Abstract:
A lightweight modular construction for use as a slide-out structure in a recreational vehicle is provided. The slide-out structure comprises a floor, a structural wall, and a roof. The floor, the roof, and the wall structure may include a plurality of reinforced foam panels, connected together in a modular fashion. A first and a second elongated bracket interconnect the floor and the structural wall by an interlocking dovetail connection. A header bracket interconnects the structural wall and the roof.

Description:
CROSS REFERENCE TO RELATED APPLICATION  
       [0001]     This application claims the benefit of application Ser. No. 60/723,535 filed Oct. 4, 2005, the advantages and disclosure of which are hereby incorporated by reference. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     The subject invention relates to a vehicle including a slide-out structure, and more specifically to the construction of the slide-out structure.  
         [0004]     2. Description of the Prior Art  
         [0005]     Recreational vehicles, such as camper trailers, motor homes, etc., are sometimes provided with slide-out structures. The slide-out structure is moveable outwardly from the vehicle by a servo motor to provide additional space when the vehicle is stationary and in use; and retractable into the recreational vehicle during transportation of the recreational vehicle.  
         [0006]     The slide-out structure includes a floor, three walls, and a roof. The construction of the slide-out structure is similar to that of a traditionally framed house, in which the walls are first roughed in using dimensional lumber and then mounted to the floor. The roof is mounted over joists in a traditional fashion. Siding is affixed to the exterior of the walls and an interior wall covering is placed over the inside of the walls. Such a construction technique is very labor intensive and therefore costly.  
         [0007]     A modular construction technique is disclosed in U.S. Pat. No. 6,745,470 which describes a semi-trailer having walls constructed from modular panels. The panels forming the walls include an outer covering, a polymeric core, and an inner covering. The panels are connected together through a tongue and groove configuration disposed along the sides of the panels. The trailer includes a floor and a roof, each preferably manufactured from a metal material, and each defining a channel for supporting the walls therein with the walls sandwiched between the floor and the roof.  
       SUMMARY OF THE INVENTION AND ADVANTAGES  
       [0008]     The subject invention provides a vehicle comprising a body, which defines an opening. A slide-out structure is disposed within the opening and is moveable laterally relative to the body. The slide-out structure includes a floor and a structural wall extending from the floor. The structural wall includes a sill plate, a top plate, and a plurality of studs extending between the sill plate and the top plate. A first elongated bracket is mounted to one of the floor and the structural wall and defines a female channel. A second elongated bracket is mounted to one of the floor and the structural wall and defines a male projection. The male projection is complimentary in configuration to the female channel and is disposed within the female channel in interlocking engagement with the female channel for connecting the floor and the structural wall.  
         [0009]     Accordingly, the subject invention provides a modular construction technique. The panels are quickly connected to the floor by an interlocking dovetail connection between the female channel and the male projection of the first and second elongated brackets respectively. Therefore, the modular construction technique provided by the subject invention reduces the time to assemble the slide-out structure, thereby lowering the cost of producing the slide-out structure. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]     Other advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:  
         [0011]      FIG. 1  is a perspective view of a vehicle having a slide-out structure;  
         [0012]      FIG. 2  is an end view of a panel;  
         [0013]      FIG. 3  is an exploded perspective view of a plurality of wall panels aligned in a straight wall segment;  
         [0014]      FIG. 4  is side view of the wall panel;  
         [0015]      FIG. 5  is a fragmentary perspective view of a first elongated bracket and a second elongated bracket interconnecting a floor and a structural wall of the structure;  
         [0016]      FIG. 6  is a fragmentary perspective view showing a plurality of adjoining flooring panels of the floor interconnected by a flooring connector;  
