeams 220; a second plurality of relatively thin crossbeams 222; a third plurality of relatively thin and short crossbeams 224 stacked under the second crossbeams 222; and a fourth plurality of crossbeams 226, all of which extend in a direction perpendicular to the longitudinal axis A. The first crossbeams 220 and fourth crossbeams 226 span substantially the entire width Ø and height H of the floor assembly 112. When stacked together, the second crossbeams 122 and third crossbeams 224 span substantially the entire height H of the floor assembly 112, with the second crossbeams 222 being even thinner than the third crossbeams 224.However, the relatively short third transverse beams 224 do not span the entire width W of the floor assembly 112 and are in turn spaced from the outer skirt 210 close to the outer perimeter 204 and from each other along the longitudinal axis A. The individual composite beams 220, 222, 224, 226 can be constructed in accordance with Sections 2 and 3 above. As discussed in Section 2 above, the individual composite beams 212, 214R, 214L, 216R, 216L, Beams 220, 222, 224, and 226 can be sized, shaped, and arranged to suit the needs of a particular application. For example, a relatively large number of closely spaced, small beams 212, 214R, 214L, 216R, 216L, 220, 222, 224, and 226 can be used for high-rise / high-strength applications, while a relatively small number of large and / or widely spaced beams 212, 214R, 214L, 216R, 216L, 220, 222, 224, and 226 can be used for low-weight / low-strength applications. Even when referring to Figure 2, the illustrative floor assembly 112 also includes an opening 230 defined by the third transverse beams 224. The opening 230 includes a generally rectangular exterior opening portion 232 that extends around the third transverse beams 224, including along the outer skirt 210, behind the first transverse beams 220, and in front of the fourth transverse beams 226. The opening 230 also includes a longitudinal interior opening portion 234 that extends between the third transverse beams spaced 224 along the longitudinal axis A. As shown in Figure 4, the illustrative floor assembly 112 further includes a top panel 240 that defines the top surface 202. The top panel 240 shown in Figure 4 is a metallic panel (for example, extruded aluminum or stainless steel) that provides strength, protection, and slip resistance to the underlying elements of the floor assembly 112, but the scope of this description also includes a top panel 240 that is a resin, gelcoat, polymer, wood, or pultruded layer, for example. The illustrative floor assembly 112 also includes a front channel plate 242. The top panel 240 and / or front channel plate 242 may be integrally molded with or otherwise attached to the underlying elements of the floor assembly 112, as discussed in Section 3 above.An illustrative method for joining the top panel 240 and / or front channel plate 242 during the molding process is described in U.S. Publication No. 2017 / 0239916, the description of which is expressly incorporated herein by reference in its entirety. Further information regarding floor assembly 112 can be found in Publication No. 2017 / 0241134, and U.S. Patent Application No. 16 / 100,276, filed on August 10, 2018, and entitled TRANSVERSE BEAM FOR COMPOSITE FLOOR STRUCTURE AND METHOD OF MAKING THE SAME, the descriptions of which are expressly incorporated herein by reference in their entirety. 5. Recessed Anchor Point Connectors Floor assembly 112 may include one or more Zfrficnn / 77P7 / B / YILI recessed anchor point connectors 300, as shown in Figures 5 and 6. The connectors 300 can serve as fasteners or anchors to mechanically couple other trailer components 100 to the floor assembly 112, such as a rear door assembly 120 (Figure 1), coupler assembly 130 (Figure 8), landing gear assembly 132 (Figure 1), fuel tank assembly 134 (Figure 1), skid rail assembly (not shown), or a suspension assembly (not shown), for example. Each connector 300 can be configured to receive one or more mechanical fasteners 301 (Figure 9) from the adjacent component. Suitable mechanical fasteners 301 include bolts, screws, rivets, and nails, for example. In certain configurations, the 300 connectors may include pre-threaded holes (not shown) capable of receiving the 301 mechanical fasteners.Depending on the specific application requirements, 301 mechanical fasteners can be used alone or in combination with structural adhesives. 301 mechanical fasteners may be preferred when the 300 connector will be susceptible to peeling, while structural adhesive may be preferred when the 300 connector will be susceptible to shear loads. When used alone, 301 mechanical fasteners can facilitate efficient and cost-effective assembly and repairs of the 100 trailer. When used in combination, 301 mechanical fasteners can also serve as clamps to stabilize the 100 trailer during the curing of the structural adhesive. The 300 connectors can be embedded in a selected subgroup of beams 212, 214R, 214L, 216R, 216L, 220, 222, 224, and 226. In the embodiment illustrated in Figure 5, the front crossbeam 212 includes three spaced 300A-300C connectors arranged perpendicular to the longitudinal axis A, each of the front longitudinal beams 214R and 214L includes two spaced 300D-300E connectors arranged parallel to the longitudinal axis A, and each of the rear longitudinal beams 216L and 216R includes at least one 300F connector, for a total of nine 300 connectors. The remaining beams 220, 222, 224, and 226 are shown without embedded 300 connectors for illustrative purposes. However, the 300 connectors They may vary in number and position.Each illustrative connector 300 is an L-shaped bracket having a lower arm 302 positioned along the lower surface 200 of the floor assembly 112 and an outer arm 304 positioned along the outer perimeter 204 of the floor assembly 112. However, connectors 300 may also be C-shaped, T-shaped, pi-shaped, flat, bent, tubular, or other suitable shapes. 