Vehicle slide-out framework

The present invention relates to a vehicle having a fixed room and a slide-out room which extends and retracts relative to the fixed room. The fixed room includes a floor section, sidewall sections, and a roof section, and the slide-out room includes a floor section, sidewall sections, and a roof section. A slide-out extension mechanism extends and retracts the slide-out room in a cantilevered manner. In a fully retracted position, the roof section and two of the sidewall sections of the slide-out room are typically concealed from exterior view, and a third sidewall section of the slide-out room forms a portion of the sidewall section of the fixed room. Furthermore, the floor section of the slide-out room is flush with the floor section of the fixed room, and proximal ends of the sidewall sections of the slide-out room are flush with an inner surface of one of the sidewall sections of the fixed room when the slide-out room is fully extended. The slide-out extension mechanism includes a first elongated member which is secured to the fixed room and a second elongated member which is slidingly coupled to the first elongated member. The second elongated member is secured to the slide-out room such that extension and retraction of the second elongated member causes the slide-out room to similarly extend and retract. In order to preferentially strengthen the second elongated tube in the z direction, the second elongated tube includes a first tube fastened to a second tube. An electric motor and brake are coupled to the second elongated member and operate in combination to selectively retract, extend and lock the second elongated member. The slide-out room in the event the motor is inoperable. The manual override system includes a remote brake release system to remotely release the brake.

FIELD OF THE INVENTION

The present invention relates generally to the field of expandable vehicles, and more particularly to an operating mechanism for selectively extending and retracting a slide-out room of a motorized or towable vehicle. The operating mechanism includes a remotely actuated brake.

BACKGROUND OF THE INVENTION

In order to increase the available interior space of a motorized or towable vehicle such as a motor home or trailer, slide-out rooms can be made integral with the vehicle. When the vehicle is in transit, the slide-out room can be retracted and stored in the vehicle's interior with the exterior wall of the slide-out room approximately flush with the vehicle's exterior. As such, there is typically adequate space within the vehicle's interior to accommodate users in transit and remain within the standard width limitations imposed upon a vehicle. When the vehicle is parked and leveled, the slide-out room is then slid outward through an opening formed in a sidewall of a fixed room, increasing the internal accommodations.

As shown inFIGS. 1A and 1B, a typical slide-out room20usually includes a floor section22, a roof section24, a first sidewall section26, a second sidewall section28, and a third sidewall section30. In the retracted position, the roof section24and the first26and second sidewall section28are concealed from exterior view, and the third sidewall section30forms a portion of the vehicle's sidewall. At the same time, the floor section22of the slide-out room20typically rests above a floor section32of a fixed room34and may form a portion of the usable interior floor during vehicle transit. Similarly, the roof section24of the slide-out room20may define the interior ceiling of that part of the vehicle during transit. The proximal ends of the roof section24, first sidewall section26, and second sidewall section28, include stop walls36. As used herein, “proximal” refers to the portion towards the vehicle body and “distal” refers to the portion away from the vehicle body. The stop walls36form a L-shaped configuration with the respective roof section24, first sidewall section26, and second sidewall section28. The stop walls36engage the inner surface38of a respective sidewall section40of the fixed room34when the slide-out room20is fully extended, and thereby limit the travel of the slide-out room20. Weather sealing material42, as in compressible strip form, is located on the abutting surfaces of the stop walls36and/or inner surface38of the respective sidewall40of the fixed room34.

A number of slide-out extension mechanisms are currently used to extend and retract the slide-out room. Typically, a slide-out extension mechanism44includes a pair of support rails46which telescopically extend and retract from a pair of channels48. The support rails46are attached to the slide-out room20and the channels48are attached to the fixed portion of the vehicle, such as the fixed room34, wherein the slide-out room20retracts and extends with the retraction and extension of the support rails46. The support rails46may be driven hydraulically, pneumatically, electrically or various combinations thereof. In the fully extended position, the support rails46extend outwardly in a cantilevered manner and support the slide-out room20. The slide-out room20is further supported by the stop walls36abutting the inner surface38of the respective sidewall section40of the fixed room34.

Since the slide-out room20is nested within a portion of the fixed room34, it is usually dimensioned smaller than the fixed room34. Thus, when the slide-out room20is in an extended position, the floor section22of the slide-out room20is higher than the floor section32of the fixed room34. Such stepped flooring50has frequently been found to be undesirable, inconvenient, and somewhat hazardous. For example, a person may easily overlook the step and trip or stumble if care is not taken. Furthermore, the step limits the positioning of furniture within the room, and the step makes it difficult to create an aesthetically pleasing floor appearance.

In response, slide-out rooms100have been developed with flooring having a flush upper surface (seeFIGS. 2A and 2B). Unfortunately, a slide-out mechanism102can be overly complicated, expensive, and relatively heavy. In the vehicular environment, unnecessary weight reduces fuel economy and may lead to an overly cumbersome vehicle. However, if the slide-out extension mechanism102is insufficiently rigid, flexing may lead to misalignment of the drive mechanism such that the support rails104are no longer extended/retracted in synchronism. As a result, the slide-out extension mechanism102may become skewed or bind during the transit sliding action. Another problem arising from an insufficiently rigid structure is that the slide-out room100may exhibit “bouncing” when a dynamic load is imposed on a floor section106. This can be particularly annoying when an occupant causes the slide-out room100to bounce while walking. In severe cases, cantilevering forces acting on the slide-out mechanism102may cause the sidewall sections108,110,112of the slide-out room100to sag and the floor section106to separate at their abutting edges. Furthermore, slide-out rooms using multiple floor panels, either completely removable or foldable on hinges, may buckle, warp, split, and crack and permit air drafts to rise from the floor through the gaps created by the misaligned panels.

Referring toFIGS. 3A and 3B, another feature which is growing in popularity is the application of a flush wall system. In the flush wall system, proximal ends of a first sidewall section150, second sidewall section152and roof section154of the slide-out room156are flush with an interior surface158of a respective sidewall section160of a fixed room162when the slide-out room156is fully extended. Weather sealing material164is placed along the edge of an opening166formed in the sidewall section160of the fixed room162to form a seal between the rooms156,162. By doing away with the stop walls36, the interior aesthetics is greatly improved. However, the load which was once supported by the stop walls36is now redirected to a slide-out extension mechanism168. As shown inFIG. 3A, cantilevered support rails170flex from the added load, and as a result, the slide-out room156extends outwardly at a downward incline relative to the fixed room162. In addition to the awkward appearance of the floor section172of the slide-out room156being inclined relative to a floor section174of the fixed room162, the proximal end of the floor section172of the slide-out room156protrudes upwardly and a gap g is formed in the flooring. Furthermore, the seal between the rooms156,162is ineffective because a gap is formed between the rooms156,162due to the misalignment of the sidewall sections150,152and roof section154of the slide-out room156. Since vehicles of this type are often used during inclement weather, water, snow, and cold/hot air drafts may leak into the interior of the vehicle and create an inhospitable environment. In addition, certain vehicles such as medical and dental trailers require sterile environments.

