Abstract:
A mobile recreational vehicle includes a body enclosing a living area designed to serve as self-contained living quarters during recreational travel. The body is supported on at least one pair of wheels (and often two or more pairs). The vehicle includes a ceiling assembly, a floor assembly; and an elongated and adjustable ceiling support extending between the ceiling assembly and the floor assembly wherein the height of the support can be adjusted during installation. In some instances, the vehicle has a shortened full length slide-out to allow for additional sidewall ceiling support, and in some instances has a slide-out opening that has cambered upper edges to minimize sagging the opening.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS  
       [0001]     This application claims the benefit of Provisional Application No. 60/630,985, filed Nov. 24, 2004. 
     
    
     FIELD OF THE INVENTION  
       [0002]     The present invention relates generally to recreational vehicles.  
       BACKGROUND OF THE INVENTION  
       [0003]     Recreational vehicles that are intended to be moved between locations at which they function as temporary housing benefit from having living areas that can be increased when the vehicles are not being transported. One way to provide an expandable living area is to use a slide-out. A slide-out typically has three walls, a floor, and a ceiling, and fits within a larger central living area when a vehicle is being transported, and is slid out to extend outward from a side of the vehicle when it is not being transported. Examples of vehicles with slide-outs can be found in at least U.S. Pat. Nos. 6,623,058, 6,293,612, 6,290,284, 6,286,883, 6,170,903, 6,135,525, 6,098,346, 5,248,180, 4,480,866, 3,719,386, 2,965,412, 2,704,203, 2,225,319, and 2,177,394, herein incorporated by reference in their entireties.  
         [0004]     Over time, recreational vehicle size has increased. Vehicle size increases, particularly increases in length, have made it desirable to increase slide-out lengths as a full wall slide-out (i.e. a slide-out extending along more than half of the length of the side of the vehicle it slides out from) provides a larger increase in living area than a shorter slide-out. Unfortunately, increased slide-out length presents difficulties in vehicle design that have yet to be overcome. As such, there is a need for improved vehicle structures and construction methods that facilitate the use of extended length slide-outs.  
       SUMMARY OF THE INVENTION  
       [0005]     The present invention is directed to a mobile recreational vehicle including a body enclosing a living area designed to serve as self-contained living quarters during recreational travel, where the body is supported on at least one pair of wheels (and often two or more pairs). The vehicle includes a ceiling assembly, a floor assembly; and an elongated and adjustable ceiling support extending between the ceiling assembly and the floor assembly wherein the height of the support can be adjusted during installation. The present invention is also directed to mobile recreational vehicles having shortened full length slide-outs to allow for additional side ceiling support, and for mobile recreational vehicles that have slide-out openings that have cambered upper edges to minimize sagging of such openings with minimal vertical supports. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0006]     The exact nature of this invention, as well as the objects and advantages thereof, will become readily apparent from consideration of the following specification in conjunction with the accompanying drawings in which like reference numerals designate like parts throughout the figures thereof and wherein:  
         [0007]      FIG. 1  is a perspective view of a recreational vehicle;  
         [0008]      FIG. 2  is a perspective view of the vehicle of  FIG. 1  with an extended slide-out;  
         [0009]      FIG. 3  is a left perspective view of the a support frame of the vehicle of  FIG. 1 ;  
         [0010]      FIG. 4  is a right perspective view of the support frame and slide-out of the vehicle of  FIG. 1 .  
