Sliding room and operating mechanism and components thereof

Abstract

The sliding room and operating mechanism include multiple corner units (32) and multiple wall panels connected to the corner units. The sliding room can be received in a mounting structure. Each corner unit (32) includes a drive mechanism. The drive mechanism cooperates with the mounting structure to enable the sliding room to be selectively translated by the mounting structure in a first direction and an opposite second direction.

Description

[0001] Cross-references to related applications

[0002] This application claims as a continuation-in-part of U.S. Patent Application No. 14 / 545,162, filed March 31, 2015, the disclosure of which is incorporated herein by reference in its entirety. This application also claims as a continuation-in-part of U.S. Patent Applications Nos. 15 / 085,373 and 15 / 085,332, filed March 30, 2016, the disclosures of which are incorporated herein by reference in their entirety. Technical Field

[0003] This disclosure relates to a slide-out cabin, an operating mechanism for the slide-out cabin, and components of the slide-out cabin. Such a device can be used in recreational vehicles and the like to selectively expand the interior space of these vehicles. More specifically, the slide-out cabin installed in a vehicle can extend to effectively increase the vehicle's interior volume and can retract to reduce the vehicle's external footprint. Background Technology

[0004] Known slide-out cabins often take the form of a box with five walls: a floor, a ceiling, an exterior wall, and two opposing side walls. A sixth side of the "box" is essentially open or fully open to allow access to the interior of the slide-out cabin from inside the vehicle. When the slide-out cabin is retracted, its exterior wall overlaps with the exterior wall of the vehicle on which it is mounted. The seal used to seal the interface between these two walls typically needs to conform to the profile of each of the two walls. In applications where the wall profiles are not flat and are not parallel to each other, complex seals may be required. Complex seals can be expensive and difficult to install.

[0005] Known mechanisms for operating such a slide-out room include a rack and pinion and a motor-driven pinion, wherein the rack is located on the outer surface of the room's floor or sidewall, and the motor-driven pinion is mounted to a vehicle that engages with the rack. The pinion is operable to drive the rack and the room to which the pinion and rack are attached to enter or exit the vehicle. When the slide-out room extends, at least some parts of such a mechanism may be exposed to the environment and may attract or otherwise engage with dirt, debris, or foreign objects that could impede the proper operation of the mechanism.

[0006] Other known mechanisms for operating such slide-out rooms include hydraulic actuators engaged between the room's floor and the vehicle's frame. Such mechanisms may struggle to position the room in a way that provides an effective seal between the room's outer walls and the vehicle's outer walls when the room retracts. Summary of the Invention

[0007] This disclosure discloses a slide-out system for a recreational vehicle having an interior compartment for receiving a user and including an outer wall. The slide-out system includes a slide-out portion arranged to be mounted to the recreational vehicle and movable between an open position and a closed position.

[0008] The sliding portion includes an outer wall, wherein, in the closed position of the sliding portion, the outer wall of the sliding portion is flush with the outer wall of the recreational vehicle.

[0009] The slide-out system includes a mounting structure having an outer frame arranged to support the slide-out portion, the outer frame being fixed to the outer wall of the recreational vehicle.

[0010] The slide-out system includes a drive mechanism that connects the slide-out portion to the outer frame for moving the slide-out portion into the vehicle and removing it from the recreational vehicle. Attached Figure Description

[0011] Figure 1 The perspective view of the travel trailer including the slide-out room and operating mechanism according to this disclosure shows the slide-out room in the extended position.

[0012] Figure 2 The perspective view of the travel trailer including the slide-out room and the operating mechanism according to this disclosure shows the slide-out room in the retracted position.

[0013] Figure 3 This is a detailed perspective view of the sliding room and operating mechanism according to this disclosure;

[0014] Figure 4 This is another detailed perspective view of the sliding room and operating mechanism according to this disclosure;

[0015] Figure 5 It is a perspective view of the slide-out room and operating mechanism according to this disclosure in a solid model installed on the side wall of a vehicle or other structure;

[0016] Figure 6 This is a perspective view of a corner unit of a sliding room component attached to a mounting structure, according to the present disclosure.

[0017] Figure 7 This is an exploded perspective view of the operating mechanism for a portion of a sliding room according to the present disclosure;

[0018] Figure 8 This is a detailed perspective view of the limiting block of the operating mechanism for a part of a sliding room according to the present disclosure;

[0019] Figure 9 This is a detailed perspective view of the drive block of the operating mechanism for a part of a sliding room according to the present disclosure;

[0020] Figure 10 This is a detailed drawing of the drive unit for an operating mechanism for a portion of a sliding room, according to this disclosure;

[0021] Figure 11 This is a detailed perspective view of the installation structure based on this disclosure;

[0022] Figure 12A It is an interior side view of the slide-out room and operating mechanism installed in the wall of the structure according to this disclosure;

[0023] Figure 12B It is a side view of the sliding room and operating mechanism according to this disclosure, installed in the wall of the structure, wherein the sliding room is fully retracted;

[0024] Figure 12C It is a side view of the sliding room and operating mechanism according to this disclosure, installed in the wall of the structure, wherein the sliding room extends fully;

[0025] Figure 12D It is a top view of the sliding room and operating mechanism according to this disclosure, installed in the wall of the structure, wherein the sliding room extends fully;

[0026] Figure 13A It is an external perspective view of the sliding room and operating mechanism according to this disclosure, installed in the wall of the structure, wherein the sliding room extends fully;

[0027] Figure 13B It is an internal perspective view of the sliding room and operating mechanism according to this disclosure, installed in the wall of the structure, wherein the sliding room extends fully;

[0028] Figure 13C It is an internal perspective view of the sliding room and operating mechanism according to the present disclosure, wherein the sliding room is in an intermediate position between fully extended and fully retracted relative to the mounting structure for the sliding room.