In order to further increase the available interior space of vehicles, there is a growing trend to provide increasingly larger slide-out rooms. To accommodate larger sized slide-out rooms, the cantilevered support rails are lengthened. As a result of lengthening the cantilevered support rails and the increased weight of the slide-out room, the slide-out extension mechanism is more prone to flexing. In addition to the weight of the larger sized slide-out room, existing slide-out mechanism must support the additional weight resulting from furnishing the vehicle with amenities more commonly found in houses such as a microwave oven, refrigerator, dishwasher, washer/dryer, entertainment centers, desktop computer and related accessories. Furthermore, the slide-out extension mechanism must support larger sized furniture such a full size dining table, book shelves, cabinets and the like.

Another feature which is commonly available, particularly when relatively large slide-out rooms are utilized, is an automatically driven slide-out extension mechanism. The slide-out extension mechanism usually includes a motive device such as an electric motor to extend and retract the slide-out room. After the slide-out room is extended or retracted to the desired position, a brake is provided to positively fix the position of the slide-out room. In the event that the electric motor is inoperable, a manual override system is provided to retract or extend the slide-out room. The manual override system usually includes a crank handle which can be manually rotated to extend and retract the slide-out room. Before manually rotating the crank handle, it is usually necessary for an operator to release the brake. The brake is usually located underneath the vehicle in a relatively inaccessible location. Thus, an operator is required to go underneath the vehicle to remove the brake from the slide-out extension mechanism. Some slide-out extension mechanism are provided with a brake release lever pivotally mounted on an end of the brake. However, an operator must still go underneath the vehicle to rotate the brake release lever to the release position.

Thus, there remains a need for an improved slide-out extension mechanism which is capable of extending and retracting a slide-out room in a reliable, easily operated, and quiet manner that can be either incorporated into a vehicle body during manufacturing or retrofitted onto existing vehicle bodies. Furthermore, there remains a need to provide a slide-out extension mechanism which is relatively inexpensive and lightweight and yet sufficiently rigid.

SUMMARY OF THE INVENTION

In accordance with the present invention, a vehicle is provided with a slide-out extension mechanism capable of extending and retracting a slide-out room in a reliable, easily operated, and quiet manner that can be either incorporated into a vehicle body during manufacturing or retrofitted onto existing vehicle bodies. Furthermore, the slide-out extension mechanism is relatively inexpensive and lightweight and yet sufficiently rigid to support large sized slide-out rooms having flush flooring and flush sidewalls.

In an exemplary embodiment, the vehicle includes a fixed room and a slide-out room which extends and retracts relative to the fixed room. The fixed room includes a floor section, sidewall sections, and a roof section, and the slide-out room includes a floor section, sidewall sections, and a roof section. A slide-out extension mechanism extends and retracts the slide-out room in a cantilevered manner. In a fully retracted position, the roof section and two of the sidewall sections of the slide-out room are typically concealed from exterior view and a third sidewall section of the slide-out room forms a portion of the sidewall section of the fixed portion of the vehicle. Furthermore, the floor section of the slide-out room is flush with the floor section of the fixed room, and proximal ends of the sidewall sections of the slide-out room are flush with an inner surface of one of the sidewall sections of the fixed room. The slide-out extension mechanism includes a channel which is secured to the fixed room and a support rail is slidingly coupled to the channel.

An electric motor and brake are coupled to the support rail and operate in combination to selectively move and lock the support rail. The brake is in a lock mode when de-energized and in a release mode when energized. The support rail is secured to the slide-out room such that extension and retraction of the support rail causes the slide-out room to similarly extend and retract. When the slide-out room is extended or retracted to the desired position, the electric motor and brake are both de-energized and the slide-out room is positively fixed.

The slide-out extension mechanism may further include a manual override system to extend, retract, and lock the slide-out room in the event the electric motor is inoperable. The manual override system includes a remote brake release system coupled to the brake and further includes a crank handle which can be manually rotated to extend and retract the slide-out room. Before manual rotation of the crank handle can be accomplished, the brake release system is activated to release the brake.

One of the problems encountered with large sized slide-out rooms with flush floor sections and sidewall sections is that large loads may cause undesired flexing of the slide-out extension mechanism. Excessive complexity, expense, and weight is reduced by preferentially increasing the rigidity of the slide-out mechanism where needed. It has been determined that existing slide-out extension mechanisms are usually sufficiently rigid in the x-y direction but require additional rigidity in the z direction. For support rails having a rectangular-shaped cross section, bending rigidity in the z direction is primarily dependent upon the thickness of the vertically oriented walls, while bending rigidity in the z-y directions is primarily dependent upon the thickness of the horizontally oriented walls. In the present invention, the combined thickness of the vertically oriented walls is increased by providing support rails including a first tube attached to a second tube, wherein the thickness of the horizontally oriented walls is not increased. With the twin tube configuration, standardized tubes having a uniform wall thickness may be utilized instead of a single tube configuration which requires a costly, custom fabricated tube with differing horizontal and vertical wall thicknesses. The combined thickness of the vertically oriented walls is further increased by providing a gear rack with a wall portion disposed between the first tube and the second tube.

In another embodiment of the present invention, a vehicle is provided with a slide-out room having a storage compartment. A distal portion of the support rail is provided with a pivot member, and a longitudinal axis of the pivot remains in a substantially horizontal position during the extension and retraction of the slide-out room. The storage compartment is attached to the pivot member and extends and retracts in unison with the extension and retraction of the slide-out room. Furthermore, the storage compartment remains in a substantial horizontal position during the extension and retraction process.

Other objects, features, and advantages of the present invention will become apparent from a consideration of the following detailed description. The drawings constitute a part of this specification and include exemplary embodiments to the invention which may be embodied in various forms. It is to be understood that in some instances various aspects of the invention may be shown exaggerated or enlarged to facilitate and understanding of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring toFIG. 4, a trailer200in accordance with the present invention is illustrated having a fixed room202and three slide-out rooms204,206,208mounted for expansion on the left and right side of the fixed room202. The fixed room202typically forms a living and/or dining room area and is stationary relative to the trailer200, while the slide-out rooms204,206,208are movable relative to the trailer200and the fixed room200by slide-out extension mechanisms210which extend the slide-out rooms204,206,208in a cantilevered manner. In retracted positions, the slide out rooms204,206,208are telescopically received or nested within the fixed room202. In the preferred embodiment, the exterior face212of slide-out rooms204,206,208are flush with the exterior sides214of the fixed room202when in a fully retracted position.

FIGS. 5A and 5Billustrate one of the slide-out rooms204in the full extended position relative to the fixed room202, andFIGS. 6A-6Cillustrate an interior view of the slide-out room204in a fully retracted position, an intermediate position, and a fully extended position. The fixed room202includes a floor section216, four sidewall sections218,220,222,224, and a roof section226. The sidewall sections218,220,222,224form part of the exterior sides of the trailer200and the first sidewall section218of the fixed room202includes an opening228through which the slide-out rooms204retracts and extends through. The slide-out room204includes a floor section230, a first sidewall section232, a second sidewall section234, a third sidewall section236, and a roof section238. In the fully retracted position, the roof section238and two of the sidewall sections232,234of the slide-out room204are typically concealed from exterior view, and the third sidewall section236forms a portion of the respective sidewall218of the trailer200. At the same time, the floor section230of the slide-out room204typically rests above the floor section216of the fixed room202and may form a portion of the usable interior floor during trailer transit. Similarly, the roof section238of the slide-out room204may define the interior ceiling of that part of the trailer200during transit. To provide an aesthetically pleasing interior when in the fully extended position, a flush wall system is provided, wherein the proximal end of the slide-out room204is flush with the interior surface of the respective sidewall section218of the fixed room202. A seal240, such as a bulb seal, is attached to an edge wall the opening228. The seal240is capable of sealing the interior of the trailer200from the weather when the slide-out room204is in the retracted position, extended position, and any intermediate position. In addition to providing an aesthetically pleasing interior, the flush wall system enables the interior width of the trailer to be maximized when the slide-out room204is in the fully extended position.

