Abstract:
The invention is a modular truck sleeper assembly that allows truck sleepers of various sizes and trim levels to be built on the same assembly line by pre-assembling the floor and sides and connecting them together during final assembly. A floor made up of a plurality of cross-members attached, with a predetermined distance between the cross-members, to a plurality of sills, with a first member of a foot/shoe combination attached to each of the cross-members&#39; ends, is previously assembled and groomed with panels and cabinetry. A plurality of sides made up of a bottom stringer, a top stringer, and a plurality of risers attached, with the same predetermined distance between the risers, between the bottom stringer and the top stringer, with a second member of the foot/shoe combination attached to each of the riser ends, are also previously assembled and groomed with panels and cabinetry. The sides and floor of the modular truck sleeper assembly are then assembled by attaching the corresponding members of the foot/shoe combinations together. The length of the assembled sleeper is substantially equal to an integral multiple of the predetermined distance.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The invention relates to the assembly of truck sleepers from previously assembled modular components. 
     2. Background and Related Art 
     Truck sleepers are extensions of truck cabs that offer living quarters on board the truck. This allows, for example, a pair of drivers who are driving a truck on a long haul to take turns sleeping and driving. Modular truck sleepers are sleepers that are composed of component sub-assemblies which were completed prior to delivery to the assembly location. 
     Truck manufacturers face differing demands from their customers. Over-the-road trucks are built in a wide variety of configurations with many optional accessories to meet these differing demands. A truck line may be offered with hundreds of different optional accessories that can be combined in millions of different ways. The same line of trucks may be sold to customers who range from a door-to-door delivery operator who drives a truck during the day, to a cross-country trucker who lives in his truck. A long-haul trucker who lives in his truck for days at a time may want a sleeper that is as much like home as possible. A short-haul operator who has a fleet of trucks, on the other hand, may want a basic truck sleeper, or no sleeper at all. One of the ways truck manufacturers distinguish their trucks is by customizing the design of the sleeper. 
     Trucks are built on assembly lines to spread the costs of production over many units. The cost to assemble a line of trucks is generally proportional to the number of combinations of options available in which it can be built. The larger the number of options available on a truck, then, the higher the cost to build the truck. One of the ways in which truck manufacturers can offer a variety of optional accessories on trucks at a common assembly location is through the use of modularity. 
     Several of the developments in vehicle construction that have occurred through the years are discussed below. 
     U.S. Pat. No. 5,820,199 to Camplin et al., for example, shows a frame assembly for an operator&#39;s compartment. The frame assembly of Camplin, however, is fabricated to a specific size, and is thus not amenable to modular assembly of truck sleepers. 
     U.S. Pat. No. 4,587,783 to McCoy et al. shows a panel joining apparatus. The panel joining apparatus of McCoy, however, is intended for lightweight, honeycomb panels, and is thus not amenable to modular assembly of truck sleepers. 
     U.S. Pat. No. 5,970,675 to Schray shows a modular panel assembly. The device of Schray, however, relies on friction produced by a deformable cam structure to secure the panel assembly, and is thus too complicated for the modular assembly of truck sleepers. 
     U.S. Pat. No. 5,634,300 to Huebner et al. shows a framed wall system. The framed wall system of Huebner, however, has extruded sections that would be too complicated for the modular assembly of truck sleepers. 
     U.S. Pat. No. 4,531,278 to Boykin shows a method for forming an insulated vehicle body. The insulated vehicle body of Boykin, however, is a temporary structure and would thus not be amenable to the modular assembly of truck sleepers. 
     U.S. Pat. No. 3,712,005 to Eschbach et al. shows an extrusion for an enclosure such as a truck or trailer canopy. The enclosure of Eschbach et al, however, are collapsible, and thus would be too flimsy for truck sleepers. 
     U.S. Pat. No. 5,735,568 to Arnold shows a cab-sleeper assembly. The cab-sleeper of Arnold is composed of a cab module joined together with a sleeper module. The sleeper module itself, however, is of welded, monocoque construction and is thus not amenable to modular assembly. 
     U.S. Pat. No. 4,991,897 to Karapetian shows a vehicle body. The components are sized for a particular vehicle body, however, and thus various sizes of vehicle bodies could not be readily assembled at the same assembly location. 
     U.S. Pat. No. 5,553,906 to Kunz shows a floor and side wall connector. The connector of Kunz, however, would be too flimsy for the modular assembly of truck sleepers. 
     U.S. Pat. No. 5,451,102 to Chuan shows a connecting mechanism for cabinets. The connecting mechanism of Chuan, however, is too fragile and complicated for the modular assembly of truck sleepers. 