         [0017]      FIG. 7  is a perspective view of one of the flooring panels of the floor;  
         [0018]      FIG. 8  is a fragmentary perspective view of the flooring connector;  
         [0019]      FIG. 9  is a perspective view of the roof showing a plurality of roofing panels interconnected together;  
         [0020]      FIG. 10  is a perspective view of one of the roofing panels of the roof;  
         [0021]      FIG. 11  is a fragmentary perspective view of a first U-shaped roofing connector for connecting adjoining roofing panels;  
         [0022]      FIG. 12  is a fragmentary perspective view of the first U-shaped roofing connector engaged with adjoining roofing panels and a roof bracket;  
         [0023]      FIG. 13  is a fragmentary end view of a second I-shaped roofing connector engaged with adjoining roofing panels;  
         [0024]      FIG. 14  is a fragmentary perspective view of the second I-shaped roofing connector for connecting adjoining roofing panels;  
         [0025]      FIG. 15  is a perspective view of the support bracket;  
         [0026]      FIG. 16  is a fragmentary perspective view of the U-shaped roofing connector and the I-shaped roofing connector interconnecting adjoining roofing panels and a support bracket connecting the U-shaped roofing connector and the I-shaped roofing connector;  
         [0027]      FIG. 17  is an end view of the first elongated bracket;  
         [0028]      FIG. 18  is an end view of the second elongated bracket;  
         [0029]      FIG. 19  is a fragmentary perspective view of the first elongated bracket and the second elongated bracket in interlocking engagement;  
         [0030]      FIG. 20  is a fragmentary perspective view of the first elongated bracket and the second elongated bracket in interlocking engagement viewed from an opposing direction relative to  FIG. 19 ;  
         [0031]      FIG. 21  is a fragmentary perspective view of the roof bracket;  
         [0032]      FIG. 22  is a fragmentary perspective view of the roof bracket interconnecting the roof and the structural wall;  
         [0033]      FIG. 23  is a fragmentary perspective view of a support for disposition within the floor;  
         [0034]      FIG. 24  is an alternative embodiment of the structure;  
         [0035]      FIG. 25  is a fragmentary perspective view of an upper portion of the structural wall of the alternative embodiment of the structure;  
         [0036]      FIG. 26  is another fragmentary perspective view of a lower portion of the structural wall of the alternative embodiment of the structure; and  
         [0037]      FIG. 27  is an exploded fragmentary perspective view of the roof and the structural wall of the alternative embodiment of the structure. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0038]     Referring to the Figures, wherein like numerals indicate corresponding parts throughout the several views, a vehicle is shown generally at  20  in  FIG. 1 . The vehicle  20  includes a body  22 , which defines an opening  24 . A slide-out structure, shown generally at  26 , is disposed within the opening  24  and is moveable laterally relative to the body  22  of the vehicle  20 . While the subject invention is primarily discussed herein related to the slide-out structure  26  disposed within the vehicle  20 , it should be understood that the subject invention disclosed herein may also be practiced with other small structures  26  not integrated into the vehicle  20 , such as a storage shed.  
         [0039]     The slide-out structure  26  includes a floor  28  and a structural wall  30  extending from the floor  28 . The structural wall  30  may include several different wall segments arranged to form the outer periphery of the slide-out structure  26 . Typically, the structural wall  30  includes three wall segments; two wall segments parallel each other with one wall segment extending therebetween, with the slide-out structure  26  being open to an interior of the vehicle  20  as is well known in the art.  
         [0040]     Referring to  FIG. 2 , the structural wall  30  may include a covering layer  32  bonded or mechanically affixed to the structural wall  30 . The covering layer  32  may include an exterior siding material, such as aluminum or vinyl if disposed on an exterior of the slide-out structure  26  or may include an interior siding material, such as a plastic or gypsum board if disposed on an interior of the slide-out structure  26 . It should be understood that the covering layer  32 , whether for the interior or exterior of the slide-out structure  26 , may include other materials not specifically mentioned herein.  