As best shown inFIGS. 7,8and9, the slide-out extension mechanism210includes a pair of parallel tubes or support rails242slidably carried in a pair of hollow parallel tubes or channels244for longitudinal translation therethrough. The pair of channels244are spaced apart along the length of the fixed room202and are aligned such that their length in the longitudinal direction is along the line of expansion and retraction of the slide-out room204. The channels244are connected to the fixed room202by a pair of transverse structural members246,248which form part of the frame250of the trailer200. The proximal end of the channels244are connected to the first transverse structural member246and a distal portion of the channels244are connected to the second transverse structural member248. The support rails242are mounted within the channels244, and distal ends of the support rails242are mounted to the distal portion of the slide-out room204by a slot member252and a pivot member254. A drive mechanism256is attached to the channels244and provides selected extension or retraction of the support rails242. However, it is noted that the orientation of the channels and support rails can be reversed such that the support rails are attached to the fixed room, and the channels are attached to the slide-out room.

Referring back toFIG. 8, each of the channels244has a closed upper wall258, closed sidewalls260, and a lower wall262which covers a proximal portion of the channel244. The remaining distal portion of the channel244is left open. The proximal end of the channels244are welded to the first transverse structural member246, while the distal portion of the channels244are passed through a pair of apertures264of the second transverse member248where they are welded in place.

Referring toFIGS. 10A-10C, each of the support rails242includes a pair of tubes266having a closed upper wall266, closed sidewalls268, and a closed lower wall269. A gear rack270is disposed between the tubes266. The gear rack270includes a wall portion271and a gear portion272. The wall portion271may be formed from a steel plate extending throughout the entire length and depth of the tubes266, and the gear portion272projects downwardly from each of the closed lower walls269. The gear rack270may be integrally formed with the steel plate or may be attached to the steel plate by welding or the like. As can be seen inFIG. 10C, the upper portion of the steel plate is flush with the upper walls267of the tubes266, and the lower portion of the steel plate is flush with the lower walls269of the tubes26. The gear rack270engages with an associated gear of the drive mechanism256which is to be described hereafter.

As best shown inFIGS. 8,9, and11, each support rail242includes a proximal roller arrangement274to slidably carry the support rails242within the channels244. The proximal roller arrangement274includes a lower wheel276which is in continuous rolling engagement with the lower wall262of the channel244and further includes an upper roller278which is in continuous rolling engagement with the upper wall258of the channel244. A distal roller arrangement280is rotatably mounted to the channel244and includes a roller282supported by the sidewalls260of the channel244. The roller282is in continuous rolling engagement with the upper walls267of the support rails242. The proximal and distal roller arrangements274,280and drive mechanism256thus provide vertical support for the slide-out room204when retracted and at the same time permit smooth, low friction in-and-out telescopic movement of the slide-out room204relative to the fixed room202. In this way, the slide-out204room has a slidable, cantilever mounting to the fixed room202.

As best shown inFIGS. 11A-11C, an alternative embodiment of a support rail283includes the pair of tubes266having a closed upper wall267, closed sidewalls268, and a closed lower wall269. The tubes266are directly secured to each other such that the closed sidewall268of the first tube266directly abuts against the closed sidewall268of the second table266. A gear portion285projects downwardly from each of the closed lower walls269and engages with an associated gear of the drive mechanism256.

As mentioned previously, there is a growing trend to provide larger slide-out rooms with flush floors and sidewalls. It is particularly important to provide a rigid slide-out extension mechanism to prevent unwanted bouncing of the slide-out room resulting from movement of the occupants and to prevent flexural bending of the floor section. Unfortunately, such structures can be overly complicated, expensive and relatively heavy. Excessive complexity, expense, and weight may be reduced by preferentially increasing the rigidity of the slide-out mechanism where needed. It has been determined that existing slide-out extension mechanisms are usually sufficiently rigid in the x-y directions but require additional rigidity in the z direction. Bending rigidity of the support rails in the z direction is primarily dependent upon the wall thickness of the vertically oriented sides A while bending rigidity in the x-y directions are primarily dependent upon the wall thickness of the horizontally oriented sides B. Thus, the support rails can be formed from tubing having a rectangular cross section with vertically oriented walls thicker than the horizontally oriented walls to preferentially increase the bending stiffness (also known as flexural rigidity) in the z-direction without substantially increasing the weight of the support rails. However, to further reduce costs, the support rails242shown inFIG. 10Cutilize standardized tubes266which are joined together to form the support rail242having vertically oriented walls268twice the thickness of the horizontally oriented walls267,269. In this manner, standardized tubes266having a uniform wall thickness may be utilized instead of custom fabricated tubes. It is also noted that the gear rack270further increases the rigidity of the support rails242in the z direction by further increasing the combined thickness of the vertically oriented walls.

Referring toFIG. 13, bending stiffness of a typical tube286in the z direction may be characterized by calculating the product of the moment of inertia (I) and the modulus of elasticity (E) of the tube286. When the tube286is subjected to a load such as the weight of a slide-out room, the moment of inertia I for the tube286is given by:
Itube=bd3/12−b1d13/12
where b is the outer width of the tube286, b1is the inner width of the tube286, d is the outer depth of the tube286, d1is the inner depth of the tube286.

The modulus of elasticity Etubefor the typical tube286formed from steel is approximately 30×106psi, and the bending stiffness of the tube286is given by:
bending stiffnesstube=Etube·Itube=(30×106)(bd3/12−b1d13/12).

As can be seen from the above formula, bending stiffness in the z direction is primarily dependent upon the thickness of the vertically oriented walls288, wherein bending stiffness is linearly dependent upon the horizontal wall290thickness and cubicly dependent upon the vertical wall thickness288. For example, the bending stiffness of a tube286in the z direction can be increased by a factor of eight by doubling the thickness of the vertically oriented walls288while maintaining the thickness of the horizontally oriented walls290at the original thickness. Bending stiffness can be further increased by only a factor of two by doubling the thickness of the horizontally oriented walls290. As a result, by doubling the vertical wall288thickness, a fifty percent increase in tube286weight will result in an eight fold increase in bending resistance in the z direction, while an additional fifty percent increase in tube weight by doubling the horizontal wall thickness will result in only a two fold increase in bending resistance in the z direction. Thus, it is desirable to preferentially increase the vertical wall288thickness. Of course, the horizontal wall290thickness should be thick enough to provide adequate bending stiffness in the x-y direction and to provide adequate torsional stiffness.

