Articulating interlocking structural extrusions for recreational vehicles and the like

A structural assembly such as for use in constructing a living space of a recreational vehicle includes a wall with vertical rails at the top and bottom. The rails fitting into complementary recess within floor and ceiling members. The bottom rail has a curved cross section and fits into a complementary shaped curved channel in a floor member such that to assemble the wall to the floor, the wall is rested on the floor member at an angle and is then tilted upright to lock it to the floor member. A first keeper is then placed into a gap between the wall and the floor member, and acts in compression to prevent rotation of the wall. A second keeper has portions that fit into recesses in the wall and the ceiling members, respectively. The second keeper acts in tension to prevent vertical separation of the wall and the ceiling.

CROSS-REFERENCE TO RELATED APPLICATIONS

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to the field of structural members. More particularly, this invention relates to the field of articulated interlocking structural extrusions for recreational vehicles and the like.

2. Description of Related Art

Structural members made of lightweight materials such as aluminum are well known. Extrusions made from aluminum are popular for use in applications in which structural members must be strong but lightweight.

In recreational vehicles such as motor homes, the need is particularly acute for strong structural members. Both towed and self propelled recreational vehicles experience vibration on the road and around curves, jars and jolts over bumps and potholes, and experience high winds associated with highway travel, sometimes into a strong headwind which greatly increases the wind speed experienced by the structure. Each structural member of a recreational vehicle must therefore not only strong by itself, but the assembled structure as a whole must be firmly and strongly held together. At the same time, the structural members in recreational vehicles must be lightweight for reasons of fuel efficiency, vehicle stability, and tire wear. For these reasons, extruded aluminum structural members have been used by some recreational vehicle manufacturers as preferred structural members.

Another requirement of the recreational vehicle industry is that the structure be easily assembled. U.S. Pat. No. 5,218,792 issued to Cooper shows a housing structure for use in recreational vehicles which uses aluminum extrusions having a honeycomb structure for strength. The aluminum extrusions are riveted together. U.S. Pat. No. 5,553,906 issued to Kunz shows extruded aluminum floors and sidewall members, and discloses a method of joining those members together which relies on sets of complementary sets of teeth to interlock those members together.

SUMMARY OF THE INVENTION

The present invention is of interlocking structural members. The members are particularly well suited for use in constructing the living space of a recreational vehicle such as a motor home or a towed trailer.

In the illustrative embodiment, the bottom portion of a wall, made of extruded aluminum, has a first and downwardly extending curved tongue or rail that has a generally J-shaped cross section. The rail is partially inserted into a corresponding curved groove or slot in a floor member at an angle thereto. The wall is then rotated to its final upright position. In this position the wall is sufficiently locked, via the curved tongue in the curved groove, to the floor member that it cannot be lifted straight out from the floor member. A floor keeper is then inserted into a gap formed between a portion of the floor member and a portion of the wall to firmly hold the wall into its upright position, i.e., locked into the floor member. The wall is now prevented from moving horizontally by the fit of the tongue into the floor groove and by other abutting surfaces of the floor and sidewall members, is prevented from moving vertically by the curve of the tongue fitting into the curve of the floor groove, and is prevented from rotating out of that position by the keeper. The floor keeper is then secured in place by a series of small fasteners such as screws or rivets. Taken together, the floor and sidewall members and the floor keeper carry virtually all of the structural stresses experienced by the assembly in use. The fasteners carry virtually none of those stresses. Furthermore, the floor and sidewall members, which are large and could be awkward to handle in large applications such as recreational vehicles, are easily assembled and locked together by a small number of workmen using minimal lifting and positioning equipment. In the illustrative embodiment, the sidewalls can be articulated and thereby locked into the floor members with only two workmen working without any assistance from mechanical lifts or other assembly machinery, and the keepers thereafter installed by those same workmen.

