Travel trailer

A travel trailer having a two-level chassis supporting at least three discrete floor sections at three different heights above the ground with at least one of those floors being suspended from the chassis. In a preferred embodiment, the chassis has a substantially horizontal forward upper portion and a substantially horizontal rearward lower portion, and an upper floor is secured to the upper portion and a lower floor is secured to the lower portion with an intermediate floor suspended from the upper portion of the chassis to a height intermediate that of the upper and lower floors. The area underneath the intermediate section and above the bottom of the trailer defines a storage area that is not blocked or limited in size by the width of the chassis beams. In a more preferred embodiment, common fixed trailer accessories, such as gray and black water tanks, their related plumbing, trailer heaters and the like are clustered together within and near a limited section of the storage area, such as near the rear of the storage area, such that the majority of the storage area remains unoccupied. Accordingly, storage space within the storage area is optimized, and the full height of the storage area is available throughout the majority of the storage area to accommodate oversized objects.

TECHNICAL FIELD

The invention is an improved travel trailer. In particular, the invention concerns a travel trailer having an improved chassis that is strong, easy, and economical to manufacture, and has at least one floor suspended from the chassis, which preferably optimizes use of available storage space beneath that floor.

BACKGROUND OF THE INVENTION

Travel trailers, which are towed vehicles usually having many of the conveniences of a home, are widely known and popular. One known type of travel trailer is commonly referred to as a fifth-wheel trailer, which is particularly adapted to be towed by a traditional pick-up truck. Namely, the forward portion of the fifth-wheel trailer is elevated above the bed of the pick-up truck and includes a mounting portion extending from the bottom of the elevated forward portion to a trailer mount, or hitch, secured to the bed of the pick-up truck.

Because of height restrictions imposed on travel trailers operating on most highways and aerodynamic considerations associated with towing a travel trailer at high speeds, the total desirable height above the ground for a fifth-wheel trailer is limited. Accordingly, the elevated forward portion typically has limited headroom, and therefore is usually used as a bedroom. The remaining aft portion of the fifth-wheel trailer typically includes a bathroom portion and general living portion.

Plumbing in trailer bathrooms typically includes gray and black water storage tanks and related tubing and valves extending from one or more toilets, shower drains, sink drains, and the like within the bathroom, to these storage tanks. To take full advantage of gravity, these types of storage tanks are typically mounted somewhere below the drains and toilet such that water from these devices flows freely through this tubing to its respective storage tanks. Accordingly, it is desirable to elevate the floor of the bathroom portion of a trailer above the bottom of the trailer.

Because of the limited headroom, it is not desirable to elevate the bathroom portion of the floor to the height of the forward bedroom floor of the trailer. Accordingly, the typical fifth-wheel trailer will usually longitudinally position the bathroom portion between the bedroom and living portion, and vertically elevate the floor of the bathroom portion to an intermediate height between the heights of the bedroom and living portion floors. The end result is a fifth-wheel trailer having three floor heights above the ground. A first height toward the aft of the trailer supporting the living portion, a second height toward the center of the trailer supporting the bathroom portion, and a third height toward the front of the trailer supporting a bedroom.

The area below the second height and the bottom of the trailer is typically enclosed and used as a storage space for the storage tanks, valves, and plumbing. In addition, this area is typically large enough to be used as a general storage area, or trunk space, for gear and the like. Accordingly, one or more access doors may be provided along the exterior walls of this storage area to provide access to this space. It is desirable for this storage area to be large and easily accessible.

The chassis of a typical fifth-wheel trailer must be sufficiently strong to support the trailer, and durable enough to resist weakening over a lifetime of prolonged use. Since the typical fifth-wheel trailer is regularly towed at high speeds and over rough or unimproved roads, the chassis must also withstand a tremendous amount of dynamic loads placed on it. Typical chassis materials are incredibly strong and durable. For example, a typical fifth-wheel chassis will be made of welded-together portions of elongate steel I-beam having an eight-inch to 12-inch vertical web. In general, the fewer parts and welds making up the primary load carrying chassis structure, the stronger and more durable the chassis.

