RV-EZ Travel Deck - an extendable self-storing deck assembly for recreational vehicles

Abstract

This invention comprises a complete deck assembly for a recreational vehicle. The deck platform can be deployed and stowed quickly and easily with the push of a button. When stowed the deck is secured into a position allowing for safe travel. When deployed the deck moves in outward and downward directions until it reaches suitable height and then continues outward until fully extended. When deployed, the flat and stable deck platform, resides at one step above ground level. Adjustable supports allow the deck platform to be easily leveled on uneven terrain. The deck's 12-volt motor receiving power from the vehicles standard electrical system allows use without land-based power. Manual operation is also possible in the event of power failure.

Description

BACKGROUND OF INVENTION

RVing and camping has been a form of recreation chosen by many for many years. In recent years the numbers choosing this form of recreation have increased dramatically as have the choices of vehicles and products associated with this form of recreation. Inventors have come to aid with many new products making the experience more pleasurable. One of the obstacles, to a pleasurable experience, has been and continues to be, the ground condition in the area of the entrance of the vehicle. The tracking of dirt, mud and sand is of constant concern. Also when relaxing outside of the vehicle, at ground level, one is exposed to low lying insects, reptiles, and poisonous vegetation. Ground covers have been extensively used, but fail to fully meet the needs. Also these tend to be quite a messy chore to pick up and stow for travel. The ground covers also destroy the vegetation and their use has been banned or severely limited in many campgrounds and resorts. The obvious solution would be a deck similar to the decks found adjacent to many homes. The deck would need to have all of the benefits of a permanent deck, and yet must be easily transferred between a usable position and a position that would allow for travel. There are numerous requirements that a travel deck would need to meet. To list just a few of those that this invention does meet:

The deck should be of a complete assembly that can be easily installed on a variety of vehicles without additional custom components. The deck platform when in use position, should be of sufficient height to remain free of aforesaid ground problems, yet low enough for access from any of three sides. Also the platform should be at such height that steps or railings are not required for safety and that adequate headroom is available for awning use. When stowed, the deck assembly must be of sufficient height to permit safe travel. Thus a deck would need to combine downward and outward movements when being deployed and combine inward and upward movements when being stowed. The deck platform should extend far enough to fully compliment the standard extended awning. The deck should have integrated, easily adjustable supports for leveling and stabilizing the platform.

DESCRIPTION OF THE PRIOR ART

Prior art has previously provided extendable decks for recreational vehicles. However the previous art does not incorporate the features of this new invention. More specifically the nearest related art in U.S. Pat. Nos. 6,869,092, 5,997,073, 4,883,306, 4,869,030, have platforms with horizontal movement, but they do not include vertical movement to optimize the deployed and stowed heights. Another somewhat related prior art, U.S. Pat. No. 5,193,878, has a form of vertical movement, in that it deploys some sort of folded element to the ground. It is not believed that this would be considered a flat, level, stabilized platform such as a deck, but would be more related to aforesaid ground cover. Also it is not believed that this art could be combined with any other to provide the actions of this new invention. Furthermore it is not believed that any prior art has provided adjustable mounting brackets, required for use on differing frame configurations, spans and heights as this new invention has. Prior art has provided for combined movement in other applications. U.S. Patent Application Publication No. 0,151,340 is a retractable step with downward and outward movements. Though the combined movements are present it is not believed that this art could be combined with any other to provide the continuing outward movement needed for the extension of a deck platform.

SUMMARY

This invention provides a complete deck assembly for installation on many recreational vehicles. Combining an unique, drive mechanism, deployment system, adjustable mounting brackets, and a platform with integrated adjustable supports, this deck assembly provides the owner with a deck that has all of the benefits of a land based deck and also has the many additional benefits and requirements of a deck that can be easily stowed for travel.

The Objects of this Invention are to Provide a Complete Deck Assembly that:

Can be easily installed on a variety of recreational vehicles without the need of additional custom fabricated components and also can be easily adapted for OEM installation.

Will combine vertical and horizontal movements to achieve optimum height, at use position, as well as when stowed for travel.

Provides a stable deck platform that, when in use position, resides at a height that protects growth, allows leveling on uneven ground, is easily accessible from three sides yet keeps one above ground problems.

Provides a deck platform, when in use position, residing at a height that does not require steps, does not require railings for safety, and does allow adequate headroom when awning is in use.

Extends far enough to fully compliment standard eight-foot awning extension.

Is simple and easy to operate and requires minimal operator effort.

Includes integral supports providing an easy method of leveling and stabilizing the deck platform.

Has a single drive unit, powered by the recreational vehicles existing 12 volt power supply.

When in stowed position, resides securely at a safe height for travel.

When stowed, is self securing, not requiring additional operator effort, fasteners or hardware.