The top portion of the wall also has a second and upwardly extending tongue or rail. That second tongue fits into a corresponding groove or slot in a roof corner member. Once the corner piece, which in most cases will already be welded to the rest of the roof frame, has been lowered onto the wall, the fit of the tongue into the groove prevents relative horizontal movement of the wall and the roof corner member. Both the wall and the top corner member also have additional generally horizontal slots in them, preferably along the outside surfaces. A roof keeper having two generally horizontal protrusions disposed vertically apart is then inserted into the two horizontal slots. The roof keeper acts in tension to prevent the corner piece from being pulled upward away from the wall. The wall and the corner piece are thus locked together, preventing relative movement either vertically or horizontally. Taken together, the fit of the top tongue into the roof corner groove, in combination with the roof keeper, carry virtually all of the structural stresses experienced by the assembly in use. The roof keeper is held in place via small fasteners such as screws or rivets which do not carry any structural stresses.

As an additional feature of the invention, the structural members have various protrusions and recesses suitable for precise positioning of other components such as floor, wall, and ceiling panels, and for tucking items such as the tail edges of ceiling fabric. Still further, the top keeper includes an integrated awning keeper, and the roof corner member includes a concave channel which defines an integrated rain gutter to channel water toward the front or back of the vehicle and thus prevent rain water from running down from the roof and staining the sides of the vehicle.

In one aspect of the invention, therefore, the invention is of a structural assembly for a recreational vehicle wall. The assembly may be fabricated from extruded aluminum, and includes a first structural member defining a wall or a wall member having a J-shaped tongue extending from a bottom edge of the wall, a second structural member defining a floor member or a wall support member having a J-shaped groove generally but not necessarily exactly complementary to the J-shaped tongue, wherein to assemble the wall to the floor the tongue is first partially inserted into the groove, and the wall is thereafter articulated upwards to insert the tongue fully into the groove thereby locking the wall to the floor member. The shape of the groove defines a tongue engagement feature, and the shape of the tongue defines a groove engagement feature. A keeper is thereafter inserted into a gap between the wall and the floor member, preventing rotation of the wall which would unlock the wall from the floor.

In another aspect, the invention is of a method of locking a vehicle wall to a vehicle floor, the method including the steps of providing a wall having an articulating locking mechanism, providing a floor or a wall support having an articulating locking mechanism to mate with and thereby lock with the articulating locking mechanism of the wall, positioning the wall at an angle relative to vertical such that the wall articulating locking mechanism partially engages the wall support locking mechanism, and tilting the wall upright into a generally vertical position, the wall articulating locking mechanism increasingly engaging the wall support locking mechanism as the wall is tilted upright to lock the wall to the wall support or floor.

In another aspect, the invention is of a structural assembly that includes a wall having a rail having a contoured cross section at or near its bottom edge, a wall support having a recess that has a contoured cross section, the rail and recess having complementary contoured shapes such that the wall may be articulated relative to the wall support to engage the wall to the wall support, the contoured shape of the recess engaging the complementary contoured shape of the rail to prevent the rail from being pulled upward away from the wall support when the wall is in its full upright position. A keeper engages respective portions of the wall member and the wall support to prevent relative rotation of those members.

In yet another aspect, the invention is of an assembly for connecting a wall to either the floor or roof of a vehicle, the assembly comprising first and second members having a tongue in one member that engages a corresponding groove in the other member to prevent relative horizontal movement of the two members, and a keeper that prevents relative vertical movement of the two members, the keeper acting in either tension or compression to carry the structural stresses without placing stresses on any fasteners other than the keeper. The invention therefore avoids placing any structural stresses on fasteners such as screws, rivets, or bolts that are used to hold walls to floors or to corners or roofs as in previous designs.

The invention is particularly well suited for use with extruded aluminum members in recreational vehicles such as motor homes and trailers. However, as those skilled in the art will appreciate the invention has broader applications as well.

Exemplary embodiments of the invention will be further described below with reference to the drawings, in which like numbers refer to like parts.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1shows a wall and floor assembly according to an illustrative embodiment of the present invention. The assembly includes a bottom wall member20, a floor member30, and a keeper40. Bottom wall member20may be welded by this time to structural channel members that define wall studs, with a wall top member welded to the wall studs, so as to define a single structural wall unit (FIG. 9). Bottom wall member20may therefore also be referred to simply as wall20.

