Abstract:
A reconfigurable lower bunk apparatus for a vehicle having a sleeping compartment with a rear wall and first and second side walls is disclosed. In one form, a mattress receiving receptacle or tray is moveably mounted to a rear wall of the vehicle to permit raising and lowering of the tray between raised and lowered positions. A storage compartment is overlaid by the tray when the tray is in the lowered position. The storage compartment may have first and second sections with one of the sections being longer than the other and desirably greater than one-half the width between the side walls of the sleeping compartment. Removable dividers may subdivide the storage compartment into respective storage sections.

Description:
CROSS REFERENCE  
       [0001]     This application is based on provisional patent application No. 60/520,487, filed on Nov. 14, 2003. The entire disclosure of the provisional application is considered to be part of the disclosure of the following application and is hereby incorporated by reference herein.  
         [0002]     The present disclosure relates to a lower bunk for a vehicle and more specifically to such a bunk which may be reconfigurable. 
     
    
     BACKGROUND  
       [0003]     Some vehicles, such as long haul truck-tractors, include a sleeping compartment in which one or more bunks, including a lower bunk, may be positioned.  
         [0004]     A need exists for improvements to these known bunk configurations.  
       SUMMARY  
       [0005]     In accordance with one aspect of an embodiment, a mattress receiving receptacle such as a tray, which may also receive a spring, or combined mattress and spring, may be movably coupled to a wall of the vehicle to permit raising and lowering of the mattress receiving tray to expose compartments positioned beneath the tray. In a desirable embodiment, the tray is hinged to a rear wall of the vehicle and comprises a lid for the compartments. Additional support to the mattress receiving tray may be provided by vehicle mounted side supports and a front bunk supporting member such as a beam. The beam which may extend between the sides of the vehicle and along the lower front of the tray. One or more supports, such as first and second upright supports spaced along the length of the bunk supporting member may also be provided.  
         [0006]     A tray raising assist mechanism, such as one or more gas shocks, may be used to bias the tray to an opened position to assist in opening the bunk.  
         [0007]     The compartment defining portion of the bunk apparatus may comprise plural sections such as a first elongated section which extends for greater than one-half the width of the vehicle compartment and a second section which is shorter and may, for example, extend the remaining distance across the vehicle compartment. The length of the second section may be adjusted to fit the width of the particular vehicle.  
         [0008]     In accordance with another aspect of an embodiment, one or more of the compartment sections, such as desirably the elongated portion of the compartment may include divider receiving receptacles, such as slots or other divider receivers, for receiving upright dividers which subdivide the elongated compartment into various subcompartments. These dividers may comprise supports for electrical components which can be assembled onto the dividers prior to placing the dividers in the compartments. This facilitates mounting of such electrical components in place.  
         [0009]     One end compartment section of the compartment assembly may have a plurality of apertures for admitting air therein. In addition, a heating, ventilation, air conditioning unit (HVAC) may be included in such compartment and may have an optional cover which also contains airways such that air from the interior of the vehicle may flow into the HVAC unit through the compartment. The HVAC compartment thus permits the flow of air through the compartment to the HVAC unit without the need for additional ducting. Less desirably, such ducting could be used.  
         [0010]     The bunk supporting tray may comprise a multi-section tray having a first mattress supporting portion. In addition, the bunk supporting tray may include a lower portion which is fastened, such as by rivets or other fasteners, solvent welded or otherwise coupled to the upper portion. Projections and receptacles may be formed in the lower major surface of the upper tray portion and in the upper surface of the lower tray portion with such projections and receptacles from the respective tray sections mating with one another to provide added support to the interior regions of the bunk tray. Rigidifying side connectors may also be included. The space between the upper and lower tray sections may define wire receiving passageways, which may be enclosed, for the passage of wire to electrical modules or other electrical components. In addition, lights may be fastened to the undersurface of the lower tray section with electrical wires being coupled to the lights to provide lighting. The lights may be activated by a switch which closes to energize the lights when the tray is lifted. The bunk receiving tray may also have a latch to retain the bunk in a lowered position.  
         [0011]     The present invention is not limited to any particular embodiment or embodiments set forth herein, nor is it limited to any particular combination or subcombination as set forth herein. Instead, the invention is directed toward all new and non-obvious features of a bunk configuration disclosed herein both alone and in all new and non-obvious combinations and subcombinations with one another. 
     
    
     DESCRIPTION OF THE DRAWINGS  
       [0012]      FIG. 1  is a perspective view of one embodiment of a bunk configuration.  
         [0013]      FIG. 2  is an exploded view of an alternative embodiment of a bunk configuration.  
         [0014]      FIG. 3  illustrates a portion of a bunk configuration with the bunk lid in a raised position and without a divider in one of the divider receiving receptacles of the form shown in  FIG. 3 .  
