Abstract:
A slide-out mechanism for moving a slide-out section of a vehicle relative to a second section of the vehicle is disclosed. The slide-out mechanism comprises a stationary frame configured to connect to the second section of the vehicle and a movable frame that movably connects to the stationary frame and is configured to connect to the slide-out section. The slide-out mechanism further comprises a drive assembly that is operable to move the movable frame, and a rack and pinion assembly that operatively connects the drive assembly and the movable frame. The rack of the rack and pinion assembly includes a back surface having an adhesive thereon to connect to an adjacent component.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims benefit to U.S. Provisional Patent Application No. 61/156,303, filed Feb. 27, 2009. 
     
    
     STATEMENT CONCERNING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not applicable. 
       FIELD OF THE INVENTION 
       [0003]    This invention relates to slide-out mechanisms for vehicles, and particularly relates to slide-out mechanisms that move a slide-out section of a vehicle relative to a second section of the vehicle. 
       BACKGROUND OF THE INVENTION 
       [0004]    In order to increase the available interior space of recreational vehicles (such as trailers or motorhomes), it is known to provide a slide-out section (such as a bedroom) as part of the structure of the vehicle. A slide-out section is a raised platform enclosed on all sides except one. Typically, the open side is positioned for access to the slide-out section from inside the vehicle. During transit, the slide-out section is retracted and stored in the interior of the vehicle, and the exterior wall of the slide-out section is generally flush with the exterior of the vehicle. The slide-out section is used after the vehicle is parked and leveled by moving the slide-out section outward from the vehicle to an extended position, thereby increasing the interior space of the vehicle. 
         [0005]    The operating mechanism for moving slide-out sections are typically designed to push the slide-out section away from the vehicle when extending the slide-out section, and pull the slide-out section toward or into the vehicle when retracting the slide-out section. The slide-out mechanism for moving the slide-out section relative to the vehicle includes a frame that is fixed to the vehicle structure, and the slide-out mechanism can include one or more sliding rails attached to the slide-out section. Typically, these sliding rails move within rail supports of the frame. Multiple sliding rails are typically utilized for wide slide-out sections. The sliding rails may be driven by a single drive assembly. Thus, in mechanisms having two sliding rails, both rails are directly driven by a drive assembly, for example by one shaft with two pinion gears, one pinion gear for each rail. In other designs, the sliding rails are driven independently of each other. The motion of the slide-out mechanisms is preferably synchronized to prevent the slide-out section from binding or becoming skewed relative to the vehicle. 
         [0006]    In addition, current slide-out mechanisms typically include certain components that support relatively high loads, such as the components of the drive train through which the drive assembly drives the sliding rail. As a result, the components of the drive train are typically formed from a relatively high strength material, such as steel. Other components of current slide-out mechanisms are not subjected to high loads, and as a result are typically formed from a relatively inexpensive material, such as aluminum. In some cases, the steel and aluminum components are adjacent components that are to be connected, but these components can be difficult and expensive to connect by processes such as welding. In addition, using fasteners to connect steel and aluminum components increases the complexity of the slide-out mechanism, and additional processing steps may be needed to add features to the components, such as drilling and tapping. 
         [0007]    Considering the limitations of current slide-out mechanisms, it would be desirable to have a slide-out mechanism with components that are simply and inexpensively connected to one another. 
       SUMMARY OF THE INVENTION 
       [0008]    In one aspect, the present invention provides a slide-out mechanism for moving a slide-out section of a vehicle relative to a second section of the vehicle. The slide-out mechanism comprises a stationary frame configured to connect to the second section of the vehicle and a movable frame that movably connects to the stationary frame and is configured to connect to the slide-out section. The slide-out mechanism further comprises a drive assembly that is operable to move the movable frame, and a rack and pinion assembly that operatively connects the drive assembly and the movable frame. The rack of the rack and pinion assembly includes a back surface having an adhesive thereon to connect to an adjacent component. 
         [0009]    In another aspect, the present invention provides a slide-out mechanism for moving a slide-out section of a vehicle relative to a second section of the vehicle. The slide-out mechanism comprises a stationary frame configured to connect to the second section of the vehicle and a movable frame that movably connects to the stationary frame and is configured to connect to the slide-out section. The slide-out mechanism further comprises a drive assembly operable to move the movable frame, and a drive train that operatively connects the drive assembly and the movable frame. The drive train includes a pinion that rotatably connects to the drive assembly, a rack that fixedly connects to the movable frame and is in engagement with the pinion, and an adhesive disposed between the movable frame and the rack to fixedly connect the rack to the movable frame. 