Wall20has a rail or tongue22extending generally downwardly from the bottom thereof. Tongue22is curved, and more particularly, is generally J-shaped, having a straight portion23, a curved portion24, and a distal most portion25. It is not strictly required that tongue22be J-shaped. The distal most extent25of tongue22could be defined by, for example, a curve of tongue22as shown in the figure, or an angle, or a protrusion therefrom. A generally horizontal and planar bottom surface26is adjacent tongue22. Wall20optionally has a ledge28, whose function will be described later, extending inwardly toward the interior living space of the vehicle.

Floor member30is preferably affixed by this time to the vehicle floor, floor support, or chassis via welding, bolting, or other means. Floor member30may therefore also be referred to simply as floor30. Because floor member30provides a support surface on which wall20will rest, floor member30may also be referred to as a wall support.

Floor30has a generally downwardly extending groove or slot32formed therein. Groove32is generally J-shaped, having a straight portion33on a first side of groove32, a curved portion33having an arc of about 90° and a recess34at a distal most portion of groove32. Groove32therefore has a shape that is generally complementary to the J-shape of tongue22. On a second side of groove32opposite the first side, groove32is defined in part by a ledge35having an uppermost extent defining a generally horizontal surface37. Groove32therefore has a shape that is not exactly the same shape as tongue22. However, the two shapes correspond sufficiently for mating engagement of tongue22into groove32. Groove32has an uppermost extent at a generally horizontal surface38which will, at least in part, support wall20. Horizontal surfaces37and38, which correspond to the uppermost extent of ledge35on a first side of groove32, and the uppermost extent of groove32on a second and opposite side of groove32, respectively, are located at different vertical levels.

Floor30has a generally downwardly extending groove or slot32formed therein. Groove32is generally J-shaped, having a straight portion33on a first side of groove32, a curved portion36having an arc of about 90° and a recess34at a distal most portion of groove32. Groove32therefore has a shape that is generally complementary to the J-shape of tongue22. On a second side of groove32opposite the first side, groove32is defined in part by a ledge35having an uppermost extent defining a generally horizontal surface37. Groove32therefore has a shape that is not exactly the same shape as tongue22. However, the two shapes correspond sufficiently for mating engagement of tongue22into groove32. Groove32has an uppermost extent at a generally horizontal surface38which will, at least in part, support wall20. Horizontal surfaces37and38, which correspond to the uppermost extent of ledge35on a first side of groove32, and the uppermost extent of groove32on a second and opposite side of groove32, respectively, are located at different vertical levels.

FIG. 3shows wall20having been tilted up nearly to its full vertical position. As can be seen from the figures, as wall20is tilted upright to approach its final vertical position, groove32increasingly engages tongue22by virtue of the tongue being slid farther into groove32as wall20is rotated up relative to the floor.

FIG. 4shows wall20now rotated into its final, full vertical and upright position relative to floor30. Tongue22is now fully inserted into groove32. The distal most portion25of tongue22rests within recess34of groove32, underneath and engaged by the edge of ledge35. In this position wall20and floor30are prevented from moving horizontally relative to each other by means of tongue22being inserted into groove32and horizontally constrained on one side by straight portion33of groove32, and on the other side by ledge35. Additional side-to-side structural support is provided by vertical portion29(FIG. 3) of wall20butting up against vertical surface39of floor member30. Furthermore, tongue22is engaged by an overhanging portion of groove32, preventing tongue22from being pulled vertically away from floor30. Wall20is thus prevented from moving either horizontally or vertically relative to floor30. The only degree of freedom remaining for wall20is rotational movement opposite the direction of the rotational arrow inFIG. 2. This last degree of freedom is eliminated by floor keeper40being installed.

