Claims:WE CLAIM:

1. A tipper bed(30, 130) comprising:
a floor plate(34, 134) for supporting objects to be carried on the tipper bed (30, 130);
an intermediate structure (40, 140) comprising at least one corrugated intermediate plate (42, 142), the intermediate structure (40, 140) beingfixed to the floorplate (34, 134)so as to form intermediate cells (44, 144) between the floor plate andthe intermediatestructure; and
a corrugated base plate (46, 146)fixed to the intermediate structure (40, 140)so as to form base cells (48, 148) between the intermediate structure and the base plate;
wherein the base plate (46, 146)forms runners (50, 150)for laying the tipper bed (30, 130) on a chassis (16).

2. A tipper bed (30, 130) according to claim 1, wherein the intermediate cells (44, 144)and base cells (46, 146) comprise elongate cavities.

3. A tipper bed (30, 130) according to claim 2, wherein the cavities extend in a longitudinal direction which is substantially parallel to a longitudinal direction of the tipper bed (30, 130).

4. A tipper bed (130) according to any preceding claim, wherein the intermediate structure (140) comprises at least two corrugated intermediate plates (142a, 142b, 142c), wherein a first corrugated intermediate plate (142a) is fixed to the floor plate (134), and at least a second corrugated intermediate plate (142b) is fixed to the first intermediate plate (142a) so as to form secondary intermediate cells (144b) between the first intermediate plate (142a) and the second intermediate plate (142b).

5. A tipper bed (30, 130) according to any preceding claim, wherein the floor plate (34, 134) comprises a plurality of rock breakers(52, 152) comprising elongate rails which are fixed to the floor bed (34, 134).

6. A tipper bed (30, 130) according to claim 5, wherein the plurality of rock breakers (52, 152a) are located on anupper surface of the floor plate (34, 134), for supporting material to be carried in the tipper bed, at locations where the intermediate structure (40, 140) is fixed to a lower surface of the floor plate (34, 134).

7. A tipper bed (30, 130) according to claim 6, wherein the plurality of rock breakers (152b) are located on the upper surface of the floor plate (34, 134) at interfaces between where the corrugated intermediate plate is fixed to the lower surface of the floor plate, and where the corrugated intermediate plate is displaced away from the lower surface of the floor plate.

8. A tipper bed (30, 130) according to any preceding claims, wherein the intermediate cells (44, 144) and base cells (48, 148) together form a honeycomb-like structure.

9. A tipper bed (30, 130) according to any preceding claim, wherein the width of the runners (50, 150) is at least 30mm or at least 70mm.

10. A tipper truck (10) comprising:
a chassis (16); and
a tipper body (18) comprising a tipper bed (30, 130) according to any one of the preceding claims.

11. A method of manufacturing a tipper bed (30, 130), the method comprising:
providing a floor plate for supporting objects to be carried on the tipper bed (202);
fixing to the floor plate an intermediate structure (208) comprising at least one corrugated intermediate plate, thereby forming intermediate cells between the floor plate and the intermediate structure;
fixing a corrugated base plate to the intermediate structure (210), thereby forming base cells between the intermediate structure and the base plate, wherein the base plate forms runners for laying the tipper bed on a chassis.

12. A method according to claim 11, wherein the intermediate structure is welded to the floor plate, and wherein the base plate is welded to the intermediate structure.

13.A method according to claim 11 or 12, wherein the floor plate comprises two modular floor units joined together.

14. A method according to any of claim 13, comprising providing a wear plate (204) and fixing the wear plate to the floor plate at the join between the modular floor units.

15.A method according to any of claims 11-14, wherein the corrugated intermediate plate comprises two modular intermediate units which are joined together.
, Description:FIELD OF THE INVENTION
The present invention relates to a tipper bed and a method of manufacturing a tipper bed.

BACKGROUND
Tipper trucks, also known as dumper trucks are known in the construction industry for receiving material or objects such as rocks, storing the material whilst travelling and dumping the material or objects at a different location.