         [0041]     Referring to  FIG. 3 , each wall segment of the structural wall  30  may include a plurality of panels  38  positioned adjacent each other along a plane, i.e., forming a straight wall segment. Referring also to  FIG. 4 , each of the plurality of panels  38  includes a first side edge  40  and a second side edge  42  defining a slot  44  that extends upward along a height of each of the panels  38 . If the wall segment includes more than one panel  38 , a spline  46  is partially disposed within each of the slots  44  of the adjacent panels  38  to interconnect the adjacent panels  38  of the structural wall  30 . Accordingly, each spline  46  is partially disposed within the slot  44  of the first side edge  40  of one panel  38  and partially disposed within the slot  44  of the second side edge  42  of an adjacent panel  38 , thereby connecting the panels  38  and restraining the panels  38  from lateral movement relative to each other. As shown in  FIG. 1 , the parallel side wall segments of the slide-out structure includes a single panel  38  and the back wall segment includes multiple panels  38  with a window cutout therein.  
         [0042]     Each panel  38  of the structural wall  30  includes a sill plate  48 , a top plate  50 , and a plurality of studs  52  extending between the sill plate  48  and the top plate  50 . The sill plate  48 , the top plate  50 , and the studs  52  are preferably manufactured from lumber, and more preferably from dimensional lumber having dimensions of two inches (2″) in by two inches (2″). However, it should be understood that the sill plate  48 , the top plate  50 , and the studs  52  may be manufactured from dimensional lumber having dimensions other than described herein, and may comprise materials other than lumber, such as a plastic or metal material. The structural wall  30  further includes a foam core  54  disposed about the sill plate  48 , the top plate  50 , and the plurality of studs  52 . Preferably, the foam core  54  at least partially encapsulates, the sill plate  48 , the top plate  50  and the plurality of studs  52 . This may be accomplished, for example, by placing the sill plate  48 , the top plate  50 , and the studs  52  in a mold and injecting the foam therein to encapsulate the panel  38 , thereby forming a lightweight reinforced foam panel  38 . Alternatively, the foam core  54  may comprise sheets cut to fit and placed between the sill plate  48 , the top plate  50 , and the studs  52 , and sandwiched between the interior covering layer  32  and the exterior covering layer  32 . It should be understood that the foam core  54  is optional and may therefore be eliminated from the panel  38  if desired.  
         [0043]     Referring to  FIGS. 5 and 6 , the floor  28  comprises a foam center  64  and may include a support  66  encapsulated within the foam center  64 , as shown in  FIG. 6 . Referring to  FIG. 23 , the support  66  has a Z shaped cross section, and provides additional bending strength to the floor  28 . It should be understood that the support  66  may include some other cross sectional shape such as a square tube, a round tube, an I beam, a C channel, or some other shape and still fall within the scope of the claims. The support  66  comprises a rigid material, such as a hard plastic or a metal. However, it should be understood that some other material may be utilized for the support  66  that is capable of providing the necessary additional bending and shear strength to the floor  28 . Referring back to  FIGS. 5 and 6 , an upper support sheet  56  and a lower support sheet  58  sandwich the foam center  64  therebetween. The upper support sheet  56  and the lower support sheet  58  preferably include a fiberglass material, but may also include some other rigid material, such as an oriented strand board or a plywood, capable of providing shear and bending strength to the foam center  64  and protect the foam center  64  of the floor  28  from damage.  