[0029] Figure 14A and Figure 14B This is a detailed drawing of a device for attaching an outer panel to a corner unit of a sliding room according to the present disclosure;

[0030] Figures 15A to 15F This is a detailed drawing of a device for attaching a mounting structure to another structural wall according to this disclosure;

[0031] Figure 16 This is a partial perspective view of a part of the main body of the corner unit of the sliding room according to this disclosure;

[0032] Figure 17 This is a perspective view showing the drive bracket of the corner unit attached to the mounting structure and the sliding room according to the present disclosure; and

[0033] Figure 18 This is an end view of the corner unit of a sliding room according to this disclosure. Detailed Implementation

[0034] Unless the context clearly indicates otherwise, directional references, such as up, down, upward, downward, upper, lower, top, bottom, left, right, etc., which may be used in this document, should be understood as relative references, not absolute orientations.

[0035] The accompanying drawings illustrate an exemplary embodiment of a slide-out room 10 and a mounting structure 12, the mounting structure 12 having an opening 14 configured to slidably receive the slide-out room therein. As discussed further below, the slide-out room 10 and the mounting structure 12 cooperate to define an operating mechanism that can be used to selectively drive the slide-out room through the opening 14 of the mounting structure 12 in a first direction and a second opposite direction.

[0036] like Figures 1 to 5 As best shown in the drawings, the slide-out room 10 and mounting structure 12 can be installed in an opening 18 in the wall 20 of a campervan 16, such as a touring trailer, or another structure. The wall 20 is shown in the drawings as a wall defining the side of the vehicle 16. In other embodiments, the wall 20 can be any other wall of the vehicle 16, such as the rear wall or ceiling (or roof) of the vehicle.

[0037] Mounting structure 12 is implemented as a peripheral frame configured for mounting into an opening 18 in the wall 20 of vehicle 16 or into an opening in the wall of another structure. Figure 11As best shown, the outer frame of mounting structure 12 may include a web 12W configured to be received within opening 18, close to the wall 20 defining the opening. The web 12W may be loosely received in opening 18 or slidably engaged with the wall 20 defining the opening. The outer frame of mounting structure 12 may include a flange 12F configured to cover the wall 20 surrounding opening 18. A seal (not shown) may be provided for mounting between flange 12F and wall 20. A flange or recess 12S for receiving the seal may be provided, as will be further discussed below, for receiving a peripheral seal S in an internal region of the outer frame, thereby engaging with the slide-out chamber 10. The seal S may be a continuous seal and may substantially conform to the outer frame around its entire circumference or a portion thereof. Holes (not shown) may be provided in either the web 12W or the flange 12F, and configured to receive screws or other fasteners for securing the mounting structure 12 to the wall 20 directly or by means of an intermediate bracket (not shown). Alternatively or additionally, such a bracket (not shown) may be riveted, welded, or bonded to or integrally formed with the outer frame. Similarly, holes (not shown) may be provided in either the web 12W or the flange 12F, and configured to receive screws or other fasteners for securing a drive bracket, as discussed further below, to the mounting structure 12. Alternatively, such a drive bracket may be riveted, welded, or bonded to or integrally formed with the outer frame.

[0038] The slide-out room 10 is shown as a six-sided box with five panels: floor 22, ceiling 24, outer wall 26, first side wall 28, and second side wall 30 opposite the first side wall. The sixth side of the "box" is opposite the outer wall 26 and is substantially open or fully open to allow access to the interior space 31 of the slide-out room 10. In this document, the collection of sides or panels other than the outer wall 26 and the open side may be referred to as the peripheral sides or peripheral panels. As shown, peripheral panels 22, 24, 28, and 30, the outer wall 26, and the open inner side may be generally rectangular.

[0039] The illustrative sliding room 10 includes four corner units 32n interconnected by outer panels 22, 24, 28, 30, and an outer wall 26. More specifically, a first corner unit 32A is connected to the outer wall 26, the floor 22, and the first side wall 28 such that the outer wall, floor, and first side wall are substantially perpendicular to each other. A second corner unit 32B is connected to the outer wall 26, the first side wall 28, and the ceiling 24 such that the outer wall, first side wall, and ceiling are substantially perpendicular to each other. A third corner unit 32C is connected to the outer wall 26, the ceiling 24, and the second side wall 30 such that the outer wall, ceiling, and second side wall are substantially perpendicular to each other. A fourth corner unit 32D is connected to the outer wall 26, the second side wall 30, and the floor 22 such that the outer wall, second side wall, and floor are substantially perpendicular to each other.

[0040] Each corner unit 32n includes a body 34. The body 34 may be formed, for example, by molding, extrusion, or other methods from plastic or aluminum. The body 34 is shown as elongated relative to its width and height, but the body may have any desired length. The length of the body 34 typically, but not necessarily, corresponds to the depth of the slide-out room 10, for example as... Figure 12D The distance d between the outer wall 26 of the sliding room 10 and the open side is shown in the best example.

[0041] The body 34 includes a first attachment portion 36 configured for attachment to a first peripheral panel. For example, the first attachment portion 36 of the first corner unit 32A is configured for attachment to the floor 22 of the sliding room 10. The body 34 also includes a second attachment portion 38 configured for attachment to a second peripheral panel, such as a side wall of the sliding room. For example, the second attachment portion 38 of the first corner unit 32A is configured for attachment to a first side wall 28 of the sliding room 10.

[0042] In an illustrative embodiment or example, the first attachment portion 36 is shown as a flange extending from a major portion of the body 34 of the corner unit 32n. This flange may define a plurality of holes 40 extending through it. The holes 40 are configured to receive mechanical fasteners, such as screws, bolts, or rivets, passing through the holes 40 and through a corresponding one of the outer perimeter panels 22, 24, 28, and 30 of the slide-out room 10. For example, the first attachment portion 36 of the first corner unit 32A is shown as attached to the floor 22 of the slide-out room 10.