         [0015]      FIG. 4  is a bottom view of an embodiment of a lower portion of a bunk receiving tray.  
         [0016]      FIG. 5  illustrates an embodiment of a bunk tray supporting structure which may be mounted to a vehicle.  
         [0017]      FIG. 6  illustrates an embodiment of a bunk configuration without the bunk receiving tray.  
         [0018]      FIG. 7  illustrates the embodiment of  FIG. 6  with the bunk receiving tray shown in a closed position.  
         [0019]      FIG. 8  illustrates an exploded view of one form of an embodiment of a bunk receiving tray.  
     
    
     DETAILED DESCRIPTION  
       [0020]     With reference to  FIG. 1 , one form of a bunk structure is indicated by the number  10 . The illustrated bunk structure comprises a bunk receiving tray  12  which is coupled to support structure carried by a vehicle. For example, the rear edge of tray  12  may be fastened, such as by rivets, or other fasteners, to a hinge plate  14  of a hinge  16 . The other hinge plate  18  of hinge  16  is mounted to the rear wall, for example, of a vehicle to allow the tray  12  to pivot upwardly about the longitudinal axis of hinge pins of the hinge  16 .  
         [0021]     A forward support comprised of an elongated cross member  20  is desirably provided to support the front edge of the bunk receiving tray  12 . First and second upright supports  22 , 24  are coupled at their respective upper end portions to cross support  20  and at their respective lower end portions to, for example, the floor of the vehicle. Side supports may also be provided, although not shown, in  FIG. 1 . To assist in opening the tray, gas shocks may be provided (or alternative biasing mechanisms) at the opposite ends of the tray  12 . One such shock is indicated at  30  in  FIG. 7 . A latch  32  may engage the tray  12  to latch the tray in a closed position until the latch is released.  
         [0022]     The bunk configuration of  FIG. 1  also comprises plural compartment sections such as a first compartment section  40  extending from one side portion of the structure to a location which is greater than midway across the length of the structure. This particular bunk configuration also comprises a second compartment section  42  which may span the remainder of the distance across the width of the vehicle. It should be noted that compartment sections  40  and  42  may be of alternative configurations. Also, although less desirable, more than two compartment sections may be used. The compartment section  42  may be adjusted in length to fit the available space for the bunk structure.  
         [0023]     The tray  12  illustrated in  FIG. 1  has a mattress retaining lip extending at least partially around the upper periphery of the tray. Desirably, the illustrated upwardly extending flange or lip  50  extends about the entire periphery of the tray. Flange  50  assists in retaining the mattress (not shown) in the tray. Additional mattress retainers such as retaining flanges or prongs indicated at  52  in  FIG. 1  may be included to grip the mattress to assist in retaining it in the tray.  
         [0024]     The embodiment of  FIG. 2  includes only one forward support  22 N. Cross support  20  may, for example, be a steel cross beam. A cover piece, such as a snapfit piece of plastic (e.g., PVC), may be mounted to cross piece  20  for decorative reasons.  
         [0025]     In the embodiment of  FIG. 2 , bunk tray end supports  60 , 62  (which are mounted typically to the sides of the vehicle in the sleeper compartment thereof) are also shown. In addition, an HVAC cover  64  is shown. Cover  64  fits within the region  66  of compartment  42  to enclose an HVAC unit if included at this location. The cover  64  is optional. In  FIG. 2 , one can see that openings are provided in cover  64  for the passage of air to the HVAC unit if included therein. In addition, openings may be provided in the front panel of compartment  42  to admit air to the compartment and to any HVAC unit contained therein. The illustrated compartment  40  is provided with first and second divider receiving receptacles  70 , 72 . The illustrated form of receptacles comprise respective spaced apart parallel U-shape wall portions which each define a slot therebetween. Although this form of divider receptacle is advantageous, any suitable form of divider support may be used. An upright partition  74  fits within slot or receptacle  70 . An upright partition  76  fits within the slot  72 . Partitions  74 , 76  may be removable to change the configuration of the storage compartment  40 . Also, electrical components, such as electrical modules, may be mounted thereto. Electrical wiring  80  is also shown in  FIG. 2 . Respective lights  82 , 84  and  86  are coupled from this wiring through a switch to an electrical source. The wiring  80  and lights  82 , 84  and  86  may be attached to the underside of tray  12 . The lights illuminate the interior of the compartment. The switch may be actuated when the tray is raised to cause these lights to turn on. Portions of the wiring  80  may be sandwiched between upper and lower sections (not shown in  FIG. 2 ) which together define the mattress receiving tray  12 .  
         [0026]      FIG. 3  shows some of the wiring  80  exposed. Lights  82  and  84  are also indicated in  FIG. 3 . The divider  74  is not installed in the  FIG. 3  embodiment.  
