GB2391841A

GB2391841A - Caravan having cellular panels

Info

Publication number: GB2391841A
Application number: GB0218679A
Authority: GB
Inventors: George Kemp
Original assignee: ADAM DALE IND Ltd
Current assignee: ADAM DALE IND Ltd
Priority date: 2002-08-12
Filing date: 2002-08-12
Publication date: 2004-02-18
Anticipated expiration: 2022-08-12
Also published as: GB2391841B; GB0218679D0

Abstract

A caravan has a cellular component 100 wherein said component comprises a panel 110 comprising a first sheet 120 forming an internal face of the component, and a second sheet 130 spaced apart from the first sheet forming an external face of the component, and a core 140 comprising dividing members 150 which section the space between the two sheets into cells 160. The floor, walls and roof of the caravan may be formed from said cellular components, and the floor component may be stronger than the others. The cells may be cylindrical or hexagonal, and the dividing members may be adhesively bonded to the sheets. The sheets may be made from a fibre reinforced material, aluminium or plywood, and the internal sheet may have a decorative finish applied thereto. Channels 170 may be located in the component for receiving services such as gas, water, electricity etc. A method for manufacturing the caravan is also disclosed.

Description

1 2391 841

CARAVAN AND CONSTRUCTION METHOD THEREFOR

The present invention relates to caravans, particularly to a caravan having a cellular wall and to a method of constructing a caravan.

The term caravan as used herein refers to any portable accommodation unit having wheels and thus includes motorised caravans (i.e.motorhomes) and non motorised caravans (i.e. touring and static caravans).

To Caravans are well known and are used by many people to provide accommodation, particularly temporary accommodation for a vacation.

It is known to construct caravans by first producing a floor, which can be mounted to a chassis, and by then attaching panel members to the floor to s produce the walls of the caravan. The panels for the walls are generally produced from fibreglass or plywood. The floor is generally produced from timber. Whilst known construction methods are adequate they can be time consuming and the caravan can require a substantial floor of considerable weight in order to give it the required strength and rigidity. It is also often 20 necessary to install ducting into the caravan to house services such as water and gas pipes and electrical cables. Again, this can be time consuming and can also detract from the aesthetics of the finished caravan.

The present invention aims to address at least one disadvantage associated 5 with the prior art whether discussed herein or otherwise.

According to a first aspect of the present invention there is provided a caravan having a cellular component wherein said component comprises a cellular panel comprising a first sheet, arranged to form an internal face of the 30 component, a second sheet spaced apart from the first sheet, arranged to form an external face of the component, and a core comprising dividing members

arranged to section the cavity between the first and second sheets off into i cells. The caravan may comprise a base component forming the floor of the caravan, an upper component forming the roof of the caravan and side components interposed therebetween forming the walls of the caravan.

The floor may comprise a cellular component. Alternatively, or in addition, the roof may comprise a cellular component. Alternatively, or in addition, one or to more of the side walls may comprise a cellular component. Preferably, each I wall of the caravan comprises a cellular component.

The cellular floor, roof and side walls may all have the same construction.

Alternatively, different materials may be employed for the side walls than are I :s employed for either the floor or roof. Alternatively, the same materials may be! employed for the floor and side walls and alternative materials may be I employed for the floor.

Preferably, if the floor, roof and side walls are all cellular but differ in 20 construction the floor is constructed to be stronger and the side walls and roof I are constructed to be lighter.

Preferably, at least one cellular panel comprises a channel extending through the core in the plane of the cellular panel. The cellular panel may comprise a; : plurality of channels. The channels may extend substantially parallel to one another. Alternatively, two or more channels may intersect one another.

Preferably, the dividing members of the cellular panel are arranged to define a break in the cellular structure of the panel and thus define a channel in so between two cellular sections of the panel. Preferably, the channel comprises a tubular member arranged to extend in the break between the dividing I members. The tubular member may comprise a metal or plastics material

Alternatively, the tubular member may comprise a card material. For example, the tubular member may comprise an aluminium box section.