     U.S. Pat. No. 5,209,541 to Janotik shows a joint construction for space frames. The space frames of Janotik are sized for a particular vehicle, and thus the joint construction would not be amenable to the modular assembly of truck sleepers. 
     U.S. Pat. No. 5,683,198 to Leutenegger shows a corner joint. The corner joint of Leutenegger, however, is quite complicated and would thus be expensive to manufacture. 
     U.S. Pat. No. 5,685,229 to O&#39;hara et al. shows a body structure for a railway car. The railway car body structure of O&#39;hara, however, involves bonding panels together to form the body, and thus would not be amenable to the modular assembly of truck sleepers. 
     U.S. Pat. No. 4,353,664 to Gibb shows a free gusset metal ledger hanger. The free gusset metal ledger hanger of Gibb, however, would not be amenable to the modular assembly of truck sleepers. 
     Thus there exists a continuing need for improved methods for assembling modular components at a common assembly location into a variety of truck sleepers. 
     SUMMARY OF THE INVENTION 
     In one aspect of the invention a modular truck sleeper assembly is comprised of a floor that includes a plurality of sills, with a plurality of cross-members disposed between them, each of the cross-members having an end with a first member of a foot/shoe combination depending from it; and a plurality of sides, each side including a bottom stringer, a top stringer, and a plurality of risers disposed between the bottom stringer and the top stringer, with each of the risers extending beyond the bottom stringer to form a riser end and a second member of the foot/shoe combination depending from each of the riser ends; with each of the first members of the foot/shoe combination attached to a corresponding second member of the foot/shoe combination. This allows truck sleepers that vary significantly in size and trim level to be built on the same assembly line by pre-assembling and grooming the floor and sides for various sizes and trim levels of sleepers and delivering them to the assembly line for final assembly. The foot/shoe combination that allows the pre-assembled floors and sides to be assembled on an assembly line is a connector in which a foot shaped protrusion fits into a U-channel shoe. The foot and shoe are then fastened together. The foot/shoe combinations thus form corner joints to connect the floor and side sub-assemblies of a modular truck sleeper assembly. 
     In a second aspect of the invention the cross-members and risers to be connected by the foot/shoe combinations are spaced at a predetermined distance apart which is preferably an integral multiple of the length or width of the various versions of truck sleeper to be assembled. This allows several different sizes of modular truck sleeper to be assembled at the same assembly location by simply adding or removing sections to the floor and side sub-assemblies. 
     In a third aspect of the invention the grooming panels and cabinetry installed in the modular truck sleeper assembly have fasteners set at the same predetermined distance apart so they may be easily fastened to the risers and cross-members. This allows the use of various designs, types, and styles of grooming panels and cabinetry to be used to customize a modular truck sleeper, since the different grooming panels and cabinetry can use a standard fastener pattern. 
     In a fourth aspect of the invention the grooming panels and cabinetry installed in the modular truck sleeper assembly are fastened to the risers and cross-members with a bolt and an oval nut that becomes trapped inside of a riser or cross-member and is thus prevented from rotating while the bolt is being tightened. The anti-rotation feature of the nut allows blind tightening of the bolt and nut if, for example, the nut is covered by a grooming panel or a cabinet, or space to reach the nut during the tightening process is otherwise limited. 
     In a fifth aspect of the invention a method of assembling a modular truck sleeper assembly is provided that includes the steps of: i) placing a plurality of sills in a substantially parallel relationship to each other, ii) disposing a plurality of cross-members a predetermined distance apart across the sills to form a floor, with each of the cross-members having an end, and a first member of a foot/shoe combination depending from each of the cross-member ends, iii) placing a bottom stringer and a top stringer in a substantially parallel relationship to each other, iv) disposing a plurality of risers the same predetermined distance apart between the bottom stringer and the top stringer to form a side, with each of the risers extending beyond the bottom stringer to form a riser end, and a second member of the foot/shoe combination depending from each of the riser ends, and v) attaching the side to the floor by attaching each of the first members of the foot/shoe combination to a corresponding second member of the foot/shoe combination. 
     In a sixth aspect of the invention the side sub-assemblies can be groomed with grooming panels and cabinetry before or after the sides are attached to the floor. 
    
    
     DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view, partly schematic and with portions broken away, showing the floor and a side of a first embodiment of the modular truck sleeper assembly of the present invention ready to be connected. 
     FIG. 2 is a perspective view of a foot of the foot/shoe combination for use with the embodiment of the modular truck sleeper assembly shown in FIG.  1 . 
     FIG. 3 is a perspective view of a U-channel shoe of the foot/shoe combination for use with the embodiment of the modular truck sleeper assembly shown in FIG.  1 . 