         [0044]     As best shown in  FIG. 6 , the floor  28  may include a plurality of flooring sheets  60  aligned adjacent each other in a generally horizontal plane. Referring also to  FIGS. 7 through 8 , each of the flooring sheets  60  includes a first lateral edge  68  and a second lateral edge  70 , with a flooring connector  72  interconnecting the first lateral edge  68  and the second lateral edge  70  of the adjacent flooring sheets  60 . Preferably, one of the first lateral edge  68  and the second lateral edge  70  includes a lateral notch  74  and the other of the first lateral edge  68  and the second lateral edge  70  includes a lateral ridge  76  having a shape complimentary to the lateral notch  74 . The lateral notch  74  and the lateral ridge  76  of the adjacent flooring sheets  60  are in interlocking engagement to secure the adjacent flooring sheets  60  together and restrain the adjacent flooring sheets  60  from vertical movement relative to each other. As shown in  FIG. 6 , the flooring connector  72  includes a shape complimentary to the lateral notch  74  and the lateral edge and disposed therebetween to increase the rigidity of the connection between adjacent flooring sheets  60 . It should be understood that the shape of the lateral notch  74 , the shape of the lateral ridge  76 , and the shape of the flooring connector  72  may differ from that described herein and still fall within the scope of the claims.  
         [0045]     Referring back to  FIG. 5 , the slide-out structure  26  further comprises a mounting plate  78  attached to the floor  28 . An extension mechanism  80 , shown schematically in  FIG. 1 , is coupled to the mounting plate  78  for moving the slide-out structure  26  laterally relative to the body  22 . The mounting plate  78  may include a rigid material, such as a metal material or a wood material, capable of transmitting forces between the extension mechanism  80  and the slide-out structure  26 . There are many different extension mechanisms  80  known in the art capable of extending and retracting the slide-out structure  26  from the body  22  that may be incorporated into the vehicle  20 . Accordingly, the extension mechanism  80  is not described in detail herein. It should be understood that when the subject invention is practiced as a stand-along structure  26 , not in relation to the vehicle  20 , then the mounting plate  78  and the extension mechanism  80  are not included in the structure  26 .  
         [0046]     Referring to  FIG. 9 , the slide-out structure  26  further includes a roof  82  in spaced relationship relative to the floor  28 . The roof  82  comprises a foam, and may include a plurality of roofing sheets  62  aligned adjacent each other, with at least one roofing connector  84  interconnecting the roofing sheets  62 . Also referring to  FIG. 10 , the roofing sheets  62  each include a plurality of ribs  86  in spaced relationship extending across a width of each of the roofing sheets  62 . As best shown in  FIG. 10 , each roofing sheet  62  includes three ribs  86 , one rib  86   a  at each end of the roofing sheet  62  and one rib  86   b  located at the approximate med-section of the roofing sheet  62 . The ribs  86   a  located at each end of the roofing sheet  62  includes a thickness approximately half that of a thickness of the rib  86   b  located at the center of the roofing sheet  62  so that two outer ribs  86   a  of adjacent roofing sheets  62 , when positioned side by side, have an approximate thickness equal to the center rib  86   b.  It should be understood that the roofing panels  38  may include any number of ribs  86  and the scope of the claims is not limited by the exact configuration of the ribs  86  described herein.  
         [0047]     Referring to  FIGS. 11 and 12 , with reference to  FIG. 9 , the roofing connector  84  includes a first roofing connector  88  having a U-shaped cross section. The U-shaped roofing connector  88  is seated on a ledge  90  presented by the a roof bracket  91 , described in detail below. The U-shaped roofing connector  88  supports at least one rib  86  of the roofing sheets  62  therein. Accordingly, the U-shaped roofing connector  88  may support a single rib, e.g., the center rib  86   b,  or the U-shaped roofing connector  88  may support a pair of ribs, e.g., two adjacent outer ribs  86   a  on adjoining roofing sheets  62 .  
