Abstract:
A travel trailer having exterior unitary lower and upper shells, an interior lower shell defining a pre-molded floor and side walls with a seating area, a cabinet for refrigerator and stove top, an opposing bench, a bathroom sink, and defining an aisle centrally therebetween; a shower pan attached to a side wall; an interior upper shell defining a pre-molded ceiling, side walls, and storage areas; a wall defining a door to a bathroom portion; and a wheeled chassis connected to the exterior lower shell with an extending tongue for attaching to a trailer hitch of a motor.

Description:
TECHNICAL FIELD 
       [0001]    The present invention relates to travel trailers. More particularly, the present invention relates to a travel trailer assembled from mating shells with features that facilitate the use of the travel trailer. 
       BACKGROUND OF THE INVENTION 
       [0002]    The travel trailer industry provides towable wheeled campers for recreational travel, sport, camping and like activities. Towable vehicles include a range of vehicles from wheeled carriers that unfold to provide a foundation and an erectable tent to towable travel housings or trailers. The travel trailers typically include sleeping space such as platforms or supports for mattresses and cushions, kitchen appliances including refrigerators, ovens, stovetops, and dishwashers, as well as washing basins, showers, cabinetry, sanitary facilities, and tables and seating areas. Often such towable travel trailers have storage tanks for freshwater and for sanitary waste, supplies of fuel, electric generators, and connector for attaching to a local electrical grid. 
         [0003]    Towable housing units include a wheeled chassis configured for connecting through a trailer tongue to a hitch on a tow vehicle. The chassis carries the frame of the housing which is closed with sidewall panels and a finished interior. Cabinetry installs with fasteners to the frame work of the housing, including, for example, overhead cabinets that attach to ceiling areas, pedestal cabinets for seating areas, and base cabinets for containing or holding appliances such as refrigerators, ovens, and stovetops, as well as television and stereo equipment. Electrical wires and water pipes mount inside walls. 
         [0004]    The manufacturing of such mobile housing trailers accommodates customization by the purchaser selecting among various alternatives for the fixtures and cabinetry. However, the manufacturer of such towable trailers is labor intensive, and requires separate components to be brought to the travel trailer for installation during construction and assembly. 
         [0005]    Accordingly, there is a need in the art for a readily assembled travel trailer. It is to such that the present invention is directed. 
       SUMMARY OF THE INVENTION 
       [0006]    The present invention meets the need in the art by providing a travel trailer, comprising an exterior lower shell and an exterior upper shell, each molded as a single unitary body and configured with a mating edge for overlapping joining of the exterior lower shell and the exterior upper shell, the opposing exterior lower shell and the exterior upper shell each defining a slotted opening extending from the respective edge for a passageway into an interior of the travel trailer. An interior lower shell received in the exterior lower shell defines pre-molded floor and side walls, and having a seating area with opposed benches, a cabinet structure configured for receiving a refrigerator and stove top, an opposing bench, a bathroom sink, and defining an aisle centrally therebetween. A shower pan seats on the floor and attaches to at least one side wall. An interior upper shell received in the exterior upper shell defines a pre-molded ceiling, opposing side walls, opposing L-shaped walls extending from the ceiling and extending to a respective side wall to define storage areas accessed through selectively operated doors. A wall defines a second door to separate a bathroom portion in which the shower pan is installed. A wheeled chassis connected to the exterior lower shell includes a longitudinally extending tongue configured for attaching to a trailer hitch of a motor vehicle for moving the travel trailer. 
         [0007]    Objects, advantages, and features of the present invention will become apparent upon a reading of the following detailed description with reference to the drawings and the appended claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         [0008]      FIG. 1  illustrates in perspective view a travel trailer according to the present invention. 
           [0009]      FIG. 2  illustrates in exploded perspective view a lower exterior shell and an interior lower shell. 
           [0010]      FIG. 3  illustrates in exploded perspective cut-away view an interior upper shell and an exterior upper shell. 
           [0011]      FIG. 4  illustrates in perspective partial view a portion of a chassis exploded from a portion of the exterior lower shell, to show the connection thereof. 
           [0012]      FIG. 5  illustrates a chassis for supporting the travel trailer shown in  FIG. 1 . 