The channel or channels may be arranged to receive services for the caravan.

5 Preferably, the channel or channels can be used to carry one or more of: electric services, water services, gas services, blown air heating or blown cool air. Preferably, the floor comprises a channel to carry services. Preferably, one or JO more side walls comprises a channel to carry services.

The dividing members of the core of the cellular panel may comprise tubular members orientated such that their axis extend perpendicularly to the planes of the first and second sheets of the cellular panel. The dividing members may thus create a plurality of cylindrical cavities or cells with a plurality of non-

cylindrical cavities or cells interposed therebetween. The tubular members may comprise a plastics material, a metal or a card material. For example, they may comprise alloy tubes or alloy foil tubes.

20 Alternatively, the dividing members of the core may comprise dividing walls arranged to produce a honeycomb structure. The dividing members may thus create a plurality of cavities or cells which have a hexagonal cross section which lies in substantially the same plane as that of the cellular panel. The dividing walls may comprise a plastics material, a metal or a card material. For : example, the dividing members may comprise a plastics honeycomb, a card honeycomb or an alloy foil honeycomb.

Preferably, the dividing members are arranged such that they reinforce the first and second sheets of the cellular panel. The cellular components of the so caravan may thus have great strength. They may also be lightweight, and in addition, they may be stiff.

The first and second sheets of the cellular component may be the prime load bearing members and may take up normal stresses applied to the cellular component. The first and second sheets may carry bending loads i. e. axial compressive and tensile loads.

s Preferably, the core of the cellular component keeps the first and second sheets of the cellular component, between which it is sandwiched, a constant distance apart. The core may also take up shear forces caused by loading and bending. Preferably, the core is rigid enough perpendicularly to the first to and second sheets to prevent crushing and its shearing rigidity may be large enough to prevent shearing deformations. The cellular component may thus resist wrinkling or buckling under axial compressive load.

The first sheet of the cellular panel may comprise a fibre reinforced material, for example fibreglass. The fibres may be carbon fibres. Alternatively, the first sheet may comprise aluminium or plywood. The first sheet may have a covering or coating applied to it. For example, it may have a decorative finish applied thereto.

so Preferably, the second sheet of the cellular panel comprises a fibre reinforced material, for example fibreglass. The fibres may be carbon fibres.

Alternatively, the second sheet may comprise aluminium or plywood. The second sheet may have a covering or coating applied to it. For example the second sheet may be painted. If a covering is employed it may comprise an z aluminium, fibreglass or polyester covering. The covering may be laminated to the second sheet. Preferably, when the cellular wall comprises a side wall of the caravan the second sheet has a covering applied thereto.

The cellular panels may be assembled by mounting dividing members of the 30 core to one of said first or second sheets and by mounting the other of said first and second sheets to the dividing members. Preferably, the dividing

members and the first and second sheets are secured to one another with an adhesive. Preferably, the floor of the caravan comprises a cellular panel having 5 fibreglass first and second sheets.

For additional insulation the cells of the cellular panel may be filled with an insulating material, for example a foam material.

To The walls of the caravan may include apertures cut into the cellular panels to define windows, doors, etc. as required.

The first and/or second sheet of the cellular panel may be strengthened with rovings. The rovings may comprise fibreglass or carbon fibre rovings.

The caravan may not comprise any frame structure to support the walls other than a chassis upon which the floor is mounted. The walls may be sufficiently strong and rigid to be self supporting. Preferably, the walls are secured together by known fixing means. The fixing means may comprise nails, bolts, 20 screws or adhesive.

According to a second aspect of the present invention there is further provided a method of making a caravan wherein the method comprises producing components comprising a floor, roof and side walls for a caravan, at least one of said components comprising a cellular component, and assembling said components together upon a chassis and wherein said cellular component comprises a cellular panel comprising a first sheet, arranged to form an internal face of the component, a second sheet spaced apart from the first sheet, arranged to form an external face of the component, and a core 30 comprising dividing members arranged to section the cavity between the first and second sheets off into cells.