[0043] In other embodiments, hole 40 may be omitted, and the first attachment portion 36 may be configured in another way to allow attachment to a corresponding one of the peripheral panels 22, 24, 28, and 30. For example, in one embodiment (not shown), an adhesive may be used to bond the corresponding peripheral panel to the first attachment portion 36. Figure 14A An embodiment is shown including a stud 124 welded or otherwise attached to the first attachment portion 36. The stud 124 can be engaged with a corresponding peripheral panel through a hole therethrough. Figure 14B One embodiment is shown in which the peripheral panel is attached to a reinforcement adjacent to the first attachment portion 36, which will be discussed below. Another embodiment (not shown) may include a second flange (not shown) extending from a major portion of the body 34 of the corner unit 32n. The second flange (not shown) may be generally parallel to the first flange. The first and second flanges may cooperate to define a pocket (not shown) configured to receive the edge portion of a corresponding one of the peripheral panels 22, 24, 28, and 30 of the slide-out room 10. Embodiments may use any combination of the above-described methods and / or other methods to attach the peripheral panel to the corner unit 32n.

[0044] The second attachment portion 38 can be configured in a manner similar to the first attachment portion 36, or in another manner that allows attachment to a corresponding other of the outer perimeter panels 22, 24, 28, and 30. The second attachment portion 38 of the first corner unit 32A is shown attached to the first sidewall 28 of the sliding room 10. Because the shown sliding room 10 has four outer perimeter panels defining a rectangular cross-section, the first attachment portion 36 and the second attachment portion 38 are configured to attach to the corresponding outer perimeter panels such that the corresponding outer perimeter panels are substantially perpendicular to each other.

[0045] The outer wall 26 may be attached to the edges of the outer panels 22, 24, 28, and 30 using adhesives, fasteners, or another suitable mechanism. These edges are close to the outer ends of the corner unit 32n.

[0046] The body 34 defines a channel 42 recessed from the outer surface 44 of the body. The channel 42 may be adjacent to the first attachment portion 36 or the second attachment portion 38. As shown, the channel 42 may extend the entire length of the body, from a first end of the body to a second end of the body. In other embodiments, the channel 42 may extend the length of the body 34 by any smaller amount. The body 34 may include one or more reinforcing ribs or stiffeners 46, etc., to provide structural integrity to the body.

[0047] The drive screw 48 is at least partially received within the channel 42. In one embodiment, the drive screw 48 is disposed within the channel 42 such that the outer diameter of the drive screw is substantially recessed from or flush with the outer surface of the body 34.

[0048] The drive screw includes a first end 48A, a second end 48C, and an intermediate portion 48B between the first and second ends. Compared to the intermediate portion 48B, the first end 48A of the drive screw 48 has a reduced diameter, thereby defining a circumferential region 96 at the interface between the first end and the intermediate portion. The first end 48A of the drive screw may include external mechanical threads. The intermediate portion 48B of the drive screw includes external drive threads, such as Acme threads with a specific pitch. Compared to the intermediate portion 48B, the second end 48C of the drive screw 48 may have, but does not necessarily have, a reduced diameter.

[0049] The limiting block 50 is attached to the body 34 at or near the first end of the body. As shown, the limiting block 50 may be fully or partially received within the channel 42. The limiting block 50 defines a hole 86 passing through this hole. (In the illustrated embodiment, as will be further discussed below, the hole 86 is defined by the cooperation of the first semi-cylindrical channel portions of a pair of corresponding split limiting blocks.) The limiting block 50 receives and supports the first end 48A of the drive screw 48 in the hole 86 with a rotatable engagement. Here, the limiting block 50 also defines a first countersunk portion 88 and a second countersunk portion 89, wherein the first countersunk portion 88 extends inwardly from a first side of the limiting block, and the second countersunk portion 89 extends inwardly from a first second side of the limiting block. (In the illustrated embodiment, as will be further discussed below, the first countersunk portion 88 is defined by the cooperation of the second semi-cylindrical channel portions of a pair of corresponding split limiting blocks, and the second countersunk portion 89 is defined by the cooperation of the third semi-cylindrical channel portions of a pair of corresponding split limiting blocks.)

[0050] The first countersunk portion 88 is configured to receive a first washer 94-1 and a nut 98, which are threadedly screwed onto the first end 48A of the drive screw 48. The nut 98 is secured to the drive screw 48 by a roller pin 100, which is inserted through a corresponding hole (not shown) and extends to or through the nut and the first end 48A of the drive screw.

[0051] The second countersunk portion 89 is configured to receive the second washer 94-2. The first washer 94-1 and the second washer 94-2 can function as thrust bearings, receiving and responding to the thrust load applied via the nut 98 and the drive screw 48 through the circumferential region 96, and limiting or preventing longitudinal displacement of the drive screw 48 relative to the limit block 50. In an embodiment, the first washer 94-1 and the second washer 94-2 can be omitted, and the surfaces of the first countersunk portion 88 and the second countersunk portion 89 adjacent to the hole 86 can be used as thrust bearings.

[0052] In one embodiment, the limiting block 50 can be formed as a single piece. In an illustrative embodiment, such as... Figure 8 As best shown, the limiting block 50 is implemented as a first limiting block 50A and a second limiting block 50B that are split apart. Each of the first limiting block 50A and the second limiting block 50B defines a first semi-cylindrical channel portion 86A, a first semi-cylindrical channel portion 86B, a second semi-cylindrical channel portion 88A, a second semi-cylindrical channel portion 88B, and a third semi-cylindrical channel portion 89A, a third semi-cylindrical channel portion 89B (part 89B is unclear and not shown). As will be further discussed below, when the first limiting block 50A and the second limiting block 50B are connected together, the first semi-cylindrical channel portion, the second semi-cylindrical channel portion, and the third semi-cylindrical channel portion cooperate to define a hole 86 through the limiting block 50 and the first countersunk portion 88 and the second countersunk portion 89.

