Abstract:
This invention comprises a complete deck assembly for a recreational vehicle. The deck platform can be deployed and stowed quickly and easily with the push of a button. When stowed the deck is secured into a position allowing for safe travel. When deployed the deck moves in outward and downward directions until it reaches suitable height and then continues outward until fully extended. When deployed, the flat and stable deck platform, resides at one step above ground level. Adjustable supports allow the deck platform to be easily leveled on uneven terrain. The deck&#39;s 12-volt motor receiving power from the vehicles standard electrical system allows use without land-based power. Manual operation is also possible in the event of power failure.

Description:
BACKGROUND OF INVENTION  
       [0001]     RVing and camping has been a form of recreation chosen by many for many years. In recent years the numbers choosing this form of recreation have increased dramatically as have the choices of vehicles and products associated with this form of recreation. Inventors have come to aid with many new products making the experience more pleasurable. One of the obstacles, to a pleasurable experience, has been and continues to be, the ground condition in the area of the entrance of the vehicle. The tracking of dirt, mud and sand is of constant concern. Also when relaxing outside of the vehicle, at ground level, one is exposed to low lying insects, reptiles, and poisonous vegetation. Ground covers have been extensively used, but fail to fully meet the needs. Also these tend to be quite a messy chore to pick up and stow for travel. The ground covers also destroy the vegetation and their use has been banned or severely limited in many campgrounds and resorts. The obvious solution would be a deck similar to the decks found adjacent to many homes. The deck would need to have all of the benefits of a permanent deck, and yet must be easily transferred between a usable position and a position that would allow for travel. There are numerous requirements that a travel deck would need to meet. To list just a few of those that this invention does meet:  
         [0002]     The deck should be of a complete assembly that can be easily installed on a variety of vehicles without additional custom components. The deck platform when in use position, should be of sufficient height to remain free of aforesaid ground problems, yet low enough for access from any of three sides. Also the platform should be at such height that steps or railings are not required for safety and that adequate headroom is available for awning use. When stowed, the deck assembly must be of sufficient height to permit safe travel. Thus a deck would need to combine downward and outward movements when being deployed and combine inward and upward movements when being stowed. The deck platform should extend far enough to fully compliment the standard extended awning. The deck should have integrated, easily adjustable supports for leveling and stabilizing the platform.  
       DESCRIPTION OF THE PRIOR ART  
       [0003]     Prior art has previously provided extendable decks for recreational vehicles. However the previous art does not incorporate the features of this new invention. More specifically the nearest related art in U.S. Pat. Nos. 6,869,092, 5,997,073, 4,883,306, 4,869,030, have platforms with horizontal movement, but they do not include vertical movement to optimize the deployed and stowed heights. Another somewhat related prior art, U.S. Pat. No. 5,193,878, has a form of vertical movement, in that it deploys some sort of folded element to the ground. It is not believed that this would be considered a flat, level, stabilized platform such as a deck, but would be more related to aforesaid ground cover. Also it is not believed that this art could be combined with any other to provide the actions of this new invention. Furthermore it is not believed that any prior art has provided adjustable mounting brackets, required for use on differing frame configurations, spans and heights as this new invention has. Prior art has provided for combined movement in other applications. U.S. Patent Application Publication No. 0,151,340 is a retractable step with downward and outward movements. Though the combined movements are present it is not believed that this art could be combined with any other to provide the continuing outward movement needed for the extension of a deck platform.  
       SUMMARY  
       [0004]     This invention provides a complete deck assembly for installation on many recreational vehicles. Combining an unique, drive mechanism, deployment system, adjustable mounting brackets, and a platform with integrated adjustable supports, this deck assembly provides the owner with a deck that has all of the benefits of a land based deck and also has the many additional benefits and requirements of a deck that can be easily stowed for travel.  
         [0000]     The Objects of this Invention are to Provide a Complete Deck Assembly that:  
         [0005]     Can be easily installed on a variety of recreational vehicles without the need of additional custom fabricated components and also can be easily adapted for OEM installation.  
         [0006]     Will combine vertical and horizontal movements to achieve optimum height, at use position, as well as when stowed for travel.  
         [0007]     Provides a stable deck platform that, when in use position, resides at a height that protects growth, allows leveling on uneven ground, is easily accessible from three sides yet keeps one above ground problems.  
         [0008]     Provides a deck platform, when in use position, residing at a height that does not require steps, does not require railings for safety, and does allow adequate headroom when awning is in use.  
         [0009]     Extends far enough to fully compliment standard eight-foot awning extension.  
         [0010]     Is simple and easy to operate and requires minimal operator effort.  
         [0011]     Includes integral supports providing an easy method of leveling and stabilizing the deck platform.  
         [0012]     Has a single drive unit, powered by the recreational vehicles existing 12 volt power supply.  
         [0013]     When in stowed position, resides securely at a safe height for travel.  