SUMMARY
According to a first aspect, there is provided a tipper bed comprising: a floor plate for supporting objects to be carried on the tipper bed; an intermediate structure comprising at least one corrugated intermediate plate, the intermediate structure being fixed to the floor plate so as to form intermediate cells between the floor plate and the intermediate structure; and a corrugated base plate fixed to the intermediate structure so as to form base cells between the intermediate structure and the base plate; wherein the base plate forms runners for laying the tipper bed on a chassis.

The corrugated base plate may comprise runner portions which are substantially planar and parallel to the floor plate and ultimate the floor plate in a vertical direction of the tipper bed. In other words, the runner portions may be planar portions of the base plate furthest away from the floor plate. The runner portions may form the runners. The tipper bed may also be known as a tipper body.

The floor plate may comprise a main planar portion, which forms the floor of the tipper bed, and one or more curved edge portions and/or one or more substantially vertical side wall portions. The vertical direction may correspond to a direction which is substantially perpendicular to the main planar portion of the floor plate.

The intermediate cells and base cells may comprise elongate cavities. The cavities may extend in a longitudinal direction which is substantially parallel to a longitudinal direction of the tipper bed.

The longitudinal direction of the tipper bed may correspond to the fore-aft direction of the tipper bed when in use on a tipper truck. The longitudinal direction of the tipper bed may correspond to the direction of the longest dimension of the floor plate or tipper bed.

The intermediate structure may comprise at least two corrugated intermediate plates. A first corrugated intermediate plate may be fixed to the floor plate, and at least a second corrugated intermediate plate may be fixed to the first intermediate plate so as to form secondary intermediate cells between the first intermediate plate and the second intermediate plate.

In other words, the intermediate structure may comprise a plurality of corrugated intermediate plates which may be fixed to one another to form a honeycomb-like structure which is fixed to the floor plate. The lowermost plate of the honeycomb-like structure may be the base plate.

The intermediate structure may also comprise one or more substantially planar plates.

The tipper bed may comprise at least two runners. The tipper bed may comprise at least three intermediate cells. The intermediate cells may be quadrilateral in cross-section, and in particular trapezoidal in cross section. The base cells may be hexagonal in cross section. Where the intermediate structure comprises a second corrugated intermediate plate or more, the secondary and subsequent intermediate cells may be quadrilateral or hexagonal in cross-section. The cross-sectional shape of the intermediate cells or base cells described herein may be in a plane perpendicular to the longitudinal direction of the tipper bed.

The floor plate may comprise a plurality of rock breakers comprising elongate rails which are fixed to the floor bed.The rock breakers may be fixed to the upper surface of the floor bed. The rock breakers may extend in a longitudinal direction corresponding to the longitudinal direction of the tipper bed. The rock breakers may be triangular in cross section and/or substantially prismatic.

The plurality of rock breakers may be located on an upper surface of the floor plate, for supporting material to be carried in the tipper bed, at locations where the intermediate structure is fixed to a lower surface of the floor plate.

In other words, the rock breakers may be fixed to the floor plate in locations where there are two plates adjacent one another and fixed together. This will reduce the likelihood of the floor plate deforming on impact of rocks on the rock breakers. Therefore, the rocks are also more likely to break on the rock breakers.

The plurality of rock breakers may be located on the upper surface of the floor plate at interfaces between where the corrugated intermediate plate is fixed to the lower surface of the floor plate, and where the corrugated intermediate plate is displaced away from the lower surface of the floor plate.In other words, the rock breakers may be located on the upper surface of the floor plate proximate a bend or fold of the intermediate plate. This will further reduce the likelihood of the floor plate deforming on impact of rocks on the rock breakers.

The plurality of rock breakers may be located on the upper surface of the floor plate where the corrugated intermediate plate is not fixed to the floor plate. In other words, the plurality of rock breakers may be located on the upper surface of the floor plate where the corrugated intermediate plate is displaced away from the lower surface of the floor plate.

The tipper bed may comprise a wear plate attached to the floor plate and arranged where the intermediate structure is not fixed to the floor plate.