[0053] A drive screw support 102 is attached to the body 34 at or near the second end of the body 34. The drive screw support 102 defines a hole 104 therethrough. The hole 104 is configured to receive and support the second end 48C of the drive screw 48 in a rotatable engagement. A bushing 106 having a hole 108 therethrough may be disposed in the hole 104 between the drive screw support 102 and the drive screw 48. The drive screw support 102 may include a mounting flange 109 defining a hole 110, wherein the hole 110 is configured to receive a screw 112 or other fastener used to secure the drive screw support to the body 34. As will be further discussed below, the drive screw support 102 may define additional holes 114 configured to receive additional screws 116 for attaching the drive unit 54 thereto.

[0054] A drive connector 118 can be attached to the second end 48C of a drive screw 48 in a fixed engagement manner, such that rotation of the drive connector causes a corresponding rotation of the drive screw 48. Here, the drive connector 118 defines a hole 119 configured to receive the second end 48C of the drive screw in a tight engagement manner. The drive connector 118 can be secured to the drive screw 48 using one or more rollers 120, which are inserted into corresponding holes (not shown) formed in or passing through the drive connector and into the drive screw. In other embodiments, the drive connector 118 can be secured to the drive screw 48 in other ways. An annular protrusion 126 extends from the first end of the drive connector 118. An O-ring, D-ring, or similar type of seal 126 can be received in a groove (covered by an O-ring, not shown) formed in the first end of the drive connector 118. A plurality of (three shown, but fewer or more may be provided) protrusions 130 extend from the second end of the drive connector 118. The protrusion 130 is configured to engage with a corresponding structure located at the output section of the gear train 58 or the output shaft 57 of the motor 57.

[0055] In the illustrative embodiments or examples, the drive unit 54 is attached to the mounting plate 60. The drive unit 54 may be attached to the mounting plate 60 using a coupling tab 132 or any other suitable mechanism. Here, the mounting plate 60 defines a drive connector receiving hole 63 and a plurality of screw receiving holes 61. The mounting plate 60 may be attached to the drive screw support 102 using screws 116, which extend through the screw receiving holes 61 and into holes 114 in the drive screw support 102.

[0056] The drive unit 54 includes a bidirectional motor 56 having an output shaft 57 and a gear train 58 connected to the output shaft. A second drive coupler (not shown), complementary to the drive coupler 118, may be located at the output of the gear train 58 or integrated with the gear train. For example, the second drive coupler (not shown) may be integrated with the output gear of the gear train 58. The second drive coupler (not shown) is configured to engage with the drive coupler 118 such that rotation of the second drive coupler causes a corresponding rotation of the first drive coupler.

[0057] In illustrative embodiments or examples, the output shaft 57 has a rotational axis perpendicular to the rotational axis of the drive screw 48. The gear train 58 is configured to receive a rotational input from the output shaft 57 and to provide a corresponding rotational output perpendicular to the rotational input to the drive coupling 60. The gear train 58 may include worm gears and roller gears, bevel gears, or other gears configured to achieve the aforementioned changes in rotational direction. The gear train 58 may also be configured to provide a rotational output speed to the drive coupling 60 that is greater than, less than, or equal to the rotational input speed of the motor 56. In some embodiments, the motor 56 may be directly connected to the drive coupling 60. In such embodiments, the gear train 58 may be omitted, and the second drive coupling may be located at or integrated with the output shaft 57.

[0058] The drive block 62 is slidably received within the channel 42 and threadedly engaged with the drive thread of the drive screw 48. The drive block 62 and the channel 42 are configured to substantially restrict or prevent rotation of the drive block within the channel. In an illustrative embodiment or example, the drive block 62 is implemented as a first drive block 62A and a second drive block 62B, both split apart. The first drive block 62A includes a generally rectangular body defining a hole 64 therethrough. As discussed further below, the hole 64 is generally circular and may define one or more keyways 68 corresponding to the key of the shaft of the drive carriage. The first drive block 62A also defines a plurality of screw holes and screw receiving shaft hole seats 66. A first face or inner face of the drive block defines a generally semi-cylindrical threaded portion 70 having drive threads. The drive threads of the threaded portion 70 are complementary to the threads of the drive screw 48. The split second drive block 62B may be a mirror image of the first drive block 62A, or otherwise configured such that the split first drive block and the split second drive block can be assembled around the drive screw 48. In an embodiment, the drive block 62 is composed of an inherent lubricating material, such as... plastic.

[0059] The pitch of the drive screw 48 and the drive block 62 can be a locked pitch. That is, the thread pitch can be selected so that rotation of the drive screw 48 is prevented only in response to a longitudinal load applied thereto by the drive block 62. Alternatively or additionally, the gear train 58 can be automatically locked so that rotation of the drive screw is prevented only in response to a longitudinal load applied thereto by the drive block 62. This feature makes it possible to retain the drive block 62, and therefore, to keep the slide-out room 10 in the left-hand position without using a motor brake or other mechanism for securing the room in place.

[0060] The drive bracket 72 is connected to the drive block 62 and the mounting structure 12. More specifically, in an illustrative example or embodiment, the drive bracket 72 includes a generally cylindrical shaft 74 configured to securely engage with a hole 64 in each of the split first drive block 62A and split second drive block 62B. One or more keys 76 may be provided on the outer surface of the shaft 74 at its first end, and these keys 76 are configured to engage with a keyway 68 of the hole. A groove 77 may extend laterally through the one or more keys 76. Additionally, as will be further discussed below, one or more keys 76 may be provided on the outer surface of the shaft 74 at its second end, and these keys 76 are configured to engage with a keyway of the mounting portion. The shaft 74 may define a bore 78 therethrough, and the bore 78 is configured to receive a drive screw 48 in a rotatable relationship.

