AU2016102069A4 - Method of construction of a caravan or recreational vehicle - Google Patents

Abstract

Abstract A method of constructing a caravan or RV uses sandwich panels located within extrusions. The extrusions interlock to form a U-shaped channel to receive the sandwich panel. The interlocking may be done after the panel is located in position. 90 114 52102 52----~14 -74 134-: \140 --- 130 Fig. 9

Description

2016102069 02 Dec 2016

AUSTRALIA

Patents Act 1990

COMPLETE SPECIFICATION

Invention title: “METHOD OF CONSTRUCTION OF A CARAVAN OR RECREATIONAL VEHICLE”

Applicant:

FLEETWOOD RECREATIONAL VEHICLES PTY LTD

The following statement is a full description of the invention, including the best method of performing it known to me: 2016102069 02 Dec 2016 2

“METHOD OF CONSTRUCTION OF A CARAVAN OR RECREATIONAL VEHICLE”

Field of the Invention [0001] The present invention relates to caravans, recreational vehicles (RVs), and similar structures made by joining panels together.

Background to the Invention [0002] Caravans and RVs are typically constructed with an outer shell often composed of sandwich panels; that is, of panels having two strong, thin outer layers (such as of aluminium) and a low density insulating material such as an expanded polystyrene in between the outer layers.

[0003] The outer shell is generally formed by a frame including U-shaped channels in which the panels can be received. The panels are arranged for a snug fit within the U-shaped channels, in order to prevent vibration and to provide a seal between the interior and exterior of the caravan.

[0004] The correct location of panels within the channels can be problematic during manufacture. It is reasonably common for a panel to become ‘wedged’ within a channel, but above a floor of the panel, during construction. If this condition is recognised, it may require the application of a considerable force to push the panel into its required positon. If the condition is not recognised, the panels will ultimately not meet as required, and a degree of disassembly and reassembly may be required.

[0005] It will be appreciated that both of these situations involve a relatively high degree of risk of damage to the panels, and involve additional time and cost of manufacture.

[0006] The present invention seeks to provide an alternative method of construction which at least partially avoids some of the problems identified with traditional methods of manufacture. 2016102069 02 Dec 2016 3

Summary of the Invention [0007] According to one aspect of the present invention there is provided a method for constructing structures or vehicles, the method including the steps of: providing a first elongate member having a guide portion which is generally L-shaped in cross section and an engagement portion; locating a panel within the guide portion such that it has an end abutting a base of the guide portion and a first side abutting a side wall of the guide portion; providing a second elongate member having an operating portion and an engagement portion; locating the second elongate member such that the operating portion abuts a second side of the panel; and engaging the engagement portion of the first elongate member with the engagement portion of the second elongate member in order to maintain the relative positions of the first elongate member and the second elongate member.

[0008] The method preferably includes the additional step of providing a fixing means, such as a bolt, to fix the operating portion of the second elongate member to the panel [0009] According to a second aspect of the present invention there is provided a supporting means for panels within a structure or vehicle, the supporting means including: a first elongate member having a guide portion which is generally L-shaped in cross section and an engagement portion; and a second elongate member having an operating portion and an engagement portion; wherein the engagement portion of the first elongate member is arranged to engage with the engagement portion of the second elongate member, such that when the respective engagement portions are engaged the operating portion of the second elongate member locates alongside the 2016102069 02 Dec 2016 4 guide portion of the first elongate member in order to produce a generally U-shaped channel.

[0010] The first elongate member may include two guide portions disposed at right angles to each other. The second elongate member may include two operating portions disposed at right angles to each other.

[0011] The first and second elongate members may be extrusions which are generally constant in cross section along their respective lengths.

[0012] The vehicle or structure may be a caravan or RV.

Brief Description of the Drawings [0013] It will be convenient to further describe the invention with reference to preferred embodiments of the present invention. Other embodiments are possible, and consequently the particularity of the following discussion is not to be understood as superseding the generality of the preceding description of the invention. In the drawings: [0014] Figure 1 is a perspective of a first embodiment of a first elongate member in accordance with the present invention; [0015] Figure 2 is a cross section of the first elongate member of Figure 1; [0016] Figure 3 is a perspective of a first embodiment of a second elongate member in accordance with the present invention; [0017] Figure 4 is a cross section of the second elongate member of Figure 3; [0018] Figure 5 is a perspective of a second embodiment of a first elongate member in accordance with the present invention; [0019] Figure 6 is a cross section of the first elongate member of Figure 5; 2016102069 02 Dec 2016 5 [0020] Figure 7 is a perspective of a second embodiment of a second elongate member in accordance with the present invention; [0021] Figure 8 is a cross section of the second elongate member of Figure 7; and [0022] Figure 9 is a cross section of a portion of a caravan constructed using the elongate members of Figures 1 to 8.