Referring back toFIG. 7and toFIGS. 14 and 15, the slide-out room204is usually automatically extended and retracted by the drive mechanism256which includes a motive device. In the exemplary embodiment, the motive device is an integral motor/brake291. The power source for the integral motor/brake291is a primary power supply294such as a standard 12-Volt lead/acid battery commonly found in motor vehicles. Other types of batteries may be used such as nickel cadmium, lithium ion, air-Zinc, solid or semi-solid polymer batteries, collection of batteries in battery packs, as well as batteries having rated voltages other than 12 Volts. The integral motor/brake291includes an electric motor292manufactured by Von Weise under model number V05726AP88 and an external brake293manufactured by Steams. The external brake293comprises an electrically controlled, spring-biased brake. When electrical power to the integral motor/brake291is terminated, the external brake293automatically and positively clamps an output shaft (not shown) of the electric motor292against further rotation to positively fix the position of the slide-out room204and to prevent unnecessary over-travel and imprecise control of the slide-out room204by inertial rotation of the motor output shaft. Furthermore, the external brake293maintains the slide-out room204in a fully retracted position during travel of the trailer200, prevents the slide-out room204from moving away from the fully extended position, and ensures proper synchronism of the support rails242to prevent binding and jamming of the slide-out extension mechanism210. Preferably, a motor/brake switch298to activate the electric motor292and the external brake293is located in the interior portion of the trailer200, but it may be located in any other convenient location such as an exterior surface of the fixed room202near the respective slide-out room204. Furthermore, the brake/motor switch298may be remotely activated by radio transmission if desired.

The drive mechanism256further includes a first housing300mounted to one of the channels244and a second housing302mounted to the other channel244. A first drive gear304is rotatively mounted to the first housing300, and a second drive gear306is rotatively mounted to the second housing302. Each of the drive gears304,306is in meshing engagement with its respective gear rack270such that rotation of the drive gears304,306causes the support rails242to slide in-and-out of their respective channels244. The drive gears304,306are driven by the electric motor292, and the electric motor292is mounted to the first housing300. The output shaft of the electric motor292is connected to a gear reducing assembly308, and the gear reducing assembly308is coupled to the first drive gear304. The second drive gear306is coupled to the first drive gear304by a drive shaft310such that rotation of the first drive gear304causes the second drive gear306to similarly rotate.

As best shown inFIG. 8, a centerline height a of the proximal end of the support rail242is higher than a centerline height b of the support rail242at the drive gear304by a distance c. Thus, the centerline height d of the distal end of the support rail242incrementally decreases at an inclined slope as the support rail242is further extended. In addition, a sloped end region312abuts the floor section216of the fixed room302, and the floor section230of the slide-out room204includes a mating inclined surface314(seeFIG. 5A). With such an arrangement, as the slide-out room204is extended from its retracted position, the floor section230of the slide-out room204is lowered in a smooth manner from its position above the floor section216of the fixed room202to a position flush with the floor section216of the fixed room202. As used herein, the term “flush” is interpreted as respective surfaces being in a substantially same plane without a noticeable elevation between them. For example, the floor section230of the slide-out room204is flush with the floor section230of the fixed room202when the top surfaces of the floor sections216,230are substantially in the same plane.

As a backup system (seeFIGS. 7,14, and15A), the slide-out extension mechanism210includes a manual override system316to extend and retract the slide-out room204relative to the fixed room202. In the event the electric motor292is inoperable, the slide-out room204may still be operated by the manual override system316which is conveniently accessible. Since the external brake293is in the locked mode when deactivated, a brake-only switch318is provided to activate the external brake293into the release mode. The brake-only switch318is coupled to the primary power supply294. However, if the primary power supply294is dead or insufficiently charge to activate the external brake293, a backup power supply296is coupled to the brake only switch318to provide sufficient power to activate the external brake293. In the exemplary embodiment, the backup power supply296can be a standard 9-Volt battery. Furthermore, a relay319may be provided to couple the electric motor292and external brake293to the motor/brake switch298, brake-only switch318, primary power supply294, and backup power supply295(seeFIG. 15B).

As best shown inFIGS. 7 and 14, the manual override system316includes a right angle gear box322mounted to the gear reducing assembly308. The right angle gear box322provides an enclosure for a gear system having a bevel gear (not shown) mounted for rotation with the gear reducing assembly308and in meshing engagement with a bevel pinion324secured at the end of a crankshaft326. The crankshaft326includes a central square tube328and a telescoping section330. The telescoping section330has a square cross section portion slidably received within a passage defined by the central square tube328. The crankshaft326extends generally perpendicularly with the drive shaft310. The end of the crankshaft326opposite the right angle gear box322passes through an aperture332of the first transverse structural member246and is received within a lead-in-tube334mounted to the first transverse structural member246. The lead-in tube334is positioned at a readily accessible location so that an operator may easily insert a removable crank handle336to manually retract/extend the slide-out room204. The crank handle336is engageable with the second end of the crankshaft326. Rotation of the crank handle336rotates the bevel pinion324, which in turn rotates the gear system of the right angle gear box322, rotates the gears in the gear reducing assembly308, and rotates the drive gears304,306in order to manually extend or retract the slide-out room204. It is noted that the configuration of the manual override system may vary depending on the location slide-out room relative to the vehicle.

The slide-out room204is operated in the following manner. With the slide-out room204in the fully retracted position, the operator sets the motor/brake switch298to the “on” position. The electric motor292and external brake293are energized, and the support rails242extend outwardly from the channels244. Since each support rail242is being driven at the same speed, binding of the slide-out extension mechanism210can be avoided even with relatively long slide-out room structures. As the support rails242extend outwardly from the channels244, the proximal end of the support rails242slide laterally but remain at a fixed height while the distal end of the support rails242move both laterally and vertically downward at an inclined slope. Since the slide-out room204is connected to the distal end of the support rails242by the pivot member254and the slot member256, the slide-out is room204is extended laterally while remaining at a fixed height. The vertical reduction in height of the distal end of the support rails242are compensated by the pivot member254and slot member256. When the slide-out room204is near the fully extended position, the mating inclined surface314of the floor section230of the slide-out room204slides downwardly along the sloped end region312, and the pivot member354and slot member256compensate for the vertically downward movement of the slide-out room204such that the floor section230of the slide-out room204remains in a substantially horizontal position during the transition. At the fully extended position, the floor sections216,230of the slide-out room204and fixed room202are flush. The motor/brake switch298is automatically reset to the “off” position, and the electric motor292is automatically deactivated and the external brake293is engaged to positively lock the slide-out room204in the fully extended position.

The slide-out room204is moved from the fully extended position to the fully retracted position by similar steps. The motor/brake switch298is set to the “on” position, the electric motor292and external brake293are energized, and the support rails242retract inwardly into the channels244at the same speed. As the support rails242retract, the proximal end of the support rails242slide laterally but remain at a fixed height while the distal end of the support rails242move both laterally and vertically upward at an inclined slope. At the same time, the slide-out room204is retracted laterally, wherein the proximal end of the slide-out room204is raised as the mating inclined surface314of the slide-out room204slides upwardly along the sloped end region312. The floor section230of the slide-out room204remains substantially horizontal because the slot member252allows the distal end of the slide-out room204to rise an equal amount and because the pivot member254pivots about the support rail242. When the mating inclined surface314of the slide-out room204clears the sloped end region312, the floor section230of the slide-out room204slides along the floor section216of the fixed room202. At the fully retracted position, the floor section230of the slide-out room204is once again positioned above the floor section216of the fixed room202, and the outer surface of the third sidewall section236of the slide-out room204is flush with the outer surface of the respective sidewall section218of the fixed room202. The motor/brake switch298is automatically set to the “off” position, the electric motor292and the external brake293are de-energized, and the slide-out room204is positively locked by the external brake293. It is noted that the slide-out room204may be partially extended or retracted by manually setting the motor/brake switch298to the “off” position during the extension/retraction of the slide-out room204.

