GB2572854A

GB2572854A - Locker frame structure

Info

Publication number: GB2572854A
Application number: GB1902651.7A
Authority: GB
Inventors: Cunningham Paul
Original assignee: Swift Group Ltd
Current assignee: Swift Group Ltd
Priority date: 2018-02-27
Filing date: 2019-02-27
Publication date: 2019-10-16
Also published as: GB201803143D0; GB201902651D0

Abstract

A locker for a caravan or motorhome comprises a frame 14 having a left and right side struts 20,22, and top and bottom bars 16,18, with a portion of the frame 14 formed by injection moulding. The frame can have fitting for shelves or joining frames together, and a door catch 54. The frame can have moulded side struts and extruded bars (figs 3 & 4); integral top arms 26,28 or side arms (326,328, figs 6-8); extension moulding (238,240 fig 5) for different sized cupboards; and a moulded plastic hinge.

Description

Locker Frame Structure

The present invention is related to a frame structure for a locker, and in particular a locker frame structure for an interior of a caravan or motor home.

Caravans and motorhome typically comprise several lockers and other storage means for storing a user’s possessions and items for use in the caravan or motorhome. The lockers may also be used to enclose equipment such as power supply units, microwave ovens, etc. It is desirable to maximise living space in a caravan or motorhome by providing appropriate storage solutions that do not impose on the living space. Furthermore, it is an aim to reduce the weight of the interior modules of a caravan or motorhome, such as the lockers, in order to reduce the overall weight of the caravan or motorhome. It is also not desirable to have weight concentrated at a high level within the caravan or motorhome as this can have a significant impact on overall vehicle dynamics, making weight saving in these areas even more critical.

Conventionally, frame structures for lockers and cupboards in caravans and motor homes are formed of extruded plastic portions, aluminium extrusions, and machined timber sections, and are typically heavy. Furthermore, the conventional lockers are formed of many parts, and so the process of manufacturing the lockers can be complex.

According to an aspect of the invention there is provided a locker for a caravan or motorhome comprising a frame structure having at least one injection moulded portion.

The frame structure may comprise a left side strut, a right side strut, a top bar and a bottom bar. The left and right side struts and top and bottom bars may be arranged to form a generally rectangular-shaped frame, with the left and right side struts arranged between the top and bottom bars, substantially perpendicularly to the top and bottom bars. The injection moulded portion may be any of, or any combination of, the left side strut, the right side strut, the top bar and the bottom bar. The frame structure may comprise at least one extruded portion. The or each extruded portion may be any of, or any combination of, the left side strut, the right side strut, the top bar and the bottom bar. For example, the frame structure may comprise injection moulded side struts and extruded top and bottom bars.

The injection moulded portion may be a unitary injection moulded frame, comprising left and right side struts and top and bottom bars. Providing a unitary injection moulded frame provides the advantage that the locker comprises fewer parts, and so the construction and assembly process is simplified.

The frame structure may comprise at least one fitting for a fixture. The at least one fitting may be integrally moulded into the right and/or left side struts. Integrating the at least one fitting in the side strut simplifies the construction and assembly process of the locker. The at least one side strut may support a removable shelf.

The bottom bar may comprise a channel for receiving electrical wiring or other service routings. The channel may extend along the width of the bottom bar. In examples where the bottom bar is injection moulded, the channel may be integrally moulded in the bottom bar. In examples where the bottom bar is extruded, the channel may be machined in the bottom bar.

The top bar may be adapted to receive an LED lighting strip. The top bar may comprise a groove that extends across the width of the top bar for receiving the LED lighting strip. The LED lighting strip may be for internal or external illumination of the locker. In examples where the top bar is injection moulded, the groove may be integrally moulded in the top bar. In examples where the top bar is an extruded portion, the groove may be machined in the top bar. The electrical wiring in the channel may be for the LED lighting strip.

The locker may comprise a door. The door may be attached to the frame structure by a hinge. The door may be attached to the top bar of the frame structure. The injection moulding of the frame structure may comprise integrally moulding at least one feature suitable to receive a device for controlling the opening of the door. The device for controlling the opening of the door may be a spring or a stay or a damper. The frame structure may include moulding elements for the hinge, preferably to cooperate with moulding elements for the hinge elements in the door.