         [0014]     When stowed, is self securing, not requiring additional operator effort, fasteners or hardware.  
         [0015]     Has a total weight that does not overly infringe on vehicle manufacturer&#39;s limit. 
     
    
     BRIEF DESCRIPTION OF DRAWINGS  
       [0016]      FIG. 1  is a photo of the deck assembly mounted to a fifth wheel and residing in the deployed position  
         [0017]      FIG. 2  is a perspective drawing of the deck assembly in a fully retracted position  
         [0018]      FIG. 3  is a perspective drawing of the right frontal bracket  
         [0019]      FIG. 4  is a perspective drawing of the right rearward bracket  
         [0020]      FIG. 5  is a perspective view of the left deployment arm assembly  
         [0021]      FIG. 6  is a perspective view of the carriage assembly  
         [0022]      FIG. 7  is a perspective view of the platform assembly  
         [0023]      FIG. 8  is a perspective view of the bottom of the platform frame  
         [0024]      FIG. 9  is perspective view of the ramp assembly  
         [0025]      FIG. 10  is a perspective view of the deck assembly in a semi-deployed position  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0026]     Referring to  FIG. 1 . This is a photo showing the deck assembly fully deployed while installed on a fifth wheel. This is an actual pre-production,  10 ′ wide, deck assembly and is actually fully operable on the fifth wheel and has been and is being used as a testing and demonstration unit. It has traveled to, from and about Michigan to Florida and all states between. An eight-foot, prototype, installed on a travel trailer (not shown) has traveled throughout Michigan and Indiana. As can be seen in  FIG. 1 , the carriage assembly and the platform are at a short distance above ground. When retracted both will reside at a height above the lowest point of brackets  54  &amp;  55   FIG. 2 .  
         [0027]     The deck assembly is comprised of:  
         [0028]     Left &amp; right, frontal bracket assemblies  FIG. 3 , opposing in nature.  
         [0029]     Left &amp; right, rearward bracket assemblies  FIG. 4 , opposing in nature.  
         [0030]     Deployment arm assemblies  FIG. 5 , again opposing in nature.  
         [0031]     A carriage assembly  FIG. 6 .  
         [0032]     And a platform assembly  FIG. 7 .  
         [0033]     Rear channel covers  9  &amp;  10 ,  FIG. 2 , are of formed aluminum and are added at final assembly. Cover  9  is attached with a hinge and latch, allowing storage access to unused portion of channel  31   FIG. 6 . Cover  10   FIG. 2 , is attached with screws and covers drive mechanism and electrical components. Electrical components are not shown, but are of a standard nature and are installed at final assembly. They include wiring, limiting type switches, push button or rocker switch, and necessary relays or similar type components.  
         [0034]     The construction of the bracket assemblies  54  &amp;  55 ,  FIG. 2 , detailed in  FIGS. 3 &amp; 4 , is preferred to be of steel, though an OEM model, where as adjustment is not necessary, this could be of lighter material. The I-beams  1 ,  FIGS. 3 &amp; 4 , are simulations of some vehicle frames. In the event of the vehicle frame being of tubular or channel shape, the angles  2 ,  FIG. 3  &amp;  FIG. 4 , would be replaced by flat steel with holes for attachment through the frame member.  
         [0035]     The brackets have similar construction, and use interchangeable parts with the exception of tube  6   FIG. 3  and tubes  11  &amp;  12 ,  FIG. 4 . On both, the angles  2 , are cut out to slide over tube  3 . One of the angles, on each tube, is welded into place, while the other slides freely to allow for varying I-beam widths. Spacers are added at a length allowing for the proper clamping pressure. Tubes  3  adjustably slide over tubes  4 . Tubes  4  are welded to tubes  5 . Tubes  6 , adjustably slide into tubes  5 . In  FIG. 4 , tubes  11  slide into tubes  5  and tubes  11  are welded to tubes  12 . Round tubes are welded into tubes  6  &amp;  12 . In  FIG. 3 , plates  8  are slid over tubes  7  and welded. Plates  8  have a hole for pivotal attachment of gas springs.  
         [0036]     Referring to  FIG. 5 , which is the deployment arm assembly, shown attached to a carriage side and having bracket assemblies  54  &amp;  55  attached. Steel has been used, though aluminum could be a good substitute, some of the reinforced plastics could also being considered. Rectangular tubing is used for members  14 ,  15  and  16 , while square tube is used for  17 .  
         [0037]     Shafts  21  are welded into tubes  15  &amp;  16 . Shafts  22  are welded into tubes  14 . Plates are welded to tubes  14 , supplying means of attachment to carriage side. Plates  18  are welded to tube  15 , supplying means of pivotal attachment to tubes  17 . Plates  19  are welded to tubes  17 , supplying means of pivotal attachment to tubes  16 . Angles  23  are welded to tubes  17 , allowing pivotal attachment of gas springs  20 . Gas springs  20 , are of necessary force to assist in the lifting action, and vary in force depending on deck width and ultimately the total weight of the entire assemblies. Shafts  29  are welded into tubes  25  and round tubes  24  are welded into tubes  16 . Shafts  27  are welded adjacent to tubes  25  and bars  26  are inserted into tubes  25  and secured.  
