Reinforcing structure for a pop-up roof of a recreational vehicle and recreational vehicle with such a reinforcing structure

Description

[0001] The invention relates to a stiffening structure for a pop-top roof of a recreational vehicle and to a recreational vehicle having such a stiffening structure. Recreational vehicles are known in the prior art. A recreational vehicle is understood to be a vehicle or trailer which has at least one mobile element for camping or can at least temporarily have a facility for camping. A recreational vehicle is understood to be a camping vehicle in particular. A recreational vehicle is understood to be a motorized recreational vehicle. In the present case, a camping vehicle is understood to be a mobile home or a caravan, i.e. preferably those vehicles or trailers in which a user has the option of sleeping or living in this vehicle. Motorization of the vehicles is not required. Another name for a mobile home is, for example, a motorhome.For example, a caravan can alternatively be referred to as a campervan or a camping trailer. A campervan, in this context, is understood to be a recreational vehicle, particularly a recreational vehicle, consisting of a transport vehicle with a standard body, particularly a sheet metal body.

[0002] Recreational vehicles, particularly mobile homes, with pop-up roofs or sleeping roofs are known in the prior art, as is known, for example, from GB 2 556 350 A or GB 2 494 750 A. For this purpose, the roof of the recreational vehicle is generally cut open over a large area, which significantly reduces the rigidity of the vehicle roof.

[0003] A pop-top roof is the roof of a recreational vehicle that can be folded upwards when the vehicle or caravan is stationary to increase the interior height and / or create additional living space above the actual height of the recreational vehicle. A pop-top roof can also be referred to as a lifting roof.

[0004] An object of the present invention is to improve the state of the art. In particular, it is an object of the invention to provide a stiffening structure for a pop-top roof of a recreational vehicle, which can be attached to a cut-open vehicle roof. The stiffening structure should be adaptable to different lengths of the cut-open vehicle roof, the pop-top roof, or the recreational vehicle. The stiffening structure should also be adaptable to different vehicle types. A further object of the invention is to enable a continuous, continuous adhesive bead to be implemented in the stiffening structure.

[0005] This object is achieved by a stiffening structure having the features of independent patent claim 1 as well as independent patent claim 4. Advantageous developments of the invention are specified in the subclaims.

[0006] The following terminology should be explained: In this context, a profile can be understood as a structural profile, i.e., an elongated semi-finished product manufactured by extrusion. Such profiles are usually made of aluminum, less frequently of other metals. On the one hand, structural profiles made of aluminum compete with profile steel; on the other hand, depending on the task, a mix of both materials may be the best solution, e.g., a frame construction made of aluminum profiles with stiffening elements made of sheet steel.

[0007] A "long side of a body" serves to attach the stiffening structure. The cut-away portion of the original roof was originally connected to this.

[0008] The stiffening structure according to the invention serves to increase the roof's reduced rigidity caused by cutting open the vehicle roof. For this purpose, a stiffening structure is preferably attached to each of the two longitudinal sides of the hole created in the roof by the cutting open, whereby the two stiffening structures can be manufactured symmetrically to a vehicle centerline. At suitable locations along the longitudinal axis of the recreational vehicle, preferably at a front and a rear end, a roof panel, preferably an aluminum sandwich panel, is preferably attached between the two stiffening structures.The resulting rectangular stiffening structure, which is attached adjacent to the cut hole in the roof, significantly strengthens the roof structure, so that additional structures, such as a hinged roof shell of the pop-up roof, can now be attached to or on this reinforcement structure and the loss of strength of the vehicle body is at least partially compensated.

[0009] The stiffening structure according to the invention can advantageously be adapted to different lengths of the cut-open vehicle roof, the pop-up roof or the recreational vehicle, in particular by cutting the profile to the required lengths as a piece of material sold by the meter.

[0010] The reinforcement structure is preferably made of aluminum. The stiffening structure is preferably manufactured using an extrusion process.

[0011] The roof panel is preferably a lightweight panel. Preferably, at least two roof panels can be used, with each roof panel being secured between the first and second profiles, and with the first profile being manufactured symmetrically to the second profile. The first profile and the second profile are mirror-symmetrical to a plane spanned by the direction of travel of the recreational vehicle and a vertical axis.