         [0010]    The foregoing and other objects and advantages of the invention will appear in the detailed description that follows. In the description, reference is made to the accompanying drawings that illustrate a preferred embodiment of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    The invention will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements, and: 
           [0012]      FIG. 1  is a perspective view of a vehicle including a slide-out mechanism of the present invention; 
           [0013]      FIG. 2  is a perspective view of the slide-out mechanism connected to the vehicle in  FIG. 1 ; 
           [0014]      FIG. 3  is an exploded perspective view of the slide-out mechanism of  FIG. 2 ; 
           [0015]      FIG. 4  is an end view of the slide-out mechanism of  FIG. 2  showing the connection between a rail and a gear rack; 
           [0016]      FIG. 5  is a side view of the slide-out mechanism of  FIG. 2  showing a drive assembly; and 
           [0017]      FIG. 6  is a bottom view of the slide-out mechanism of  FIG. 2  showing the engagement of the gear rack and a pinion. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0018]    Referring to  FIGS. 1 and 2 , a slide-out mechanism  20  of the present invention is used with a vehicle  10  having a slide-out section  12 . As described above, the slide-out section  12  increases the available interior space of the vehicle  10  by moving from a retracted position to an extended position. The slide-out mechanism  20  includes different components that connect to a lower surface  16  of the slide-out section  12  and a second section of the vehicle or a vehicle structure  14  ( FIG. 5 ), such as a portion of the chassis, to move the slide-out section  12  between the extended and retracted positions. The vehicle  10  may include multiple slide-out mechanisms  20  depending on the size of the slide-out section  12  and/or the power output of the slide-out mechanisms  20 . 
         [0019]    Referring now to  FIGS. 2-6 , the slide-out mechanism  20  of the present invention moves the slide-out section  12  between the extended and retracted positions. The slide-out mechanism  20  generally includes a stationary frame  22  that fixedly connects to the vehicle structure, a movable frame  24  that fixedly connects to the slide-out section  12  and movably connects to the stationary frame  22 , a drive assembly  26 , and a drive train  28  that operatively connects the drive assembly  26  and the movable frame  24 . 
         [0020]    Referring to  FIGS. 2 and 3 , the stationary frame  22  includes several brackets in addition to guide rollers and bearings to connect to other components of the slide-out mechanism  20 . The stationary frame  22  includes two side brackets  30 , two end brackets  32  that connect the side brackets  30 , two angled brackets  34  that connect the stationary frame  22  to the vehicle structure, and a spacer bracket  35  that fixedly connects one of the side brackets  30  to the drive assembly  26 . The side brackets  30  and the end brackets  32  are generally flat components that may include holes to accommodate fasteners. Each angled bracket  34  includes two sections that are generally positioned at right angles from one another. Each angled bracket  34  also includes holes to accommodate fasteners that connect to either the end brackets  32  or the vehicle structure. Connecting the brackets  30 ,  32 , and  34  to one another and the vehicle structure with fasteners may permit the brackets  30 ,  32 , and  34  to be repositioned or easily replaced. Alternatively, the brackets  30 ,  32 , and  34  may be connected to one another and the vehicle structure in other manners, such as welding and the like. The guide rollers  36  pivotally connect to the upper corners of the side brackets  30 . The guide rollers  36  support and provide a movable connection to the movable frame  24 . The bearings  38  pivotally connect to the side brackets  30  and provide a connection between the drive train  28  and the side brackets  30 . 
         [0021]    Still referring to  FIGS. 2 and 3 , the movable frame  24  includes a rail  40  and several stops  42  to limit the range of motion of the rail  40 . The rail  40  is preferably made from a relatively inexpensive material, such as aluminum. As best shown in  FIGS. 2 and 4 , the sides of the rail  40  include channels  46  through which the guide rollers  36  pass as the movable frame  24  moves relative to the stationary frame  22 . The rail  40  has a general triple I-beam shape that defines an upper section  44  that connects to the slide-out section  12  by fasteners or the like. In addition, a central section  48  of the rail  40  is generally T-shaped and connects to the drive train  28  as described below. The stops  42  limit the range of motion of the rail  40  by contacting the guide rollers  36 . The stops  42  are preferably connected to foot sections  50  by set screws, thereby permitting the stops  42  to be repositioned. The stops  42  preferably connect to the foot sections  50  of the rail  40  near the ends of the channels  46  and, as a result, are preferably C-shaped. In addition, the stops  42  may be positioned along a single channel  46  or both channels  46  of the rail  40 . 