           [0013]      FIG. 6  illustrates in perspective view portions of the exterior lower shell for the travel trailer shown in  FIG. 1 . 
           [0014]      FIG. 7  illustrates an opening in a side wall for a window. 
           [0015]      FIG. 8  illustrates in perspective view a portion of the travel trailer in which benches molded in the inerior lower shell in the interior of the travel trailer with openings that will receive covers for selective access to storage space and to equipment such as wiring and pipes and molded cabinets in the upper interior shell. 
           [0016]      FIG. 9  illustrates a bathroom assembly that inserts into the exterior lower shell to define a wall that separates the bathroom area from the living space of the travel trailer. 
           [0017]      FIG. 10  illustrates a portion of the bathroom assembly including a shower tub and a sink. 
           [0018]      FIG. 11  illustrates the wall of the bathroom assembly in the lower exterior shell separating the living space of the travel trailer. 
           [0019]      FIG. 12  illustrates a fragmentary rear view of the travel trailer with a bumper member in a first position. 
           [0020]      FIG. 13  illustrates a fragmentary rear view of the travel trailer with the bumper member in a second position. 
           [0021]      FIG. 14  illustrates a fragmentary rear view of the travel trailer with the bumper member in the second position. 
           [0022]      FIG. 15  illustrates a fragmentary view of the bumper member in the second position and a sanitary pipe connected to a sanitary outlet. 
           [0023]      FIG. 16  illustrates a detailed side perspective view of the bumper member in the first position and connected to a side of a bumper housing. 
           [0024]      FIG. 17  illustrates a pin used for securing the bumper member in the first position connected to a side of a bumper housing. 
           [0025]      FIG. 18  illustrates the travel trailer in perspective detailed front view and showing a storage cowling. 
           [0026]      FIG. 19  illustrates the storage cowling with a cover removed to show propane fuel tanks contained in the cowling. 
           [0027]      FIG. 20  illustrates the travel trailer in perspective rear side view. 
       
    
    
     DETAILED DESCRIPTION  
       [0028]    With reference to the drawings, in which like parts have like identifiers,  FIG. 1  illustrates in perspective view a travel trailer  10  according to the present invention. The travel trailer includes a wheeled ladder-frame chassis (best illustrated in  FIG. 5  and discussed below) having an axle and opposing wheels, with the axle supported by conventional suspension devices. As shown in  FIG. 5 , the suspension includes shock absorbers and leaf springs. A travel trailer hitch  12  protrudes from a first end for conventionally connecting the travel trailer  10  to a ball hitch of a tow vehicle (not illustrated). The roof supports a satellite antennae  13  as an optional entertainment feature, a vent  14 , and an HVAC device  15  for cooling and heating the travel trailer  10 . 
         [0029]    The travel trailer  10  assembles from shells molded of fiberglass. The travel trailer  10  has an exterior lower shell  16  and an exterior upper shell  18 . The shells enclose separate interior shells, discussed below. The shells  16 ,  18  matingly connect at opposing open edges to define substantially a mid-point of the height of the travel trailer  10 . The exterior shells enclose the interior shells and the space between the shells receives insulation materials and provides room for wiring and plumbing pipes. Fasteners secure overlapping edges of the exterior lower shell  16  and exterior upper shell  18  to rigidly connect the shells together. A cowling  19  mounts to a tongue portion of the chassis. The cowling  19  encloses propane fuel tanks. 
         [0030]    The travel trailer  10  assembles from modular construction to minimize labor and assembly.  FIG. 2  illustrates the exterior lower shell  16  exploded away from the interior lower shell  20 . The exterior lower shell  16  defines a sub-floor space generally  22 . 
         [0031]    With reference to  FIGS. 2 and 6 , the sub-floor space  22  defines opposed wheel wells  24  and spaced-apart frame channels  26  and an intermediate channel  28 . A holding tank  30  for gray water or sanitary waste mounts in the space between one of the frame channels  26  and the intermediate channel  28 . The gray water tank  30  includes a discharge  32  which couples to a suction hose (illustrated in  FIG. 15 ) for removal of waste gray water from the holding tank to a treatment facility. A fresh water tank  34  mounts in the opposing space between the other frame channel  26  and the intermediate channel  28 . The fresh water tank  34  connects to an inlet  36  for filling the tank with fresh water. The fresh water tank  34  communicates through a pump (not illustrated) to piping for communicating the water to a sink, a shower, and a toilet within the travel trailer  10 . A sidewall defines a gap  38  for a doorway. A rear portion generally  33  provides space for equipment such as a water pump and a hot water heater (not illustrated). 