         [0011]      FIG. 5  is a perspective view of an adjustable center ceiling support of the support frame of  FIG. 3 ;  
         [0012]      FIG. 6  is a side view of the support of  FIG. 5 ;  
         [0013]      FIG. 6A  is a cutaway view of the top portion of  FIG. 5 ;  
         [0014]      FIG. 7  is a partial side view of a portion of the sidewall support framing of the frame of  FIG. 3  that includes a sidewall ceiling support;  
         [0015]      FIG. 8  is an exaggerated illustration of the cambering of a portion of the support frame of the vehicle of  FIG. 3 ;  
         [0016]      FIG. 9  is a cutaway view of the vehicle of  FIG. 1  with the slide-out retracted;  
         [0017]      FIG. 10  is a partial perspective view of the vehicle of  FIG. 1  with the slide-out retracted;  
         [0018]      FIG. 11  is a cutaway view of the vehicle of  FIG. 1  with the slide-out extended;  
         [0019]      FIG. 12  is a partial perspective view of the vehicle of  FIG. 1  with the slide-out extended;  
         [0020]      FIG. 13  is a perspective view of an alternative recreational vehicle;  
         [0021]      FIG. 14  is a perspective view of the vehicle of  FIG. 13  with an extended slide-out  
         [0022]      FIG. 15  is a perspective view of another alternative recreational vehicle; and  
         [0023]      FIG. 16  is a perspective view of the vehicle of  FIG. 15  with an extended slide-out 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0024]     Reference will now be made to the preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. While the invention will be described in conjunction with the preferred embodiments, it will be understood that these embodiments are not intended to limit the invention. On the contrary, the invention is intended to cover alternatives, modifications and equivalents, which may be included within the spirit and scope of the invention as defined by the appended claims. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. However, it will be understood by one of ordinary skill in the art that the present invention may be practiced without these specific details. In other instances, well known methods, procedures, components, and circuits have not been described in detail so as not to unnecessarily obscure the important aspects of the present invention. Moreover, the embodiments of the present invention described herein comprise multiple novel features with each described embodiment including either a single such feature or a combination of such features. Other contemplated embodiments include all combinations of one or more such novel features not explicitly described herein as such combinations are readily discernable from the embodiments described.  
         [0025]     Although recreational vehicles slide-outs have been in use for several decades, recent increases in vehicle size and in expectations regarding vehicle weight, durability, and features necessitate improvements in vehicle structure that have not previously been provided. As an example, as slide-out length increases, the length of slide-out openings increases with a corresponding decrease in the amount of ceiling structure support provided by the sidewalls. The decrease in support occurs in regard to both vertical movement of the ceiling structure as well as in regard to lateral movement, twisting, and vibration of the ceiling structure. Decreased support is an issue both when the vehicle is in motion with any slide-outs retracted, and when the vehicle is at rest with slide-outs extended.  
         [0026]     Compensating for the decreased support is complicated by the fact that it is undesirable to fill the expanded living area of the recreational vehicle with supports. Further complications arise from the fact that it is desirable to keep the total vehicle weight to a minimum, and to minimize the cost, at least in regard to time, labor, and materials, of manufacturing the vehicle.  
         [0027]     As will be discussed herein, a balance between conflicting design criteria is achieved through the use of one or more of the following: a shallower slide-out coupled with an adjustable center ceiling support, a shortened sidewall coupled with a sidewall ceiling support, and a cambered horizontal support positioned above the slide-out opening. The term “shortened” in this instance indicates that, although it is desirable to maximize the length of the slide-out, it is beneficial in some instances to sacrifice some of the length to a sidewall ceiling support. As such, a “full wall” slide-out as described herein is any slide-out that extends along at least 50% of the length of the vehicle, and preferably extends at least 70% of the length of the vehicle.  
         [0028]     Referring primarily to  FIGS. 1 and 2 , a recreational vehicle  1  that is a motor-home comprises a hull  3 , a full wall slide-out  5 , and a slide-out opening  7 , as well as a top/ceiling/roof  9 , a bottom/floor  11 , a front  13 , a rear  15 , a right side  17 , and a left side  19 . In  FIG. 1 , the slide-out  5  is in a retracted position, and in  FIG. 2  is in an extended position. Extending the slide-out  5  increases the size of an expandable living area cavity  21  (see  FIGS. 3 and 11 ) enclosed by the ceiling  9 , the floor  11 , the front  13 , the rear  15 , the sides  17  and  19 , and slide-out  5 . In addition to the features shown, the vehicle  1  will typically comprise a gas or diesel engine, a transmission, a cab including controls used while driving the vehicle  1 , and also including a driver&#39;s seat and a passenger seat positioned to facilitate control of the vehicle while looking out the front of the vehicle.  