     FIG. 4 is a side view of a foot of the type shown in FIG. 2 inserted into a shoe of the type shown in FIG.  3  and fastened with two bolts. 
     FIG. 5 is a front view of a foot of the type shown in FIG. 2 inserted into a shoe of the type shown in FIG.  3  and fastened with two bolts. 
     FIG. 6 is a section through a riser showing the grooming panels fastened to the riser for use with the embodiment of the modular truck sleeper assembly shown in FIG.  1 . 
     FIG. 7 is an axial view of an oval anti-rotation nut used to attach the grooming panels for use with the embodiment of the modular truck sleeper assembly shown in FIG.  1 . 
     FIG. 8 is a perspective view of some of the custom cabinetry that can be attached to the floor or side subassemblies of a 45″ long truck sleeper assembled according to the embodiment of the modular truck sleeper assembly shown in FIG.  1 . 
     FIGS. 9A-9F are perspective views of some of the custom cabinetry that can be attached to the floor or side subassemblies of a 78″ long truck sleeper assembled according to the embodiment of the modular truck sleeper assembly shown in FIG.  1 . 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     In FIG. 1 is shown an exploded view of the side  1  and the floor  2  of a first embodiment of the modular truck sleeper prior to assembly. The side  1  is composed of top stringer  3   a,  bottom stringer  3   b,  and risers  4 . The top stringer  3   a,  bottom stringer  3   b  and risers  4  are preferably formed from 40 mm×40 mm square section tubes, but any strong, lightweight size or section may be used. Top stringer  3   a,  bottom stringer  3   b  and risers  4  may be, for example, U-channels, L-channels, I-beams, or round or rectangular solid sections. Top stringer  3   a  and bottom stringer  3   b  are attached to the risers  4  in a previous operation to form a ladder-like structure and delivered to the modular truck sleeper cab assembly location. Top stringer  3   a  and bottom stringer  3   b  may be welded, bolted, riveted, joined with an adhesive, or otherwise securely attached to risers  4 . The risers  4  are spaced a predetermined distance apart. In a preferred embodiment of the invention, the length of a modular truck sleeper assembly assembled from the side  1  and floor  2  is substantially an integral multiple of the predetermined distance between risers  4 . In one embodiment the risers  4  are spaced 22.5″ apart. In a second embodiment, the risers  4  are spaced 33″ apart. Since the length of a modular truck sleeper assembled from side  1  becomes an integral multiple of the predetermined distance between risers  4 , risers  4  set at 22.5″ apart can be used to fabricate modular truck sleepers with lengths of 45″, 67.5″, 90″, or any multiple of 22.5″, exclusive of trim. Similarly, risers  4  set at 33″ apart can be used to fabricate modular truck sleepers of 33″, 66″, 99″, or any multiple of 33″ in length, respectively. Predetermined distances between risers  4  of 22.5″ and 33″ are exemplary embodiments. Any predetermined distance between risers  4  may be chosen without deviating from the spirit of the invention. 
     The risers  4  are shown extending beyond bottom stringer  3   b  in FIG. 1 to form ends  5 . A foot  6  is further shown attached to end  5  of each riser  4  in FIG.  1 . Foot  6  is preferably a U-channel that is made of similar material to that used to form riser  4 . 
     Also shown in FIG. 1 is floor  2 . Floor  2  is fabricated by attaching cross-members  8  to sills  7  prior to assembly of the modular truck sleeper. Sills  7  may be attached to the truck frame (not shown) when the truck is assembled. The periphery  20  of the floor  2  is formed of L-sections joined to the cross-member  8  ends. The floor (not shown) is sealed to the periphery  20 . Floor  2  is preferably fabricated by welding but any suitable method of fabrication may be used, including bolting, riveting, pinning, hydroforming, casting or forging. In a preferred embodiment, cross-members  8  are spaced the same predetermined distance apart as were risers  4 . In one embodiment, risers  4  are spaced 22.5″ apart. In that case cross-members  8  would also be spaced 22.5″ apart to match the spacing of risers  4 . If, in the alternative, risers  4  are spaced 33″ apart then the cross-members  8  would also be spaced 33″ apart. The number of risers  4  is equal to the number of cross-members  8 , so that each riser  4  corresponds to a cross-member  8 . 
