Method and apparatus for attaching crossmembers to a pair of flanged beams

Abstract

A pair of elongate attachment members, or “Z-rails” for attaching an end of a trailer crossmember to a flanged beam each include a first end section, an L-shaped portion comprising a horizontal leg and a vertical leg extending from the first end section, and a second end section extending from the vertical leg. The horizontal leg has a bottom surface with a width equal to the distance between the web of the flanged beam and the end of the flange. The vertical leg has an outer surface with a width equal to the width of the end of the flange. The Z-rails are attached to opposite ends of the crossmember to form a subassembly. The subassembly is fixed to and between the flanged beams by welding the first end sections to the web of the corresponding beam, with the horizontal leg on the flange, without directly heating the flange, thereby not diminishing the toughness of the flange.

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows: 
     
         1 . An elongate attachment member for attaching an end of a crossmember to a main beam of a trailer, the main beam having a web portion and a flange extending away from the web portion, wherein the flange defines an upper surface having a first width and an end surface having a second width, the elongate attachment member comprising:
 (i) a first end section,   (ii) an L-shaped portion comprising a horizontal leg extending from the first end section and a vertical leg extending from the horizontal leg, and   (iii) a second end section extending from a bottom end of the vertical leg;   wherein the horizontal leg of the L-shaped portion defines a lower surface having a width equal to the first width and the vertical leg of the L-shaped portion defines an outer surface having a width equal to the second width.   
     
     
         2 . The elongate attachment member of  claim 1 , wherein the elongate attachment member is configured to attach a plurality of crossmembers to the main beam. 
     
     
         3 . The elongate attachment member of  claim 1 , wherein the second end section is perpendicular to the vertical leg of the L-shaped portion. 
     
     
         4 . The elongate attachment member of  claim 3 , wherein the first end section is perpendicular to the horizontal leg of the L-shaped portion. 
     
     
         5 . The elongate attachment member of  claim 1 , wherein the horizontal leg is configured to be bolted to the flange and the second end section is configured to be bolted to the crossmember. 
     
     
         6 . The elongate attachment member of  claim 1 , wherein the second end section comprises a first portion and a second portion spaced apart from the first portion. 
     
     
         7 . The elongate attachment member of  claim 6 , wherein the elongate attachment member is configured to be fixedly attached to a cross member for a trailer suspension assembly. 
     
     
         8 . A crossmember subassembly comprising:
 a first attachment member in accordance with  claim 1  and a second attachment member in accordance with  claim 1 ; and   a plurality of crossmembers fixedly connecting the first attachment member to the second attachment member.   
     
     
         9 . The crossmember subassembly of  claim 8 , wherein the plurality of crossmembers each comprises a first end that is welded to the first attachment member, and a second end that is welded to the second attachment member.