         [0048]     Referring to  FIGS. 10 and 13 , the roofing sheets  62  include a thickened edge  92 , with an alignment slot  94  extending through each rib  86  at the thickened edge  92 . The thickened edge  92  is opposite a narrow edge  96 , which is positioned near the outer wall of the roof bracket  91 . Accordingly, two roofing sheets  62  may be positioned “back to back”, with the thickened edge  92  of one roofing sheet  62  abutting the thickened edge  92  of the other roofing sheet  62 , to form a roof  82  that includes a crowned cross section defining a ridge running the length of the roof  82 . As shown in  FIG. 13  and  14 , the roofing connector  84  further includes a second roofing connector  98  having an I-shaped cross section. A portion of the I-shaped roofing connector  98  is disposed within the alignment slot  94  and interconnects the adjoining roofing sheets  62 . In other words, a lower flange of the I-shaped roofing connector  98  is disposed in the alignment slots  94  of the adjacent roofing sheets  62 , and an upper flange of the I-shaped roofing connector  98  extends over a top surface of the roofing sheets  62 , thereby connecting the adjoining roofing sheets  62  together.  
         [0049]     Referring to  FIGS. 15 and 16 , a spacer bracket  100  is disposed between and connects the first U-shaped roofing connector  88  and the second I-shaped roofing connector  98  at each of the ribs  86  of the roofing sheet  62  to reinforce the roof  82  system. The spacer bracket  100  may be attached to the U-shaped roofing connector  88  and the I-shaped roofing connector  98  by any suitable method appropriate for the materials utilized in the U-shaped roofing connector  88  and the I-shaped roofing connector  98 . Suitable methods of attaching the spacer bracket  100  to the U-shaped roofing connector and the I-shaped roofing connector may include a plurality of threaded fasteners, an adhesive, welding, or some other method known in the art. The roofing connector  88 , the second I-shaped roofing connector  98 , and the spacer bracket  100 , may comprise a hard plastic material, a metal material, or some other rigid material suitable for supporting the plurality of roofing sheets  62 .  
         [0050]     Referring to  FIGS. 5 and 17 , a first elongated bracket  102  is mounted to one of the floor  28  and the structural wall  30  for connecting the floor  28  to the structural wall  30 . As shown in the Figures, the first elongated bracket  102  is mounted to the floor  28 . The first elongated bracket  102  defines a female channel  104 . Referring to  FIGS. 2, 3 ,  4  and  18 , a second elongated bracket  106  is mounted to the other of the floor  28  and the structural wall  30 , and defines a male projection  108  complimentary in configuration to the female channel  104 . As shown in the Figures, the second elongated bracket  106  is mounted to the structural wall  30 . As best shown in  FIGS. 19 and 20 , the male projection  108  is disposed within the female channel  104  in interlocking engagement with the female channel  104 , and securely connects the floor  28  and the structural wall  30 . The first elongated bracket  102  and the second elongated bracket  106  extend the length of the structural wall  30 , i.e., each wall segment will have a corresponding length of the first and second elongated brackets  102 ,  106  to interconnect each wall segment to the floor  28  along the entire length of the wall segment. It should be understood that the second elongated bracket  106  may be integrally formed with the sill plate  48 . It should also be understood that if the second elongated bracket  106  is not integral formed with the sill bracket  48 , then either the first elongated bracket  102  or the second elongated bracket  106  may be attached to the structural wall  30 , with the other of the first elongated bracket  102  and the second elongated bracket  106  attached to the floor  28 .  
         [0051]     At least one of the female channel  104  and the male projection  108  define a plurality of grooves  110  extending along a length of the first elongated bracket  102  and the second elongated bracket  106 . It is also contemplated that both the female channel  104  and the male projection  108  include the plurality of grooves  110 . The plurality of grooves  110  permit a sufficient quantity of an adhesive to be disposed along the entire length of the connection interconnecting the first elongated bracket  102  and the second elongated bracket  106  to adequately bond the male projection  108  to the female channel  104 .  
         [0052]     Referring to  FIGS. 17, 19 , and  20 , the first elongated bracket  102  defines a floor support channel  112  for supporting an outer edge of the floor  28  thereon. Preferably, the foam center  64  of the floor  28  is molded into the floor support channel  112  of the first elongated bracket  102  to mount the first elongated bracket  102  to the floor  28 . This may be accomplished, for example, by placing the first elongated bracket  102 , the upper support sheet  56  and the lower support sheets  58  into a mold, and injecting the foam therebetween to form the foam center  64  of the floor  28  about the floor support channel  112  of the first elongated bracket  102  and between the upper and lower support sheets  56 ,  58 .  