The intermediate cells and base cells together may form a honeycomb-like structure. The intermediate cells may have a smaller cross-sectional area than the base cells. The intermediate cells or the base cells may be filled with a foam core or other reinforcement and/or absorbent material.

The width of the runners may be at least 70mm.This may allow the tipper bed to be used with a variety of chassis’ having different widths. The width of the runners may be at least 30 mm. This will ensure that the runners are suitably strong and stiff to support the tipper bed on the chassis when in a resting configuration.

According to a second aspect, there is provided a tipper truck comprising a chassis and a tipper body comprising a tipper bed according to the first aspect above. The tipper body may be pivotable with respect to the chassis between one or more raised or tipping positions (i.e. for tipping out the contents of the tipper body) and a lowered or resting position in which the runners of the tipper bed are in contact with the chassis. The chassis may comprise chassis runners for contacting the runners of the tipper bed in the lowered position.

According to a third aspect, there is provided a method of manufacturing a tipper bed, the method comprising:providing a floor plate for supporting objects to be carried on the tipper bed;fixing to the floor plate an intermediate structure comprising at least one corrugated intermediate plate, thereby forming intermediate cells between the floor plate and the intermediate structure;fixing a corrugated base plate to the intermediate structure, thereby forming base cells between the intermediate structure and the base plate, wherein the base plate forms runners for laying the tipper bed on a chassis.

The intermediate structure may be slot welded to the floor plate and the base plate may be slot welded to the intermediate structure. Slot welding the plates together may increase the total length of welded material or weld bead between two plates, so that the plates are fixed to one another more securely. The method may be for manufacturing a tipper bed according to the first aspect.

The intermediate structure may be welded to the floor plate. The base plate may be welded to the intermediate structure.

The floor plate may comprise two modular floor units joined together. The modular floor units may be welded together.

The method may comprise providing a wear plate and fixing the wear plate to the floor plate at the join between the modular floor units.This may increase the stiffness of the floor plate at the join and reduce wear of the join between the modular floor units. A wear plate may be fixed to the floor plate at any location where the floor plate is likely to be less stiff such as locations where the intermediate structure is not fixed to the floor plate.

The corrugated intermediate plate may comprise two modular intermediate units which are joined together. The modular intermediate units may be welded together.

Except where mutually exclusive, it should be understood that features described in relation to the tipper bed of the first aspect may be applied in the method of the second aspect and vice-versa. By way of non-limiting example only, the tipper bed of the first aspect may be slot-welded, or the fixing of the intermediate structure and base plate in the method of the second aspect may form a honeycomb-like structure.

BRIEF DESCRIPTION
Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 schematically shows aside view of a tipper truck;

Figure 2 schematically shows a cross sectional view of the tipper truck with a first example tipper bed;

Figure 3 schematically shows a cross sectional view of a second example tipper bed; and

Figure 4 is a flow chart showing a method of manufacturing a tipper bed.

DETAILED DESCRIPTION
Figures 1 and 2 show a tipper truck 10 comprising a tractor 12 and a trailer 14.Figure 1 shows a side view of the tipper truck. The trailer 14comprises a chassis 16 extending from a front end at the tractor 12, in a longitudinal direction away from the tractor 12 to a rear end, and a tipper body 18 which is pivotably mounted to the chassis 16 about a transverse pivot axis 20 located at the rear of the chassis 16.The tipper body 18 is aligned with the chassis 16 at the rear end of the chassis 16, extends along the length of the chassis 16 towards the tractor 12, and terminates at a position on the chassis 16 offset from the tractor 12.

A pair of chassis runners 22 extend from the rear end of the chassis 16in the longitudinal direction towards the tractor 12, and terminate just beyond the edge of the tipper body 18.The tipper body 18 rests on the chassis runners 22 when in a resting or lowered configuration. In other examples, the tipper body 18 may rest directly on a flat surface of the chassis 16 or the chassis runners 22 may be mounted flush with the chassis 16 and not raised from the chassis 16 as shown in Figure 1.