[0061] The drive bracket 72 also includes a mounting portion 80 configured to facilitate attachment to the mounting structure 12. The mounting portion 80 is shown as an angled bracket having an attached first flange 80A that is substantially perpendicular to the second flange 80B. Here, a third flange 80C extends substantially perpendicularly from the second flange 80B and is substantially parallel to the first flange. Each of the first flange 80A and the third flange 80C defines a corresponding hole 81 through it (the first flange 80A may also define a second hole 81 through it). The shaft 74 is securely received in the corresponding holes 81 defined by the first flange 80A and the third flange 80C, for example by welding and / or pressure fit or interference fit. The holes 81 defined by the first flange 80A and the third flange 80C may define one or more keyways 83 configured to engage with one or more corresponding keys 76 that may be provided at a second end of the shaft 74. As will be further discussed below, one or more locking members 85 may be provided to connect to the drive block 62 and the drive bracket 72 to secure the shaft 74 to the drive block, thereby preventing or limiting longitudinal movement of the shaft relative to the drive block.

[0062] Seal 84 covers channel 42 and drive screw 48. For example... Figure 18As best shown, the seal 84 may include a first sealing member 84A and a second sealing member 84B. The seal 84 may be made of rubber or another flexible, elastic material. The first sealing member 84A and the second sealing member 84B may be attached to the outer surface of the body 34. A first end of the first sealing member 84A may be attached to the body 34 near a first side of the channel 42. The first sealing member 84A may extend from the attachment point with the body 34 toward a second side of the channel 42 and through at least a portion of the channel. A first end of the second sealing member 84B may be attached to the body 34 near a second side of the channel 42. The second sealing member 84B may extend from the attachment point with the body 34 toward the first side of the channel 42 and through at least a portion of the channel, such that a second free end of the second sealing member overlaps with a second free end of the first sealing member 84A. With the first corner unit 32A oriented such that the second side of the channel 42 is higher than the first side of the channel, this arrangement can prevent or mitigate the intrusion of water or other contaminants into the channel.

[0063] As will be further discussed below, the first sealing member 84A and the second sealing member 84B are sufficiently flexible to deviate from their normal positions by means of the shaft 74 therebetween, and the first sealing member 84A and the second sealing member 84B are sufficiently resilient to return to their normal state in the absence of the shaft 74.

[0064] The corner unit 32n shown can be assembled, for example, by inserting the first end 48A of the drive screw 48 through the second washer 94-2 and the first washer 94-1 in that order. The nut 98 can then be threaded onto the first end 48A of the drive screw 48, spaced a distance from the circumferential region 96 of the drive screw, such that the first and second washers can be received in the first countersunk portion 88 and the second countersunk portion 89 of the split first top block 50A and the split second top block 50B, respectively. The nut 98 can be secured to the drive screw 48 using a pin 100 or other suitable means, such as riveting or applying a mating thread to the nut and the first end of the drive screw. The first end 48A of the drive screw 48 can be received in the channel 86A of the split first limiting block 50A and the channel 86B of the split second drive block 50B, and the first washer 94-1 and the washer 94-2 can be received in the first countersunk portion 88 and the second countersunk portion 89, respectively.

[0065] The drive block 62 can be assembled to the drive screw 48 by inserting the shaft 74 of the drive bracket into the hole 64 of the split second drive block 62B in a keyed manner. The drive screw 48 can be inserted into the hole 78 in the shaft 74. The locking member 85 can be fitted into the slot 77 of the key 76. The split second drive block 62B can be placed adjacent to the drive screw 48 such that the thread 70 of the split second drive block engages with the thread of the drive screw, and thus the locking member retainer 67 defined by the split second drive block engages with the locking member 85. The shaft 74 can be inserted into the hole 64 of the split first drive block 62B, keyed therewith, and placed adjacent to the drive screw 48 such that the thread 70 of the split first drive block engages with the thread of the drive screw, and thus the locking member retainer 67 defined by the split first drive block engages with the locking member 85. Screws (not shown) are threadedly received in screw receiving holes 66 of the split first drive block 62A and / or the split second drive block 62B to secure the split first limit block and the split second limit block together.

[0066] The drive screw 48 can be inserted through a hole 104 in the drive screw support 102. In embodiments including a bushing 106, the bushing can be inserted into the hole 104 in the drive screw support 102, and the drive screw 48 can be inserted through a hole 108 in the bushing. The drive coupling 120 can be fitted to and secured to the second end 48C of the drive screw 48 using one or more rollers 120 or other suitable means.

[0067] The aforementioned components, including the limiting block 50, drive screw 48, drive block 62, drive screw support 102, and drive connector 118, can be assembled and secured to the body 34 by the following steps: sliding the limiting block 50 from the second end of the channel toward the first end of the channel into the channel 42; inserting the screw 92 through the hole 128 in the body (see... Figure 17 The limiting block is fixed to the body 34; and the screw is threaded into the screw receiving hole 90 of the split first limiting block 50A and / or split second limiting block 50B. The drive screw support 102 can be fixed to the body 34 at or near the second end of the channel 42 by the following steps: connecting the drive screw support to the body; inserting the screw 112 through the hole in the body; and threading the screw into the screw receiving hole 110 of the mounting flange 109.

[0068] The drive unit 54 can be attached to the drive screw support 102 by the following steps: inserting the drive connector 118 attached to the drive screw 48 through the hole 63 in the mounting bracket 60; engaging the drive connector with the corresponding second drive connector (not shown) of the drive unit; inserting the screw 116 through the hole 61 of the mounting bracket and into the corresponding hole 114 of the drive screw support.