         [0022]    Referring now to  FIGS. 3 ,  5 , and  6 , the drive assembly  26  preferably includes an electric motor  52  that drives a speed reducer  54 . The electric motor  52  is preferably selected in conjunction with the speed reducer  54  and the drive train  28  such that sufficient torque is provided to move the movable frame  24  and the slide-out section  12 . In addition, the electric motor  52  may be powered by the conventional battery of the vehicle or a separate battery that is dedicated to powering the slide-out mechanism  20 . The speed reducer  54  operatively connects the electric motor  52  and the drive train  28  through a first gear  56 . The speed reducer  54  may also include a worm (not shown) and a worm gear (not shown) that advantageously provide a relatively compact slide-out mechanism  20 . However, other components may also be used, such as spur gears, helical gears, and the like. 
         [0023]    Referring now to  FIGS. 3 and 6 , the drive train  28  includes a second gear  58  that operatively connects the drive train  28  to the drive assembly  26 , a rack and pinion assembly that connects to the movable frame  24 , and a shaft  60  that operatively connects the second gear  58  to the rack and pinion assembly. The second gear  58  is positioned outside the stationary frame  22  along the shaft  60  and engages the first gear  56  to operatively connect the drive assembly  26  and the movable frame  24 . The second gear  58  may be fixedly connected to the shaft  60  by welding or the like. In addition, the second gear  58  may have more teeth than the first gear  56  to provide an additional speed reduction and torque increase. 
         [0024]    The rack  62  of the rack and pinion assembly is preferably made from a relatively strong material, such as steel. The rack  62  connects to a central channel  63  positioned on the bottom surface of the central section  48  of the rail  40 . An adhesive is positioned between the central channel  63  and a back surface  65  of the rack  62  to connect the rack  62  to the rail  40 . The adhesive may be an adhesive tape or an adhesive paste that is dispensed from a cartridge. The adhesive is preferably an acrylic adhesive, such as Lord 406 manufactured by Lord Corporation of Cary, N.C., USA. Other specific adhesives may be advantageous depending on the climate in which the slide-out mechanism  20  is used. For example, Lord 403 and Lord 410 may be advantageously used in cold and hot climates, respectively. The adhesive may be applied with an adhesive accelerator, such as Lord accelerator 19GB, to reduce the curing time of the adhesive. The adhesive preferably has a tensile strength greater than 32 MPa and a lap shear strength at room temperature greater than 17 MPa. In addition, the adhesive preferably has a glass transition temperature greater than 70° C. 
         [0025]    The rack  62  and the central channel  63  preferably have a butt connection, which should be understood as meaning that the adhesive is positioned between the back surface  65  of the rack  62  and a lower surface of the central channel  63 . The central channel  63  also preferably has side surfaces that simplify positioning of the rack  62  during assembly of the slide-out mechanism  20 . 
         [0026]    The pinion  64  of the rack and pinion assembly engages the rack  62  and may have fewer teeth than the second gear  58 . The pinion  64  is preferably held in position on the shaft  60  by spacers  66 . In addition, the shaft  60  rotatably connects to the side brackets  30  through the bearings  38  and preferably has a square cross section. Therefore, the second gear  58 , the bearings  38 , the spacers  66 , and the pinion  64  preferably have square internal bores. Pins  70  positioned adjacent the bearings  38  outside the stationary frame  22  may connect to the shaft  60  to prevent the shaft  60  from moving axially. 
         [0027]    The present invention advantageously provides a slide-out mechanism in which components made of dissimilar materials are simply and inexpensively connected to one another. However, the adhesive may also be used to connect components made of the same or similar materials. This may advantageously reduce the complexity of the assembly or the number of processing steps needed to assemble the slide-out mechanism. 
         [0028]    A preferred embodiment of the invention has been described in considerable detail. Although some attention was given to various alternatives within the scope of the invention, it is anticipated that one skilled in the art will likely realize alternatives that are now apparent from disclosure of embodiments of the invention. Accordingly, the scope of the invention should be determined from the following claims and not limited by the above disclosure.