In the event that the electrical motor292is inoperable such as when the primary power supply294is incapable of delivering sufficient power to drive the electric motor292, the manual override system316may be used to retract or extend the slide-out room204. Before manual rotation of the drive shaft310can be accomplished, it is necessary for the operator to release the external brake293. The brake-only switch318is set to the “on” position to release the external brake293. The backup power supply296may be used when the primary power supply294is insufficiently charged. If the slide-out room204is in the fully retracted position and the operator wishes to fully extend the slide-out room204, the operator may insert the crank handle336into the lead-in tube334and rotate the crank handle336until the slide-out room204is fully extended. The slide-out extension mechanism210operates in a manner similar to the above-mentioned procedure for automatically extending and retracting the slide-out room204. After the slide-out room204is fully extended, the brake-only switch318is repositioned to the “off” position, and the external brake293positively locks the slide-out room204. Similarly, the slide-out room204may be manually retracted from the fully extended position by setting the brake-only switch318to the “on” position to release the external brake293, inserting the crank handle336into the lead-in tube334, and rotating the crank handle336until the slide-out room204is fully retracted. After the slide-out room204is fully retracted, the brake-only switch318is set to the “off” position, and the external brake293positively locks the slide-out room204. It is noted that the slide-out room204can be manually retracted/extended to any desired intermediate position by simply terminating the rotation of the crank handle336when slide-out room204is retracted/extended to the desire position and setting the brake only switch318to the “off” position.

Referring toFIGS. 16A,16B, and17, another embodiment of a slide-out room350according to the present invention is shown which is similar to the prior embodiment and further includes storage compartments352. Those elements considered unique are discussed in detail, and similar elements are numbered with the same number and with a prime. The storage compartment352includes five walls354and a front panel356hingedly attached to allow access to an interior portion358. The storage compartment352is located underneath a floor section230′ of the slide-out room with the panel flush with the exterior surface of a third sidewall section236′ of the slide-out room350. By providing such an arrangement, the storage compartment352is readily accessible when the slide-out room350is in the extended position. One of the problems with existing storage compartments is that they are directly attached to the fixed portion of the vehicle and access to the storage compartment is limited when the slide-out mechanism is extended. With such storage compartments, an operator must either fully retract the slide-out room to access the storage compartment or crawl underneath the extended slide-out room.

Referring back toFIGS. 16A-16Band17, the slide-out room350includes the floor section230′, a first sidewall section232′, a second sidewall section234′, the third sidewall section236′, and a roof section238′. In the fully retracted position, the roof section238′ and the first232′ and second sidewall section234′ of the slide-out room350are typically concealed from exterior view. The third sidewall section236′ of the slide-out room350and the front panel356of the storage compartment352form a portion of the sidewall of the trailer. A slide-out extension mechanism210′ includes a pair of support rails242′ slideably carried in a pair of channels244′ for longitudinal translation therethrough. The pair of channels244′ are spaced apart along the length of a fixed room202′ and are aligned such that their length in the longitudinal direction is along the line of expansion and retraction of the slide-out room350. The channels244′ are connected to the fixed room202′, and the support rails242′ are connected to the slide-out room202′. The distal end of the support rail242′ is attached to the distal portion of the slide-out room350′ by a pivot member254′ and a slot member256′. The pivot member254′ is lengthened to accommodate the storage compartment352, wherein the storage compartment352is directly attached to the pivot member254′. In the exemplary embodiment, the pivot member254′ is about 17.5 inches in length. The slide-out extension mechanism210′ is configured such that the longitudinal axis of the pivot member254′ remains substantially horizontal when in a fully retracted position, fully extended position, and any intermediate position. By maintaining the pivot member254′ in a substantially horizontal position, the storage compartment352similarly remains substantially horizontal during the retraction/extension process. As a result, disturbance of the stored items is kept to a minimum, and the stored items are less likely to fall out of the storage compartment352while opening the storage compartment352.

Operation of the slide-out room350is similar to the prior embodiment with the exception that the storage compartment352extends/retracts with the extension/retraction of the slide-out room350. In the event that the primary power supply294is incapable of delivering sufficient power to drive the electric motor292, the manual override system316may be used to retract/extend the slide-out room350.

Referring toFIGS. 18-21, another embodiment of a slide-out extension mechanism400having a drive mechanism402and a manual override system404in accordance with the present invention is illustrated. The drive mechanism402includes an integral motor/brake406having an electric motor408and an external brake410. The electric motor408may be any motor such as the previously identified model manufactured by Von Weise, and the external brake410is an electrically controlled, spring-biased brake. As contrasted with the external brake293illustrated inFIG. 14, the external brake410in this embodiment has a manually releasable brake mechanism412. That is, the mechanism412includes a lever414which is rotatably mounted on the end of the electric motor408so that movement of the lever414in the direction of the arrow (from a locked position to a release position) releases the external brake410and allows free rotation of an output shaft of the electric motor408. Under normal operating conditions, the electric motor408and external brake410are activated by a motor/brake switch416which is preferably located in the interior portion of the trailer200, but it may be located in any readily accessible location such as an exterior portion of the fixed room202near the respective slide-out room204. Furthermore, the brake/motor switch416may be remotely activated by radio transmission if desired. The brake/motor switch416is coupled to a primary power supply417.

The drive mechanism400further includes a first housing418mounted to a channel420, and a second housing422mounted to another channel424. A first drive gear426is rotatively mounted to the first housing418, and a second drive gear428is rotatively mounted to the second housing422. Each of the drive gears426,428is in meshing engagement with its respective gear track429,431such that rotation of the drive gears426,428causes support rails430,432to slide in-and-out of their respective channels420,424. The drive gears426,428are driven by the electric motor408, and the electric motor408is mounted to the first housing418. The output shaft of the electric motor408is connected to a gear reducing assembly434, and the gear reducing assembly434is coupled to the first drive gear426. The second drive gear428is coupled to the first drive gear426by a drive shaft436wherein rotation of the first drive gear426causes the second drive gear428to similarly rotate.

The manual override system404may be used to extend and retract the slide-out room204in the event that the electric motor408is inoperable. The manual override system404includes a right angle gear box438mounted to the gear reducing assembly434. The right angle gear box438provides an enclosure for a gear system having a bevel gear (not shown) mounted for rotation with the gear reducing assembly434and is in meshing engagement with a bevel pinion440. A first end of a crankshaft442is slidingly connected to the bevel pinion440. The crankshaft442includes a central square tube446and a telescoping section448. The telescoping section448has a square cross section portion slidably received within a passage defined by the central square tube446, and the crankshaft442extends generally perpendicularly with the drive shaft436. A second end of the crankshaft442passes through an aperture450of a first transverse structural member452and is received within a lead-in tube454mounted to the first transverse structural member452. The lead-in tube454is located at a readily accessible location so that an operator may easily insert and rotate a removable crank handle456to manually retract/extend the slide-out room204. The crank handle456is engageable with the second end of the crankshaft442, wherein rotation of the crank handle456rotates the bevel pinion440, which in turn rotates the gear system of the right angle gear box438, rotates the gears in the gear reducing assembly434and rotates the drive gear426,428in order to manually extend or retract the slide-out room204.

