Modular Aluminum Trailer Frame With Low-Weld Assembly
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Solution Overview
Problem
Existing metal frames for utility trailers require extensive welding, adding weight and making it difficult to change dimensions, and prior art modular trailers add additional weight and production steps.
Innovation Solution
A trailer design using extruded aluminum floor and side wall members connected by interference fits, glue, and minimal welding, with a tongue assembly attached to the side wall members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal frames are used for trailer construction, then structural strength is achieved, but weight increases significantly
Solution Approach 1:
The patent changes the material parameter from steel to aluminum alloy, which has lower density and weight while maintaining adequate structural strength through optimized extrusion profiles and design. This material substitution directly addresses the contradiction by reducing weight while preserving the required structural integrity for trailer application.
2Strength
If welded metal frames are used, then structural integrity is achieved, but manufacturing complexity and time increase
Solution Approach 1:
The trailer frame is segmented into multiple extruded aluminum members with standardized cross-sections and connection details. These pre-fabricated segments are manufactured separately and then assembled together, eliminating the need for extensive welding operations. The segmentation allows for simplified manufacturing processes while maintaining structural integrity through the standardized connection design.
3Stability of the object's composition
If pre-welded frames are used, then structural stability is achieved, but adaptability for dimension changes is lost
Solution Approach 1:
The frame is divided into modular segments that can be easily assembled and disassembled. This segmentation allows for flexible configuration and dimension changes while maintaining structural stability through the standardized connection system. The modular design enables adaptation to different trailer sizes and requirements without compromising the structural integrity of the assembled frame.
4Strength
If extensive welding is used for frame construction, then structural strength is achieved, but production time increases
Solution Approach 1:
The frame construction is segmented into pre-fabricated extruded members that are assembled through mechanical connections rather than welding. This segmentation enables parallel manufacturing of individual members and simplifies the final assembly process, dramatically reducing production time while maintaining frame strength through the designed connection system.
5Strength
If tongue assemblies are attached to subframes, then structural support is achieved, but weight and production steps increase
Solution Approach 1:
The tongue assembly is merged with the side wall members, eliminating the need for separate subframe structures. This integration reduces the overall weight by removing redundant structural elements while maintaining the required structural support function. The combined design simplifies the construction by reducing the number of separate components and assembly steps.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Facilitates lightweight, easily customizable, and cost-effective trailer construction with reduced assembly time and no need for painting or galvanization.
Implementation Method 1
Each of the floor members is preferably connected to an adjacent floor member by an interference fit
Implementation Method 2
In one embodiment, each floor member is additionally glued to an adjacent floor member
Implementation Method 3
The side wall members are preferably glued to the floor
Implementation Method 4
The floor members are preferably made from extruded aluminium
Data Source
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AI summary
A trailer having a plurality of elongate floor members, each of the floor members connected to an adjacent floor member to define a floor of the trailer, side wall members attached to opposed sides of the floor, an axle assembly attached to the side wall members, and a tongue assembly attached to the side wall members.