The hinge may be formed by injection moulding. A part of the hinge may be integrally moulded with the frame structure. Alternatively, the frame structure may comprise an integrally moulded fitting for receiving a fixture of the hinge. Use of an injection moulded hinge formed of a plastics material provides the advantage that the weight of the locker is reduced compared to lockers which use metal hinges.

The door may comprise a handle and a latch. The latch may be part of the handle or may be independent of the handle. The frame structure may comprise a catch for retaining the latch, in order to hold the door in a closed position. The door catch may be an opening for receiving the latch. The door catch may be integrally moulded in a part of the frame structure, for example in the bottom bar. Alternatively, the door catch may be machined into an extruded portion of the frame structure, for example the bottom bar.

The door may be adapted to receive a wrapping material or other cover stock. For example, the door may comprise moulded recesses to receive the wrapping material or other cover stock.

The bottom bar may comprise a recess for receiving a baseboard. The recess may extend along the width of the bottom bar. The recess may be adjacent the channel for receiving the wiring or other service routings, or the channel may form part of the recess. The baseboard may be a flat baseboard that forms the bottom surface of the locker. The recess in the bottom bar may extend along the length of the bottom bar. A front edge of the baseboard may slot inside the recess, while a back edge of the baseboard may slot into a recess in a back extrusion which may be attached to a wall of the caravan or motorhome.

The baseboard may be injection moulded. The injection moulding of the baseboard may comprise integrally moulding at least one feature suitable to suspend lighting units and/or a decorative surface below. The baseboard may be fixed directly to the side wall of a caravan. The baseboard may include notched portions to allow airflow into the locker volume. The notched portions may be integrally injection moulded in the baseboard.

The frame structure may comprise arms, which may be top arms, that may extend from the top ends of the side struts in a direction perpendicular to the top bar and side struts. The arms may be mid-level arms that extend from a mid section of the side struts. The arms may be attachable to a wall or a ceiling of the caravan or motorhome. The top arms may be integrally moulded with the side struts. The arms may comprise integrally moulded fittings for attachment of the locker to the wall or ceiling of the caravan or motorhome. The frame structure may comprise means for receiving and/or supporting internal shelving.

In examples where the bottom bar is an extruded portion, the bottom bar may comprise slots for receiving the side struts. The slots may be machined in the bottom bar.

The frame structure may comprise one or more extension mouldings, for extending the height and/or depth of the locker. An extension moulding may be attachable to a top or bottom end of each of the left and right side struts, to extend the height of the locker. An extension moulding may be attachable to a front or back end of the arms to extend the depth of the locker.

The locker may comprise an interior liner. The liner may be a moulded liner. The liner may be formed of rigid thermoformed plastics material or lightweight reinforced plastics sheet. The liner may be removably insertable into the locker. The liner may comprise a closed front face, with an access panel. This liner may provide the advantage that a user can remove the liner from the locker and load the liner with items, such as clothes from within the user’s home, and then insert the loaded liner directly back into the locker. The user can then easily access the contents of the liner via the access panel in the front closed face of the liner.

A plurality of the lockers according to the invention may be provided in the caravan or motorhome. The lockers may be arranged next to each other such that the baseboard links the lockers together. The plurality of lockers may be modular. The left side strut of a first locker may be attachable to a right side strut of a second locker.

According to an aspect of the invention there is provided a method of manufacturing a locker for a caravan or motorhome comprising injection moulding at least one portion of a frame structure.

The method may comprise injection moulding a unitary frame having left and right side struts and top and bottom bars. Alternatively, the method may comprise injection moulding left and right frame structures and extruding top and bottom bars, and connecting the left and right frame structures to the top and bottom bars to form a frame.

The method may comprise integrally moulding a door catch in the bottom bar for receiving a latch. The method may comprise integrally moulding a recess in the bottom bar for receiving an edge of a baseboard. The method may comprise integrally moulding a channel in the bottom bar for receiving wiring. The method may comprise integrally moulding fittings in the side struts for receiving fixtures. The method may comprise integrally moulding a part of a hinge in the top bar for connecting a door to the frame structure.

The method may comprise machining an opening in the bottom bar for receiving a latch of a door handle. The method may comprise machining a slot in the bottom bar for connecting the side strut to the bottom bar.