[0069] The slide-out room 10 can be assembled by the following steps: attaching the outer panels to the corresponding corner units 32n using any suitable method as discussed above; and attaching the outer wall 26 to the edges of the outer panels 22, 24, 28, and 30 adjacent to the outer wall. For example, the first attachment portion 36 of the first corner unit 32A can be attached to the floor 22, and the second attachment portion 38 of the first corner unit can be attached to the first side wall 28. The second attachment portion 38 of the second corner unit 32B can be attached to the first side wall 28, and the first attachment portion 36 of the second corner unit 32B can be attached to the ceiling 24. The first attachment portion 36 of the third corner unit 32C can be attached to the ceiling 24, and the second attachment portion 38 of the third corner unit can be attached to the second side wall 30. The second attachment portion 38 of the fourth corner unit 32D can be attached to the second side wall 30, and the first attachment portion 36 of the fourth corner unit 32D can be attached to the floor 22. (It is evident that the first corner unit 32A and the fourth corner unit 32D may be mirror images of each other, as may the second corner unit 32C and the third corner unit 32D, so that the drive unit of each corner unit can be positioned close to the open side of the sliding room 10. Except that the sealing members of all corner units 32n can be arranged such that the upper part of the sealing member overlaps with the lower part of the sealing member to reduce or prevent water intrusion into the corresponding channel 42, the first corner unit 32A and the second corner unit 32B may be mirror images of each other, as may the third corner unit 32C and the fourth corner unit 32D.) The outer wall 26 may be attached to the edges of the peripheral panels 22, 24, 28, and 30 adjacent to the outer wall using adhesives, screws, clamps, or other suitable fasteners.

[0070] Each motor 56 in each of the corner units 32n is electrically connected to a controller 122, which is configured to operate the motors of all the corner units. The controller 122 can be configured to operate the motors 56 synchronously or asynchronously, selectively. The controller 122 can be configured to cause the motors to selectively rotate the corresponding drive screw 48 in a first rotational direction or a second rotational direction. In the illustrative example or embodiment, the threads of all drive screws 48 in all corner units 32n have the same rotational orientation. Alternatively, it is possible that the rotational orientation of the threads of the drive screws of some corner units, such as corner units 32A and 32B, is opposite to that of the drive screws of other corner units, such as corner units 32C and 32D. Therefore, the controller 122 can be configured to cause the corresponding motor 56 to selectively rotate the corresponding drive screw 48.

[0071] The slide-out chamber 10 can be inserted through an opening in the mounting structure 12, and the mounting portion 80 of the drive bracket 72 of each of the corner units 32n can be attached to the mounting structure at a corresponding location. As discussed above, the outer surface 44 of the corner unit 32n and the peripheral panel of the slide-out chamber can engage with the peripheral seal S mounted to the mounting structure. The mounting portion 80 can be attached to the mounting structure 12 in any suitable manner, such as by welding or using mechanical fasteners. For example, Figure 17 The drive bracket 72 is shown attached to the mounting structure 12 using screws 130, which extend through corresponding holes (obscured, not in the drive bracket and mounting frame). Figure 17 (as shown in the image).

[0072] The slide-out room 10 and mounting structure 12 assembly can be installed as units into the opening 18 in the wall 20 of the vehicle 16 or other structure, and secured to the wall or vehicle using any suitable means, such as mechanical fasteners, clamps, brackets or other means. Figures 15A to 15F Various means for attaching the mounting structure 12 to the wall 20 of the vehicle are shown, including mechanical fasteners that extend through the mounting structure and into the wall. Figure 15A and Figures 15E to 15F ), and clamps that extend between the mounting structure and the wall and are secured to the mounting structure using mechanical fasteners. Figures 15B to 15D ).

[0073] The controller 122 is electrically connected to a control switch (not shown), which can be operated by a user to control the operation of the slide-out room 10. For example, the user can operate the switch, causing the controller 122 to actuate the motor 56 to operate in a first rotational direction. Since the drive screw 48 is mechanically connected to the output shaft 57 of the motor 56 directly or via a gear train 58, operation of the motor in the first rotational direction causes operation of the drive screw in the corresponding first rotational direction. Since the drive screw is threadedly engaged with the corresponding drive block 62, and since the drive block is prevented from large-scale rotation within the channel 42, rotation of the drive screw in the first rotational direction causes the drive block to slide relative to the corresponding channel 42 and the body 34 in a first translational direction. Since the drive block 62 is attached to the mounting frame via the drive bracket 72, the sliding of the drive block 62 relative to the channel 42 and the body 34 causes the body to slide relative to the wall 20 of the mounting frame 12 and the vehicle 16 in the first translational direction, and thus causes the slide-out room 10 to slide relative to the wall 20 of the mounting frame 12 and the vehicle 16 in the first translational direction. The user can also operate the switch to produce the opposite effect.

[0074] The controller 122, the slide-out chamber, and the operating mechanism are configured such that when the slide-out chamber is in its normal, fully retracted position, the outer surface of the outer wall 26 of the slide-out chamber is substantially flush with the outer surface of the wall 20 of the vehicle or other structure. The controller 122, the slide-out chamber, and the operating mechanism are also configured such that the outer surface of the outer wall 26 of the slide-out chamber can retract from the outer surface of the wall 20 of the vehicle or other structure and away from the seal S attached to the outer frame of the mounting structure, allowing the seal to be replaced without removing the slide-out chamber from the mounting structure.

[0075] In this document, the slide-out room 10 is described as a straight, six-sided box. In other embodiments, the slide-out room 10 may have other configurations. For example, the outer wall 26 and the open side of the slide-out room 10 may define an n-sided polygon, and n panels may extend from corresponding edges of the outer wall to the open side. In one embodiment, the outer wall 26 and the open side may define a triangle, and three panels may connect corresponding sides of the outer wall and the open side. In another embodiment, the outer wall 26 and the open side may define a pentagon, and five panels may connect corresponding sides of the outer wall and the open side. In yet another embodiment, the outer wall 26 and the open side may have curved profiles, and a plurality of curved panels may connect corresponding portions of the perimeter of the outer wall and the open side.

[0076] Slide-out room embodiments with an additional n-sided polygonal outer wall 26 and an open-side configuration typically include n corner units 32 configured to connect to the outer wall and two adjacent peripheral panels. For example, a slide-out room 10 with a triangular outer wall 26 and an open inner side typically includes three corner units 32, and a slide-out room with a pentagonal outer wall and an open inner side typically includes five corner units. Slide-out room embodiments with curved outer walls and open sides may include any number of corner units 32 (typically two or more) configured to connect to the outer wall and two curved panels. Thus, the term "corner unit" may include components configured to receive peripheral panels at locations where a angular corner need not be defined.

