Abstract:
A service door assembly for a recreational vehicle including a sidewall defining an opening, the sidewall including an inner panel, an outer panel and a cavity therebetween filled with an insulation material. The service door assembly includes a door frame and a door. The door frame is adapted to be disposed in the opening. The door frame includes a plurality of integrally formed mounting tabs interconnected to a remainder of the frame through a living hinge. Each mounting tab is articulable between a first position and a second position such that in the second position a portion of the locking tab extends into the cavity of the sidewall. The door is mounted to the door frame. The door includes an inner member and an outer member connected with a securing arrangement integrally formed therewith. The securing arrangement includes an opening defined by the outer member of a pair of walls of the outer member and a mounting member integrally formed with the inner member. The mounting member includes first and second fingers spaced apart in a generally parallel relationship and a pin disposed between the first and second fingers. The pin is movable between a first and second position such that when the pin is in the second position it forces the first and second fingers into engagement with the walls of the first component and thereby retains the first and second fingers within the opening.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]    This application claims the benefit of U.S. Provisional Application No. 60/379,914, filed on May 13, 2002. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    This invention is related to doors for recreational vehicles (RVs) which are used to alternatively seal off and provide access to internal compartments and more particularly to an improved type of flush mounted service door assembly for a recreational vehicle which offers substantial improvements in appearance and assembly.  
         BACKGROUND OF THE INVENTION  
         [0003]    Vehicles, including but not limited to recreational vehicles which are commonly referred to in the United States as RVs and in Europe as caravans, often incorporate exterior service doors for accessing internal compartments. For example, known service doors are shown and described in commonly assigned U.S. Pat. Nos. 5,746,466 and 4,906,033 which are hereby incorporated by reference as if fully set forth herein.  
           [0004]    U.S. Pat. No. 5,746,466 discloses a service door assembly attached to a cutout in the side wall of a recreational vehicle for alternatively closing off and providing access to an internal compartment. A body frame of the service door assembly is attached to the cut out in the side wall. A door panel is attached by a hinge to the body frame. A pair of push button latch mechanisms, one of which contains an integrated lock, retains the door panel in the closed position. The door panel includes a separate door wall and inner and outer door frames which are joined by a retaining clip. The metal retaining clip has a return bent upon itself shape and pointed wedge shaped upset portions for joining the outer and inner door frames. The hinge is formed by portions of the frame and door panel that are flush with or recessed from the maximum protrusion distance of the door panel from the side wall, joined by a hinge pin that is not accessible when the door is closed and which is designed to break away if destructive forces are placed on the door assembly.  
           [0005]    In U.S. Pat. No. 4,906,033, a service door arrangement is disclosed in which hinge members mount the upper end of the door member on the frame for up and down swinging movement between an open position disposed above the access opening and a closed position fitting in the opening. A continuous seal carried by the door engages the frame in order to maintain the compartment water tight. Separate latching and locking functions are incorporated in the door assembly and are separately accessed from side-by-side latch and lock members in the frame at a convenient position above the door.  
           [0006]    While known service doors including those described above have proven to be satisfactory for their intended uses, a need exists to continually advance the pertinent art.  
         SUMMARY OF THE INVENTION  
         [0007]    It is one general object of the present invention to provide a service door assembly having a reduced width frame that provides for an improved aesthetic appearance.  
           [0008]    It is another object of the present invention to provide a service door assembly which reduces the required number of discrete fasteners for securing the door assembly to a recreational vehicle and for connecting components of the door assembly.  
           [0009]    It is a related object of the present invention to provide a service door assembly having a frame with integrally formed locking tabs for engaging a sidewall of the recreational vehicle.  
           [0010]    It is another related object of the present invention to provide a service door assembly having a door proper with inner and outer members, one of the inner and outer members being integrally formed to include a break-away element which can be hit with a hammer to operatively engage the inner and outer members.  
           [0011]    It is another general object of the present invention to provide a service door assembly for a recreational vehicle having a reduced width frame which reduces required materials and enhances visual appearance.  
           [0012]    It is a related object of the present invention to provide a service door assembly for a recreational vehicle having a door with inner and outer members with integrally molded attachment members to facilitate engagement and maintain a narrow profile.  
           [0013]    It is yet another object of the present invention to provide a service door assembly for a recreational vehicle that latches at a plurality of spaced apart points.  