[0012] The first fastening element and / or the second fastening element run horizontally when the stiffening structure is used as intended. The intended use of the stiffening structure refers to the position and orientation the stiffening structure occupies when installed.

[0013] According to a preferred embodiment, the second fastening element is arranged above the first fastening element when the stiffening structure is used as intended. This is advantageous because the second fastening element is to be fastened to the roof panel, which is generally located above the body, in particular the part of the body to which the first fastening element is to be fastened.

[0014] Preferably, the expression that the second fastening element is arranged above the first fastening element means that a vertical center of the second fastening element is arranged above the vertical center of the first fastening element. This can also be understood to mean that a lower end of the second fastening element is arranged above the upper end of the first fastening element.

[0015] According to a further preferred embodiment, the profile comprises a base element. The first fastening element is arranged or fastened on an outer side of the base element, and the second fastening element is arranged or fastened on an inner side of the base element. The outer side of the base element faces an outer side of the recreational vehicle, and the inner side of the base element faces an inner side or center of the recreational vehicle, which is preferably defined by a center plane of the recreational vehicle.

[0016] According to yet another preferred embodiment, the base element has a chamber-like profile section which is such that it can be fastened at a longitudinal end of the stiffening structure to a further component, in particular a spoiler, which runs in particular parallel to the transverse direction of the recreational vehicle.

[0017] In this context, a comb-like profile section is understood to be a part of a profile that has a chamber-like shape and, in particular, a square or polygonal cross-section. Such a comb-like profile section advantageously exhibits both high stability and low weight. Furthermore, the chamber-like profile section has the advantage that other components can be easily attached to an open section of the chamber-like profile section, which can be milled, for example.

[0018] Preferably, the second fastening element is fastened to the chamber-like profile section, in particular to a lateral outer wall, in particular the inner side, of the chamber-like profile section of the base element.

[0019] The problem is also solved by a stiffening structure having the features of independent patent claim 4.

[0020] Advantageously, a corner connector, for example made of die-cast aluminum, which is inserted into the hollow sections of the profile with insert sections, can create a rigid and force-transmitting connection between the profile and the corner connector. This insert section can be fixed over a certain length via at least three lines or surfaces. However, it is preferably inserted into a closed hollow profile, to which it corresponds in its cross-sectional shape.

[0021] According to yet another preferred embodiment, the base element has a profile section for attaching an interior panel of the recreational vehicle, an accessory, the roof panel, or a transverse reinforcement of the roof panel. This advantageously ensures that the reinforcement structure can also be used for attaching interior paneling.

[0022] The first fastening element is preferably fastened to the profile section for fastening and / or to the chamber-like profile section, in particular to an outer side of the profile section for fastening and / or the chamber-like profile section.

[0023] According to another embodiment, the profile section comprises a C-profile or C-rail for attaching an interior panel of the recreational vehicle, an accessory, the roof panel, or a transverse reinforcement of the roof panel. A variety of different fastening elements, such as T-shaped T-nuts, sliding nuts, hammer-head bolts, etc., can advantageously be attached to the C-profile, for example, to secure elements of the interior panel thereto.

[0024] According to another preferred embodiment, the profile section for attaching an interior panel of the recreational vehicle, an accessory, the roof panel, or a transverse reinforcement of the roof panel is arranged below the chamber-like profile section during intended use of the reinforcement structure. This arrangement is advantageous, practical, and space-saving, since the interior space is arranged below the roof panel or roof.

[0025] According to the invention, an underside of the first fastening element can be fastened, in particular glued, to the body. According to the invention, the first fastening element has a second chamber-like profile section, the underside of which is designed and configured such that it can be fastened, in particular glued, to the body. For this purpose, the first fastening element has an adhesive flange on its underside.

[0026] According to a further embodiment, a receiving element for a seal, in particular a rubber seal, is arranged on the outer side of the second chamber-like profile section. The receiving element preferably has a channel open at the bottom, into which a seal, in particular a rubber seal, can be inserted, in particular inserted, from below.