         [0032]    With continuing reference to  FIG. 2 , an interior lower shell  40  is illustrated exploded from the exterior lower shell  16 . The interior lower shell  40  is molded of fiberglass and provides opposing side walls  42 , a back wall  44 , a front wall  46 , and an integral floor  48 . A sink  50  is molded in a bathroom portion of the interior shell  40 . A shower stall  52  and a commode  54  is installed in the bathroom area. A bracket for installation of a shower stall tub is disclosed in co-pending U.S. application Ser. No. 60/912,889 filed Mar. 19, 2007, and incorporated herein it its entirety by reference. 
         [0033]    The sink, shower  52 , and commode  54  communicate with piping (not illustrated) with the fresh water tank  34  and the gray water tank  30 . A wall  56  mounts to the floor  48  to separate the living area from the bathroom area. The wall includes an opening or notch  58  for a door (not illustrated). The interior lower shell  40  receives kitchen cabinet structures generally  60  including spaces for a microwave  62 , a refrigerator  64 , a sink  66 , and a range  68 . A bench  70  mounts to a sidewall and includes openings (illustrated in the front face for access into storage). A table  72  mounts on a pedestal  74 . Opposing cabinets  76  mount to the opposite wall  72  and include similar closable openings  78  for access to storage space and to infrastructural piping such as electrical and water handling conduits. The storage benches  70 ,  76  can be molded with the interior lower shell or be separate assemblies installed separately. 
         [0034]    The benches  70  and  76  each have recessed notches  80  in facing upper edges. Respective edges of the table top  72  seat in the notches  80  for supporting the table top level with the benches  70  and  76 . Mattress or cushions (not illustrated) placed on the benches  70 ,  76  and table top  72  enable the rear area of the travel trailer to be used for sleeping. The pedestal  74  is a conventional type that permits the table top to be moved to a lowered or recessed position for use as a sleeper support and an elevated position for use as a table top with seating provided by the benches  70 ,  76 . 
         [0035]      FIG. 3  illustrates in an exploded perspective view the interior upper shell  80  formed as a unitary member. Openings  82  for windows are illustrated and align with openings in the exterior upper shell  18 .  FIG. 7  illustrates in perspective detailed view a side wall portion of the upper exterior shell  18  and upper interior shell  80  with a cut edge  81  that defines an opening  82 . With continued reference to  FIG. 3 , the interior upper shell  80  includes cabinets  84  on opposing sides of the shell. The cabinets  84  include openings  86  for access into the interior space of the cabinets. The openings are readily selectively closed with doors such as cabinet doors having hinges that attach with fasteners to side faces around the openings. In addition, sliding panel doors can be used, and a track member for use with sliding panel doors is disclosed in pending U.S. application Ser. No. 60/912,880 filed Apr. 19, 2007, and incorporated herein in its entirety by reference. 
         [0036]      FIG. 8  illustrates in perspective view a portion of the travel trailer  10  in which benches  76 ,  70  molded in the inerior lower shell  40  define openings that will receive covers for selective access to storage space and to equipment such as wiring and pipes. The upper interior shell  80  includes molded cabinets generally  84  that define openings  86  for storage. 
         [0037]      FIG. 5  illustrates in perceptive view a chassis  90 . The chassis is a “ladder-frame” structure. The chassis has two spaced-apart longitudinal tubular members  92  that define sides of the chassis. The members  82  interconnect with spaced-apart transverse members  94 . A tongue portion generally  96  terminates in a hitch  12  for connecting the chassis to a tow vehicle. 