300 series connectors can be constructed from metallic materials (e.g., steel, aluminum, titanium), polymeric materials, wood, or composite materials. In certain In accordance with Zfrficnn / 77P7 / B / YILI modalities, the 300 connectors are constructed from materials that are different from the composite material used to construct the corresponding 212, 214R, 214LM, 216R, and 216L beams. The 300 connectors can be manufactured by extrusion, pultrusion, sheet forming, coil forming, and / or casting, for example. The 300 connectors can also be single-piece or multi-piece constructions. For multi-piece constructions, the pieces can be welded, mechanically fastened, bonded, press-fitted, or otherwise joined together. The left rear longitudinal beam 216L and its corresponding connector 300F are shown in Figure 6 and described below, but it is understood that this description may apply to other floor assembly elements 112, including beams 212, 214R, 214L, 216R, and other connectors 300A-300E. The illustrative beam 216L includes a core 250 (e.g., foam), a first outer cover 252 (e.g., fiberglass fabric), and a second outer cover or cap 254 (e.g., fiberglass fabric), wherein the outer covers 252, 254 cooperate to surround the core 250. The lower arm 302 and outer arm 304 of the connector 300F are embedded in the core 250, such that the outer covers 252, 254 also cooperate to surround the connector 300F. Referring later to Figure 7, an illustrative method 350 is provided for embedding the connector 300F in the illustrative beam 216L (Figure 6). The illustrative method 350 involves fabricating the beam 216L as a preform and then incorporating the preform into the final floor assembly 112. In step 352, a mold having a desired shape is provided. In step 354, interior surfaces of the mold are covered with the outer covers 252, 254. In step 356, the connector 300F (as well as any other connectors in the beam 216L) is placed inside the outer covers 252, 254 in the mold. In step 358, the extensible core material 250 is injected or otherwise introduced into the outer covers 252, 254 to contact the connector 300F. In step 360, the 250 core material expands and cures around the 300F connector, which holds the 300F connector in place.In step 362, a preform resembling beam 216L is removed from the mold. In step 362, the preform is incorporated into the final floor assembly 112, which may involve selectively arranging the preform with other preforms (for example, other beams 212, 214R, 214L, 216R, 220, 222, 224, 226) and reinforcing layers, wetting the materials with at least one resin and catalyst to impregnate and / or coat the materials, and curing the materials to form the final floor assembly 112. Additional details regarding Method 350 may be provided in Section 3 above. Returning to Figure 6, the illustrative 216L beam also includes an embedded 310 conduit (e.g., PVC pipe). The illustrative 310 conduit is circular in cross-section, but this shape may vary. The 310 conduit may be embedded in the 250 core of the 216L beam in the same manner and at the same time as the 300F connector described above. Similar 310 conduits may extend through other elements of the 112 floor assembly, including beams 212, 214R, 214L, and 216R. In use, adjacent 310 conduits may cooperate with each other to accommodate electrical wiring, air lines, fuel lines, or other equipment in the 112 floor assembly. Coupler Assembly Referring later to Figures 8-11, an illustrative coupler assembly 130 is provided for use with floor assembly 112. As discussed above with respect to Figure 1, coupler assembly 130 can be used to couple load body 110 to a powered tractor (not shown). The illustrative coupler assembly 130 includes a substantially flat lower surface 400 (Figure 10) that faces downward when in use and an upper surface 402 (Figure 11) that faces upward toward the lower surface 200 of the floor assembly 110. The illustrative coupler assembly 130 also includes an approach plate subassembly 410, a grid plate subassembly 420, and a latch bolt subassembly 430, some or all of which may be metal structures. The coupler assembly 130 may be a one-piece or multi-piece construction. For multi-piece constructions, the pieces may be welded, mechanically fastened, bonded, press-fitted, or otherwise joined at the joints. The grating plate subassembly 420 of the illustrative coupler assembly 130 is sized and shaped to mate with the floor assembly 112. As shown in Figure 11, the top surface 402 of the grating plate subassembly 420 includes transverse frame members 422, outer longitudinal frame members 424, and inner longitudinal frame members 426. As shown in Figure 9, the transverse frame members 422 and outer longitudinal frame members 424 are arranged in a generally rectangular shape and sized for reception in the generally rectangular outer opening portion 232 of the floor assembly 112, and the inner longitudinal frame members 426 are sized for reception in the longitudinal inner opening portion 234 of the floor assembly 112. The illustrative coupler assembly 130, which includes a coupler assembly 430, comprises a coupler 432 extending vertically downward from the lower surface 400 of the coupler assembly 130 (Figure 10) and a base 434 engaged with the upper surface 402 of the coupler assembly 130 (Figure 11). The coupler subassembly 430 may be mechanically fastened (e.g., bolted), bonded, or otherwise attached to the grid plate subassembly 420. The base 434 of the coupler subassembly 430 may be supported by internal longitudinal frame members 426 of the grid plate subassembly 420. Coupler assembly 130 can be removably coupled to floor assembly 112 using a plurality of mechanical fasteners 301. More specifically, coupler assembly 130 can be removably coupled to recessed connectors 300A-300F in floor assembly 112 using a plurality of mechanical fasteners 301. In the embodiment illustrated in Figure 9, coupler assembly 130 includes a plurality of openings 440A-440F, each sized to receive a corresponding mechanical fastener 301 and aligned with a corresponding connector 300A-300F in floor assembly 112. In this way, mechanical fasteners 301 can be inserted through openings 440A-440F in coupler assembly 130 and secured to connectors. 300A-300F in floor assembly 112.As discussed in Section 5 above, structural adhesives can also be used in combination with the mechanical fasteners 301, which can make the connection between the coupler assembly 130 and the floor assembly 112 permanent. When coupler assembly 130 is coupled to floor assembly 112, as shown in Figure 8, coupler assembly 130 may be sized and formed to extend across the width W of floor assembly 112. Approach plate subassembly 410 and grate plate subassembly 420 may be substantially flush with the lower surface 200 of floor assembly 112, while hitch pin 432 of hitch pin subassembly 430 may extend vertically downward from the lower surface 200 of floor assembly 112 to couple with the powered tractor (not shown). Although this invention has been described as having an illustrative design, the present invention may be further modified within the spirit and scope of this description. This application therefore seeks to cover any variation, use, or adaptation of the invention by employing its general principles. Furthermore, this application seeks to cover such deviations from the present description as are within the known or customary practices of the art to which this invention belongs. Zfrficnn / 77Π7 / Β / YΙΛΙ It is hereby stated that, as of this date, the best method known to the applicant for putting the aforementioned invention into practice is the one that is clear from the present description of the invention.

