USRE44002E1 - Retractable room actuation assembly for recreational vehicle - Google Patents

Abstract

A slide-out or retractable room for a mobile living quarters, such as a recreational vehicle, is provided with actuating assemblies mounted on opposite side walls of the slide-out room and the adjacent wall of the main living area. The actuating assemblies include a pair of parallel gear racks mounted on the side wall, which are engaged by pinions rotated by torque shafts mounted on the main living quarters. Each torque shaft is rotated by a separate motor. A roller engages a bearing surface on the lower portion of the gear racks. Accordingly, the slide-out room is extended and retracted by rotating the torque shafts to cause the gear racks and the attached slide-out room to extend and retract. The weight of the slide-out room is supported by the rollers, thereby supporting the slide-out room off of the floor of the main living quarters as it extends and retracts. A synchronizing control operates the motors.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims domestic priority based upon U.S. Provisional Patent Application Ser. No. 61/205,551, filed Jan. 21, 2009, the disclosure of which is hereby incorporated by reference.

BACKGROUND OF THE INVENTION

This invention relates to a slide-out or retractable room for mobile living quarters, such as a recreation vehicle.

Recreational vehicles, such as motor homes, fifth-wheel trailers, and travel trailers may be provided with a retractable or slide-out room for increasing the living space of the vehicle. The retractable or slide-out room is extended for use when the vehicle is parked and is retracted into the main living area of the vehicle when the vehicle is to be moved. Existing retractable or slide-out rooms can be time-consuming and difficult to install. Frequently, the operating mechanisms consist of many separate components that must be individually installed, connected and adjusted by highly-trained employees when the unit is assembled. After the vehicle is put into service, adjustments by the vehicle owner are often necessary. Furthermore, existing slide-out rooms require substantial space for mounting large electrical motors and hydraulic units that require the construction of expensive covers and thus reduce the overall space inside the vehicle. Such slide-out or retractable rooms are generally moved in and out of the vehicle across the floor of the main living area. Because the slide-out or retractable room is exposed to weather when extended, extension and retraction of the slide-out room causes staining and wear on the interior floor of the vehicle.

Generally, the physical size of the operating mechanism or slide-out room is large and bulky and somehow has to be hidden. Concealing the operating mechanism requires space either inside the vehicle, which lessens the living space, or under the vehicle, which lessen room for the mechanical systems such as storage tanks and axles. The object of any slide-out room is to add space, so a need exists for a slide mechanism that requires no interior or exterior space.

Generally, existing mechanisms for extending and retracting slide-out rooms employ powerful hydraulic or electro-mechanical systems that have a fixed amount of working stroke. When actuated, these powerful devices will push or pull the slide room until they run out of useable stroke. When obstructions, such as trees on the exterior or furniture and suitcases on the interior, are encountered before the wholly extended or wholly retracted position is attained, the actuation mechanism has more then enough power to overcome the obstruction and keep going. This can destroy the slide-out room, which is generally made from light weight wood or aluminum tube. Sadly, sometimes human beings are encountered, often resulting in injury or death. Therefore, it is desirable that obstructions be sensed and the actuation mechanism stopped,

Tolerances needed to construct slide-out rooms are large. Therefore, the side walls of the same slide-out room rarely have the same dimensions. When one side wall is deeper than the other side wall, only the shorter side wall can be adjusted to properly seal against the weather. An example is a slide-room that has one side wall built incrementally longer than the other side wall. With a fixed stroke equal to the length of the shorter side wall, the longer side is unable to attain full stroke and properly seal. This permits moisture to enter the unit and cause extensive damage. Therefore, a need exists for a slide room mechanism that can independently sense and automatically adjust stroke to a sealed position on each side of the slide room.

All known prior art for slide room mechanisms attach the actuating mechanism to the unit. Sometimes the mechanism is mounted to the floor of the unit, or to the side wall, chassis or frame of the unit. After the actuating mechanism is mounted on the unit, the slide-out room is attached. Due to natural manufacturing tolerances, the opening to accept the slide-out room typically varies from unit to unit in both height and width, while the slide-out room itself also varies in height and width. However, the seal used to keep weather out of the unit is manufactured to a set dimension. Numerous adjustments up and down and left and right are required to center the slide-out room to the opening in the unit in order to provide a weather-tight seal when the room is extended and retracted. As the unit is used, normal road vibrations tend to cause the slide-out room to come out of adjustment, allowing moisture to enter the interior of the vehicle causing extensive damage. Therefore, a need exists for a slide room mechanism that requires no mechanical adjustment, both at installation and as it is used.