A hydraulic cylinder 24 is disposed between,and fixed to, the chassis 16 and the tipper body 18 at a front end of the trailer 14, adjacent the tractor 12. The hydraulic cylinder 24 is configured to extend and retract so as to pivot the tipper body18 about the pivot axis 20.

The tipper body18can therefore be moved between the resting configuration and a tipping configuration. In the resting configuration, the hydraulic cylinder 24 is retracted, and the tipper body 18 rests on the chassis runners 22. In the tipping configuration, the hydraulic cylinder 24 is extended to pivot the tipper body 18 about the pivot axis20 so that the tipper body 18 is tilted at an angle to the chassis 16.

The tipper body 18 is configured to receive and carry material in the resting configuration, and to release the material off the rear end of the tipper bed 18 when in the tipping configuration.

Figure 2 shows a cross sectional view, in a longitudinal direction, of the tipper truck 10 with a first example tipper body 18 in the resting configuration.

The tipper body 18 comprises a tipper bed 30 and side walls 32. The tipper bed 30 extends in a longitudinal direction i.e. in a direction parallel to the longitudinal direction of the chassis 16. The tipper bed 30 comprises a floor plate 34 for receiving and supporting objects to be carried on the tipper bed on an upper surface of the floor plate 34.

The floor plate 34 comprises two modularplates, side-by-side, which extend in a longitudinal direction and are joined together along longitudinal edges of the plates alongthe centre of the floor plate 34. The floor plate 30 comprises a central portion 36 and a transition portion 38 on either side of the central portion 36. The central portion 36 is substantially planar and the transition portions 38 curve away from the central portion 36 in an upwards direction. The side walls 32 are each attached to respective transition portions 38 and are substantially perpendicular to the central portion 36 of the floor plate 34 (i.e. extend substantially vertically).

The tipper bed 30 further comprises an intermediate structure 40 which is fixed, for example by welding, to a lower surface of the floor plate 34 which is on an opposing side to the upper surface of the floor plate 34. In this example, the intermediate structure 40 comprises a corrugated intermediate plate 42 which is fixed to the lower surface of the floor plate 34. The intermediate plate 42 comprises two modular intermediate plates which are joined together in a similar manner to the floor plate 34 described above.The intermediate corrugated plate 42 comprises corrugations which extend in a longitudinal direction with respect to the tipper body 18.

Accordingly, as the intermediate plate 42 is fixed to the flat lower surface of the floor plate 34, intermediate cells 44 are formed between the corrugated intermediate plate 42 and the floor plate 34. In this example there are three intermediate cells 44 formed between the intermediate plate 42 and the floor plate 40. In other examples, there may be more or fewer corrugations formed laterally across the corrugated intermediate plate, and therefore more or fewer intermediate cells formed.

The tipper bed 30 further comprises a corrugated base plate 46 which is fixed, for example by welding, to the intermediate structure 40 and, in this example,directly to the intermediate plate 42. The corrugated base plate 46 also has corrugations which extend in the lateral direction with respect to the tipper body 18. Therefore, base cells 48 are formed between the intermediate structure 40and the base plate 46. In this example, two base cells 48 are formed between the intermediate structure 40 and the base plate 46, although more or fewer base cells 48 could be formed dependent upon the number of corrugations in the intermediate plate 42 and the base plate 46.

The intermediate cells 44 and base cells 48 define cavities which extend in the longitudinal direction of the tipper bed 30. The intermediate cells 44 and base cells 48 together form a honeycomb-like structure. The intermediate cells 44 have a smaller cross section than the base cells 48.

The base plate 46 comprises runner portionswhich are substantially planar and parallel to the floor plate 34. The runner portions are planar portions of the base plate 46 which are furthest away from the floor plate 34. The runner portions form runners 50 at the bottom of the tipper bed 34 which extend along the longitudinal length of the tipper bed 34.

The runners 50 are configured to rest on the chassis runners 22 of the chassis 16, so that the tipper bed 30 is supported on the chassis 16 when in the resting configuration. The runners 50 are substantially planar to contact uniformly along the planar upper surfaces of the chassis runners 22. The runner portions (runners 50) in this example are at least 70mm wide. This allows the tipper bed 30 to be used with a number of different chassis designs, having chassis runners 22which are spaced apart at different widths. In this example, there are two runners 50, although in other examples, other numbers of runners 50 may be provided by the base plate 46.