[0077] Slide-out room systems are typically designed for use in recreational vehicles. These systems offer the following benefits: lower likelihood of leaks, lower manufacturing and maintenance costs, reduced vehicle weight, greater reliability over extended operation, and an aesthetically pleasing appearance.

[0078] Slide-out systems for recreational vehicles may use an outer wall that is flush with the vehicle's outer wall, rounded corners around the slide-out perimeter, continuous peripheral seals, a drive mechanism mounted in the slide-out portion rather than on the vehicle, and weather-resistant seals on the drive shaft.

[0079] Figure 1 A recreational vehicle of type 16, a tour trailer, is shown. This tour trailer includes interior compartments to accommodate users and provides space for shelter, eating, or sleeping. The trailer also includes exterior walls, for example, in a generally vertical plane.

[0080] The slide-out portion is installed to the trailer and is movable between an open position and a closed position. In the open position, the slide-out portion increases the usable space of the compartment. The slide-out portion includes an outer wall, for example, in a generally vertical plane. In the closed position, the outer wall of the slide-out portion is flush with the outer wall of the trailer, meaning that the outer wall of the slide-out portion is in substantially the same, for example, vertical plane as the outer wall of the trailer.

[0081] The mounting structure with a peripheral frame may include a slide-out portion. When assembling a vehicle, once an opening for the slide-out portion is made, the slide-out portion can be attached to the vehicle by securing the peripheral frame to the vehicle. The frame may include a continuous seal of conventional nature that extends along the entire periphery of the slide-out portion. The slide-out portion may include rounded corners. Because the seal does not need to move through any right-angle corners, the seal does not need to be cut and / or overlapped at the corners.

[0082] The drive mechanism for moving the slide-out portion into or out of the vehicle may include four motors, for example, mounted in association with rounded corners, serving as its power source. Each of these motors may be connected to rotate a threaded drive shaft (or drive screw), wherein the threaded drive shaft (or drive screw) is mounted between the motor and a bracket connected to the frame. To protect the drive shafts from environmental influences and to prevent accidental contact between the user and the drive shafts, each drive shaft may be covered with a flexible, weather-resistant seal. These weather-resistant seals may, for example, be formed of two longitudinally extending rubber strips, forming an overlapping connection from the upper to the lower portion of the adjacent drive shaft. These strips may be flexible enough to allow the bracket connector to separate the strips as the slide-out portion moves through the bracket, but may also be resilient enough to close the connector once the strips move away from the bracket.

[0083] Specific examples or embodiments of the slide-out room and operating mechanism, as well as components of the slide-out room, have been described herein. Various modifications and variations can be made thereto without departing from the spirit of the invention as defined by the appended claims. For clarity and conciseness, features are described herein as part of the same or separate embodiments. However, alternative embodiments are also contemplated, having combinations of all or some of the features described in these separate embodiments. It should be understood that the scope of the invention may include embodiments having combinations of all or some of the described features. Other modifications, variations, and substitutions are also possible. Therefore, this specification, drawings, and examples should be considered illustrative rather than restrictive.

[0084] In the claims, any reference numerals placed between parentheses should not be construed as limiting the claims. The word "comprising" does not exclude the presence of features or steps other than those listed in the claims. Furthermore, the words "a" and "an" should not be construed as limited to "only one," but rather as indicating "at least one," and do not exclude multiple. The minor fact that certain measures are stated in mutually different claims does not indicate that a combination of these measures cannot produce a beneficial effect.

Claims

1. A slide-out system for installation in an opening in the exterior wall of a vehicle, the vehicle having an interior compartment for receiving a user, the slide-out system comprising a slide-out portion arranged to be mounted to the vehicle and movable between an open position and a closed position. in, The sliding portion includes an outer wall, wherein, in the closed position of the sliding portion, the outer wall of the sliding portion is flush with the outer wall of the vehicle. The slide-out system includes a mounting structure with an outer frame, wherein the slide-out portion is connected to the outer frame via a drive mechanism for moving the slide-out portion into and out of the vehicle. The slide-out system is configured to be installed into an opening in the outer wall of the vehicle by fixing the outer frame to the outer wall of the vehicle, such that the outer frame supports the slide-out portion.

2. The system according to claim 1, wherein, The peripheral frame includes a continuous seal that extends along the entire periphery of the slide-out portion.

3. The system according to claim 1 or 2, wherein, The sliding portion includes a rounded corner around its periphery.

4. The system according to claim 1 or 2, comprising 4 corners.

5. The system according to claim 3, wherein, The drive mechanism includes a motor, which serves as its power source, and is mounted in association with each of the rounded corners.

6. The system according to claim 5, wherein, Each of the motors is connected to rotate a threaded drive shaft, wherein the drive shaft is mounted between the motor and a bracket connected to the outer frame.

7. The system according to claim 6, wherein, The drive shaft is covered with a flexible, weather-resistant seal.

8. The system according to claim 7, wherein, The weather-resistant seal is formed by two longitudinally extending rubber strips that overlap from the upper to the lower part of the drive shaft.

9. The system according to claim 2, wherein, The continuous seal is configured to selectively engage simultaneously with both the mounting structure and the sliding portion; and The slide-out system also includes a controller, wherein the controller, the slide-out portion, and the mounting structure are configured such that the outer surface of the outer wall of the slide-out portion can retract from the outer surface of the outer wall of the vehicle, and further from the continuous seal of the peripheral frame attached to the mounting structure, so that the continuous seal can be replaced without removing the slide-out portion from the mounting structure.