SUMMARY OF THE INVENTION

According to the present invention, actuating mechanisms are installed on opposite side walls of the slide-out room and the adjoining portions of the wall of the main living area through which the slide-out room extends and retracts. Each of the actuating assemblies include a pair of pinion gears mounted on a rotatable torque shaft, which are supported for rotation on the main living quarters adjacent to the aperture in the wall of the main living quarters through which the slide-out room extends and retracts. The two pinion gears rotate with a common shaft, and are meshed with the teeth of corresponding gear racks which are mounted on the adjacent side wall of the slide-out room. Rollers engage corresponding bearing surfaces defined on the racks to support the slide-out room as it extends and retracts and also to assure that the pinions remain meshed with the racks. In an optional embodiment of the invention, racks are provided with an inclined section, which permits the room to drop as it approaches the extended position to bring the floor of the slide-out room flush with the floor of the main living quarters, thereby eliminating the unsightly and inconvenient step-up between the slide-out room and the main living quarters.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a view in perspective of the left hand actuating assembly of the slide-out room as it is shipped from the factory for installation on the slide-out room; the right hand assembly being a mirror image thereof;

FIG. 2 is a view in perspective of a portion of the actuating mechanism illustrated inFIG. 1, with the bearing blocks and cover eliminated to show the internal torque shaft and pinions;

FIG. 3 is a view taken substantially along line3-3 ofFIG. 2;

FIG. 4 is an exploded view in perspective of a recreational vehicle including a slide-out room, with actuating assemblies of the present invention shown exploded off of the sides of the slide-out room;

FIG. 5 is a view in perspective of a slide-out room with actuating assemblies made according to the present invention installed thereon;

FIG. 6 is a view similar toFIG. 5, but illustrating the manner in which the slide-out room slides into the main living quarters and the manner in which the actuating assemblies are attached to the main living quarters;

FIG. 7 is a view taken substantially along line7-7 ofFIG. 6;

FIG. 8 is a view taken substantially along line8-8 ofFIG. 7;

FIG. 9 is a view in perspective of a rack used in an alternate embodiment of the invention;

FIG. 10 is a schematic illustration of the control system used to control system used to control the actuating assemblies used in the present invention; and

FIG. 11 is a detailed schematic of the control logic used in the control system illustrated inFIG. 10.

DETAILED DESCRIPTION OF INVENTION

Referring now to the drawings, a mobile living quarters, such as a recreational vehicle, is indicated generally at10, and includes a side wall12 (the remaining side walls of thevehicle10 not being shown).Side wall12 defines anaperture14 through which a slide-out room generally indicated by thenumber16 extends and retracts. Slide-outroom16 includes afront wall18, twoside walls20,22 extending from thefront wall18, aceiling24 and afloor26.

An actuating mechanism comprisesactuation assemblies28,30 that are mounted on theside walls20,22 respectively, theactuation assembly30 being a mirror image of theactuation assembly28. As illustrated inFIGS. 1 and 4, each actuation assembly includes an upper rack orengagement member32, a lower rack orengagement member34, and acover36 defining a column which covers the mechanism that drives therack32,34. Each of the racks orengagement members32,34 includes a plurality of slots, as shown. Although rack and pinion actuators are shown, other equivalent interengaging, relatively movable members, such as welded chains and sprockets, a cog and stamping, timing belt and pulleys and other similar structures may be used; furthermore, although two rack and pinion assemblies are illustrated for each of theassemblies28,30, any number of assemblies may be used as necessary or convenient.Assembly straps38,40 are illustrated inFIGS. 1 and 4; these assembly straps are temporary to assure that the alignment of theracks32,34 remain parallel to each other.Assembly strap38 includes a projectingflange42 that projects beyond theracks32,34 and is adapted to engagefront wall18 of the slide-outroom16 to thereby locateactuating assembly28 laterally with respect to the slide-outroom16. As will hereinafter be described, a bearing block covered by the cover ofcolumn36 engages thefloor26 of the slide-out room when the actuatingassembly28 is installed to thereby locate the actuating assembly vertically with respect to the slide-out room16. Accordingly, theactuating assemblies28,30 are fully assembled when they are manufactured and shipped to the assembly plant for attachment to the slide-out room16 and to the main living quarters. Accordingly, no separate components are required, andassemblies28,30 are inherently self-locating. Once theactuating assemblies28,30 have been installed, the assembly straps38,40 are removed and discarded.