         [0053]     Referring to  FIGS. 18 through 20 , the second elongated bracket  106  of each wall segment includes a bottom member  114 , an inner vertical member  116  and an outer vertical member  118 . The inner vertical member  116  and the outer vertical member  118  extend from the bottom member  114 , and define a U-shaped channel between the bottom member  114 , the inner vertical member  116 , and the outer vertical member  118 . The U-shaped channel receives the sill plate  48  and a portion of the plurality of studs  52  therein so that the inner vertical member  116  and the outer vertical member  118  may be attached to the studs  52  to secure the second elongated bracket  106  to the studs  52 .  
         [0054]     Referring to  FIG. 21 , the roof bracket  91  of each wall segment includes a roof support wall  120 , an inner vertical wall  122  and an outer vertical wall  124 . The inner vertical wall  122  and the outer vertical wall  124  extend from the roof support wall  120 , and define a U-shaped channel between the roof support wall  120 , the inner vertical wall  122 , and the outer vertical wall  124 . The U-shaped channel receives the top plate  50  and a portion of the plurality of studs  52  therein so that the inner vertical wall  122  and the outer vertical wall  124  may be attached to the studs  52  to secure the roof bracket  91  to the studs  52 .  
         [0055]     As shown in  FIGS. 21 and 22 , the roof bracket  91  includes an outer wall  126  extending from the roof support wall  120  to a distal retention end  128  spaced from the roof support wall  120 . The retention end  128  is in interlocking engagement with the roof  82  to secure the roof  82  and the roof bracket  91  together in interlocking engagement. As shown, the retention end  128  includes a curvilinear shape to hook over the top surface of the roof  82  to restrain the roof  82  both laterally and vertically relative to the structural wall  30 . It should be understood that the retention end  128  may be configured other than described herein and still fall with in the scope of the claims.  
         [0056]     The roof bracket  91 , the first elongated bracket  102 , and the second elongated bracket  106  preferably comprise a rigid material such as a hard plastic material, a metal material. The metal material is preferably aluminum, but may comprise some other suitable metal such as steel. It should be appreciated that the roof bracket  91 , the first elongated bracket  102 , and the second elongated bracket  106  may all comprise the same material, or may all comprise different materials i.e., the roof bracket  91 , the first elongated bracket  102 , and the second elongated bracket  106  may all be manufactured from the same material or from different materials.  
         [0057]     An alternative embodiment of the slide-out structure  26  is shown in  FIGS. 24 through 27 . As depicted in the alternative embodiment, the structural wall  30  includes a rectangular portion  130  and an angled portion  132  disposed between the rectangular portion  130  and the roof  82 . The angled portion  132  of the structural wall  30  supports the roof  82  in a non-parallel relationship relative to the floor  28 , i.e., the angled portion  132  provides a slope to the roof  82  relative to the floor  28 .  
         [0058]     As is shown in the alternative embodiment, the top plate  50  includes a tongue  134 , with the roof  82  defining an interlocking groove  136  having a shape complimentary to the tongue  134 . The tongue  134  is disposed within the interlocking groove  136  for connecting the structural wall  30  and the roof  82 . The roof  82  is bonded to the header bracket  50  by an adhesive disposed within the tongue  134  and groove  110  connection, or by some other mechanical connection, such as by screws, bolts, etc.  
         [0059]     The foregoing invention has been described in accordance with the relevant legal standards; thus, the description is exemplary rather than limiting in nature. Variations and modifications to the disclosed embodiments may become apparent to those skilled in the art and do come within the scope of the invention. Accordingly, the scope of legal protection afforded this invention can only be determined by studying the following claims.