[0027] According to a further preferred embodiment, the profile is bent for attachment to the longitudinal side of the body and for attachment to the roof panel, in particular perpendicular to the longitudinal direction. Preferably, the profile manufactured by an extrusion process is bent using a CNC bending process so that the stiffening structure is adapted to the shape of the body.

[0028] According to a further embodiment, the chamber-like profile section of the base element has a groove on its upper side for receiving a piping profile when the stiffening structure is used as intended. For example, a piping profile or a piping rail of a folding bellows or tent bellows of the pop-up roof can be reversibly and detachably fastened in the groove.

[0029] Preferably, at least one recess for establishing a positive connection with a roof section of the recreational vehicle is arranged on an underside of the second chamber-like profile section of the first fastening element. Preferably, a plurality of recesses, for example chambers, are milled along a longitudinal direction of the profile at different locations on the underside of the second chamber-like profile section. Several recreational vehicles have tabs on their bodies as standard. The recess serves to establish a positive connection with such a tab. The stiffening structure, in particular the first fastening element, can be screwed to such a tab. In steel construction, a tab is a flat piece of material, in particular with fastening holes, with which two components, e.g., steel beams, are connected by means of screws and nuts or rivets.

[0030] According to another preferred embodiment, the stiffening structure further comprises a corner connector for connecting the stiffening structure to a roof panel running parallel to the transverse direction of the recreational vehicle.

[0031] The corner connector is preferably manufactured by die-casting, preferably from aluminum. The corner connector preferably serves to provide a positive connection between a roof panel, preferably a roof panel at a front end of the roof area, and the stiffening structure, whether on a left or right longitudinal side of the roof as seen in the direction of travel.

[0032] At one longitudinal end of the corner connector, at least one tab of the corner connector is inserted into at least one chamber-like profile section and screwed in place. On its underside, the corner connector has an adhesive flange for bonding to the body. Furthermore, an upper side of the corner connector has screw points, preferably with positioning aids, to which the corner connector can be screwed to a roof panel.

[0033] The stiffening structure preferably has two symmetrically manufactured corner connectors, which preferably connect a front roof panel to two symmetrically manufactured profiles, each attached to a longitudinal side of the body. It is further preferred that this stiffening structure has a rear roof panel, which is arranged at the rear ends of the two profiles between the two profiles. It is further preferred that a further component, in particular a spoiler, is attached to the rear ends of the two profiles, in particular running parallel to the transverse direction of the recreational vehicle.

[0034] In this case, a component of the further component, in particular the spoiler, which runs parallel to the longitudinal axis of the recreational vehicle, is preferably inserted and fastened into the chamber-like profile section of the base element.

[0035] According to yet another embodiment, the second fastening element has a third chamber-like profile section, in which the roof panel can be fastened after partial removal of a chamber wall of the third chamber-like profile section. Preferably, the third chamber-like profile section is attached to an outer wall of the first chamber-like profile section. Preferably, a height of the third chamber-like profile section is smaller than a height of the first chamber-like profile section. Preferably, an inward-facing wall and / or a lower wall is removed in order to fasten, in particular to glue, a roof panel inside the third chamber-like profile section.

[0036] According to another embodiment, a length of the profile corresponds to a predetermined length of a recreational vehicle. This advantageously ensures that a stiffening structure according to the invention can be manufactured for recreational vehicles of any predetermined length.

[0037] According to a further embodiment, the stiffening structure further comprises a second profile, which is mirror-symmetrical to the profile. Here, the profile and the second profile are mirror-symmetrical to a plane spanned by the direction of travel and a vertical axis.

[0038] In a further aspect, the invention is achieved by a recreational vehicle with a stiffening structure as described above.

[0039] Embodiments of the invention are illustrated in the drawings and are explained in more detail in the following description. Figure 1shows an illustration of a section through a stiffening structure according to an embodiment of the invention. Figure 2 shows the stiffening structure of the Figure 1 in a three-dimensional representation. Figure 3 shows a recreational vehicle with a stiffening structure according to an embodiment of the invention. Figure 4 shows a three-dimensional sectional view through a stiffening structure connected to a roof panel, a spoiler and a body according to an embodiment of the invention. Figure 5 shows a sectional view along a plane parallel to the longitudinal axis of the recreational vehicle through the stiffening structure and the body at a tab of the body. Figure 6 shows a connection of a roof panel to the stiffening structure using a corner connector. Figures 7 and 8 show the in Figure 6 corner connectors shown.