     A shoe  9  is shown in FIG. 1 to be suspended from the ends of each of the cross-members  8 . Each of risers  4  substantially intersects a corresponding cross-member  8  when side  1  is connected to floor  2 , as shown in FIG.  1 . Each foot  6  will thus correspond to a shoe  9 . The side  1  is assembled to the floor  2  by inserting each foot  6  into a corresponding shoe  9 . Although a side is illustrated in FIG. 1, the principle of modular truck sleeper assembly would apply equally well to a rear, a front, or a top. The words side  1  and floor  2  are simply labels and are meant to imply no particular orientation in space. Thus side  1  could be a vertical, horizontal, or arbitrarily oriented member. Floor  2  could also be a vertical, horizontal, or arbitrarily oriented member. And since the principle of the invention does not depend on the orientation of side  1  or floor  2  in space, the disclosure applies equally well to a shoe  9  depending from riser  4  or from cross-member  8 , and for a foot  6  depending from cross-member  8  or from riser  4 . 
     Riser end  5  is shown in FIG. 2 depending from riser  4  below bottom stringer  3   b,  in a manner consistent with the embodiment of the invention shown in FIG. 1. A foot  6  is shown attached to riser end  5  in FIG.  2 . In this embodiment, foot  6  is U-shaped and has ears  21  that are welded to riser end  5 . Any suitable mode of attachment, however, such as riveting, bolting, pinning, or forming the foot  6  directly from riser end  5  by cold-forming, extruding, hydroforming, casting, machining foot  6  from a billet, or forging foot  6  could be used. Foot  6  is pierced by a foot hole (not shown in this view). 
     Shoe  9  is shown in FIG. 3 depending from the end of cross-member  8 , where it intersects periphery  20 , in a manner consistent with the embodiment of the invention shown in FIG.  1 . In this embodiment, shoe  9  is U-shaped and includes flanges  25  and bottom plate  26 . Flanges  25  are welded to the sides of the end of cross-member  8 . Any suitable mode of attachment, however, such as riveting, bolting, pinning, or forming the shoe  9  directly from the end of cross-member  8  by cold-forming, extruding, hydroforming, casting, machining shoe  9  from a billet, or forging shoe  9  could be used. The internal dimensions of shoe  9  are about the same size as the external dimensions of foot  6  shown in FIG. 2 so shoe  9  can receive foot  6  when the foot/shoe combination is assembled. The internal dimensions of shoe  9  may, however, be larger than or slightly smaller than the external dimensions of foot  6 . If the internal dimensions of shoe  9  are larger than the external dimensions of foot  6  a slip fit will exist between shoe  9  and foot  6 , as would be known to one skilled in the art. If the internal dimensions of shoe  9  are slightly smaller than the external dimensions of foot  6 , on the other hand, a press or interference fit will exist between shoe  9  and foot  6 , as would be also be known to one skilled in the art. Such a press or interference fit would allow side  1  and floor  2  to be joined temporarily before shoe  9  and foot  6  are fastened with a fastener. Shoe  9  is pierced by shoe hole  50 . 
     A side view of a preferred embodiment of the assembled foot  6  and shoe  9  combination is shown in FIG.  4 . Foot  6  and shoe  9  are fastened together with a fastener. The fastener may be, for example, bolts  11 . Bolts  11  are inserted through foot holes  51  in foot  6  and plate holes  50  in bottom plate  26  and secured by tightening nuts  12  as shown in FIG.  4 . Although the foot  6  and shoe  9  are shown fastened together with bolts  11 , any suitable means of attachment may be used, including rivets, a weldment, pins, or a flexible connection member such as a loop of cable. Shoe hole  50  in shoe  9  is co-axial with a corresponding foot hole  51  in foot  6  when foot  6  is inserted into shoe  9 . A fastener used to fasten shoe  9  to foot  6  would thus pass through shoe hole  50  and a corresponding foot hole  51 . 
     A front view of the embodiment of the assembled foot  6  and shoe  9  combination that was shown in FIG. 4 is shown in FIG.  5 . In this embodiment, bolts  11  are inserted through foot hole  51  in foot  6  and plate hole  50  in bottom plate  26  and secured by tightening nuts  12  as shown in FIG.  5 . 
     In a second aspect of the invention, grooming panels  13  are shown in FIG. 6 attached to risers  4 . The grooming panels  13  would attach in a similar manner to cross members (not shown in this view). In this aspect of the invention, each grooming panel  13  is fastened to a pair of risers  4  or cross-members, but a larger or smaller number of risers  4  or cross-members could be used. In a preferred embodiment of the invention the fasteners that fasten grooming panels  13  to risers  4  or cross-members are spaced the same predetermined distance apart as the risers  4  or the cross-members. Grooming panels  13  may be fastened to risers  4  or cross-members with, for example, oval nut  15  and bolt  16 , as shown in FIG.  6 . Bolt  16  is shown passing through grooming panel hole  52  in grooming panel  13  and riser hole  53  in riser  4 . Oval nut  15  is rotatably attached to the end of bolt  16  to secure grooming panel  13  to riser  4 . Although the grooming panel  13  is shown in FIG. 6 to be fastened to a riser  4  or a cross-member with oval nut  15  and bolt  16 , any suitable means of attachment may be used, including rivets, a weldment, pins, or a flexible connection member such as a loop of cable. 