Preferably, the caravan assembled according to the method of the second aspect comprises a caravan according to the first aspect.

Preferably, the floor comprises a cellular panel. Preferably, at least one of the s side walls comprises a cellular panel.

Preferably, at least one cellular component of the caravan comprises a channel for receiving services. Preferably, the method further includes installing services into said channel.

Preferably, the method further comprises adding interior and exterior fittings to the caravan.

The present invention will now be described by way of example with reference to the accompanying drawings in which: Figure 1 is a side view, showing hidden detail, of a first side wall of a caravan according to the invention; so Figure 2 is an end view of a part of the side wall of Figure 1; Figure 3 is a side view, showing hidden detail, of a second side wall of a caravan; Figure 4 is a plan view, showing hidden detail, of the floor of a caravan; Figure 5 is an end view of a part of the floor of Figure 4; Figure 6 is a plan view, showing hidden detail, of the roof of a caravan; Figure 7 is an end view of a part of the roof of Figure 6.

As illustrated by Figures 1 and 2, a first side wall 100 of a caravan has a cellular wall comprising a cellular panel 110. The cellular panel comprises a first sheet 120 arranged to form the inner face of the wall 100 and a second sheet 130, spaced apart therefrom, arranged to form the outer face of the wall s 100. The first and second sheets 120, 130, are separated by a core 140 comprising dividing members 150 arranged to define cells 160 in the cavity between the sheets 120, 130. The cellular structure provides strength and rigidity to the wall 100 The cells may also be filled with insulating material (not shown) to improve the insulating properties of the cellular side wall 100.

The first sheet 120 comprises fibreglass having a decorated finish applied thereto (not shown). The second sheet 130 comprises fibreglass having a paint coating (not shown) applied thereto.

s In one embodiment, as shown generally at A the dividing members 150 of the core 140 comprise dividing walls arranged to create a honeycomb arrangement of cells. The dividing walls comprise a plastics material. In an alternative embodiment shown generally at B the dividing members 150 of the core 140 comprise tubular members arranged to create a plurality of cylindrical so cells with non-cylindrical cells interposed therebetween.

The side wall 100 further comprises a channel 170 extending for the length thereof. The channel is defined by a break in the dividing members 150 of the core 140 and is enclosed between the first and second sheets 120,130. The as channel 170 comprises an aluminium box section 180 arranged to extend in the break between the dividing members 150 of the core 140. The channel 170 is arranged to receive services (not shown).

The side wall defines apertures 190 into which windows (not shown) are 30 installed.

Figure 3 shows a second side wall 200 of a caravan. The wall 200 is substantially identical in construction to the first side wall 100. Accordingly, like parts have been given the same reference numerals. The apertures 190 differ in that they also define a doorway.

Figures 4 and 5 show a floor 300 of a caravan. The floor 300 is substantially the same as the side walls 100, 200 and accordingly like parts are given the same reference numerals. The floor 300 differs in that both the first and second sheets 220, 230 simply comprise fibreglass having no decorative or JO paint finish applied thereto. In addition, the floor 300 comprises a number of interconnected channels 170 rather than just one channel and does not comprise any apertures other than for the wheel arches 240.

Figures 6 and 7 show a roof 400 of a caravan. The roof 400 is substantially the 15 same as the side walls, 100, 200 and accordingly like parts are given the same reference numerals. The roof 400 differs in that it contains no channel. It does however comprise apertures 190 for skylights.

In the preferred embodiment the remaining side walls of the caravan, which 20 form the front and back thereof (not shown) also comprise cellular walls.

Alternatively, the remaining side walls may comprise GRP (glass reinforced polymer) or plastic components. The walls are secured to one another and to the floor and roof to produce the shell of a caravan.