A particularly strong chassis design is commonly known as a two level chassis. It's general design is shown and identified as prior art in FIG. 1A of U.S. Pat. No. 5,746,473 to Crean, the disclosure of which is hereby incorporated by reference. A two level chassis features an elongate horizontal lower beam ( 114 , FIG. 1A of Crean), an elevated elongate horizontal tipper beam ( 116 , FIG. 1A of Crean), and an interconnecting vertical section ( 115 , FIG. 1A of Crean) joined to both the lower and upper beams as shown if FIG. 1A of Crean, usually by welding. The elevated bathroom portion ( 122 , FIG. 1A of Crean) of the typical two level chassis is typically a platform structure constructed of elongate wood members, metal members, or the like, and is supported above and by the lower beam ( 114 , FIG. 1A of Crean). A storage space ( 140 , FIG. 1A of Crean) is defined as the area below the elevated bathroom floor, but above the lower beam.

While the typical two level chassis is particular strong, the design also limits the amount of available storage in the storage area and access to that storage area. In particular, since the lower beam defines the lower portion of the storage area, the total volume of the storage area is narrowed by the vertical width of the webbing on that beam. For example, using typical chassis materials having an eight-inch to twelve-inch vertical web, the height of the storage area would be reduced by eight to twelve inches, thereby reducing the total volume of the storage area.

In practice, the height limitations imposed by positioning the chassis beam in this area prevents common oversized travel trailer-related items, such as traditional elongate, cylindrical 40 pound Liquid Petroleum Gas ( LPG ) tanks, from being accommodated easily in the storage area. In particular, in order for these types of items to fit within such known storage areas, they must either 1) be stored on their sides, thereby taking up much desirable floor space in the storage area, or 2) in some models be stored upright within a limited outrigger area between the chassis beam and storage area door, thereby blocking access to the majority of the storage area.

Some inventors have attempted to improve access to and the overall amount of storage space available in the storage area of a traditional fifth-wheel trailer. However, such improvements typically compromise chassis integrity and significantly increase chassis construction costs. For example, U.S. Pat. No. 5,746,473 to Crean teaches using a three-level chassis structure, which is also commonly referring to as a three-step chassis. FIG. 2A of Crean shows the general layout of such a three level chassis. Basically, the bottom level, or step, is a horizontal elongate lower chassis beam ( 202 , FIG. 2A of Crean) that supports the aft living portion of the fifth wheel trailer. The forward bedroom is supported by a horizontal elongate upper chassis beam ( 210 , FIG. 2A of Crean), and the bathroom portion is supported by a horizontal elongate intermediate chassis beam ( 208 , FIG. 2A of Crean). The forward end of the lower chassis beam is joined to the back end of the intermediate chassis beam at an aft vertical section, and the forward end of the intermediate chassis beam is joined to the back end of the upper chassis beam at a forward vertical section. Accordingly, the chassis structure forms three steps from the lower chassis beam to the intermediate chassis beam and then the upper chassis beam.

As a result, the thick lower beam does not block the lower entrance to the storage area, thereby, Crean suggests, the storage area is more easily accessible. Crean also teaches mounting the black and gray water tanks to the intermediate chassis beam, thereby elevating them within the storage area. Accordingly, Crean reports that heavy objects need not be lifted as high to place them in the storage area.