Before manual rotation of the crank handle456can be accomplished, the operator should manually release the external brake410. In an effort to eliminate the necessity for an operator to directly access and rotate the lever414to the release position, a link member458is provided so that the lever414is rotated to the release position when the crank handle456engages with the crankshaft442. The link member458is pivotally connected at point a to the right angle gear box438and is movable between a locking position and an unlocking position. When the crank handle456engages the crankshaft442, the crankshaft442slides towards the link member458and the first end of crankshaft442abuts a first contact surface460of the link member458and causes the link member458to pivot to the unlocking position. As the link member458pivots towards the unlocking position, a second contact surface462of the link member458engages the lever458and causes the lever414to rotate to the release position. Since the link member458is biased in the locking position by a bias member464such as a spring, the link member458pivots back to the locking position when the crank handle456is disengaged from the crankshaft442, the lever414returns to the locked position, and the external brake410is locked.

It is noted that present invention is not limited to the exemplary embodiment described above and that various adaptations and modifications of the present embodiment may be accomplished without departing from the spirit and scope of the invention. For instance, the lever may be remotely actuated by a separate mechanism which is not coupled to the crankshaft. A shaft may be slidably coupled to a link member such that the operator may release the external brake by pushing the shaft towards the right angle gear box wherein an end adjacent to the link member abuts the first contact surface of the link member. As the link member rotates towards the unlocking position, the second surface of the link member engages and rotates the lever to the release position.

In the event that the electric motor408is inoperable, the manual override system404may be used to retract or extend the slide-out room204in the following manner. If the slide-out room204is in the fully retracted position and the operator wishes to fully extend the slide-out room204, the external brake410is released by inserting the crank handle456into the lead-in tube454. The crankshaft442is slidingly driven towards the link member458, and the first end of the crankshaft442abuts the first contact surface460of the link member458and causes the link member458to pivot to the unlocking position. As the link member458pivots towards the unlocking position, the second contact surface462of the link member458engages the lever414and rotates the lever414to the release position. With the external brake410released, the crank handle456is rotated until the slide-out room204is fully extended. After the slide-out room204is fully extended, the crank handle456is disengaged from the crankshaft442, the link member458pivots to the locking position, the lever414is rotated to the locked position, and the external brake410is locked.

Referring toFIGS. 22-24, another embodiment of a slide-out extension mechanism500having a drive mechanism502and a manual override system504in accordance with the present invention is illustrated. As contrasted with the drive mechanism256ofFIG. 14, the drive mechanism500in this embodiment has an external brake506mounted on a right angle gear box508. That is, braking action is performed by the external brake506automatically and positively clamping a shaft of the right angle gear box508instead of an output shaft of an electric motor when electrical power to the electric motor and external brake is terminated.

The slide-out room204is usually automatically extended and retracted by activation of a motor/brake switch510which is coupled to an electric motor512, the external brake506, and a primary power supply514. The drive mechanism502includes a first housing516mounted to a channel and a second housing520mounted to another channel522. A first drive gear524is rotatively mounted to the first housing516, and a second drive gear526is rotatively mounted to the second housing520. Each of the drive gears524,526is in meshing engagement with its respective gear track such that rotation of the drive gears524,526causes support rails528,530to slide in-and-out of their respective channels518,522. The drive gears524,526are driven by the electric motor512, and the electric motor512is mounted to the first housing516. The output shaft of the electric motor512is connected to a gear reducing assembly532, and the gear reducing assembly532is coupled to the first drive gear524. The second drive gear526is coupled to the first drive gear524by a drive shaft534wherein rotation of the first drive gear524causes the second drive gear526to similarly rotate.

In the event the electric motor512is inoperable, the slide-out room204may still be operated by the manual override system504. Since the external brake506is in the locked position when in the deactivated mode, a brake-only switch536is provided to activate the external brake506into the release mode. The brake-only switch536is coupled to the primary power supply514. However, if the primary power supply514is dead or insufficiently charged to activate the external brake506, a backup power supply538is coupled to the brake-only switch536to provide sufficient power to activate the external brake506. Furthermore, a relay540may be provided to couple the electric motor512and external brake506to the motor/brake switch510, brake-only switch, primary power supply514, and backup power supply538.

As best shown inFIGS. 22 and 23, the right angle gear box508is mounted to the gear reducing assembly532and provides an enclosure for a gear system mounted for rotation with the gear reducing assembly532. The right angle gear box508is in meshing engagement with a bevel pinion542, and the bevel pinion542is secured to a first end of a crankshaft544. A second end of the crankshaft544is received within a lead-in-tube546mounted to a first transverse structural member548. The lead-in tube546is positioned at a readily accessible location so that an operator may easily insert a removable crank handle550to manually retract/extend the slide-out room204. The crank handle550is engageable with the second end of the crankshaft544. Rotation of the crank handle550rotates the bevel pinion542, which in turn rotates the gear system of the right angle gear box508, rotates the gears in the gear reducing assembly532, and rotates the drive gears524,526in order to manually extend or retract the slide-out room204.

The slide-out room204is operated in the following manner. With the slide-out room204in the fully retracted position, the operator sets the motor/brake switch510to the “on” position. The electric motor512and external brake506are energized, and the support rails528,530extend outwardly from the channels518,522. At the fully extended position, the motor/brake switch510is automatically reset to the “off” position, the electric motor512is automatically deactivated, and the external brake506is engaged to positively lock the slide-out room204in the fully extended position. The slide-out room204may be moved from the fully extended position to the fully retracted position by setting the motor/brake switch510to the “on” position. The electric motor512and external brake506are energized, and the support rails528,530retract inwardly into the channels518,522at the same speed. At the fully retracted position, the motor/brake switch510is automatically set to the “off” position, the electric motor512and the external brake506are de-energized, and the slide-out room204is positively locked by the external brake506. It is noted that the slide-out room204may be partially extended or retracted by manually setting the motor/brake switch510to the “off” position during the extension/retraction of the slide-out room204.

In the event that the electric motor512is inoperable such as when the primary power supply514is incapable of delivering sufficient power to drive the electric motor512, the manual override system504may be used to retract or extend the slide-out room204. Before manual rotation of the drive shaft534can be accomplished, the operator releases the external brake506by setting the brake-only switch510to the “on” position. The backup power supply538may be used when the primary power supply514is insufficiently charged to energize the external brake506. If the slide-out room204is in the fully retracted position and the operator wishes to fully extend the slide-out room204, the operator may insert the crank handle550into the lead-in tube546and rotate the crank handle550until the slide-out room204is fully extended. After the slide-out room204is fully extended, the brake-only switch510is repositioned to the “off” position, and the external brake506positively locks the slide-out room204. Similarly, the slide-out room204may be manually retracted from the fully extended position or any intermediate position by setting the brake-only switch536to the “on” position to release the external brake506, inserting the crank handle550into the lead-in tube546, and rotating the crank handle550until the slide-out room204is fully retracted. After the slide-out room204is fully retracted, the brake-only switch536is set to the “off” position, and the external brake506positively locks the slide-out room204.