Claims

1. A vehicle load body, the load body characterized in that it comprises: a composite floor assembly comprising a plurality of beams, the plurality of beams including a subgroup of beams, wherein the subgroup of beams includes: a front crossbeam including a plurality of embedded connectors arranged perpendicular to a longitudinal axis of the vehicle; at least one right longitudinal beam including a plurality of embedded connectors arranged parallel to the longitudinal axis of the vehicle; and at least one left longitudinal beam including a plurality of embedded connectors arranged parallel to the longitudinal axis of the vehicle.

2. The load-bearing body according to claim 1, characterized in that it further comprises a coupler assembly with a grid plate subassembly and a latch bolt subassembly, the grid plate subassembly being coupled to the plurality of connectors in the beam subgroup.

3. The load-bearing body according to claim 2, characterized in that the floor assembly defines a central recess that receives an inner frame member of the grid plate subassembly such that the latch bolt subassembly is aligned with the central recess.

4. The load-bearing body according to claim 3, characterized in that the central gap is defined between a first plurality of transverse beams.

5. A vehicle cargo body, the cargo body characterized in that it comprises: a coupler assembly with a grid plate subassembly and a hitch pin subassembly; a composite floor assembly comprising: a plurality of beams, the plurality of beams including a subgroup of beams, a first plurality of crossbeams, and a second plurality of crossbeams, wherein the first plurality of crossbeams is stacked on top of the second plurality of crossbeams, the first plurality of crossbeams spanning a partial width of the floor assembly and the second plurality of crossbeams spanning substantially a full width of the floor assembly;and a defined central gap between the first plurality of crossbeams, the central gap receiving an inner frame member of the grid plate subassembly such that the latch bolt subassembly is aligned with the central gap; and a plurality of connectors embedded in the beam subgroup, the grid plate subassembly being coupled to the plurality of connectors in the beam subgroup.

6. The load-bearing body according to claim 5, characterized in that the first plurality of transverse beams is spaced from an outer perimeter of the floor assembly to define an outer recess that receives an outer frame member of the grid plate subassembly.

7. The load-bearing body according to claim 5, characterized in that: the grid plate subassembly is substantially level with a lower surface of the floor assembly, and the latch bolt subassembly extends vertically downwards from the lower surface of the floor assembly.

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