         [0027]      FIG. 4  illustrates one embodiment of a lower tray section  12 A of tray  12 . In the embodiment of  FIG. 4 , four of the underside lights are provided including light  87 . As can be seen in  FIG. 4 , the wires  80  are coupled to the tray section  12 A along the rear of the tray section and then extend forwardly between the tray sections to the location of the respective lights  82 , 84 ,  86  and  87 . As also can be seen in  FIG. 4 , the illustrated form of hinge plate  16  is generally L-shape with a base section extending beneath the underside of tray section  12 A where it may be riveted or otherwise fastened thereto. Also, the mattress retainers  52  may be L-shaped with a base portion extending along and being fastened to the undersurface of tray section  12 A.  
         [0028]     The various projections depicted in the underside of the tray assist in reinforcing the tray. In particular, as will be apparent from the figures discussed below, upwardly extending projections from the surface of tray section  12 A, not visible in  FIG. 4 , may be provided to mate with corresponding receptacles in the other tray section (the undersurface of the top tray section) to provide additional support for these members. The tray sections may be fastened together.  
         [0029]      FIG. 5  illustrates a portion of a sleeping compartment of a vehicle having a floor  96  and upwardly extended rib members of various configurations, some of which are indicated at  98 . The forward portion of the sleeper compartment may be defined by a post member  100  (one such member being positioned at each of the opposite sides of the vehicle with only one being shown in  FIG. 5  for convenience). A cross piece  104  in the rear wall of the vehicle is positioned at the level of the hinge to provide support for mounting the hinge to the rear wall of the vehicle. Exemplary tray supporting side pieces  108 , 110  are shown in  FIG. 5 . Each of these side supports may include a respective rear portion  112 , 114  which wraps around the interior rear cover of the vehicle to engage a portion of the rear wall of the vehicle. In addition, the side supports  108 , 110  may have respective forwardly projecting portions  116 , 118 . Extensions  116 , 118  may be eliminated or extended in length to accommodate sleeper compartments of various front-to-rear depths.  
         [0030]      FIG. 6  is similar to  FIG. 5  except that  FIG. 6  includes the bunk compartment structure shown installed. In addition, both shocks  30 , 31  are visible in  FIG. 6 . Like components in  FIG. 6 , have been assigned like numbers to those previously discussed, such as in  FIG. 1 .  
         [0031]      FIG. 7  illustrates an embodiment of a bunk configuration with the bunk receiving tray shown in a closed position. The upper tray section  12 B of tray  12  is indicated in  FIG. 7 . In addition, a number of recesses  140  (which correspond to projections at the opposite side of the tray  12 B) are indicated in  FIG. 7 . These projections intermesh with projection receiving slots in tray section  12 A to rigidify the construction.  
         [0032]     In  FIG. 8 , the tray sections  12 A and  12 B are shown in an exploded view. Some intermediate reinforcing components indicated generally by the number  150  may also be used to rigidify the bunk receiving tray.  
         [0033]     The lights discussed above may snap-fit into light receiving receptacles of the tray  12 A at the underside thereof. Wiring  80  at the rear edge of the tray may be supported by fasteners mounted to the underside of the tray. These fasteners may snap-fit into receptacles at the underside of the tray to hold the wire at such locations. Alternatively, wire clips or retainers may simply be mounted to the underside of the tray.  
         [0034]     The side reinforcing members  108 , 110  are typically of a durable light material such as aluminum.  
         [0035]     The upwardly extending flanges at the rear edge of the compartments  40 , 42  shown in  FIG. 2  (some of which are indicated by number  162  and  164 ) may be riveted or otherwise attached to the back wall of the vehicle. These components may be releasably attached if desired. A groove may be defined along the back edge of the compartments  40 , 42  (e.g., between partition receiving components  70 , 72  and flanges  162 , 164 ). Such a groove, if provided, may support or accommodate a wiring bundle for electrical components of the vehicle.  
         [0036]     Although not required, in the construction described above, desirably the compartments  40 , 42  do not support the bunk receiving tray  12  as the tray is supported instead by the hinge and by the respective side elements  108 , 110  and front support  20 .  
         [0037]     Any of a number of electrical component modules may be mounted to the partitions  74 , 76 . For example, power components, a transmission electronic control unit and a low voltage disconnect, as well as other such modules and components. These components are easily accessible and are protected within the compartments. Also, these modules may be coupled by plug and connectors to a mating connector on a wiring harness for easy electrical coupling thereto. The components may be installed onto the dividers prior to placing the dividers within the compartments.  
         [0038]     The tray may be formed of a durable polymer material (as well as the compartments  40 , 42  and partitions  74 , 76 ). For example, high density polyethylene may be used.  
         [0039]     Having illustrated and described the principles of our invention with respect to several embodiments, it should be apparent to those of ordinary skill in the art that these embodiments may be modified in arrangement and detail without departing from the principles of our invention. All such modifications are included within our invention.