While the three-level chassis in Crean offers these limited benefits, the design essentially doubles the number of parts and welds comprising the load carrying chassis components over a traditional two-level chassis. Accordingly, a three-level chassis is more costly to manufacturer and less durable than a similarly sized two-level chassis structure. Moreover, because the upper edge of the storage area is defined by the intermediate beam, and the thickness of the intermediate beam is essentially as thick as a traditional lower beam on a two-level chassis, the height of the storage area, and accordingly its volume, is still limited by the chassis structure. For example, where the intermediate beam is made of typical chassis materials having an eight-inch vertical web, the height of the storage area would be reduced by eight inches, thereby reducing the total volume of the storage area. Accordingly, as with a traditional two-level chassis, the height limitations imposed by positioning the intermediate chassis beam in this area still prevents common oversized travel trailer-related items, such as 40 pound LPG tanks, from being accommodated easily in the storage area. Moreover, positioning the black and gray storage tanks adjacent to the intermediate beams, as taught by Crean, further reduces the height of the storage area, thereby further compromising the storage area's ability to accommodate common large objects. Because the intermediate chassis beam is a primary load carrying chassis element, any reduction in the thickness of this beam around the storage area of a three-level chassis to increase the height of the storage area would compromise the strength of the chassis.

Accordingly, despite the known improvements to fifth-wheel travel trailer chassis designs, there remains a need for a chassis that has the strength, durability, and economy of a traditional two-level chassis, but also optimizes the height of the storage area beneath the bathroom portion to easily accommodate common large objects used with travel trailers. In addition to other benefits that will become apparent in the

SUMMARY OF THE INVENTION

The present invention is a travel trailer having a two-level chassis supporting at least three discrete floor sections at three different heights above the ground. In particular, an aft floor section is positioned at a lower height, a fore floor section is positioned at an upper height, and an intermediate section is positioned at a height intermediate to the lower and upper heights. The area underneath the intermediate section and above the bottom of the trailer, defines a storage area.

The two-level chassis includes generally horizontal upper and lower chassis beams. The aft floor section is supported by the lower chassis beam, and the fore floor section is supported by the upper beam. The intermediate section is suspended from the upper chassis beams such that the height of, and general access to, the storage area is optimized because the chassis beams do not interfere with access to this area.

In a preferred embodiment, common fixed trailer accessories, such as gray and black water tanks, their related plumbing, trailer heaters and the like are clustered together within a limited section of the storage area, such as near the rear of the storage area, whereby the majority of the storage area remains unoccupied. Accordingly, storage space within the storage area is optimized, and the full height of the storage area is available throughout the majority of the storage area to accommodate oversized objects.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

An improved travel trailer 10 having an enclosed shelter 12 supported by a two-level chassis 14 defining a forward upper portion 16 and a rearward lower portion 18 , wherein the chassis 14 supports at least three discrete floor sections 20 a , 20 b , 20 c by suspending at least one floor section 20 b from the forward upper portion 16 is disclosed in FIGS. 1-7 .

As best shown in FIG. 2 , the chassis 14 preferably includes a left and right chassis beam assembly 22 a , 22 b respectively, with each beam assembly 22 a , 22 b including an elongate lower chassis beam 24 a , 24 b and an elongate upper chassis beam 26 a , 26 b joined together at vertical riser assemblies 28 a , 28 b . Each upper chassis beam 26 a , 26 b and lower chassis beam 24 a , 24 b has a front end 30 and a back end 32 , with the front end 30 of the lower chassis beams 24 a , 24 b secured to the back ends 32 of their respective upper chassis beams 26 a , 26 b at the vertical riser assemblies 28 a , 28 b such that the upper chassis beams 26 a , 26 b and lower chassis beams 24 a , 24 b are aligned parallel with each other and the upper chassis beams 26 a , 26 b are horizontally-aligned above the lower chassis beams 24 a , 24 b as shown.

The left and right beam assemblies 22 a , 22 b are spaced apart from each other and joined together with a plurality of chassis cross-members 40 a-i positioned along the longitudinal length of the chassis 14 , such that the lower chassis beams 24 a , 24 b and cross members 40 c-i define the rearward lower portion 18 of the chassis 14 and the upper chassis beams 26 a , 26 b and cross-members 40 a , 40 b define the forward upper portion 16 of the chassis.

Preferably, the upper and lower chassis beams 26 a , 26 b , 24 a , 24 b are constructed with strong and durable materials, such as steel I-beams. More preferably, the lower chassis beams 24 a , 24 b have a 12-inch vertical web 41 a , and the upper beams have an 8-inch vertical web 41 b.