         [0029]     Although most of the figures depict a motor-home, the methods and apparatus disclosed herein are equally applicable to other recreational vehicles, and particularly to recreational vehicles comprising a mobile chassis. As such, the term recreational vehicle includes at least motor-homes and travel trailers. As an example, in  FIGS. 13 and 14  a recreational vehicle  201  that is a standard travel trailer is shown with its slide-out  205  retracted and extended. In  FIGS. 15 and 16 , a recreational vehicle  301  that is a fifth wheel travel trailer is shown with its slide-out  305  retracted and extended.  
         [0030]     Although the figures depict a single slide-out embodiment, the features described are also applicable to vehicles comprising multiple slide-outs such as vehicles having both left and right slide-outs.  
         [0031]     Referring to  FIGS. 3 and 4 , the hull  3  of the vehicle  1  comprises an internal support frame  23 . The roof/ceiling portion of the frame  23  includes longitudinal supports (“ceiling extrusions”)  25  and transverse supports (“ceiling ribs”)  27 . The ceiling extrusions  25  and the ceiling ribs are preferably pre-assembled into a layered ceiling assembly having an external roof/skin layer separated from an internal ceiling layer by an insulating layer that includes the ceiling ribs and ceiling extrusions. After a substantial portion of the floor and sidewalls of the frame  23  are assembled, the ceiling assembly can be put in place as a single piece. The frame  23  also includes vertical supports  29 , an adjustable center ceiling support  31 , a sidewall ceiling support  33 , cambered tubular members  57  and  63 , an adjustable center ceiling support receiving transverse support (“transverse cantilever”)  59 , lower longitudinal supports  26 , lower transverse supports  28 , a lower transverse support  64 , and a ceiling support arch  61 . The supports  31  and  33  help support the layered ceiling assembly of ceiling  9 . The support  33 , members  57  and  63 , and vertical support  29  are preferably incorporated into a pre-assembled sidewall in a manner similar to the roof/ceiling portion of the frame  23 .  
         [0032]     The arch support  61  is coupled to a top surface of the transverse cantilever  59  and comprises one or more openings extending through it to facilitate routing of wires and the like. The arch support  61  maintains a minimum distance between the transverse cantilever  59  and any points on the roof/ceiling assembly immediately above the arch support  61 .  
         [0033]     In addition, to the elements shown, a recreational vehicle hull will typically comprise one or more of the following: external and internal panels including or covering support frame  23 , windows permitting light and/or air to pass through the sides of the hull  3 , vents permitting air to pass through the sides, floor, and/or ceiling of the hull  3 , exterior access doors permitting entry into the living area cavity  21 , dividers for dividing the living area cavity  21  into smaller areas, cabinets for storage, interior doors permitting movement between rooms, and electrical and plumbing components.  
         [0034]     Referring to  FIGS. 5, 6 , and  6 A, the adjustable center ceiling support  31  comprises horizontal members  35 , vertical members  37 , cross-braces  39 , alignment plates  41 , support plates  42 , and adjustment assemblies  43 . The adjustment assemblies  43  each comprise an adjustment bolt  45 , nuts  47 , and washers  49 . The members  35  and  37  and braces  39  may be hollow or solid, comprise a single pieces or an assembly of pieces, and/or comprise a single material or a plurality of materials. Moreover, the members  35  and  37  may be coupled together in any manner. However, in some instances it may be advantageous if the support  31  comprised steel or aluminum tubing welded together such that the members  35  and  37  form a rectangular frame with the cross-braces  39  extending between points at or near the internal corners of the frame. In the embodiment shown, the cross-braces  39  are coupled to the horizontal members  35  at points near but not in the corners of the rectangle formed by the members  35  and  37 . Positioning the ends of the members  39  away from the members  37  allows the adjustment assemblies  43  to be positioned closer to the members  37 . The plates  41  and  42  add rigidity to the support  31 . Having the plates  41  extend beyond the edge formed by the upper horizontal member  35  allows the plates  41  to be used to align the support  31  under the transverse cantilever  59 . There will typically be a gap  67  between an upper horizontal member  35  and transverse cantilever  59 . The size of the gap  67  as well as the distance between supports  59  and  64  can be adjusted using the adjustment assemblies  43 .  