Detailed Description of Preferred Embodiments [0023] Referring to Figures 1 and 2, there is shown a first elongate member, being a first extrusion 10. The first extrusion 10 has a U-shaped channel 12 formed by a lower channel wall 14, a channel end wall 16 which is perpendicular to the lower channel wall 14, and an upper channel wall 18 which is parallel to the lower channel wall 14.

[0024] The first extrusion 10 also has a generally L-shaped guide portion 20. The guide portion 20 is formed by a base 22, which is an outer side of the upper channel wall 18, and a side wall 24 which is parallel to the channel end wall 16, and laterally spaced from the channel end wall 16 by the width of the upper channel wall 18.

[0025] The base 22 includes a recessed groove 26 located centrally of the base 22.

[0026] The first extrusion 10 includes an engagement portion formed by a lip 28. The lip 28 is located on an outer side of the channel end wall 16, alongside the upper channel wall 18. The lip 28 is structured so as to form an elongate recess 30 which opens in a direction away from the guide portion 20.

[0027] Referring to Figures 3 and 4, there is shown a second elongate member, being a second extrusion 40. The second extrusion 40 has an operating portion being a shallow U-shaped channel 42 formed by a lower wall 44, a flat side wall 46 and an upper wall 48. The lower wall 44 and the 2016102069 02 Dec 2016 6 upper wall 48 each include grooves 50, arranged in use to receive and maintain covering flaps 52.

[0028] The second extrusion 40 has an engagement portion formed by a hook 54. The hook 54 extends downwardly from an outer end of the lower wall 44, and turns inwardly at a lower end thereof to form an engaging ridge 56.

[0029] The arrangement is such that the engaging ridge 56 is arranged to locate within the elongate recess 30 of the first extrusion 10. When thus located, the second extrusion 40 combines with the guide portion 20 of the first extrusion 10 to form a generally U-shaped channel, having a base formed by the base 22, a first side formed by the side wall 24, and a second side formed by the flat side wall 46 which locates parallel to, and spaced from, the side wall 24.

[0030] Referring to Figures 5 and 6, there is shown an alternative first elongate member, being a third extrusion 60. The third extrusion 60 has a first generally L-shaped guide portion 62 having a base formed by an upper wall 64 and a side wall formed by a first side 66 of a vertical wall. The third extrusion 60 has a second generally L-shaped guide portion 70, having a base formed by a second side 72 of the vertical wall and a side wall formed by a lower wall 74. The lower wall 74 is parallel to the upper wall 64, and vertically spaced from the upper wall 64 by the width of the second side 72 of the vertical side wall.

[0031] The third extrusion 60 includes an engagement portion formed by an upper extension 76. The upper extension 76 comprises two spaced apart raised walls 78 located on an upper edge of the upper wall 64. The raised walls 78 each have a curved upper lip 80, with the upper lips 80 combining to form a generally convex receiving surface 82.

[0032] The third extrusion 60 includes a diagonally oriented internal fitment channel 84 located between the lower wall 74 and a lower extension 86 of the vertical side wall. 2016102069 02 Dec 2016 7 [0033] Referring to Figures 7 and 8, there is shown an alternative second elongate member, being a fourth extrusion 90. The fourth extrusion 90 has a first operating portion being a shallow U-shaped channel 92 formed by a lower wall 94, a flat side wall 96 and an upper wall 98. The lower wall 94 and the upper wall 98 each include grooves 100, arranged in use to receive and maintain covering flaps 52.

[0034] The fourth extrusion 90 has a second operating portion, being a straight edge 102 arranged to be perpendicular to the flat side wall 96.

[0035] The first operating portion and the second operating portion are connected by an engagement portion 110. The engagement portion 110 is sized and shaped so as to position over and about the upper wall 64 of the third extrusion 60, such that the flat side wall 96 is arranged to locate in a position facing the first side 66 of the vertical wall of the third extrusion 60, and the straight edge 102 is arranged to locate in a position facing the lower wall 74 of the third extrusion 60.

[0036] The engagement portion 110 includes a generally concave recess 112 oriented downwardly; that is, oriented generally away from the straight edge 102, and in a direction parallel to the flat side wall 96. The recess 112 is sized and shaped to locate over and around the receiving surface 82 of the upper extension 76.

[0037] The engagement portion 110 includes an outer recess 114 opposed to the concave recess 112; that is, facing upwardly away from the concave recess 112. The outer recess 114 includes grooves 116 arranged to receive and maintain covering flaps 52 such that the covering flaps 52 generally form an extension of the straight edge 102.