[0040] Figure 1shows a stiffening structure 100 for a pop-up roof of a Figure 3 The illustrated recreational vehicle 110. The stiffening structure 100 has a profile 120 produced by an extrusion process, to which a piping profile 135 and a seal 198 are attached. The profile 120 is a lightweight aluminum profile.

[0041] The profile 120 is used for fastening to one of the long sides 172 of a body 170 of the recreational vehicle 110 and for fastening to a roof panel 180, as in Figure 3 to see. In Figure 3 one can see a stiffening structure 100 which has the profile 120, a second profile 220 which is manufactured mirror-symmetrically to the profile 120, a front roof panel 180 and a rear roof panel 180, two corner connectors 190 and a spoiler 195, in particular a rear spoiler.

[0042] Here, the profile 120 and the second profile 220 are mirror-symmetrical to a plane which is spanned by the direction of travel 111 and a vertical axis 113.

[0043] The rear roof panel 180 is attached between the first profile 120 and the second profile 220. The two corner connectors 190 are each connected to the profile 120 and the second profile 220, respectively, and the front roof panel 180 is attached to the two corner connectors 190. The spoiler 195 is connected to the respective profile 120, 220 at a rear end of the profile 120 and the second profile 220, respectively.

[0044] The rear roof panel 180 and / or the front roof panel 180 are aluminum sandwich panels.

[0045] As in Figure 1As can be seen, the profile 120 has a centrally mounted base element 124, a first fastening element 150 for fastening to the longitudinal side 172 of the body 170 and a second fastening element 160 for fastening to the roof panel 180, wherein the second fastening element 160 is fastened to the profile 120 at a position 122 opposite the first fastening element 150.

[0046] The first fastening element 150 is attached to an outer side 125 of the base element 124, and the second fastening element 160 is attached to an inner side 126 of the base element 124. The outer side 125 points toward an outer side of the recreational vehicle 110, and the inner side 126 points toward a center of the recreational vehicle, i.e., toward the roof panel 180. Both the first fastening element 150 and the second fastening element 160 extend substantially horizontally during intended use.

[0047] The base element 124 has a chamber-like profile section 128 at an upper end and a profile section 130 having a C-profile 131 below the chamber-like profile section 128, to which an interior panel of the recreational vehicle 110 can be fastened. The interior of the recreational vehicle 110 is located from the profile section 130 in the view of the Figure 1bottom left. The chamber-like profile section 128 and the profile section 130 have the same width along the transverse direction 112. The chamber-like profile section 128 has a substantially hexagonal hollow cross-section. A left part of the chamber-like profile section 128 is substantially rectangular, with a right end of the chamber-like profile section 128, i.e. a wall running vertically to the right, running significantly below the left wall of the chamber-like profile section 128. An upper end of the right wall of the chamber-like profile section 128 corresponds approximately to a lower end of the left wall of the chamber-like profile section 128. This is due to the fact that the roof panel 180, which is fastened to the second fastening element 160, is vertically higher than the body 170 of the recreational vehicle 110, which is fastened to the first fastening element 150.

[0048] The axis of the profile 120 runs essentially parallel to a longitudinal axis 111 of the recreational vehicle 110. A transverse axis 112, which points from a right to a left side of the recreational vehicle 110, is, together with a vertical axis 113, in Figure 3 shown.

[0049] The first fastening element 150 is attached to the profile section 130 and to the chamber-like profile section 128. The lower wall of the chamber-like profile section 128 is identical to the upper wall of the profile section 130.

[0050] The second fastening element 160 has a third chamber-like profile section 162. The second fastening element 160 is fastened to an inner side 126 of the base element 124 on a wall of the chamber-like profile section 128. Here, a lower wall of the second fastening element 160 is at the same height as a lower wall of the chamber-like profile section 128 facing the inner side 126. A height of the second fastening element 160 is lower than the height of the chamber-like profile section 128 facing the inner side 126. In order to fasten a roof panel 180 to the second fastening element 160, the wall facing the inner side as well as the lower wall of the second fastening element 160 are removed and the upper side of the roof panel 180 is glued to an underside of the upper wall of the second fastening element 160, as in Figure 4 to see.