         [0038]      FIG. 4  illustrates in exploded perspective detail view a portion of the chassis  90  and a portion of the exterior lower shell  16 , to illustrate the connection of the exterior lower shell to the chassis. The longitudinal members  92  are received within a respective channel  26  of the exterior lower shell  16 . The transverse members  94  support the intermediate floor portion between the adjacent channels  26 ,  28 . Openings  98 ,  100  are formed in the channel  26  and the member  92 , respectively. A plate  102  seats on the channel  26 . The plate  102  defines an opening  104  that aligns with the openings  98 ,  100 . A bolt  103  extends through the opening  104  of the plate  102  and through the openings  98 ,  100 . A nut  108  threadly engages the bolt  103 . A least four such fastening connections are made to secure the exterior lower shell to the chassis  90 . Other securing structures are readily applicable to connect the chassis  90  and the exterior lower shell  16 . 
         [0039]      FIG. 9  illustrates a rear perspective view of a bathroom assembly  61  that inserts into the exterior lower shell  16  as a unit to define a transverse wall  56  that separates the bathroom area from the living space of the travel trailer. An opening  63  receives a door (not illustrated) for closing the bathroom area. The assembly  61  provides a molded in-place sink  50  with a storage space  65  below (closed by a cabinet door attached after installation of the assembly) and an area  67  (shown cut-away) for a shower stall or tub  52 . A storage space  69  is defined by a wall  71  extending from the wall  56 . As illustrated, a faucet readily attaches to the sink  50  for connection to water supply and drain pipes. 
         [0040]      FIG. 10  illustrates a portion of the bathroom assembly  61  including the shower tub  52  and the sink  50 . The molded assembly includes the storage space accessed through an opening that is closed by a cabinet door added during construction of the trailer  10 . 
         [0041]      FIG. 11  illustrates the wall  56  of the bathroom assembly  61  positioned in the lower exterior shell  16  and separating the living space of the travel trailer from the bathroom area. A gap between the wall  71  and appliance cabinets  60  provides space from walking into the travel trailer from the doorway and an adjacent storage space  69 . 
         [0042]      FIG. 12  illustrates a fragmentary rear view of the travel trailer  10 . Brake lights generally  202  mount in recessed fields  204  on opposing sides of the back. A cover  206  attaches to the back to enclose a spare tire that mounts to a threaded shaft for securing the tire from movement during travel, or other conventional spare tires support device. A bumper  208  attaches to the back of the travel trailer. The bumper  208  includes a bumper housing  210  and a bumper member  212 . The bumper housing and bumper member are manufactured of aluminum, although other materials are usable. 
         [0043]    With reference to  FIGS. 13 and 14 , the bumper member  212  includes two spaced-apart pairs of flanges  214 ,  216 . The flanges  214 ,  216  extend from an interior lower face of the bumper member  212 . The flanges define a through-bore that receives a shaft such as a bolt  227  or other axle member. 
         [0044]    The bumper housing  210  includes a top plate  218  an opposing lower plate  220  and sidewalls  222  defined by a tube structure. The sides  222  have an opening that aligns with the through-bore opening in the flanges  214 ,  216 . The bolt  227  extends through the flanges and the side. The bumper member  212  thereby pivotally attaches to the bumper housing  210 . The bumper member  212  moves from a first position shown in  FIG. 12  to a second position as shown in  FIGS. 13 and 14  whereby the bumper housing  210  is open. The top plate  218 , lower plate  220 , and sides  222  define a receiving cavity  224  for storage of tools and other items in the bumper  208 . 
         [0045]    With reference to  FIG. 15 , the cavity  224  of the bumper housing  210  communicates between the exterior lower shell  16  and the interior lower shell  40 . Particularly, a discharge  226  connects with a pipe to the waste water tank  30 . A hose  228  connects to the discharge for coupling the waste tank  30  to a sanitary water treatment system. 
         [0046]      FIGS. 16 and 17  illustrate detailed side perspective views of the bumper member  212  connected to the side  222 . The flanges  216 ,  214  each define an opening  230  and the respective side  222  defines an aligned opening. A pin  232  extends through the aligned openings to lock the bumper member  212  in the first position closing the cavity  224  of the bumper housing  210 .  FIG. 17  depicts a push-button, quick release spring-biased connector for the pin  232 , but the pin  232  could readily be a through bolt or other longitudinal member that extends through the aligned openings in the flanges  214 ,  216  and the respective side  222 . 