10. A slide-out system for a vehicle, comprising: A vehicle having a main body having a compartment for receiving a user, the vehicle having an outer wall in a generally vertical plane having an opening; The sliding portion of the vehicle can move into and out of the main body to change the amount of available space within the compartment. The sliding portion has an outer wall in a generally vertical plane; as well as A mounting structure for connecting the sliding portion to the main body portion, the mounting structure having a peripheral frame, wherein the sliding portion is connected to the peripheral frame via a drive mechanism for moving the sliding portion into and out of the vehicle. The slide-out system is configured to be installed into an opening in the outer wall of the vehicle by fixing the outer frame to the outer wall of the vehicle, such that the outer frame supports the slide-out portion. The mounting structure includes means for aligning the outer wall of the vehicle with the outer wall of the sliding portion, such that when the sliding portion moves into the main body, these outer walls are flush in the same vertical plane. The drive mechanism includes: a power source mounted on the sliding portion and movable with the sliding portion; a positioning bracket mounted on the outer frame and fixed relative to the vehicle; and a drive shaft connected between the power source and the positioning bracket.

11. The system according to claim 10, wherein, The mounting structure also includes a continuous seal surrounding the periphery of the sliding portion, the continuous seal not separating from one end to the other.

12. The system according to claim 10 or 11, wherein, The sliding portion is formed with rounded corners around its perimeter.

13. The system according to claim 10 or 11, wherein, The sliding portion includes a weather-resistant seal that protects the drive shaft from weather conditions, the weather-resistant seal comprising overlapping elastic sealing members.

14. The system of claim 11, wherein the continuous seal is configured to selectively engage both the mounting structure and the sliding portion simultaneously; and The slide-out system also includes a controller, wherein the controller, the slide-out portion, and the mounting structure are configured such that the outer surface of the outer wall of the slide-out portion can retract from the outer surface of the outer wall of the vehicle, and further from the continuous seal of the peripheral frame attached to the mounting structure, so that the continuous seal can be replaced without removing the slide-out portion from the mounting structure.

15. A method for assembling a vehicle including a sliding portion, comprising the following steps: - An opening for the sliding portion is formed in the outer wall of the vehicle; - The sliding portion is attached to the outer frame using a drive mechanism installed between the sliding portion and the outer frame, such that the sliding portion is connected to the outer frame via the drive mechanism, the drive mechanism being used to move the sliding portion into and out of the vehicle; as well as - Secure the outer frame to the outer wall of the vehicle.

16. The method according to claim 15, wherein, The drive mechanism includes: a power source mounted on the sliding portion and movable with the sliding portion; a positioning bracket mounted on the outer frame and fixed relative to the vehicle; and a drive shaft connected between the power source and the positioning bracket.

17. The method according to claim 15 or 16, further comprising: Align the outer wall of the vehicle with the outer wall of the sliding portion so that when the sliding portion moves into the main body of the vehicle, these outer walls are flush in the same vertical plane.

18. A slide-out system, comprising: A mounting structure for mounting in an opening in the outer wall of a vehicle, the mounting structure defining the opening through which the mounting structure is located, and the mounting structure including an outer frame; The sliding portion is operably connected to the mounting structure to selectively translate through the opening in the mounting structure; as well as A continuous seal, attached to the outer frame of the mounting structure, is configured to selectively engage both the mounting structure and the sliding portion simultaneously. The slide-out system is configured such that the outer surface of the outer wall of the slide-out portion can retract from the outer surface of the outer wall of the vehicle, and further retract from the continuous seal of the peripheral frame attached to the mounting structure, so that the continuous seal can be replaced without removing the slide-out portion from the mounting structure.

19. The system according to claim 18, wherein, The sliding portion is formed with rounded corners around its perimeter.

20. The system of claim 18 or 19, comprising a plurality of drive mechanisms, each of the plurality of drive mechanisms being mounted to the slide-out portion and the peripheral frame.

21. The system according to claim 20, wherein, Each of the plurality of drive mechanisms includes: a power source mounted on the sliding portion; and a positioning bracket mounted on the outer frame and fixed relative to the vehicle.

22. The system according to claim 21, wherein, Each of the plurality of drive mechanisms further includes a threaded drive shaft connected between the power source and the positioning bracket for rotation relative to the power source and the positioning bracket.

23. The system according to claim 22, wherein, The sliding portion includes a seal that protects the corresponding drive shaft in the drive shaft from weather conditions, the weather-resistant seal comprising overlapping elastic sealing members.

24. The system according to claim 21, 22 or 23, wherein, The power source includes an electric motor.

25. The system of claim 24 further includes a controller electrically connected to the motor, the controller controlling the operation of the motor.

26. The system of claim 22 further includes a plurality of corner units, each corner unit including one of the plurality of drive mechanisms.

27. The system of claim 26, wherein each corner unit comprises: The body, to which the threaded drive shaft is rotatably attached; and the drive block, which is threadedly engaged with the threaded drive shaft and slidably engaged with the body, and connected to the peripheral frame via the positioning bracket.

28. The system according to claim 27, wherein, The drive shaft of the thread is disposed in a channel defined by the body.

29. The system according to claim 27 or 28, wherein, The sliding portion also includes: Multiple panels are connected between adjacent corner units.

30. The system according to claim 29, wherein, At least one of the panels has a curved profile.

31. The system according to claim 29, wherein, Each corner unit includes: a first attachment portion configured to attach to a first panel in the panel; and a second attachment portion configured to attach to a second panel in the panel, the body being elongated in the depth direction of the sliding portion.

32. The system according to claim 26, wherein, The sliding section includes two, three, or four corner units.

33. The system according to claim 29, wherein, The first panel of the panel is the floor, the second panel of the panel is the first sidewall, the third panel of the panel is the ceiling, and the fourth panel of the panel is the second sidewall opposite to the first sidewall.

34. The system according to claim 27, wherein, The drive block and the drive shaft of the thread include complementary drive threads having a pitch that prevents rotation of the drive shaft of the thread only in response to a longitudinal load applied by the drive block to the drive shaft of the thread.

35. The system according to claim 18, wherein, The outer frame is arranged to be fixed to the outer wall of the vehicle and is also arranged to support the sliding portion.

36. The system of claim 18, configured such that when the slide-out portion is in its normal fully retracted position, the outer surface of the outer wall of the slide-out portion is flush with the outer surface of the outer wall of the vehicle.

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