The method may comprise injection moulding an extension moulding. The method may comprise connecting the extension moulding to a top or bottom end of the side strut. The method may comprise connecting the extension moulding to a front or back end of a top arm which extends perpendicularly from the top bar and side strut.

The method may comprise injection moulding a baseboard. The injection moulding the baseboard may include at least one feature suitable to suspend lighting units and/or a decorative surface below. The integral moulding the baseboard may include notched portions.

According to an aspect of the invention a kit of parts for a caravan or motorhome locker comprises a frame structure having at least one injection moulded portion, wherein the frame structure comprises a left side strut, a right side strut, a top bar and a bottom bar.

The frame structure may comprise injection moulded side struts and extruded top and bottom bars.

The kit of parts may include a plurality of top bars having different lengths. The kit of parts may include a plurality of bottom bars having different lengths.

The kit of parts may comprise a moulded liner. The moulded liner may be formed of rigid thermoformed plastics material or lightweight reinforced plastics sheet. The moulded liner may be removably insertable into the locker. The liner may comprise a closed front face, with an access panel. This may provide the advantage that a user can remove the liner from the locker and load the liner with items, such as clothes from within the user’s home, and then insert the loaded liner directly back into the locker. The user can then easily access the contents of the liner via the access panel in the front closed face of the liner.

The kit of parts may comprise at least one of lighting means for the locker, sub-harnesses, catches, fittings, and means for supporting or receiving shelves.

All of the features disclosed herein may be combined with any of the above aspects in any combination.

For a better understanding of the invention, and to show how embodiments of the same may be carried into effect, reference will now be made, by way of example only, to the accompanying diagrammatic drawings, in which:

Figure 1 shows a perspective view of a first example of a locker in an open configuration;

Figure 2 shows a cut-away portion of the locker of figure 1.

Figure 3 shows a perspective view of a second example of a locker in an open configuration; and

Figure 4 shows a perspective view of a third example of a locker in an open configuration; and

Figure 5 shows an exploded view of part of the frame structure of the third example of the locker with extension mouldings.

Figure 6 shows a perspective view of a fourth example of a locker in a closed configuration;

Figure 7 shows a cross-section of the locker in figure 6; and

Figure 8 shows a perspective view of the locker in figure 6 in an open configuration.

As shown in figure 1, a locker 10 according to a first example includes a door 12 and a frame structure 14 having an injection moulded portion. The frame structure comprises a top bar 16, a bottom bar 18, a left side strut 20 and a right side strut 22 forming an injection moulded unitary frame. The side struts 20, 22 extend between the left and right ends of the top and bottom bars 16, 18, substantially perpendicularly to the top and bottom bars 16, 18, forming the rectangular unitary frame. Arms 26, 28 extend from the top left and right corners 30, 32 perpendicular to the top bar 16 and the side struts 20, 22 and define the depth of the locker 10. Fittings are integrally moulded into the arms 26, 28 for attaching the frame structure 14 to the wall or ceiling of the caravan or motorhome. Side and top panels (not shown) may be attached to the frame structure 14.

The side struts 20, 22 comprise fittings 34 for receiving fixtures. These fittings 34 may be for receiving fixtures such as shelves for the locker, and also may be for receiving fixtures for attaching adjacent lockers together. The fittings 34 are integrally moulded in the side struts 20, 22.

A recess 36 is provided along the length of the bottom bar 18, for receiving a flat composite baseboard 38 which provides the bottom surface of the interior of the locker 10. A back extrusion 40 that is attachable to the caravan or motorhome wall is provided at the back edge of the baseboard 38. The front edge of the baseboard 38 slots into the recess 36, and the back edge of the baseboard 38 slots into the back extrusion 40.

The door 12 is pivotally attached to the top bar 16 of the frame structure 14 by a hinge. The hinge is a moulded hinge formed of plastics material. A first part of the hinge is integrally moulded to the top bar 16 of the frame structure 14, and a second part of the hinge is attached to the door 12.

A detent may extend from the front surface 48 of each of the left and right side struts 20, 22. The detents control the closing motion of the door 12, providing a soft-close feature.