The rearward lower portion 18 of the chassis 14 includes at least one perpendicularly aligned wheel assembly 42 a , 42 b , 42 c , preferably including an axle tube 44 a , 44 b , 44 c secured to the lower side 46 of the lower chassis beams 24 a , 24 b at suspension elements (not shown). An axle hub (not shown) is journaled to each axle tube 44 a , 44 b , 44 c and secured to wheels 50 a , 50 b , 50 c , preferably having tires 52 a , 52 b , 52 c attached to them and aligned substantially parallel to the lower chassis beams 24 a , 24 b.

The underside 54 of the forward upper portion 16 of the chassis includes a mounting portion 56 for detachable securing the chassis 14 to a trailer mount (not shown), or hitch. Preferably, a pair of jack legs 58 a , 58 b , each having a support tube 59 a , 59 b and a retractable extension portion 60 a , 60 b , is secured to the underside 54 of the forward upper portion 16 as shown to support the forward upper portion 16 when the trailer 10 is detached from its towing vehicle (not shown). More preferably, the support tubes 59 a , 59 b are steel 4-inch by 2-inch tubes having a thickness of {fraction (3/16)} of an inch and include jack leg reinforcement members 62 a , 62 b having slightly angled front ends 64 a , 64 b and gussets 66 a , 66 b as best shown in FIGS. 2 & 4 .

The vertical riser assemblies 28 a , 28 b each preferably include a generally vertically aligned perimeter chassis post 68 a , 68 b and an inner chassis post 70 a , 70 b joined together by transition members 72 a-f . As best shown in FIG. 2 , the front ends 30 of the lower chassis beams 24 a , 24 b are secured to the lower ends of the inner chassis posts 70 a , 70 b , and the back ends 32 of the upper chassis beams 26 a , 26 b are secured to the upper ends of the perimeter chassis posts 68 a , 68 b preferably by welding. More preferably, the chassis posts 68 a , 68 b , 70 a , 70 b are constructed of elongate steel tube, such as 5-inch by 3-inch tube having a thickness of {fraction (3/16)} of an inch. Each riser assembly 28 a , 28 b preferably includes reinforcing gussets 74 a , 74 b , 75 a , 75 b , and the upper and lower transition members 72 a , 72 c , 72 d , 72 f are angled as shown with respect to the chassis posts 68 a , 68 b , 70 a , 70 b to increase the strength and durability of the joints.

As best shown in FIG. 2 , cross-members 40 c-h in the rearward lower portion 18 of the chassis 14 each include upper and lower members 82 , 84 secured together by extension members 86 , which are preferably angled. More preferably, cross-member 40 i is positioned at the back ends 32 of the lower chassis beams 24 a , 24 b and is a Z-beam having a vertical web.

Cross-members 40 a , 40 b in the forward upper portion 16 of the chassis 14 are preferably elongate steel 8-inch by 2-inch tubes having a {fraction (3/16)}-inch thickness with one cross-member 40 a positioned at the front ends 30 of the upper chassis beam 26 a , 26 b . More preferably, supports 90 extend between cross members 40 a , 40 b as shown in FIG. 2 .

An elongate chassis rail lateral tie 92 is secured to and suspended below the upper chassis beams 26 a , 26 b . Preferably, the lateral tie 92 has a generally Z-shaped cross-section, forming an upper lip 94 and a lower lip 96 separated by an angled web 98 , with the upper lip 94 extending toward the front of the chassis 14 and the lower lip 96 extending toward the back of the chassis 14 . More preferably, the ends of the lateral tie 92 are secured to the angled ends 64 a , 64 b of the jack-leg reinforcement members 62 a , 62 b as best shown in FIGS. 4 & 7 .