A plurality of elongate rock breakers 52 with triangular cross sections are provided on the upper surface of the floor plate 34. In this example, there are six rock breakers 52 provided on tipper bed 30. The rock breakers 52 are fixed to the floor plate 34 such that they extend in the longitudinal direction.

The rock breakers 52 are positioned on the floor plate 34 at locations where the intermediate structure 40 is fixed to the lower surface of the floor plate 34. More specifically, each of the rock breakers are located on the upper surface of the floor plate at interfaces between where the corrugated intermediate plate 42 is fixed to the lower surface of the floor plate 34, and where the corrugated intermediate plate 42 is displaced away from the lower surface of the floor plate 34 (i.e. proximate a fold or bend line of the intermediate plate 42 at an edge of an area of connection between the intermediate plate 42 and the floor plate 34). Locating the rock breakers 52 in these positions reduces the likelihoodof the floor plate deforming on impact of rocks on the rock breakers as ribs of the corrugation extending away from the floor plate will absorb some of the impact of rocks.

The tipper bed 30 comprises a wear plate 54 which is located at the join between the two plates of the floor plate 34. The wear plate 54 is fixed to the floor plate 34 on the upper surface of the floor plate 34 and protects the floor plate 34, and in particular the join in the floor plate 34, from wear.

In other examples, a wear plate may be alternatively or additionally placed on other areas of the floor plate 34, including areas on the upper surface of the floor plate where the intermediate structure is displaced away from the lower surface of the floor plate. This may reduce overall wear of the floor plate during use, and locally increase the stiffness of the floor plate.

Figure 3 shows another example of a tipper bed 130.In this example, the tipper bed 130 comprises a floor plate 134 corresponding to the floor plate 34 described with reference to Figure 2. The tipper bed 130 comprises an intermediate structure 140 which is fixed to the lower surface of the floor plate 134.

The intermediate structure 140 comprises a plurality of corrugated intermediate plates 142. In this example, the intermediate structure140 comprises three corrugated intermediate plates 142a, 142b, 142c. In other examples, the intermediate structure may comprise any number of intermediate plates, some of which may be planar, corrugated or shaped in any suitable profile. Each intermediate plate 142 comprises two modular intermediate plates joined together in a similar manner to the intermediate plate 42 described with reference to Figure 2.

One of the corrugated intermediate plates 142a (i.e. the uppermost intermediate plate) is fixed to the lower surface of the floor plate 134 so that intermediate cells 144a are formed between the intermediate plate 142a and the floor plate 134. A further corrugated intermediate plate 142b is fixed to the intermediate plate 142a to form secondary intermediate cells 144b therebetween. A yet further corrugated intermediate plate 142c is fixed to the intermediate plate 142b to form tertiary intermediate cells 144c therebetween.

Accordingly, the corrugated intermediate plates 142a, 142b, 142c together form a honeycomb-like structure comprising intermediate cells 144 formed between each of the intermediate plates 142. In this example, there are a total of 12 intermediate cells 144 formed. However, in other examples, there may be any suitable number of corrugated intermediate plates 142 and therefore and suitable number of intermediate cells 144, or number of layers of intermediate cells 144.

The tipper bed 130 comprises a corrugated base plate 146 which is fixed to the intermediate structure 140 so that base cells 148 are formed between the intermediate structure 140 and the base plate 146.
The base plate 146 comprises runner portions which are substantially planar and parallel to the floor plate134. The runner portions are planar portions of the base plate 146 which are furthest away from the floor plate134. The runner portions form runners150 at the bottom of the tipper bed 134 which are the same as the runners 50 described with reference to Figure 2.Two runners 150 are provided in this example, but another number of runners may be provided by suitable design of the base plate 146 and the intermediate structure 140.

The intermediate cells 144 and base cells 148 are each filled with a foam core156in this example. This may increase the stiffness of the tipper bed 130 whilst minimising an increase in the weight of the tipper bed 130. In other examples having intermediate structures 140 of this type, no foam cores may be provided.