As shown in figure 2, the door 12 comprises a handle 50 with a retaining latch 52. A door catch 54 is moulded in the bottom bar 18, for receiving the retaining latch 52. The door catch 54 is an opening in the bottom bar 18 for receiving the latch 52.

A channel 56 is provided in the bottom bar 18, adjacent the recess 36, for receiving wiring. The channel 56 extends along the length of the bottom bar 18. The wiring may be for an LED spotlight that may be provided in the locker 10, and/or may be for an LED lighting strip 58 provided in a groove across the top bar 16 of the frame structure 14.

In a second example shown in Figure 3, a locker frame structure 110 comprises injectionmoulded left and right side struts 112, 114, and top and bottom extruded bars 116, 118, as shown in figure 3. The injection moulded side struts 112, 114 comprise corner projections 120, 122,124, 126 for connecting to the top and bottom extruded bars 116, 118.

During manufacture, the extruded bars 116, 118 are cut to the desired length, so that the width of the locker frame 110 may be customisable. This simplifies the method of manufacture in that the same moulded side struts 112, 114 may be used for lockers having a variety of widths using extruded bars 116, 118 of different lengths.

The locker comprises a door 128 which includes the same features of the door 12 shown in the first example in figure 1.

The extruded top bar 116 comprises a groove for supporting an LED lighting strip 130. Similarly the top corner projections 120, 124 each comprise a corresponding recess for supporting the LED lighting strip 130.

The extruded bottom bar 118 comprises a machined opening 136 for receiving the latch of the door and a machined recess for receiving a baseboard 140. The side struts 112, 114 comprise integrally moulded fittings 142 for receiving fixtures.

In a third example, shown in figure 4, a locker frame structure 210 comprises injection moulded left and right side struts 212, 214 and top arms 216, 218, and extruded top and bottom bars 220, 222.

The side struts 212, 214 and top arms 216, 218 form the general shape of an inverted L. The left top arm 216 and the left side strut 212 are integrally moulded, and the right top arm 218 and right side strut 214 are integrally moulded. The back end 224, 226 of each of the top arms 216, 218 is attachable to a wall of the caravan or motorhome. The bottom end 228, 230 of each of the side struts 212, 214 is attachable to the extruded bottom bar 222.

The extruded bottom bar 222 comprises machined slots for receiving the bottom ends 228, 230 of the side struts 212, 214 and a recess 234 that extends across the width of the bottom bar 222 for receiving a baseboard 236. In some embodiments, the extruded bottom bar may be the width of several adjacent lockers and may include several machined slots for receiving the bottom ends of the side struts, such that several adjacent lockers can be provided using the one extruded bottom bar. Similarly, the baseboard may be the width of several adjacent lockers, so that the several adjacent lockers can be provided using one baseboard.

Similar to the example shown in figure 3, a variety of lockers having different widths may be manufactured using the same injection moulded side struts 212, 214 and extruded bars 220, 222 of different widths.

As shown in figure 5, the locker according to the third example of the invention may comprise extension mouldings 238, 240, for extending the height and/or depth of the locker. A height extension moulding 238 is attachable to a bottom end 228, 230 of the side strut 212, 214. A depth extension moulding 240 is attachable to the back end 224, 226 of top arms 216, 218. The extension mouldings being attachable to the injection moulded portion simplify the method of manufacturing the lockers in that the same moulded side struts may be used for a variety of differently sized cupboards, using differently sized extension mouldings.

As shown in figures 6 to 8, the locker 310 according to the fourth example of the invention comprises a door 312 and a frame structure 314 having an injection moulded portion. The frame structure 314 comprises an injection moulded front pane and arms 326, 328 that define the depth of the locker 310 and project from mid-way up the frame.

Fittings are integrally moulded into the arms 326, 328 for attaching the frame structure 314 to the wall or ceiling of the caravan or motorhome.

A recess 336 is provided along on the frame structure 314.

The frame structure 314 also comprises fixing points 362 for attachment of the locker 310 to the caravan or motorhome.

The locker 310 also comprises a baseboard 338 which provides the bottom surface of the interior of the locker 310. The baseboard 338 is attached to the frame structure 314. The baseboard 338 also comprises fixing points 360 that allow the baseboard to be attached to the caravan or motorhome.