           [0014]    In one form, the present invention provides a service door assembly for a recreational vehicle including a sidewall defining an opening, the sidewall including an inner panel, an outer panel and a cavity therebetween filled with an insulation material. The service door assembly includes a door frame and a door. The door frame is adapted to be disposed in the opening. The door frame includes a plurality of integrally formed mounting tabs interconnected to a remainder of the frame through a living hinge. Each mounting tab is articulable between a first position and a second position such that in the second position a portion of the locking tab extends into the cavity of the sidewall. The door is mounted to the door frame.  
           [0015]    In another form, the present invention provides a securing arrangement of a service door assembly of a recreational vehicle for securing first and second components of the assembly in combination with the first and second components. The securing arrangement includes an opening defined by a pair of walls of the first component and a mounting member integrally formed with the inner member of the second component. The mounting member includes first and second fingers spaced apart in a generally parallel relationship and a pin disposed between the first and second fingers. The pin is movable between a first position and a second position such that when the pin is in the second position it forces the first and second fingers into engagement with the walls of the first component and thereby retains the first and second fingers within the opening. The securing arrangement functions to secure the first and second components of the assembly without the need for discrete fasteners.  
           [0016]    Additional advantages and features of the present invention will become apparent from the following description and appended claims, taken in conjunction with the accompanying drawings.  
           [0017]    Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0018]    The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:  
         [0019]    [0019]FIG. 1 is a perspective view of a recreational vehicle incorporating a service door assembly constructed in accordance with the teachings of a preferred embodiment of the present invention.  
         [0020]    [0020]FIG. 2 is an enlarged perspective view of the service door assembly of the present invention shown removed from the recreational vehicle for purposes of illustration  
         [0021]    [0021]FIG. 3 is an exploded perspective view of the service door assembly of the present invention.  
         [0022]    [0022]FIG. 4 is an enlarged front view of an inner member of the door of the service door assembly of the present invention.  
         [0023]    [0023]FIG. 5 is a cross-sectional view taken along the line  5 - 5  of FIG. 4.  
         [0024]    [0024]FIG. 6 is an enlarged view of the detail shown in circle  6  of FIG. 5.  
         [0025]    FIGS.  7 A- 7 C represent a series of simplified views showing attachment of the door inner with the door outer.  
         [0026]    [0026]FIG. 8 is an enlarged side view of an inner member of the frame of the service door assembly of the present invention.  
         [0027]    [0027]FIG. 9 is an enlarged view of the detail shown in circle  9  of FIG. 3.  
         [0028]    [0028]FIG. 10 is a cross-sectional view taken along the line  10 - 10  of FIG. 8.  
         [0029]    [0029]FIG. 11 is a cross-sectional view taken through a portion of the service door assembly of the present invention and an adjacent portion of a sidewall of the recreational vehicle, one of the integrally formed mounting tabs of the frame shown in solid lines prior to engagement with the sidewall and shown in hidden lines subsequent to engagement with the sidewall.  
         [0030]    [0030]FIG. 12 is an enlarged perspective view of a cover plate of a locking mechanism of the service door assembly of the present invention.  
         [0031]    [0031]FIG. 13 is a rear perspective view of the cover plate of FIG. 12.  
         [0032]    [0032]FIG. 14 is an enlarged perspective view of one of the hinge members of a hinge assembly of the present invention.  
         [0033]    [0033]FIG. 15 is a front view of the hinge member of FIG. 14.  
         [0034]    [0034]FIG. 16 is a cross-sectional view taken along lines  16 - 16  of FIG. 1, illustrating the door articulated to a closed position.  
         [0035]    [0035]FIG. 17 is a cross-sectional view similar to FIG. 16 showing the door in a partially opened position in which it extends in a direction  900  to the sidewall of the recreational vehicle.  
         [0036]    [0036]FIG. 18 is another cross-sectional view similar to FIG. 16 illustrating the door articulated to a fully opened position and extending in a direction parallel to the sidewall of the recreational vehicle. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0037]    The following description of the preferred embodiment of the present invention is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.  