B. Suspended Floor Assembly And Storage Area Details

As best shown in FIGS. 3 & 4 , a lower floor 20 c is supported by the lower portion 18 of the chassis 14 , preferably by extending space d apart elongate lower floor joists 100 from the lower ends of the vertical riser assemblies 28 a , 28 b to the back ends 32 of the lower chassis beams 24 a , 24 b and securing planar floor members 102 thereon. Similarly, the upper floor 20 a is supported by the upper portion 16 of the chassis 14 , preferably by extending spaced apart elongate upper floor joists 104 from an area generally near the front of the chassis 14 to the upper lip 94 of the chassis rail lateral tie 92 and securing planar floor members 102 thereon.

The intermediate floor 20 b is suspended below the upper portion 16 of the chassis in an area between the upper floor 20 a and lower floor 20 c . Preferably, the upper floor 20 a defines a bedroom, the lower floor 20 c defines a living area, and the intermediate floor 20 b defines a bathroom section of the trailer 10 .

One known apparatus for suspending the intermediate floor 20 b includes extending an elongate generally horizontal aft intermediate floor support 106 between the vertical chassis riser posts 68 a , 68 b at a height generally horizontally-aligned with the lower lip 96 of the chassis rail lateral tie 92 . In an area that is preferably equal distance between the lateral tie 92 and the aft intermediate floor support 106 , a suspended girder 108 having an upper edge 110 is suspended from the upper chassis beams 26 a , 26 b such that tie upper edge 110 is on the same horizontal plane as the lower lip 96 of the lateral tie 92 , preferably by extending suspension elements 112 a , 112 b from the upper chassis beams 26 a , 26 b and securing the girder 108 to the suspension elements 112 a , 112 b . Spaced apart intermediate floor joists 120 extend from the lower lip 96 of the lateral tie 92 to the aft intermediate floor support 106 . The intermediate floor joists 120 are also supported at the upper edge 110 of the suspended girder 108 as shown. Planar floor members 102 are secured to the intermediate floor joists 120 thereby defining the intermediate floor 20 b at a height between the upper and lower floors 20 a , 20 c , respectively. Preferably, a step 124 is provided between the lower floor 20 c and intermediate floor 20 b to facilitate access between these floors.

The area between the support tubes 59 a , 59 b and vertical riser assemblies 28 a , 28 b , above the bottom of the lower side 46 of the lower chassis beams 24 a , 24 b , and below the intermediate floor joists 120 defines a storage area 126 , or trunk space, of the trailer 10 . The intermediate floor 20 b is suspended from the upper chassis beams 26 a , 26 b such that the height 127 of, and general access to, the storage area 126 is optimized because the chassis beams 24 a , 24 b , 26 a , 26 b do not interfere with access to this area.

Preferably, the floor 128 of the storage area 126 is supported by a storage area lateral tie 130 extending between the lower end portions of the support tubes 59 a , 59 b and spaced apart elongate extension members 132 extending from the storage area lateral tie 130 to the lower chassis beam 24 a , 24 b as best shown in FIG. 5 . Spaced apart storage area floor joists 134 , extending between the sides of the storage area 126 , are secured to the elongate extension members 132 . Planar floor members 102 are secured to the storage area floor joists 134 , defining the floor 128 of the storage area 126 , Accordingly, the distance between the floor 128 of the storage area 126 and the lower edge of the intermediate floor joists 120 defines the height 127 of the storage area.

The upper floor joists 104 , lower floor joists 100 , and intermediate floor joists 120 , storage area lateral tie 130 , and elongate extension members 132 do not carry that great of a load as that carried by the chassis 14 . Accordingly, these components need not be as strong as the chassis components, and accordingly can have smaller cross-sectional dimensions. For example, the upper, lower, and intermediate floor joists 104 , 100 , 120 , respectively, are preferably constructed with 1-inch by 1-inch 11 gauge steel tubes, and the storage area lateral tie 130 and elongate extension members 132 are preferably constructed with 2-inch by 2-inch steel tubes having a -inch thickness. Of course these components can be made with any other suitably sized, shaped, and strong materials, including wood, other metals, and synthetic or composite materials.