         [0047]      FIG. 18  is a detailed front view of the travel trailer  10 . A storage compartment is defined by a cowling  240  that mounts to the frame members of the chassis  90 . The trailer hitch  12  extends from the chassis. A jack  244  mounts to the chassis for supporting the travel trailer level when positioned at a camp site or storage. A detachable cover  246  connects with latches  248  to the cowling  240 . As illustrated in  FIG. 19 , the cowling  240  encloses propane tanks  250  that are secured in place with supports  252 . The propane tanks communicate through a valve  254  to supply propane to the kitchen equipment including the range and a propane operated refrigerator optionally provided with the travel trailer  10  as well as optionally to a propane water heater. 
         [0048]      FIG. 20  illustrates in perspective rear side view the travel trailer  10 . The cover  206  is removed illustrating a spare tire  260  mounted to the back of the travel trailer  10 . The wheel well  24  is recessed in the sidewall of the lower exterior shell  16 . A support jack  262  mounts to the chassis proximate the suspension for the wheel and chassis. The jack  262  retracts inwardly of the shell  16  and extends downwardly to the ground to maintain the travel trailer level and stable when positioned at a campsite or other location for use of the travel trailer. The jack  266  includes a connector  264  for manual operation of the jack  266 . 
         [0049]    The roof of the travel trailer  10  holds the satellite antenna  13  as an optional entertainment feature. The HVAC air conditioning/heating unit  15  mounts to a back portion of the roof. The HVAC unit is a conventional device such as a DUO THERM unit provided by Dometic USA, of Elkhart, Ind., which provides other conventional equipment for the recreational vehicle industry, including awnings, refrigerators, toilet systems, microwaves, and accessories. 
         [0050]    The travel trailer  10  incorporates power supplies. A first such supply is a reel-out plug-in extendable cord that connects to a conventional electrical outlet. Propane gas is provided, such as for operating the range. Also, battery power provided by a battery pack mounted in a rear compartment of the travel trailer provides electrical supply such as for lighting. 
         [0051]    The refrigerator is a conventional travel industry type refrigerator that operates on propane, electrical current supplied from conventional electrical outlets, or battery. 
         [0052]    Lighting fixtures are conventional and includes runner lights positioned close to the floor for illumination and light attached to undersurfaces of cabinets. 
         [0053]    A housing (not illustrated) for an awning optionally mounts to the roof on the entrance side of the travel trailer. 
         [0054]    A hot water tank communicates with the fresh water tank for supplying hot water to the kitchen sink, the bathroom sink, and the shower. 
         [0055]    An inverter optionally provides power at conventional 120 volts. 
         [0056]    With reference to  FIGS. 2 and 3 , the travel trailer  10  assembles from molded fiberglass shells in which the exterior lower shell  16  receives the sanitary holding tank  30  and fresh water supply tank  34 , with appropriate piping to connect to infeed and discharge supply. The exterior lower shell mounts to the chassis  90 . With reference to  FIG. 4 , fasteners extend through openings  98 ,  100  and with plates  102  are secured with nut to attach the shell and chassis together. 
         [0057]    The interior lower shell  40  defines structural features for the interior of the travel trailer. Piping, electrical wiring and insulation install between the shells. The bathroom assembly inserts into the lower interior chassis. The exterior upper shell  18  and interior upper shell  80  similarly connect together after appropriate wiring and insulation. The shells connect together at mating edges to form the enclosed housing. Cabinets are closed with doors, the windows install in cut-out openings in the side walls, and doors are attached. Appliances install in the areas provided for supporting such and connected to electrical supplies or fuel supply. The air conditioning/heating system installs on the roof. The travel trailer is completed with upholstery cushions and pads on seating areas and for sleeping areas. 
         [0058]    For use, the travel trailer is connected by the hitch to a tow vehicle. At a camping location, the jacks  244  and  262  are operated to fix the trailer level relative to the ground. The power and fuel systems are operated to provide electrical current to the travel trailer and to provide fuel to the stove and other fuel operated appliances. 
         [0059]    The travel trailer disclosed herein can be made and executed without undue experimentation in light of the present disclosure. While the apparatus and methods of this invention have been described in terms of illustrative embodiments, it will be apparent to those of skill in the art that variations may be applied to the apparatus and in the method steps or in the sequence of steps thereof described herein without departing from the concept, spirit and scope of the invention. All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope and concept of the invention as defined by the appended claims.