         [0038]    With initial reference to the environmental view of FIG. 1, a service door assembly constructed in accordance with the teachings of a preferred embodiment of the present invention is illustrated and generally identified at reference element  10 . The service door assembly  10  is shown operatively associated with a recreational vehicle  12 . It will be understood by those skilled in the art that the particular recreational vehicle  12  shown in the environmental view of FIG. 1 is merely exemplary and that the teachings of the present invention are applicable to other recreational vehicles, tractor trailers and virtually any other type of moving vehicle for which it is desired to provide an exterior service door for accessing external compartments. The service door assembly  10  is shown mounted within an opening (not particularly shown with respect to FIG. 1) of a sidewall  14  of the recreational vehicle  12 .  
         [0039]    With continued reference to the environmental view of FIG. 1 and additional reference to FIGS. 2 and 3, the service door assembly  10  of the present invention is shown to generally include a door or door proper  16  and a frame  18 . The door  16  and the frame  18  are connected by a hinge assembly  20 . The hinge assembly  20  defines a pivot axis about which the door  16  can articulate relative to the frame  18  between an opened position and a closed position. The closed position is shown in the environmental view of FIG. 1. The open position is shown in the cross-sectional view of FIG. 18, for example.  
         [0040]    As shown in the cross-sectional view of FIG. 16, the door  16  is preferably a laminated structure having an inner wall  17 , an outer wall  19  and a foam core  21 . The door  16  is further shown to include an outer member  32  and an inner member  24  (see FIG. 3, for example). A seal  26  is captured between the outer and inner members  22  and  24 . The door  16  is further illustrated to include a locking mechanism  28  for selectively securing the door  16  to the frame  18 .  
         [0041]    The frame  18  is illustrated to similarly generally include an inner member  30  and an outer member  32 . Further similarly, a seal  34  is captured between the inner and outer member  30  and  32 . In a manner to be more fully discussed below, the frame  18  is mounted within an aperture  36  (see FIG. 11) defined by the sidewall  14  of the recreational vehicle  12 .  
         [0042]    With additional reference to FIGS.  4 - 7 C, the door  16  is shown to include a plurality of connecting members  38  for securely connecting the inner and outer member  22  and  24  of the door  16  without discrete fasteners. The connecting members  38  are preferably integrally formed with one of the inner and outer members  22  and  24  and in a manner discussed below are adapted to engage and be retained within openings  40  defined by the other of the inner and outer members  22  and  24  of the door  16 . In the exemplary embodiment illustrated, the connecting members  38  are integrally formed with the inner member  24  of the door  16  and the cooperating openings  40  are defined by the outer member  22 . Alternatively, it will become apparent to those skilled in the art that the door  16  could be designed such that the connecting members were integrally formed with the outer member  22  and the openings  40  defined by the inner member  24 .  
         [0043]    As particularly shown in FIG. 4, the inner member  24  of the door is illustrated to include eight connecting members  38  spaced about the perimeter. Further in the preferred embodiment, each of the four sides of the inner member  24  are shown to include two connecting members  38 . Those skilled in the art will readily appreciate that a greater or lesser number of connecting members  38  may be provided within the scope of the present invention so long as the connecting members  38  function to securely connect the inner and outer members  22  and  24  of the door  16 .  
         [0044]    In the particular embodiment illustrated, the connecting members  38  of the door  16  will be understood to be substantially identical to one another. For this reason, this detailed description need only to address one of the connecting members  38  for a complete understanding. As perhaps most particularly shown in the enlarged detailed view of the FIG. 6, each of the connecting members  38  includes first and second parallel and spaced apart fingers  42  and  44 . Each connecting member  38  further includes a pin  46  positioned between the first and second fingers  42  and  44 . The pin  46  is movable relative to the first and second fingers  42  and  44  between a first position and a second position.  
         [0045]    The first position of the pin  46  relative to the first and second fingers  42  and  44  is a molded position and is shown, for example, in FIG. 6. In the first position, the pin  46  is connected to the first and second fingers  42  and  44  through breakaway connections at points  48  and  50 , respectively. In the second position, which will be further described immediately hereafter, the pin  46  is moved downward relative to the first and second fingers  42  and  44  and the breakaway connection at the points  48  and  50  is destroyed.  