         [0038]     Referring to  FIG. 6 , the carriage consists of two side rails  30 , a channel  31 , channel inserts  32 , a motor  33 , and an acme screw  34 . Also, but not shown are, nylon miter gears, timing belt, and timing belt pulleys for the drive system. Those are matched with the gas springs dependent on deck size and weight and can be determined using standard engineering formulas and tables. One acme screw is indicated here, though, two may used in the event of an extremely large deck. The acme screw  34 , is mounted in bearings in the rear channel  31 , and the acme screw has a hex end for manual operation, accessible through a hole in channel  31 .  
         [0039]     Referring to  FIG. 7 , the platform assembly consists of an aluminum frame  FIG. 8 , a series of vinyl deck boards  38 ,  FIG. 7 , and ramp assemblies  36 ,  FIG. 7 , detailed in  FIG. 9 .  
         [0040]     The acme screw  34 ,  FIG. 6 , is inserted through an acme nut attached to angle  35 ,  FIG. 7  and into the center vinyl deck board of the platform. This provides for the acme screw to be stabilized, protected and lubricated. A grease fitting is attached to the bottom side of the platform for the purpose of inserting lubricant into the deck board. A wiper  37 ,  FIG. 7 , with an enclosed seal, cleans the acme screw and retains lubricant. The ramp assemblies  36 ,  FIG. 7 , are attached to angle  35 ,  FIG. 7 .  
         [0041]     Referring to  FIG. 8 , the platform frame assembly is constructed of aluminum extrusions of various shapes. Pads  40  are pivotally attached to steel tubes  39 . Support tubes  39 , pivot on shafts  41 , to which they are attached. Support tubes  39  also have fixed pins located, nearer the end, on the same end as shaft  41 . Springs  42 , are situated between support tubes  39 , and frame member  44 . Springs hold pin in support tubes  39 , locked, into one of several holes in frame member  43 . For each support, one hole is positioned, to lock the support in a maximum upward position, for travel.  
         [0042]     Referring to  FIG. 9 , the ramp assemblies are shown as weldments, with aluminum rails  45 . These could be of cast aluminum or molded plastic. Plates  46 ,  47 ,  48  are welded as are shafts  49 . Rollers are of nylon. Shaped steel plates  50 , slide over shafts  53 , and are secured with a machine screw.  
         [0000]     Operation  
         [0043]     When the deck is in the stowed position, as in  FIG. 2 , the gas springs  20 ,  FIGS. 2 &amp; 5 , are slightly compressed, securing the entire deck assembly for travel. The acme screw acts as a safety device, preventing the deck from accidentally deploying, in the event both gas springs fail. Also at the stowed position, blocks  26 ,  FIG. 5 , are seated tangent to rollers  51 ,  FIG. 9 . Also hook plates  50 ,  FIG. 9 , are engaged to shaft  27 ,  FIG. 5 . When activated to deploy, the motor  33 ,  FIG. 6 , rotates the acme screw and the platform begins outward movement. At this time hook plates  50 ,  FIG. 9 , engaged to shaft  27 ,  FIG. 5 , pull the entire carriage forward and further depress the gas springs. After short movement, the weight of the deck, begins to help in depressing the gas springs. The gas springs help prevent jerky movement and once compressed in the deployed position are ready to aid in the lifting action required during the retraction process. As the movement continues, tube  25 ,  FIG. 5 , pivots upward until reaching a fixed stop. At this point the hook plates  50 ,  FIG. 9 , have rotated out of engagement of shafts  27 ,  FIG. 5 . and rollers  28 ,  FIG. 5 , are tangent to and rolling down ramp rail  45 ,  FIG. 9 . Once the rollers leave the ramp rails, downward motion stops and the platform continues in a horizontal direction until fully deployed. The process is simply reversed for retraction, with the compressed gas springs aiding in the lifting. The ramps start the upward travel until such point as the “push arms” tubes  25 ,  FIG. 5 , have reached the proper angle to allow taking over the lifting motion.  
         [0044]     Basic operator instructions would be:  
         [0045]     For deployment:  
         [0046]     Depress support shafts  41 ,  FIG. 8 , allowing supports to pivot to deployment position, release shaft allowing supports to lock into place.  
         [0047]     Depress deployment button and hold until deployment has stopped.  
         [0048]     Adjust supports if necessary.  
         [0049]     For stowing:  
         [0050]     Depress stow button and hold until retraction has stopped.  
         [0051]     Depress support shaft, swing support to stow position, release shaft allowing support to lock into place. Happy Camping!!