In this example, rock breakers 152a, 152b, corresponding to the rock breakers 52 described above, are fixed to the upper surface of the floor plate 134 at two types of locations; some rock breakers 152a are located where the intermediate structure 140 is fixed to the lower surface of the floor plate 134, and some rock breakers 152b are located where the corrugated intermediate plate 142 is displaced away from the lower surface of the floor plate 134. In this example, there are six rock breakers 152 in total. However, in other examples, there may be any number of rock breakers.

Locating the rock breakers 152 where the intermediate structure 140 is fixed to the floor plate 134 reduces the likelihood of the floor plate deforming on impact of rocks compared to locating them where the intermediatestructure 140 is displaced away from the floor plate 134. However, the foam core also reduces the likelihood of the floor plate 134 deforming on impact of rocks on the rock breakers 152, so that it is possible to locate the rock breakers 152 in locations where the intermediate structure 140 is displaced away from the floor plate 134 whilst still reducing the likelihood of the floor plate 134 deforming.
The tipper bed 130 comprises a wear plate 154 which is located at the join between the two plates of the floor plate 134 in the same manner as the wear plate 54 described with reference to Figure 2.

Figure 4 is a flow chart which shows the steps of themethod of manufacturing a tipper bed as described with reference to Figures 1-3. In block 202, a floor plate is provided which is substantially planar. In this example, the floor plate begins in two modular parts which are welded together in the centre of the floor plate, but it should be understood the floor plate may be provided as a single continuous plate.The floor plate, as described above, is for supporting objects to be carried on the tipper bed.

In block 204, a wear plate is fixed to the floor plate on an upper surface of the floor plate at the join between the two parts of the floor plate. The wear plate provides increased resistance to wear at the join, in particular from impacting objects on the floor plate. In other examples, a wear plate may not be provided.

In block 206, an intermediate structure is provided which in this example comprises acorrugated intermediate plate. The corrugated intermediate plate comprises twomodular parts in this example which are joined together along a centre line of the corrugated intermediate plate by welding.In other examples, the intermediate structure may comprise more than one corrugated intermediate plate, which are welded together to form a honeycomb-like structure. In yet further examples, the intermediate structure may comprise a plurality of intermediate plates, some of which are corrugated and others of which are planar.

In block 208, the intermediate structure, in this case the corrugated intermediate plate, is fixed to a lower surface of the floor plate(i.e. on an opposing side of the floor plate to the wear plate). In this example, the intermediate structure is fixed to the floor plate by welding. More specifically, the corrugated intermediate plate is slot welded to the floor plate. Fixing the corrugated intermediate plate (i.e. intermediate structure) to the floor plate forms intermediate cells between the intermediate structure and the floorplate.

In block 210, a corrugated base plate is fixed to the intermediate structure on an opposing side of the intermediate structure to the floor plate by welding. The faces of the corrugated base plate which meet the intermediate structure are slot welded to the structure, forming base cells between the intermediate structure and the base plate. The base plate also forms runners at the furthest point away from the floor plate, for laying the tipper bed on a chassis.

Although it has been described that the central portion of the floor plate is substantially planar, the floor plate may have any profile which allows it to receive material. Further, although it has been described that the floor plate comprises two modular plates which are joined together, in other examples, the floor plate may be made from a single plate, or it may be made from a plurality of plates joined together. In yet further examples, the floor plate may comprise two or more plates joined together which are not modular.

Although the intermediate plates have been described as having two modular plates which are joined together, in other examples the intermediate plates may comprise a single plate, or a plurality of modular plates joined together. In yet other examples, the intermediate plates may comprise two or more plates joined together which are not modular.

Although it has been described that the runners are at least 70mm wide, the runner widths may be at least 30mm wide to provide a suitably strong runner which can support the tipper bed when resting on the chassis in the resting configuration.

Features of each example tipper bed described herein may be combined with the features of any other example tipper bed described herein, except to the extent where such features are mutually exclusive.