         [0046]    With particular reference to the series of views provided at FIGS.  7 A- 7 C, cooperation of one of the connecting members  38  with an associated opening  40  defined by the inner member  22  of the door  16  will be described. In FIG. 7A, the connecting member  38  is shown prior to insertion into the associated opening  40 . The opening is defined by a pair of walls or fins  52 . The fins  52  are substantially parallel to one another and spaced apart a distance which is slightly less than a maximum width w (see FIG. 6) of the first and second fingers  42  and  44 . As shown particularly in FIG. 7B, upon insertion of the connecting members  38  in the direction of arrow A (see FIG. 7A), the free ends of the first and second fingers  42  and  44  are urged toward one another. This movement is facilitated by tapered lead-in surfaces  54  carried by the first and second fingers  42  and  44 . Insertion of the connecting member  38  is limited by flanges  56  carried at the fixed ends of the first and second fingers which abut the free ends of the fins  52 .  
         [0047]    At this point of engagement between the connecting members  38  and the openings  40 , the pin  46  is struck with a hammer or similar tool to destroy the breakaway connection at the points  48  and  50  and force a lower end of the pin between the free end of the first and second fingers  42  and  44 . As resultantly shown in FIG. 7C, the first and second fingers  42  and  44  are returned to their initial parallel orientations and points  58  carried by the first and second fingers  42  and  44  engage the fins  52  to prevent withdrawal of the connecting member  38  relative to the opening  40 .  
         [0048]    With continued reference to the exploded view of FIG. 3 and additional reference to FIGS.  8 - 11 , the frame  18  of the assembly  10  of the present invention is illustrated to include a plurality of integrally formed locking members or tabs  60 . In the embodiment illustrated, the locking tabs are substantially identical and are integrally formed with the inner member  30  of the frame  18 . Alternatively, it will be understood by those skilled in the art that the present invention can be adapted such that the locking tabs  60  are integrally formed with the outer member  32  of the frame  18 . The locking tabs  60  function to secure the frame  18  to the sidewall  14  of the recreational vehicle  12  without the need for discrete fasteners.  
         [0049]    In the particular embodiment illustrated, the inner member  30  of the frame  18  is formed to integrally include ten locking tabs  60 . The locking tabs  60  are spaced about the perimeter of the inner member  30  of the frame  18  such that three locking tabs  60  are provided on each of the top and bottom sides of the inner member  30  and two locking tabs  60  are provided on each of the lateral sides of the inner  30 . It will be understood by those skilled in the art that the particular number of locking tabs  60  is a matter of design choice and may be adjusted up or down within the scope of the present invention. It may be necessary to adjust the number of locking tabs  60  in response to factors such as the size of the frame  18 , the construction of the recreational vehicle sidewall  14 , and the like.  
         [0050]    Each of the locking tabs  60  generally include a generally planar base portion  62  and a pair of prongs  64  depending from and generally perpendicular to the base portion  62 . The base portion  62  is connected to the remainder of the inner portion  30  of the frame  18  through a living hinge  66 . The living hinge  66  defines an axis about which each locking tab  60  articulates between a first position and a second position. The first position is shown, for example, in FIGS. 3, 9,  10  and in solid lines in FIG. 11. The second position is shown, for example, in hidden lines in FIG. 11. The locking tabs  60  articulate from their first positions to their second positions so to engage a foam core  68  provided in a cavity  70  defined between inner and outer panels  72  and  74  of the sidewall  14 . This articulation from the first position to the second position also functions to securely connect the inner and outer members  30  and  32  of the frame  18 . Explaining further, the prongs  64  of the locking tabs  60  extend through openings  76  (see FIG. 2) of the outer member  32  of the frame  18 . The prongs  64  displace a portion of the foam core  68 . The outer panels  72  of the sidewall  14  is effectively captured between the prongs  64  and a peripheral flange portion  78  of the outer member  32  of the frame  18 . In the preferred embodiment, a surface  80  of the prong  64  positioned adjacent an inner side of the outer panel  72  has an arcuate shape to facilitate insertion of the prong  64  into the cavity  70  and also to wedge the outer panel  72  between the prongs  64  and the peripheral flange  78 .  
         [0051]    With reference to FIGS. 12 and 13, a cover plate  82  of the locking mechanism  28  of the assembly  10  is illustrated. The cover plate  82  is also shown in FIG. 3. In the embodiment illustrated, the cover plate  82  is shown to include a pair of integrally formed locking members  38  substantially identical to those described above in connection with the inner member  24  of the door  16 . The head of the pin  46  of the locking members  38  extends from a rearward surface  84 . The fingers  42  and  44  extend from a forward facing surface  86  of the cover member  82 . The locking members  38  of the cover plate  82  engage apertures (not shown) defined by the outer member  22  of the door  16 .  