The column or cover36 includes a generallyu-shaped portion44 that extends around the actuating components for theracks32,34, as will hereinafter be described. Aflange46 projects from theu-shaped portion44 and is provided withapertures48, which receivefasteners49 used to attach the actuating assemblies to theside wall12 adjacent to theaperture14. In addition to concealing and protecting the actuation components, thecolumn36 trims up the edges of theaperture14 and also carries a vertically extendingbulb seal50, which seals the unit when the retractable room is fully retracted into the main living area.

A drive member in the form of asplined torque shaft52 extends substantially vertically in the cover ofcolumn36 and is rotatably supported by alower bearing block54 and an upper bearing block (not shown). The upper and lower bearing blocks have been omitted fromFIG. 2 for clarity and are substantially identical, so that onlylower bearing block54 will be described in detail.Bearing block54 has been illustrated in phantom inFIGS. 3 and 7 for clarity.Torque shaft52 is defined by circumferentially spacedsplines56, which are received in corresponding grooves inpinions58,60, thepinions58,60 comprising engagement features which mesh with the gear racks32,34, respectively. Upper and lower gear racks32,34 are substantially identical, except that thelower gear rack34 includes aflange62 which projects therefrom and engages the lower side of thefloor26 of the slide-out room16 to thereby locate theactuation assembly28 vertically with respect thereto.

Aroller64, having a substantially v-shaped cross section to define bearing faces66,68, is rotatably mounted on aspindle70 projecting from bearingblock54. Rollers of other complex shapes may be used instead of v-shaped rollers illustrated, it only being necessary that the rollers be shaped to control the relative positions of the rack and the roller, and to permit the slide-out room to move relative to the unit. Theracks32,34 are each provided with a horizontally extending bearing surface defined by angled bearing faces72,74. The bearing faces will, of course, be shaped complementary to the cross section of the roller. A hooked extension extends from the bearingblock54 into a longitudinally extending groove78 (FIG. 2) of therack34.Hooked extension76 is covered by a low friction, plastic (Delrin)shoe80 which rides in thegroove78 as the slide-out room extends and retracts. Theshoe80 andgroove78 maintain engagement of theroller64 with therack34 and maintain engagement of the rack with the pinion by maintaining a fixed predetermined distance therebetween. As described above, abulb seal50 extends alongu-shaped portion44 of thecolumn36. As can be seen inFIG. 8, when the slide-out room16 is in the fully retracted position, anextension84 carried by the slide-out room16 engagesbulb seal50, compressing the latter, to assure a weather-tight seal protecting the pinions, torque shafts, and motor from the environment.

Anelectric motor82 is supported on the upper most end of thetorque shaft52 for rotating the latter. Themotor82 is a bi-directional motor, and rotates the shaft in one direction to extend the slide-out room from the main living quarters, and in the opposite direction to retract the slide-out into the main living quarters. Theactuation assembly30 on theopposite side wall22 is a mirror image of theactuation assembly28. Another motor identical to the motor83 operatesactuation assembly30. Both motors are driven by a synchronizing drive control90, as illustrated inFIG. 10 andFIG. 11, so that both the actuating assemblies extend and retract at substantially the same rate, as will hereinafter be described. Alternatively, a transverse shaft extending over the slide-out room and connected to bothtorque shafts52 by a gear drive may be used with only one motor.

Referring now toFIG. 10, synchronizing drive control90 includes aprocessor92, which transmits data to, and receives data from, amemory94.Input bus96 forprocessor92 receives a voltage input fromvoltage sensor98,current sensor inputs100 and102, which input signals measuring current draw of the corresponding motor, and tachometers orspeed sensor inputs104,106, which are connected to speed sensors for each of the motors and which generate pulse trains that are proportional to the rotational speed of the motors. Other inputs include108 and110, which transmit a signal from a wall switch within the unit which is operated when the user desires to extend or retract the slide-out room. The effect of theinputs108 and110 is to reverse the direction of rotation of the motors, but operation of the system90 is otherwise the same if the slide-out room is either extended or retracted.Processor92 includes a pulse width modulator which generates pulse width modulated voltage signals which are transmitted to the motors throughoutput bus112, as indicated at114 and116.