FIG. 5shows floor keeper40inserted into a gap defined by the space between generally horizontal surface27of wall member20and generally horizontal surface37of floor member30. Referring toFIG. 3for clarity, floor keeper40includes a rail42that extends into and fills the gap between wall member20and floor member30. Keeper rail42has a horizontal portion having a first upwardly facing generally horizontal surface43, and two vertical ribs44and46which define downwardly facing generally horizontal surfaces45and47. Constructing keeper rail42in this way is both extrusion friendly, and provides vertical ribs44and46which provide strong resistance in compression against rotation of wall member20. Keeper rail42therefore effectively fills the gap for structural purposes without needing to be a solid structure that completely fills the gap. Keeper40may be held to floor member30by small fasteners such as screws100which may be self tapping screws, sheet metal screws, or machine screws or bolts which screw into tapped holes in floor member30. Rivets or other fasteners could be substituted.

As will be apparent from the foregoing description, tongue22defines a wall articulating locking means, and groove32defines a floor articulating locking means or a wall support articulating locking means, with the wall and the floor being locked together by positioning the wall at an angle relative to vertical and such that the wall articulating locking means partially engages the wall support locking means, and tilting the wall upright into a generally vertical position, the wall articulating locking means increasingly engaging the wall support locking means as the wall is tilted upright to lock the wall to the wall support.

FIG. 6is a perspective view showing the components of the top wall and corner assembly. The assembly includes top corner member50, top wall member60, and roof keeper70. Top wall member60may be welded by this time to structural channel members that define wall studs, with a bottom wall member welded to the wall studs, so as to define a single structural wall unit (FIG. 9). Top wall member60may therefore also be referred to simply as wall60. Top corner member50may be referred to as corner50for short.

Wall60has a generally vertically protruding tongue62which fits into corresponding generally vertically recessed groove52formed in corner50. Wall60also has a channel66in it having a generally horizontal surface67. Corner50has a channel56in it having a generally horizontal surface57. Channels56and66define channels that extend longitudinally along the length of the vehicle.

Roof keeper70has two rails72and74having horizontal surfaces73and75, respectively. Rails72and74define rails that extend longitudinally along the length of the vehicle. In the embodiment shown roof keeper70also has an integrally formed awning keeper78which in the embodiment shown is a tubular member having a generally C-shaped cross section, and extending longitudinally along the length of the vehicle. Although integrated awning retainers have been incorporated into motor homes before, such as in U.S. Pat. No. 6,224,125 issued to McCormack which shows an awning retainer integrally formed in a recreational vehicle structural corner member, by forming the awning retainer78as part of roof keeper70, awning retainer78can be easily replaced if it is damaged, or a different awning retainer may be incorporated into the vehicle simply by installing a different roof keeper. The awning retainer of the present invention therefore provides greater flexibility and replaceability.

For structural integrity, wall60is preferably a single piece that extends the entire length of the living area, and may be fabricated by welding or otherwise fastening together different sections to form a single structural piece. In contrast, the keeper70may include several different discrete keeper sections which need not be welded or otherwise affixed together because keeper70does not carry structural stresses of the vehicle other than to prevent corner50from pulling upward away from wall60.

FIG. 7shows corner50positioned onto wall60so that tongue62is received into groove52. In this position corner50and wall60are prevented from moving horizontally with respect to each other. Roof keeper70is ready to be installed.

FIG. 8shows the top corner assembly including installed roof keeper70. Roof keeper70has been installed by being slid generally horizontally so that first keeper rail72fits into corresponding channel56in corner member50, with generally horizontal surface73of keeper rail72butting against generally horizontal surface57of corner member50. Similarly, second keeper rail74fits into channel66in wall member60, with generally horizontal surface75of keeper rail74butting against generally horizontal surface67of wall member60. In the installed position shown, roof keeper70acts in tension to prevent vertical separation of corner50from wall60. Corner50is thus prevented from moving either horizontally or vertically relative to wall60.

Roof keeper70may be held to wall60or to corner50by small fasteners such as screws101(FIG. 9) which may be self tapping screws, sheet metal screws, or machine screws or bolts which screw into tapped holes in wall60or corner50. Rivets or other fasteners could be substituted.