         [0052]    Substantially identical locking members are used to secure a sliding lock plate  88  of the lock assembly to the outer member  22  of the door  16 . Different from those previously described, the locking members  38  are not carried by a component, but are rather discrete. The discrete locking members  38  pass through elongated apertures provided by the locking plate  88  and engage apertures (not shown) defined by the outer member  22  of the door  16  substantially as described above. In this matter, the locking plate  88  may slide relative to the outer member  22 .  
         [0053]    A button  100  is attached to the locking plate  88 . The button  100  is normally biased along with the locking plate  88  to a latched position by a spring. The latched position is to the left direction in the drawings. The button  100  is manually movable to an unlatched position, again along with the locking plate  88 , when the locking mechanism  28  is unlocked. The particular construction of the door assembly  10  allows for this movement from the latched to unlatched position to be accomplished with a single hand. In this regard, the user can insert his or her thumb into an aperture  102  adjacent the button  100  and his or her finger in a second aperture  104 .  
         [0054]    In the particular embodiment illustrated, the locking plate  88  is shown to include a plurality of tabs  106 . As shown, the locking plate  88  includes five tabs  106 . The tabs  106  cooperate with a corresponding number of apertures or slots (not particularly shown) carried by the outer member  32 . The slots are provided in an upper side of an inwardly extending flange  108 . When the button  100  and locking plate  88  are translated to the unlatched position, the tabs  106  align with the slots. In this position, the door proper  16  can be articulated to its open position. Upon releasing the button  100 , the spring force translates the locking plate  88  to its latched position and the tabs  106  are positioned behind the flange  108 . The plurality of tabs  106  at spaced apart positions along the locking plate  88  serve to secure the door proper  16  to the frame  18  in an improved manner. In this regard, the door proper  16  is secured along the length of an upper side of the frame  18 .  
         [0055]    As shown in FIG. 3, the hinge assembly  20  includes a pair of hinge members  90  that support the door  16  in a manner to be more fully described below. The hinge members  90  will be understood to be identical in all respects. With reference to FIGS. 14 and 15, an alternatively constructed hinge member  90 ′ is shown removed from the door assembly  10 . Both the hinge members  90  and  90 ′ are shown to includes a plurality of hinge bars  92  connected by a generally planar plate  94 . The primary difference between the hinge members  90  and the hinge members  90 ′ is that the hinge bars  92  of the former are foreshortened. Otherwise, insofar as the present invention is concerned the hinge members  90  and  90 ′ are identical.  
         [0056]    The hinge bars  92  are generally parallel to and spaced from the plate  94 . In the embodiments illustrated, the hinge bars  92  are four (4) in number and arranged in pairs. Each pair of hinge bars  92  have an upper hinge bar  92 A and a lower hinge bar  92 B.  
         [0057]    With continued reference to FIGS. 3, 14 and  15 , and additional reference to the cross-sectional views of FIGS.  16 - 18 , the hinge assembly  20  will be further described. The upper hinge bars  92 A are rotatably mounted on the outer member  22  of the door  16 . The lower hinge bars  92 B are rotatably mounted on the outer member  32  of the frame  18 .  
         [0058]    During assembly of the door assembly  10 , a first one of the hinge members  90  or  90 ′ is oriented with its hinge bars  92  extending in an outboard direction. The hinge bars  92  engage apertures defined by the door  16  and the frame  18  by moving the hinge member  90  in the outboard direction. This outboard direction is generally identified in FIG. 15 at arrow A. The second one of the hinge members  90  or  90 ′ is oriented with its hinge bars  92  extending in an opposite direction. In a similar manner, the apertures defined by the door  16  and the frame  18  are engaged by the second hinge member  90  or  90 ′ by moving the second hinge member  90  or  90 ′ in this opposite direction. When the hinge members  90  or  90 ′ are in place, adjacent ends abut one another to thereby prevent inboard movement. In some application, it may be desirable to incorporate a tongue and groove arrangement between the opposing ends of the hinge members  90  or  90 ′. The hinge members  90  or  90 ′ are preferably constructed of plastic or other suitable material that may be inelastically deformed to facilitate assembly.  
         [0059]    The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.