Referring now toFIG. 11, when the user operates the wall switch to either extend or retract the slide-out room,processor92 responds by starting the control routine, as indicated at118. Both motors are accelerated to their maximum speed, as indicated at120, it being noted that the maximum speed of the motors may be different (due, for example, to differences in weight carried on different sides of the slide-out room). A test is made, as indicated at122, to determine if either motor has reached the stall threshold. This is done by comparing the current draw of each motor, as sensed bysensor inputs100 and102. The current draw of the motors increases substantially when the motor stalls out at the end of the stroke of the slide-out room (such as when it attains the fully extended or fully retracted position, or when the slide-out room encounters an obstruction requiring greatly increased power). If both motors are operating below the stall threshold, a check is made to determine if the motors are operating within a predetermined speed range of one another, as indicated at124. If the motors are operating outside of the speed range, the pulse width of the voltage signal to the faster motor is altered to slow the faster motor to within the speed range, as indicated at126.

If the test at122 indicates that one of the motors has reached the stall threshold, the stalled motor is dynamically braked, as indicated at128 (by switching terminals of the motor together), and a stall timer is started. As indicated at130, the current draw of the other motor is then tested to determine its stall threshold has been reached. If the stall threshold of the second motor has been reached, the second motor is braked (as indicated at132), the values of the counts from the motor speed sensors stored in memory are reset to zero (as indicated at134), and the routine is ended. If the test made at130 indicates the second motor has not yet stalled out, a test is made at136 to determine if the stall timer has timed out. If the stall timer has timed out, the other motor is stopped (as indicated at138), whereupon the routine is ended. By continuing to operate the motor not reaching the stall threshold after the first motor reaching the stall threshold has been stopped, both sides of the slide-out room are independently brought into engagement with their corresponding bulb seals50, thus assuring sealing completely around the slide-out room. The stall force timer assures that one motor will not be operated longer than a predetermined time period after the other motor has stalled, so that if the stalling is caused by one side of the slide-out room striking an obstruction, the motor actuating the other side will not operate indefinitely, or if the clearances across the slide-out room are sufficiently different that both sides of the slide-out room cannot be sealed, the system will not be operated indefinitely.

In operation, when the user desires to extend the slide-out room16, themotors82 are caused to turn in a direction turning thepinions58,60 to cause the racks, due to their engagement therewith, to be driven outwardly with respect to the main living quarters, thereby carrying the slide-out room with the rack.Rollers64, due to their engagement with therack34, carry the weight of the slide-out room and maintain thefloor26 of the slide-out room raised above the floor of the main living quarters. Accordingly, damage to the floor of the main living quarters, common in the prior arts when slide-out rooms are extended or retracted, is avoided. Since, as described above,actuating assemblies28,30 are shipped as a unit to the manufacturing plant, assembly and adjustment of separate components is not necessary. The slide-out room16 is retracted into the main living quarters by causing themotor82 to turn in the reverse direction, thereby moving theracks32,34 into the main living quarters, carrying the slide-out room16 with them.

As discussed above, prior art slide-out rooms require multiple adjustments to center the slide-out room in the opening in the unit in order to provide a weather-tight seal when the room is extended and retracted, and require periodic adjustments to re-center the slide-out room to compensate for normal road vibrations. In the present invention, theactuating assemblies28,30 are located vertically on theircorresponding side walls20,22 by engagement of theflange62 with thefloor26, and are located horizontally on theircorresponding side walls20,22 by theflange42 of the assembly straps38,40. The clearance between the slide-out room and the side of theaperture14 is set by attachment offlange62 to theside wall12. Since thebulb seal50 is attached to thecolumn36 when theactuating assemblies28,30 are manufactured and proper positioning of theactuating assemblies28,30 on their corresponding side walls is assured, no adjustment of the slide-out room after installation on the unit is required or possible.

Slide-out rooms tend to tip downward relative to the unit when extended, and this tipping must be resisted, requiring heavier and more powerful actuators than would otherwise be necessary. In the present invention, tipping forces are transmitted throughupper rack32 andpinion60 to apply a twisting force to thetorque shaft52, which is resisted by the torsional stiffness of thetorque shaft52. The twisting forces are transmitted through thetorque shaft52 to thelower pinion58 and thelower rack34, to thereby apply a countervailing force to the lower portion of the slide-out room, thereby tending to right the slide-out room. Accordingly, the power required of themotor82 remains relatively small compared to prior art actuating mechanisms.