:s A caravan produced in accordance with the invention may thus be strong, lightweight and simple to construct.

The floor 300 is at least as strong as known timber floors but is lighter and can more easily be arranged to house pipe work and cabling. All the panels have 30 good heat insulation properties and so the caravan has good heat retention.

The reader's attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this

application and which are open to public inspection with this specification, and

the contents of all such papers and documents are incorporated herein by 5 reference.

All of the features disclosed in this specification (including any accompanying

claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except 10 combinations where at least some of such features and/or steps are mutually exclusive. Each feature disclosed in this specification (including any accompanying

claims, abstract and drawings), may be replaced by alternative features Is serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

The invention is not restricted to the details of the foregoing embodiment(s) 20 The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims,

abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Claims

1. A caravan having a cellular component wherein said cellular component comprises a cellular panel comprising a first sheet, arranged to form an internal face of the component, a second sheet spaced apart from the first sheet, arranged to form an external face of the component, and a core comprising dividing members arranged to section the cavity between the first and second sheets off into cells.

To

2. A caravan according to claim 1, wherein the caravan comprises a base component forming the floor of the caravan, an upper component forming the roof of the caravan and side components interposed therebetween forming the walls of the caravan.

s

3. A caravan according to claim 2, wherein the floor comprises a cellular component.

4. A caravan according to claim 2 or 3, wherein the roof comprises a cellular component.

5. A caravan according to any of claims 2, 3 or 4, wherein one or more of the walls comprises a cellular component.

6. A caravan according to claim 5, wherein each wall of the caravan 25 comprises a cellular component.

7. A caravan according to any of claims 2 to 6, wherein the cellular components all have the same construction.

so

8. A caravan according to any of claims 2 to 6, wherein the floor, roof and side walls are all cellular but differ in construction with the floor being

constructed to be stronger and the side walls and roof being constructed to be lighter.

9. A caravan according to any preceding claim, wherein at least one cellular panel comprises a channel extending through the core in the plane of the cellular panel.

10. A caravan according to claim 9, wherein the cellular panel comprises a plurality of channels.

11. A caravan according to claim 9 or 10, wherein the dividing members of the cellular panel are arranged to define a break in the cellular structure of the panel and thus define a channel in between two cellular sections of the panel.

15

12. A caravan according to claim 11 wherein the channel comprises a tubular member arranged to extend in the break between the dividing members.

13. A caravan according to any of claims 9 to 12, wherein the channel or channels are arranged to receive services for the caravan.

14. A caravan according to any preceding claim, wherein the dividing members of the core of the cellular panel comprise tubular members orientated such that their axis extend perpendicularly to the planes of the first and second sheets of the cellular panel.

15. A caravan according to any of claims 1 to 14, wherein the dividing members of the core comprise dividing walls arranged to produce a honeycomb structure.

so

16. A caravan according to any preceding claim, wherein the core of the cellular component keeps the first and second sheets of the cellular component, between which it is sandwiched, a constant distance apart.

17. A caravan according to any preceding claim, wherein the dividing members and the first and second sheets are secured to one another with an adhesive. s

18. A caravan according to any preceding claim, wherein the caravan does not comprise any frame structure to support the walls other than a chassis upon which the floor is mounted.

19. A caravan substantially as herein described with reference to the To accompany drawings.

20. A method of making a caravan wherein the method comprises producing components comprising a floor, roof and side walls for a caravan, at least one of said components comprising a cellular component, and assembling said s components together upon a chassis and wherein said cellular component comprises a cellular panel comprising a first sheet, arranged to form an internal face of the component, a second sheet spaced apart from the first sheet, arranged to form an external face of the component, and a core comprising dividing members arranged to section the cavity between the first 20 and second sheets off into cells.

21. A method according to claim 20 wherein the caravan assembled according to the method comprises a caravan according to any of claims 1 to 19.