FIG. 10shows a completed wall assembly including bottom wall member20locked into floor member30, and top wall member60locked into corner member50. Aluminum structural channels90defining wall studs are welded at welds92and94to bottom wall member20and top wall member60, respectively. The voids between studs are filled with foam material (not shown) for additional structural support and rigidity, and to provide thermal insulation.

As additional and optional features of the invention, the structural components may include various non-structural features integrated therein including various panel positioning features. In the embodiment shown inFIG. 6, corner member50includes a rain gutter82integrally formed therein as a channel having a generally semicircular cross section. Rain gutter82extends along left and right corners from near the front of the vehicle to the rear of the vehicle in order to channel rain water away from running down the sides of the vehicle, which can leave unsightly water stains.

In the embodiment shown inFIG. 10wall member20includes a ledge28extending longitudinally along the length of the vehicle, which is used to position and support an interior wall panel102which may be made of plywood. Ledge28preferably protrudes a distance from the wall member20equal to the thickness of interior wall panel102. Ledge28also extends over floor plywood panel104and carpet106to help cover the edges of those components.

A gap48, defined by a space between bottom wall member20and floor keeper40(FIG. 9), may be used to position and hold an exterior wall panel103such as a sheet of fiberglass siding (FIG. 10).

A recess84(FIG. 9) formed in corner member50is used to hold an upper edge of interior wall panel102, and also to tuck therein a tail111of fabric from ceiling covering material such as vinyl head liner110(FIG. 10).

A recess86(FIG. 9) positions and helps hold a ceiling panel such as plywood panel108(FIG. 10).

An exterior recess88(FIG. 9) positions and holds roofing material112such as a sheet of suitable roofing material (FIG. 10).

In the illustrative embodiment floor keeper40fits snugly into its corresponding gap between wall20and floor member30. Similarly, rails72and74of roof keeper70fit snugly into the corresponding channel56in corner member50and channel66in wall60, respectively. A snug fit helps prevent rattling or movement between the components of the assembly during use of the vehicle, and helps maintain the pieces in place during assembly.

It will be appreciated that the term “present invention” as used herein should not be construed to mean that only a single invention having a single essential element or group of elements is presented. Similarly, it will also be appreciated that the term “present invention” encompasses a number of separate innovations which can each be considered separate inventions. Although the present invention has thus been described in detail with regard to the preferred embodiments and drawings thereof, it should be apparent to those skilled in the art that various adaptations and modifications of the present invention may be accomplished without departing from the spirit and the scope of the invention. For example, although the invention is well suited for use with structural members made of extruded aluminum, the members could be made of materials other than aluminum and formed in ways other than by extrusion. Although the invention has been described with reference to the wall members having tongues and the floor and top corner members having associated grooves or recesses, the wall members could have the grooves and the floor and top corner members could have the tongues. Differently shaped tongues and grooves could be used. Although the roof and its corners have been described as being dropped onto both the left and right side walls of the vehicle for ease of assembly, the roof could be articulated to lock it to one of the walls in accordance with the present teaching of articulated locking means. The keepers could be held in place by a number of different fasteners, or possibly even with double backed tape or glue, or other fastening means. Although particular cross sectional shapes have been shown in the drawings, those particular shapes have been chosen because they are believed to be extrusion friendly and otherwise well suited for manufacturing. Many different shapes could be used. Furthermore, many variations on the illustrative embodiments shown and described are possible. Although the invention is described as eliminating structural stresses on small fasteners such as screws, the teachings of the present invention could, in theory, be used in structures in which some stresses are carried by fasteners such as screws or rivets, while still incorporating the teachings of the invention. That is, use of the present invention, and the placing of some structural stresses on small fasteners, are not necessarily mutually exclusive. Accordingly, it is to be understood that the detailed description and the accompanying drawings as set forth hereinabove are not intended to limit the breadth of the present invention, which should be inferred only from the following claims and their appropriately construed legal equivalents.