Referring now toFIG. 9, a modifiedrack86 is provided with an upwardly incliningportion88. The operation of the unit equipped with theinclined rack86 is the same as in the preferred embodiment, except that when the pinion travels along theinclined section88 the slide-out room is allowed to drop gradually, thereby bringing the floor of the slide-out room into registry with the floor of the main living quarters. The pinions are allowed axial movement along the torque shaft, thereby permitting the pinions to remain in driving engagement with the rack teeth after theinclined section88 is reached. Instead of the hookedextension76 andshoe80, the unit using theinclined rack86 is provided with a secondary roller having a v-shaped cross section (not shown). This secondary roller is much smaller than theroller64, and engages bearingsurfaces89 in thegroove91, which extends longitudinally just above the tooth portion of the rack. The function of the secondary roller is the same as the hookedextension76 andshoe80.

This invention is not limited to the details above, but may be modified within the scope of the following claims.

Claims (17)

1. An actuating mechanism for living quarters having a main living area and a retractable room movable relative to the main living area between a retracted position retracted within the main living area and an extended position extended from the main living area to provide an auxiliary living area, said retractable room movable through an aperture in a side-wall of said living quarters, and an actuating mechanism for moving said retractable room between the extended and retracted positions, said actuating mechanism comprising:

a first pair of engagement members fixed relative to said retractable room and moving with said retractable room, each said engagement member having a plurality of slots;

a pair of drive members, each drive member having engagement features for engaging a corresponding engagement member, said drive members being driven together to move said retractable room between its retracted and extended positions;

said drive members and engagement members being maintained at a constant distance between each other regardless of changes in spacing between said retractable room and said aperture, and

said drive members being mounted for lateral movement within an elongate column on said sidewall at said aperture.

2. An actuating mechanism as claimed inclaim 1, wherein said engagement actuating mechanism includes a roller held at a fixed predetermined distance from one said drive member, said roller having rolling engagement with a complementary bearing surface carried on said retractable room, said fixed predetermined distance between said roller and said bearing surface on said retractable room preventing movement of said drive members away from said engagement member.

3. An actuating mechanism as claimed inclaim 1, wherein said engagement actuating mechanism includes a pair of rollers each being held at a predetermined distance from a corresponding drive member, each said roller in rolling engagement with a corresponding complementary bearing surface carried on said retractable room so that said roller is restrained from lateral movement relative to said complementary bearing surface, said rollers restraining lateral movement of said drive members away from their corresponding engagement members.

4. An actuating mechanism as claimed inclaim 2, wherein said complementary bearing surfaces carried on said retractable room are included on said engagement members.

5. An actuation mechanism as claimed inclaim 4, including a means for ensuring said engagement members are substantially parallel.

6. An actuation mechanism as claimed inclaim 4, wherein said rollers support the weight of said retractable room.

7. An actuation mechanism as claimed inclaim 1, wherein said drive members are gears rotating together and fixed from rotation relative to each other on a common shaft.

8. An actuation mechanism as claimed inclaim 7, wherein said engagement members are racks having a plurality of slots for interengaging teeth on said gears.

9. An actuating mechanism as claimed inclaim 8, wherein said engagement actuating mechanism includes an upper engagement member for ensuring said rollers remain in contact with said bearing surfaces.

10. An actuating mechanism as claimed inclaim 8, wherein said engagement actuating mechanism includes a pair of rollers each being held at a predetermined distance from a corresponding gear, each said roller in rolling engagement with a corresponding complementary bearing surface carried on said retractable room so that said roller is restrained from lateral movement relative to said complementary bearing surface, said rollers restraining lateral movement of said drive members away from their corresponding engagement members.

11. An actuating mechanism as claimed inclaim 10, wherein said complementary bearing surfaces carried on said retractable room are included on said racks.

12. An actuation mechanism as claimed inclaim 11, wherein said rollers support the weight of said retractable room.

13. An actuation mechanism as claimed inclaim 12, wherein said gears, common shaft, and said rollers are laterally movable together and restrained from longitudinal movement within said elongate column.

14. An actuation mechanism as claimed inclaim 12, wherein said elongate column includes a mounting flange for mounting to the sidewall of a vehicle.

15. An actuation mechanism as claimed inclaim 7, wherein the weight of said room is supported on rollers.

16. An actuation mechanism as claimed inclaim 1, including a means for ensuring said engagement members are substantially parallel.

17. An actuation mechanism as claimed inclaim 1, wherein said engagement members are racks, said drive members are gears rotating together and fixed from rotation relative to each other on a common shaft, said gears being slidable on said shaft to maintain engagement with their corresponding racks said gears follow the inclined section of said rack.

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