     A preferred embodiment of the oval nut  15  and of the foot  6  and shoe  9  combination are shown in an axial view in FIG.  7 . In this embodiment, each oval nut  15  resides inside a riser  4  or a cross-member (not shown in this view). Oval nut  15  has a major dimension  30  and a minor dimension  31 . The major dimension  30  of an oval nut  15  is larger than the internal width of a riser  4  or a cross-member, while the minor dimension  31  is smaller than the internal width of a riser  4  or a cross-member. Oval nut  15  can thus be inserted into a riser  4  or a cross-member if oval nut  15  is oriented such that major dimension  30  is substantially parallel to the long axis of the riser  4  or the cross-member. Since major dimension  30  is larger than the internal width of the riser  4  or the cross-member, oval nut  15  will be prevented from turning inside the riser  4  or the cross-member. Bolt  16  can thus be tightened without further manipulation of oval nut  15 , after the threads of bolt  16  have begun to mesh with the threads of oval nut  15 . 
     In a third aspect of the invention shown in FIG. 8, cabinets that could be used to groom the side, floor, and rear walls of a b  45   41   long modular truck sleeper assembly are shown. The walls are groomed by fastening the cabinets, which may be, for example, a right hand side assembly  32 , a left hand side assembly  33 , a bunk  34 , a rear side assembly  35 , or a floor sub assembly  36  to the risers or the cross-members. Further examples of cabinets may include beds, tables, chairs, sound systems, cupboards, refrigerators, stoves, dishwashers, clothes washers, clothes dryers, closets, televisions, computers, flat panel displays, bars, bookcases, sinks, showers, storage bins, or trim panels. Cabinets and trim panels may be installed before, during, or after the modular truck sleeper is assembled. In a preferred embodiment of the invention the fasteners that fasten the cabinets to the risers or the cross-members are spaced the same predetermined distance apart as the risers or the cross-members. Although FIG. 8 shows cabinets arranged around the inside of a 45″ long modular truck sleeper assembly, the principles exemplified in FIG. 8 would apply equally well to a modular truck sleeper assembly of arbitrary dimensions. The modular truck sleeper assembly is finished by bonding outer panels (not shown) to the risers or the cross members and covering the modular truck sleeper assembly and the cab assembly with a roof (not shown). 
     In a fourth aspect of the invention shown in FIGS. 9A-9F, cabinets that could be used to groom the side, floor, and rear walls of a 78″ long modular truck sleeper assembly are shown. The walls are groomed by fastening the cabinets, which may be, for example, a right hand side assembly  32 , a left hand side assembly  33 , a bunk  34 , a rear side assembly  35 , or a floor sub assembly  36  to the risers or the cross-members. Cabinets such as an overhead shelf  37 , a TV  38 , an upper shelf with a microwave  39 , a refrigerator  40 , and a pantry  41 , are also shown in FIGS. 9A-9F. Further examples of cabinets may include beds, tables, chairs, sound systems, cupboards, stoves, dishwashers, clothes washers, clothes dryers, closets, computers, flat panel displays, bars, bookcases, sinks, showers, storage bins, or trim panels. Cabinets and trim panels may be installed before, during, or after the modular truck sleeper is assembled. In a preferred embodiment of the invention the fasteners that fasten the cabinets to the risers or the cross-members are spaced the same predetermined distance apart at which the risers or the cross-members are placed. Although FIGS. 9A-9F shows cabinets arranged around the inside of a 78″ long modular truck sleeper assembly, the principles exemplified in FIGS. 9A-9F would apply equally well to a modular truck sleeper assembly of arbitrary dimensions. The modular truck sleeper assembly is finished by bonding outer panels (not shown) to the risers or the cross members and covering the modular truck sleeper assembly and the cab assembly with a roof (not shown). 
     While the present invention has been shown and described with reference to preferred embodiments presently contemplated as the best modes for carrying out the invention, various changes may be made to the described embodiments without departing from the broader inventive concepts disclosed herein. Among other modifications, as noted, the various sizes and shapes of the exemplary embodiments can be varied based on circumstances. In addition, it is contemplated that various features of the above-described embodiments can be interchanged and/or incorporated into other embodiments described or encompassed herein.