[0051] The first fastening element 150 has a second chamber-like profile section 152, the underside 153 of which has an adhesive flange so that the underside 153 can be adhesively bonded to parts of the body 170.

[0052] On the underside 153 of the second chamber-like profile section 152 of the first fastening element 150, a plurality of recesses 155 are arranged along the longitudinal axis 111 of the profile 120 for producing a positive connection with tabs 157 of the body 170 of the recreational vehicle 110, see Figure 5 . At the positions of holes 158, which are machined into an upper side of the second chamber-like profile section 152, the first fastening element 150 is screwed to the tabs 157 of the body 170.

[0053] An upper side of the second chamber-like profile section 152 of the first fastening element 150 further has the function of a water barrier and a screw surface for attachments such as kinematics, gas pressure steamer or locking system.

[0054] On an outer side of the second chamber-like profile section 152 or the first fastening element 150, a receiving element 197 for a seal 198, in particular a rubber seal, is arranged, see Figures 1 and 2 . The receiving element 197 has the shape of a downwardly opening channel into which the seal 198 is inserted.

[0055] Profile 120 is bent longitudinally using a CNC bending process to fit the shape of body 170. Profile 120 is first extruded and then bent using the CNC process. The second profile 220 is similar to profile 120, but is manufactured with mirror symmetry to the aforementioned plane.

[0056] The chamber-like profile section 128 of the base element 124 has a groove 134 on an upper side 133 extending along the longitudinal axis of the profile 120 for receiving a piping profile 135. The piping profile 135 belongs to a bellows or a tent bellows of the pop-up roof.

[0057] The width from outside to inside of the keder profile 135 is exactly the same as the upper width of the surface of the chamber-like profile section 128. The keder profile 135 also forms a water barrier between the inside and outside of the stiffening structure 100.

[0058] Figure 4shows a rear end of the profile 120, where a spoiler 195 running parallel to the transverse direction 112 of the recreational vehicle 110 is connected to the profile 120. For this purpose, the upper wall of the chamber-like profile section 128 has been removed so that a part of the spoiler 195 can engage in the chamber-like profile section 128. Furthermore, an underside of the spoiler 195 has a surface such that the spoiler 195 can be glued to the upper side of the first fastening element 150 and the upper side of the second fastening element 160.

[0059] In the Figures 6 to 8 You can see how the front roof panel 180 is connected to a front end of the profile 120 using a corner connector 190. The Figures 7 and 8The corner connector 190 shown from above and below is inserted into the profile 120 at the tabs or insertion sections 192 and 193. The insertion section 192 is inserted into the second chamber-like profile section 152 of the first fastening element 150 and the insertion section 193 is inserted into the third chamber-like profile section 162 of the second fastening element 160 and screwed to the profile 120. The underside of the corner connector 190 is glued to the body 170 at an adhesive flange 191. The corner connector 190 is screwed to the front roof panel 180 at three screw points 194. Another corner connector 190, which is symmetrical to the Figure 6 shown corner connector 190, is connected in a corresponding manner to the front roof panel 180 and the second profile 220.

[0060] One of the major advantages of the reinforcement structure 100 is that the length of the profile 120 and the second profile 220 can be adapted to the length of the recreational vehicle 110 or the length of the body 170. Because the profile 120 and the second profile 220 can be bent using a CNC process, the profile 120 and the second profile 220 can also be adapted to different types of recreational vehicles.

Claims

1. A stiffening structure (100) for a pop-up roof of a recreational vehicle (110), having a profile (120) for mounting to a long side (172) of a bodywork (170) and for mounting to a roof panel (180), the profile (120) having: a first mounting means (150) for mounting to the long side (172) of the bodywork (170); and a second mounting means (160) for mounting to the roof panel (180), wherein the second mounting means (160) is attached to the profile (120) at a position (122) opposite the first mounting means (150), characterized in that the first mounting means (150) has a second chamber-like profile section (152), the underside (153) of which is designed and adapted such that it can be attached to the bodywork (170), in particular by adhesive bonding.