         [0035]     Although the size and dimensions of the support  31  may vary between embodiments, it is preferred that it fit between the ceiling and the floor of the living area, i.e. between the ceiling ribs  27  and the lower transverse supports  28 . As shown, the support  31  fits between the transverse cantilever  59  and a lower transverse support  64 . It is contemplated that in some instances the support  31  will have a width between 24 and 48 inches, a height without including adjustment assemblies between 79 and 96 inches, and adjustment assemblies that can maintain a maximum sidewall opening size of between 76 and 93 inches, and will be able to support static loads of at least 400 pounds.  
         [0036]     Although a single support  31  is shown, in some instances an embodiment may comprise two or more supports  31 . Although shown positioned in the center of vehicle  1  and perpendicular to the side comprising the slide-out, in some instances the support  31  may be positioned other than in the center of the vehicle and/or other than perpendicular to the slide-out side(s). Although shown comprising bolts, nuts, and washers, the adjustment assemblies  43  may comprise any mechanism that supports the ceiling  9  of the hull  3  but allows the distance between the ceiling ribs  27  and the lower transverse supports  28  adjacent to support the 31 to be adjusted. An alternative mechanism might include a pivot opposite of the slide-out  5  and a single adjustment assembly.  
         [0037]     The adjustment assemblies  43  can be operated to increase or decrease the gap  67  between an upper horizontal member  35  and the transverse cantilever  59 . Both the transverse cantilever  59  and the upper member  35  will include holes through which the bolts  45  pass with the nuts  47  and the washers  49  being used to fasten the bolts  45  in place, and to establish the size of the gap  67 . The bolts  45  are preferably welded to the transverse cantilever  59 . As such, the nuts  47  adjacent to transverse cantilever  59  shown in the figures may in some instances be eliminated as they are not necessary to prevent movement of the bolts  45  relative to the transverse cantilever  59 . It should be noted that the transverse cantilever  59  is rotatable relative to the upper member  35  in that the angle at which it extends from the support  31  can be adjusted using the adjustment assemblies  43 . It is contemplated that having adjustment assemblies that can be operated independently of each other so as to be able to adjust the slope of the transverse cantilever  59  in such a manner provides a number of advantages.  
         [0038]     Referring to  FIG. 7 , the sidewall ceiling support  33  comprises horizontal members  51 , portions of  57  and  63 , vertical members  53 , and cross-braces  55 . The members  51 ,  53 ,  57 , and  63  and braces  55  may be hollow or solid, comprise single pieces or an assembly of pieces, and/or comprise a single material or a plurality of materials. Moreover, the members  51 ,  53 ,  55  and  57  may be coupled together in any manner. However, in some instances it may be advantageous if the support  33  comprised aluminum tubing welded together such that the members  51 ,  53 , and  55 , and a portion of the members  57  and  63 , form a rectangular frame with the cross-braces  55  extending between the internal corners of the frame.  
         [0039]     Although the size and dimensions of the support  33  may vary between embodiments, it is advantageous to have the support  33  have a height (vertical length) at least equal to the height of the opening  7 , and to have a smaller width. If the slide-out  5  extends along most of the length of the side  19  of the hull  3 , a single support  33  may extend as shown between an edge of the opening  7  and the rear  15  of the hull  3 . In other instances, a plurality of adjacent supports  33  may extend between a side of the slide-out opening and the front  13  and/or the rear  15  of the hull  3 . In some instances, a slide-out opening may comprise supports  33  adjacent to both ends of the slide-out opening. It is contemplated that in some instances the support  33  will have a height between 79 and 96 inches and a width between 18 and 48 inches, and will be able to support static loads of at least 1200 pounds.  