The locker comprises a door 312 which includes the same features of the door 12 shown in the first example in figure 1, including a handle 350 with a retaining latch 352. The door 312 is pivotally attached to frame structure 314 by a hinge 330. The hinge is a moulded hinge formed of plastics material. A first part of the hinge is integrally moulded to the frame structure 314, and a second part of the hinge is attached to the door 312.

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 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 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 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). 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 locker for a caravan or motorhome comprising a frame structure having a left side strut, a right side strut, a top bar and a bottom bar, wherein at least a portion of the frame structure is formed by injection moulding.

2. The locker according to claim 1, wherein the left side strut, the right side strut, the top bar and the bottom bar form a unitary injection moulded frame.

3. The locker according to claim 2, wherein the bottom bar comprises an integrally moulded channel for receiving wiring.

4. The locker according to claim 2 or claim 3, further comprising an injection moulded hinge, wherein at least a part of the injection moulded hinge is integrally moulded with the side struts or top bar.

5. The locker according to any of claims 2 to 4, wherein the locker comprises a door having a handle with a latch and the bottom bar comprises an opening for receiving the latch, the opening being integrally moulded in the bottom bar.

6. The locker according to claim 5, wherein the door is injection moulded

7. The locker according to claim 6, wherein the injection moulded door comprises at least one integrally moulded feature suitable to receive a device for controlling the opening of the door.

8. The locker according to claim 1, wherein the at least a portion of the frame structure is formed by extrusion.

9. The locker according to claim 8, wherein the left side strut and the first side strut are injection moulded and the top bar and bottom bar are extruded.

10. The locker according to claim 8 or claim 9, wherein the frame structure comprises first and second extension mouldings for extending the height of the locker, the first extension moulding being attached to an end of the left side strut and the second extension moulding being attached to an end of the first side strut.

11. The locker according to any of claims 8 to 10, wherein the frame structure comprises arms extending from the left and right side struts to define the depth of the locker, and the frame structure comprises third and fourth extension mouldings for extending the depth of the locker, the third extension moulding being attached to a back end of the left arm and the fourth extension moulding being attached to a back end of the right arm.

12. The locker according to any of claims 3 to 11, wherein the frame structure comprises at least one fitting for a fixture, the at least one fitting being integrally moulded in at least one of the left or right side struts.

13. The locker according to any preceding claim, further comprising a moulded interior liner, wherein the moulded interior liner is removably insertable into the locker.

14. The locker according to claim 13, wherein the moulded interior liner comprises a closed front face having an access panel for accessing the interior of the liner.

15. The locker according to claim 13 or claim 14, wherein the moulded interior liner is formed of rigid thermoformed plastics material or lightweight reinforced plastics sheet.

16. A method of manufacturing a locker for a caravan or motorhome comprising injection moulding a portion of a frame structure.

17. The method of claim 16 wherein injection moulding the portion of the frame structure comprises injection moulding a unitary frame having left and right side struts and top and bottom bars.

18. The method of claim 17, wherein the injection moulding comprises integrally moulding a channel in the bottom bar for receiving wiring.

19. The method of any of claims 16 to 18, wherein the injection moulding comprises integrally moulding a part of a hinge in the top bar for connecting a door to the frame structure.

20. The method of any of claims 16 to 19, wherein the injection moulding comprises integrally moulding a door catch in the bottom bar for receiving a latch of a door handle. The method may comprise integrally moulding fittings in the side struts for receiving fixtures.

21. The method of claim 16, wherein the injection moulding the portion of the frame structure comprises injection moulding left and right side struts, and wherein the method further comprises extruding top and bottom bars.

22. The method of claim 21, further comprising injection moulding first and second height extension mouldings, attaching the first height extension moulding to an end of the left side strut and attaching the second height extension moulding to an end of the right side strut, to extend the height of the locker frame structure.

23. The method according to claim 21 or claim 22, wherein the injection moulding the left

5 and right side struts comprises integrally moulding a left arm and a right arm extending from an end of the left and right side struts respectively, and wherein the method further comprises injection moulding first and second depth extension mouldings, attaching the first depth extension moulding to an end of the left top and attaching the second depth extension moulding to an end of the right top arm, forextending the depth of the locker frame structure.