As best shown in FIG. 1 , the enclosed shelter 12 encloses the storage area and includes a plurality of access doors 136 . Preferably, the access doors 136 a-c open outward and the height of the access doors 136 is substantially equivalent to the height of the storage area 126 , thereby not becoming a limiting factor in the size of objects that may be placed in the storage area 126 .

More preferably, and as best shown in FIGS. 4 and 7 , a planar sliding mechanism 138 having a pair of rail sliders 140 secured to the storage area floor 128 , and a platform 142 sized to support a conventional 40 pound LPG removable bottle 144 is slidably secured to the rail sliders 140 . An appropriately sized access door 136 a is aligned with the sliding mechanism to permit easy access.

C. Plumbing and Related Hardware Details

Optimal storage space is provided by clustering the common fixed trailer accessories, such as gray and black water tanks, their related plumbing, trailer heaters and the like within the same area in or near the storage area. As best shown in FIG. 4 & 7 , an elongate black water tank 150 having a substantially rectangular cross-section preferably rests on the storage area floor 128 in the back of the storage area 126 with a drain 152 extending upward from the black tank 150 through the bathroom intermediate floor 20 b . A remotely-actuated valve, such as a cable actuated black water tank dump valve 154 is positioned adjacent to and in fluid communication with the black water tank 150 , and associated plumbing (not shown) is preferably installed to the valve 154 to accommodate easy emptying of the tank 150 .

An elongate gray water tank 156 having a substantially rectangular cross section is preferably secured within an area below the lower floor joists 100 , above the bottom of the trailer 46 , and between the lower chassis beams 24 a , 24 b and lower cross-members 40 c , 40 d . A remotely-actuated valve, such as a cable actuated gray water tank dump valve 158 is positioned adjacent to and in fluid communication with the gray water tank 156 and associated plumbing (not shown) is preferably installed to accommodate easy emptying of the gray water tank 156 . Preferably the cable actuation control handles 160 a , 160 b for the black and gray water dump valves 154 , 158 are positioned together, adjacent to the outside of the trailer, and outside of the storage area for easy actuation, even if the storage area 126 is full.

If desired, a traditional trailer furnace ( 162 , FIG. 4 ) may be secured to the intermediate floor joists 120 near the black water tank 150 .

D. Use and Operation

The travel trailer 10 accordingly to the present invention is used like any other fifth-wheel trailer. Appropriate home furnishings and conveniences are placed in the living, bathroom, and bedroom portions of the trailer, which has the strength and durability of any trailer having a conventional two-level chassis.

However, volume of the storage area 126 , and access to that area, is optimized. For example, thick chassis beams do not limit the height of the storage area, or require a user to lift items to be stored above any bottom chassis beam. Moreover, by clustering the common fixed trailer accessories within the same area in or near the storage area, the remaining useful area within the storage area is optimized. Accordingly, oversized objects can be easily accommodated in the storage area with minimal lifting. For example, a conventional 40 pound LPB removable bottle 144 typically is an elongate canister of about 29 inches having a flat bottom end 164 on which it rests, defining its standing position. The height 127 of the storage area can be high enough to easily accommodate this type of bottle in its standing position. Moreover, in trailers so equipped, the sliding platform 142 and special access door 136 a further facilitate loading and storage of these types of bottles.

In view of the wide variety of embodiments to which the principles of the invention can be applied, it should be apparent that the detailed description of a preferred embodiment is illustrative only and should not be taken as limiting the scope of the invention. For example, although the preferred chassis beams 24 a , 24 b , 26 a , 26 b are I-beams, any suitably strong shape or material could be used without departing from the scope of the invention. Moreover, although preferred sizes and materials for the various beams, tubes, posts and the like have been disclosed, any suitably strong materials, shapes, and dimensions may be used depending on the specific design needs of a particular trailer. Also, although three wheel assemblies 42 a , 42 b , 42 c are shown in the figures, one, two, or even more such assemblies could be used depending on the load to be incurred by the chassis. Accordingly, the claimed invention includes all such modifications as may come within the scope of the following claims and equivalents thereto.