         [0040]     Although increased slide-out lengths are desirable, reducing the slide-out length in order to enable the support  33  to be positioned in an end portion of the side  19  adjacent to the opening  7  provides substantial improvement in the support provided to the ceiling assembly. Similarly, reducing slide-out depth enables the support  31  to be positioned perpendicular to the support  33  without interfering with the slide-out  5  as it is retracted, and possibly without interfering with a second slide out opposite the slide out  5  when both slide-outs are retracted.  
         [0041]     Referring to  FIGS. 3, 4 ,  7  and  8 , the cambered tubular members  57  and  63  are positioned above the slide-out opening  7  and help counter any tendency of the upper edge of the opening  7  to sag. The members  57  and  63  are cambered such that there is a 0.5 to 1.5 inch gap C 1  between a center point of the member  57  and a line extending between the ends of the member  57 . This cambering is achieved by flexing the members  57  and  63  while they are adjacent to each other but not coupled together, and then welding the members  57  and  63  together to prevent them from sliding relative to each other such that they remain cambered. The member  57  and  63  are preferably at least as long as the length of the slide-out opening  7 . In some instances the length of the members  57  and  63  will be between 18 and 36 feet.  
         [0042]     As can be seen, the members  57  and  63 , the support  31 , and the support  33  are all coupled together as part of the support frame  23  with the supports  31  and  33  being perpendicular to each other, and the support  33  and the members  57  and  63  being parallel or coplanar to each other. The support  33  incorporates an end of each of the members  57  and  63  which are welded together. The support  31  is coupled to transverse cantilever  59  which in turn is coupled to cambered member  63 .  
         [0043]     In  FIGS. 9-12 , a roller assembly is pictured which can add additional support to the cambered members  57  and  63  when the slide-out  5  is either fully retracted or fully extended. As shown, a roller assembly  69  is coupled to member  57  and is aligned with roller biasing members  65  and  67  which are coupled to an upper surface/ceiling of the slide-out  5 . Retracting the slide-out  5  places the roller biasing member  65  in contact with the roller assembly  69  so as to push the ceiling support  57  away from the slide-out  5 . Extending the slide-out  5  also places the roller biasing member  67  in contact with the roller assembly  69  so as to push the member  57  away from the slide-out  5 . As such, when retracted or extended, the slide-out  5 , roller assembly  69 , and one of the biasing members  65  and  67  function to push the member  57  upward. This has numerous advantages such as decreasing relative movement between the ceiling  9  and the slide-out  5  during travel, and providing additional support to the ceiling  9 .  
         [0044]     It should be noted that the biasing member  67  extends further from the slide-out  5  than does the biasing member  65 . This permits the slide-out  5  to move downward relative to the rest of hull  3  such that a floor of the slide-out is substantially co-planar to the rest of the floor of the living area when the slide-out is extended even though the slide-out must be raised above the living area floor when the slide-out is retracted. As can be seen, the biasing member  67  is preferably a bracket that first extends upward against the wall  71  (which may function to stop movement of the slide-out  5  out of the living area  21 , and/or fills the gap left between the member  57  and the top of the slide-out  5 . The bracket has a sloped portion positioned to initially contact the roller assembly  69  as the slide-out  5  is extended. The biasing member  65  is preferably a solid block that has a sloped portion to initially contact the roller assembly  69  as the slide-out  5  is retracted.  
         [0045]     A method of manufacturing a mobile recreational vehicle as described herein may include one or more of the following steps: (a) providing an elongated and adjustable ceiling support; (b) adjusting and positioning the support such that it has a desired height and extends between the floor assembly and the ceiling assembly; and (c) adjusting the height of the adjustable support to obtain a desired vertical dimension of at least a portion of the slide-out opening. In some instances, adjusting the height of the support may include rotating an elongated support member coupled to the adjustable support and extending between the adjustable support and an upper edge of the opening in the side wall.