[0038] The arrangement is such that the concave recess 112 is arranged to be bolted to the upper extension 76. When thus located, the fourth extrusion 90 combines with the guide portions 62, 70 of the third extrusion 60 to form two generally U-shaped channels. The first U-shaped channel has a base 2016102069 02 Dec 2016 8 formed by the upper wall 64, a first side formed by the first side 66 of the vertical wall, and a second side formed by the flat side wall 96 which locates parallel to, and spaced from, the first side 66 of the vertical wall. The second U-shaped channel has a base formed by the second side 72 of the vertical wall, a first side formed by the lower wall 74, and a second side formed by the straight edge 102 which locates parallel to, and spaced from, the lower wall 74.

[0039] Figure 9 shows how a caravan or RV can be formed using the extrusions discussed above. A floor panel 120 can be located within the U-shaped channel 12 of the first extrusion 10. It can be maintained in position by the use of bolts 122 driven into the floor panel 120 through apertures in the recessed groove 26. It will be appreciated that the bolts are sized so as to have a head which locates entirely within the recessed groove 26.

[0040] A wall panel 130 can then be located within the guide portion 20. Once the wall panel 130 is located, the second extrusion 40 can be engaged with the first extrusion 10 via their respective engagement portions. The second extrusion 40 can be fixed to the wall panel 130 by the use of bolts 132 driven into the wall panel 130 through apertures in the channel 42. These bolts can be hidden from view by locating covering flaps 52 in the grooves 50. The bolts 132 can extend through to engage with the side wall 24, thus acting to further lock the second extrusion 40 to the first extrusion 10.

[0041] A seal 53 can be located between an upper ridge of the second extrusion 40 and the wall panel 130, thus preventing the ingress of moisture through the joint.

[0042] The wall panel 130 can be readied for connection to a roofing panel 140 by locating the third extrusion 60 with its first guide portion 62 about an upper edge of the wall panel 130. The roofing panel 140 can then be positioned in the second guide portion 70 of the third extrusion 60. The roofing panel 140 can be bolted to the third extrusion 60 via bolts 142 passing through 2016102069 02 Dec 2016 9 the lower wall 74. The bolts 142 can be hidden from view by the location of a corner piece 146 in the internal fitment channel 84.

[0043] Once the wall panel 130 and roofing panel 140 are in their required positions relative to the third extrusion 60, the fourth extrusion 90 can be introduced to maintain them in position. The fourth extrusion 90 can be fixed to the wall panel 130 by the use of bolts 134 driven into the wall panel 130 through apertures in the channel 92. These bolts 134 can be hidden from view by locating covering flaps 52 in the grooves 100.

[0044] The fourth extrusion 90 can be fixed to the third extrusion 60 by bolts 136 passing through apertures in the recess 112, through the upper extension 76 of the third extrusion 60 and into the upper end of the wall panel 130. These bolts 136 can be hidden from view by locating covering flaps 52 in the grooves 116.

[0045] It will be appreciated that the wall panel 130 and the roofing panel 140 are maintained within U-shaped channels, as is traditionally the case. In the present case, however, the channels are effectively formed around the panels, rather than the panels being forced into premade channels.

[0046] Modifications and variations as would be apparent to a skilled addressee are deemed to be within the scope of the present invention.

Claims (5)

1. Claims

   1. A method for constructing structures or vehicles, the method including the steps of: providing a first elongate member having a guide portion which is generally L-shaped in cross section and an engagement portion; locating a panel within the guide portion such that it has an end abutting a base of the guide portion and a first side abutting a side wall of the guide portion; providing a second elongate member having an operating portion and an engagement portion; locating the second elongate member such that the operating portion abuts a second side of the panel; and engaging the engagement portion of the first elongate member with the engagement portion of the second elongate member in order to maintain the relative positions of the first elongate member and the second elongate member.
2. 2. A method for constructing structures or vehicles as claimed in claim 1, wherein the method includes the additional step of providing a fixing means, to fix the operating portion of the second elongate member to the panel.
3. 3. A supporting means for panels within a structure or vehicle, the supporting means including: a first elongate member having a guide portion which is generally L-shaped in cross section and an engagement portion; and a second elongate member having an operating portion and an engagement portion; wherein the engagement portion of the first elongate member is arranged to engage with the engagement portion of the second elongate member, such that when the respective engagement portions are engaged the operating portion of the second elongate member locates alongside the guide portion of the first elongate member in order to produce a generally U-shaped channel.
4. 4. A supporting means as claimed in claim 3, wherein the first elongate member includes two guide portions disposed at right angles to each other.
5. 5. A supporting means as claimed in claim 3 or claim 4, wherein the second elongate member includes two operating portions disposed at right angles to each other.