Referring toFIGS. 25-27, another embodiment of a slide-out extension mechanism600having a drive mechanism602and a manual override system604in accordance with the present invention is illustrated. As contrasted with the drive mechanism256ofFIG. 14, the drive mechanism602in this embodiment has a pawl brake606mounted on a right angle gear box608, wherein braking is performed by the pawl brake606positively locking a shaft of the right angle gear box608when electrical power to an electric motor610and pawl brake606is terminated. Under normal operating conditions, the electric motor610and pawl brake606are activated by a motor/brake switch607which is preferably located in the interior portion of the trailer200, but it may be located in any readily accessible location such as an exterior portion of the fixed room200.

As best shown inFIGS. 26A-26D, the pawl brake606includes a rotatable disk614which is connected to a shaft of the right angle gear box608, and a plurality of apertures616are located circumferentially near an outer portion of the disk614. A first rocker arm618and a second rocker arm620are pivotally coupled to the right angle gear box608, wherein the rocker arms618,620are parallel to each other. Each rocker arm618,620includes a latching member622,624which engages with the plurality of apertures616of the disk614. The first latching member622includes a locking surface626which prevents clockwise rotation of the disk614when engaged with the one of the apertures616, and the second latching member624includes a locking surface628which prevents counterclockwise rotation of the disk614when engaged with one of the other apertures616. Thus, both clockwise and counterclockwise rotation of the disk614may be prevented when both rocker arms618,620engage with the apertures616of the disk614. An actuator, which is mounted to the right angle gear box608, causes the first618and second rocker arm620to simultaneously engage (seeFIG. 26A) and disengage (seeFIG. 26B) with the disk614. In the exemplary embodiment, the actuator is a solenoid630having a pin632. The pin632is coupled to the first618and second rocker arm620by a cross member634, and the pin632is-extended when the solenoid630is de-energized and retracted when the solenoid630is energized. The actuator may be any electronic solenoid, as shown in the drawings, or other device known in the art for selectively moving a pin or other element to and from and extended and retracted position.

Referring back toFIG. 25, the drive mechanism602further includes a first housing636mounted to one channel638and a second housing640mounted to another channel642. A first drive gear644is rotatively mounted to the first housing636, and a second drive gear646is rotatively mounted to the second housing640. Each of the drive gears644,646is in meshing engagement with its respective gear track such that rotation of the drive gears640,646cause support rails648,650to slide in-and-out of their respective channels638,642. The drive gears644,646are driven by the electric motor610, and the electric motor610is mounted to the first housing636. The output shaft of the electric motor610is connected to a gear reducing assembly652, and the gear reducing assembly652is coupled to the first drive gear644. The second drive gear646is coupled to the first drive gear644by a drive shaft654wherein rotation of the first drive gear644causes the second drive gear646to similarly rotate.

In the event the electric motor610is inoperable, the slide-out room204may still be operated by the manual override system604. Since the pawl brake606is in the locked position when in the deactivated mode, a brake-only switch656is provided to activate the pawl brake606into the release mode. The brake-only switch656is coupled to the electric motor610, the pawl brake606, and a primary power supply658(seeFIG. 27A). However, if the primary power supply658is dead or insufficiently charged to activate the pawl brake606, a backup power supply660is coupled to the brake-only switch656to provide sufficient power to activate the pawl brake606. Furthermore, a relay662may be provided to couple the electric motor610and pawl brake606to the motor/brake switch607, brake-only switch654, primary power supply656, and backup power supply660(seeFIG. 27B).

Referring back toFIG. 25, the right angle gear box608is mounted to the gear reducing assembly652and provides an enclosure for a gear system mounted for rotation with the gear reducing assembly652. The right angle gear box608is in meshing engagement with a bevel pinion664, and the bevel pinion664is secured to a first end of a crankshaft666. A second end of the crankshaft666is received within a lead-in-tube668mounted to a first transverse structural member670. The lead-in tube668is positioned at a readily accessible location so that an operator may easily insert a removable crank handle672to manually retract/extend the slide-out room204. The crank handle672is engageable with the second end of the crankshaft666. Rotation of the crank handle672rotates the bevel pinion664, which in turn rotates the gear system of the right angle gear box608, rotates the gears in the gear reducing assembly652, and rotates the drive gears in order to manually extend or retract the slide-out room204.

The slide-out room204is operated in the following manner. As shown inFIG. 26A, the solenoid630and electric motor610are usually de-energized, the pin632is extended, the first618and second rocker arm620are engaged with the disk614, and the slide-out room204is prevented from retracting or extending. With the slide-out room204in the fully retracted position, the operator sets the motor/brake switch607to the “on” position. As shown inFIG. 26B, the electric motor610and solenoid630are energized, the pin632is retracted, the first618and second rocker arm620are disengaged from the disk616, the support rails648,650extend outwardly from the channels638,642, and the slide-out room204extends outwardly. At the fully extended position, the motor/brake switch607is automatically reset to the “off” position, the electric motor610is automatically de-energized, and the pawl brake606is engaged to positively lock the slide-out room204in the fully extended position. The slide-out room204may be moved from the fully extended to the fully retracted position by setting the motor/brake switch607to the “on” position. The electric motor610and solenoid630are energized, the pin632is retracted, the first618and second rocker arm620are disengaged from the disk614, the support rails648,650retract inwardly into the channels638,642, and the slide-out room204is retracted. At the fully retracted position, the motor/brake switch607is automatically set to the “off” position, the electric motor610and solenoid630are de-energized, the pin632is extended, the first618and second rocker620are engaged with the disk614, and the slide-out room204is positively locked by the pawl brake606.

The manual override system604may be used to retract or extend the slide-out room204when the electric motor610is inoperable. Before manual rotation of the drive shaft654can be accomplished, the operator releases the pawl brake606by setting the brake-only switch656to the “on” position. In order to extend the slide-out room204, the operator may insert the crank handle672into the lead-in tube668and rotate the crank handle672until the slide-out room204is fully extended. After the slide-out room204is fully extended, the brake-only switch656is repositioned to the “off” position, the solenoid630is de-energized, the pin632is extended, the first618and second rocker arm620are engaged with the disk614, and the slide-out room204is locked. In order too retract the slide-out room204, the operator releases the pawl brake606by setting the brake-only switch656to the “on” position, inserts the crank handle672into the lead-in tube668, and rotates the crank handle672until the slide-out room204is retracted. After the slide-out room204is retracted to the desired position, the brake-only switch656is set to the “off” position to positively lock the slide-out room204.

Referring toFIGS. 28-30, another embodiment of a slide-out extension mechanism700having a drive mechanism702and a manual override system704in accordance with the present invention is illustrated. As contrasted with the drive mechanism602described inFIGS. 25-27, a pawl brake706may be mechanically released by an link member708in the event that an electric motor710is inoperable. Under normal operating conditions, the electric motor710and pawl brake706are activated by a motor/brake switch712which is preferably located in the interior portion of the trailer200, but it may be located in any readily accessible location such as an exterior portion of the fixed room202. The motor/brake switch712is coupled to a primary power supply711.