2. The stiffening structure (100) according to claim 1, characterized in that the profile (120) has a base element (124), wherein the first mounting means (150) is arranged or mounted to an exterior (125) of the base element (124) and the second mounting means (160) is arranged or mounted on an inside (126) of the base element (124).

3. The stiffening structure (100) according to any one of the preceding claims, characterized in that the second mounting means (160) is arranged above the first mounting means (150) when used as intended.

4. A stiffening structure (100) for a pop-up roof of a recreational vehicle (110), having a profile (120) for mounting to a long side (172) of a bodywork (170) and for mounting to a roof panel (180), the profile (120) having a first mounting means (150) for mounting to the long side (172) of the bodywork (170), characterized in that the profile (120) is connected to a corner connector (190) for connecting the stiffening structure (100) to a roof plate (180) running parallel to the transverse direction (112) of the recreational vehicle (110), by inserting the corner connector into hollow profiles of the profile, preferably by means of at least three opposing surfaces of hollow profiles holding an insertion section of the corner connector, most preferred closed hollow profiles.

5. The stiffening structure (100) according to claim 4, characterized in that the profile (120) has a base element (124), wherein the first mounting means (150) is arranged or mounted to an exterior (125) of the base element (124).

6. A stiffening structure (100) having the features of any one of claims 1 to 3 and having the features of any one of claims 4 or 5.

7. The stiffening structure (100) according to any one of the claims 2, 3, 5 or 6 characterized in that the base element (124) has a chamber-like profile section (128) which is designed such that it can be mounted at a longitudinal end of the stiffening structure (100) to a further component, in particular a spoiler (195), which in particular runs parallel to the transverse direction (112) of the recreational vehicle.

8. The Stiffening structure (100) according to any one of the claims 2, 3, 5, 6 or 7, characterized in that the base element (124) has a profile section (130) for mounting an interior trim of the recreational vehicle (110), an accessory, the roof panel (180) or a transverse stiffening of the roof panel (180).

9. The stiffening structure (100) according to claim 8, characterized in that the profile section (130) for mounting an interior trim of the recreational vehicle (110), an accessory, the roof panel (180) or a transverse stiffening of the roof panel (180) has a C-profile (131).

10. The stiffening structure (100) according to claim 7 and any one of the claims 8 or 9, characterized in that the profile section (130) for mounting an interior trim of the recreational vehicle, an accessory, the roof panel (180) or a transverse stiffening of the roof panel (180) is arranged, when the stiffening structure (100) is used as intended, below the chamber-like profile section (128).

11. The stiffening structure (100) according to claim 7 or 10, characterized in that the chamber-like profile section (128) of the base element (124), when the stiffening structure (100) is used as intended, has a groove (134) on an upper side (133) for receiving a piping profile (135).

12. The stiffening structure (100) according to the preceding claim, characterized in that the profile (120) is bent for mounting to the long side (172) of the bodywork (170) and / or for mounting to the roof panel (180).

13. The stiffening structure (100) according to any one of the claims 1 to 3 or 6 to 12, characterized in that at least one recess (155) is arranged on the underside (153) of the second chamber-like profile section (152) of the first mounting means (150) for establishing a form-fitting connection with the bodywork (170) of the recreational vehicle (110).

14. The stiffening structure (100) according to any one of the claims 1 to 3 or 6 to 13, characterized in that the second mounting means (160) comprises a third chamber-like profile section (162) in which, after partial removal of a chamber wall of the third chamber-like profile section (162), the roof panel (180) can be mounted.

15. The Stiffening structure (100) according to any one of the preceding claims, further comprising: a second profile (220), which is made mirror-symmetrical to the profile (120), wherein the profile (120) and the second profile (220) are mirror-symmetrical to a plane which is spanned by the direction of travel (110) and a vertically running vertical axis (113).

16. A recreational vehicle (110) comprising a stiffening structure (100) according to any one of the claims 1 to 15.