Referring back toFIGS. 29A-29C, the pawl brake706includes a rotatable disk714which is connected to a shaft of a right angle gear box716. A plurality of apertures718are located circumferentially near an outer portion of the disk714. A first rocker arm720and a second rocker arm722are pivotally coupled to the right angle gear box716, wherein the rocker arms722,724are parallel to each other. Each rocker arm722,724includes a latching member726,728which engages with the plurality of apertures718. The first latching member724includes a locking surface728which prevent clockwise rotation of the disk714when engaged with one of the apertures718, and the second latching member726includes a locking surface730which prevents counterclockwise rotation of the disk714when engaged with one of the other apertures718. Thus, both clockwise and counterclockwise rotation of the disk714may be prevented when both rocker arms720,722engage with the apertures718of the disk714. An actuator, which is mounted to the right angle gear box716, causes the rocker arms720,722to simultaneously engage (seeFIG. 29A) and disengage (seeFIG. 29B) with the disk714. In the exemplary embodiment, the actuator is a solenoid732having a pin734. The pin734is coupled to the first720and second rocker arm722by a cross member736, and the pin734is extended when the solenoid732is de-energized and retracted when the solenoid732is energized. It is noted that the actuator may be any device known in the art for selectively moving a pin or other to and from and extended and retracted position.

Referring back toFIG. 28, the drive mechanism702further includes a first housing738mounted to one channel740and a second housing742mounted to another channel. A first drive gear746is rotatively mounted to the first housing738, and a second drive gear748is rotatively mounted to the second housing742. Each of the drive gears746,748is in meshing engagement with its respective gear track such that rotation of the drive gears746,748cause support rails750,752to slide in-and-out of their respective channels740,744. The drive gears746,748are driven by the electric motor710, and the electric motor710is mounted to the first housing730. An output shaft of the electric motor710is connected to a gear reducing assembly754, and the gear reducing assembly754is coupled to the first drive gear746. The second drive gear748is coupled to the first drive gear746by a drive shaft756wherein rotation of the first drive gear746causes the second drive gear748to similarly rotate.

The manual override system704may be used to extend and retract the slide-out room204in the event that the electric motor710is inoperable. The right angle gear box716provides an enclosure for a gear system having a bevel gear (not shown) mounted for rotation with the gear reducing assembly754. A bevel pinion758is in meshing engagement with the gear reducing assembly754. A first end of a crankshaft760is slidingly connected to the bevel pinion758. The crankshaft760includes a central square tube762and a telescoping section764. The telescoping section764has a square cross section portion slidably received within a passage766defined by the central square tube. A second end of the crankshaft760is received within a lead-in tube768mounted to a first transverse structural member770. A removable crank handle772engages with the second end of the crankshaft760when inserted into the lead-in tube768. Rotation of the crank handle772rotates the bevel pinion758, which in turn rotates the gear system of the right angle gear box, rotates the gears in the gear reducing assembly754and rotates the first drive gear746in order to manually extend or retract the slide-out room204. A link member708is pivotally connected to the right angle gear box716and is movable between a locking position and an unlocking position. When the crank handle776is inserted into the lead-in tube768, the crank handle772engages the crankshaft760. The crankshaft760slides towards the link member708, and the first end of the crankshaft760abuts a first contact surface776of the link member708. As the link member708pivots to the unlocking position, a second contact surface778of the link member708engages a lever portion780,782of each of the rocker arms720,722. The rocker arms720,722pivot to their disengaged position and the slide-out room204is free to be retracted or extended. A bias member784such as a spring is provided between the bevel pinion758and link member708to bias the link member708in the locking position. Thus, the link member708pivots to the locking position and the pawl brake706is locked when the crank handle772is disengaged from the crankshaft760.

The slide-out room204is operated in the following manner. As shown inFIG. 29A, the electric motor710and solenoid732are usually de-energized, the pin734is extended, the first720and second rocker arm722are engaged with the disk714, and the slide-out room204is prevented from retracting or extending. With the slide-out room204in the fully retracted position, the operator sets the motor/brake switch712to the “on” position. As shown inFIG. 29B, the electric motor710and solenoid732are energized, the pin734is retracted, the first720and second rocker arm722are disengaged from the disk714, the support rails750,752extend outwardly from the channels740,744, and the slide-out room204extends outwardly. At the fully extended position, the motor/brake switch712is automatically reset to the “off” position, the electric motor710is de-energized, and the pawl brake706is engaged to positively lock the slide-out room204in the fully extended position. The slide-out room204may be moved from the fully extended position to the fully retracted position by setting the motor/brake switch712to the “on” position. The electric motor710and solenoid732are energized, the pin732is retracted, the first720and second rocker arm722are disengaged from the disk714, the support rails750,752retract inwardly into the channels740,744, and the slide-out room204is retracted. At the fully retracted position, the motor/brake switch712is automatically set to the “off” position, the electric motor710and solenoid730are de-energized, the pin732is extended, the first720and second rocker arm722are engaged with the disk714, and the slide-out room204is positively locked by the pawl brake706.

The manual override system704may be used to retract or extend the slide-out room204when the electric motor710is inoperable. In order to extend the slide-out room204, the pawl brake706is released by inserting the crank handle776into the lead-in tube768. The crankshaft760is slidingly driven towards the link member708, and the first end of the crankshaft760abuts the first contact surface776of the link member708and causes the link member708to pivot to the unlocking position. As the link member708pivots towards the unlocking position, the second contact surface778of the link member708engages the lever portion780,782of each of the rocker arms720,722. The rocker arms720,722pivot and disengage from the disk714. With the pawl brake706released, the crank handle772is rotated until the slide-out room204is extended to the desired position. After the slide-out room204is extended to the desired position, the crank handle772is disengaged from the crankshaft760, the bias member784pivots the link member708to the locking position, and the rocker arms720,722pivot and engage with the disk714. With the pawl brake706locked, the slide-out room204is prevented from retracting or extending. The slide-out room204may be retracted by inserting the crank handle772into the lead-in tube768, wherein the crankshaft760is slidingly driven towards the link member708. The first end of the crankshaft760abuts the first contact surface776of the link member708and causes the link member708to pivot to the unlocking position. As the link member708pivots towards the unlocking position, the second contact surface778of the link member708engages the lever portion780,782of each of the rocker arms720,722. The rocker arms720,722pivot and disengage from the disk714. With the pawl brake706released, the crank handle772is rotated until the slide-out room204is retracted to the desired position. After the slide-out room204is retracted to the desired position, the crank handle772is disengaged from the crankshaft760, the bias member784pivots the link member708to the locking position, and the rocker arms720,722pivot and engage with the disk714. With the pawl brake706locked, the slide-out room204is prevented from retracting or extending.

Although the present invention has been described in detail with regarding the exemplary embodiments and drawings thereof, it should be apparent to those skilled in the art that various adaptations may be accomplished without departing from the spirit and scope of the invention. For example, the present invention is suitable for use in vehicles other than trailers such as motor homes, motor coaches, or other towable vehicles. Furthermore, the present is not limited to slide-out mechanisms utilizing an electric motor and gear mechanism to extend and retract the slide-out room. The slide-out room may be automatically driven by a hydraulic, pneumatic, or any other system commonly known to one skilled in the art.