Has a total weight that does not overly infringe on vehicle manufacturer's limit.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a photo of the deck assembly mounted to a fifth wheel and residing in the deployed position

FIG. 2 is a perspective drawing of the deck assembly in a fully retracted position

FIG. 3 is a perspective drawing of the right frontal bracket

FIG. 4 is a perspective drawing of the right rearward bracket

FIG. 5 is a perspective view of the left deployment arm assembly

FIG. 6 is a perspective view of the carriage assembly

FIG. 7 is a perspective view of the platform assembly

FIG. 8 is a perspective view of the bottom of the platform frame

FIG. 9 is perspective view of the ramp assembly

FIG. 10 is a perspective view of the deck assembly in a semi-deployed position

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1. This is a photo showing the deck assembly fully deployed while installed on a fifth wheel. This is an actual pre-production, 10′ wide, deck assembly and is actually fully operable on the fifth wheel and has been and is being used as a testing and demonstration unit. It has traveled to, from and about Michigan to Florida and all states between. An eight-foot, prototype, installed on a travel trailer (not shown) has traveled throughout Michigan and Indiana. As can be seen in FIG. 1, the carriage assembly and the platform are at a short distance above ground. When retracted both will reside at a height above the lowest point of brackets 54 & 55 FIG. 2.

The deck assembly is comprised of:

Left & right, frontal bracket assemblies FIG. 3, opposing in nature.

Left & right, rearward bracket assemblies FIG. 4, opposing in nature.

Deployment arm assemblies FIG. 5, again opposing in nature.

A carriage assembly FIG. 6.

And a platform assembly FIG. 7.

Rear channel covers 9 & 10, FIG. 2, are of formed aluminum and are added at final assembly. Cover 9 is attached with a hinge and latch, allowing storage access to unused portion of channel 31 FIG. 6. Cover 10 FIG. 2, is attached with screws and covers drive mechanism and electrical components. Electrical components are not shown, but are of a standard nature and are installed at final assembly. They include wiring, limiting type switches, push button or rocker switch, and necessary relays or similar type components.

The construction of the bracket assemblies 54 & 55, FIG. 2, detailed in FIGS. 3 & 4, is preferred to be of steel, though an OEM model, where as adjustment is not necessary, this could be of lighter material. The I-beams 1, FIGS. 3 & 4, are simulations of some vehicle frames. In the event of the vehicle frame being of tubular or channel shape, the angles 2, FIG. 3 & FIG. 4, would be replaced by flat steel with holes for attachment through the frame member.

The brackets have similar construction, and use interchangeable parts with the exception of tube 6 FIG. 3 and tubes 11 & 12, FIG. 4. On both, the angles 2, are cut out to slide over tube 3. One of the angles, on each tube, is welded into place, while the other slides freely to allow for varying I-beam widths. Spacers are added at a length allowing for the proper clamping pressure. Tubes 3 adjustably slide over tubes 4. Tubes 4 are welded to tubes 5. Tubes 6, adjustably slide into tubes 5. In FIG. 4, tubes 11 slide into tubes 5 and tubes 11 are welded to tubes 12. Round tubes are welded into tubes 6 & 12. In FIG. 3, plates 8 are slid over tubes 7 and welded. Plates 8 have a hole for pivotal attachment of gas springs.

Referring to FIG. 5, which is the deployment arm assembly, shown attached to a carriage side and having bracket assemblies 54 & 55 attached. Steel has been used, though aluminum could be a good substitute, some of the reinforced plastics could also being considered. Rectangular tubing is used for members 14, 15 and 16, while square tube is used for 17.

Shafts 21 are welded into tubes 15 & 16. Shafts 22 are welded into tubes 14. Plates are welded to tubes 14, supplying means of attachment to carriage side. Plates 18 are welded to tube 15, supplying means of pivotal attachment to tubes 17. Plates 19 are welded to tubes 17, supplying means of pivotal attachment to tubes 16. Angles 23 are welded to tubes 17, allowing pivotal attachment of gas springs 20. Gas springs 20, are of necessary force to assist in the lifting action, and vary in force depending on deck width and ultimately the total weight of the entire assemblies. Shafts 29 are welded into tubes 25 and round tubes 24 are welded into tubes 16. Shafts 27 are welded adjacent to tubes 25 and bars 26 are inserted into tubes 25 and secured.

Referring to FIG. 6, the carriage consists of two side rails 30, a channel 31, channel inserts 32, a motor 33, and an acme screw 34. Also, but not shown are, nylon miter gears, timing belt, and timing belt pulleys for the drive system. Those are matched with the gas springs dependent on deck size and weight and can be determined using standard engineering formulas and tables. One acme screw is indicated here, though, two may used in the event of an extremely large deck. The acme screw 34, is mounted in bearings in the rear channel 31, and the acme screw has a hex end for manual operation, accessible through a hole in channel 31.

Referring to FIG. 7, the platform assembly consists of an aluminum frame FIG. 8, a series of vinyl deck boards 38, FIG. 7, and ramp assemblies 36, FIG. 7, detailed in FIG. 9.

The acme screw 34, FIG. 6, is inserted through an acme nut attached to angle 35, FIG. 7 and into the center vinyl deck board of the platform. This provides for the acme screw to be stabilized, protected and lubricated. A grease fitting is attached to the bottom side of the platform for the purpose of inserting lubricant into the deck board. A wiper 37, FIG. 7, with an enclosed seal, cleans the acme screw and retains lubricant. The ramp assemblies 36, FIG. 7, are attached to angle 35, FIG. 7.

Referring to FIG. 8, the platform frame assembly is constructed of aluminum extrusions of various shapes. Pads 40 are pivotally attached to steel tubes 39. Support tubes 39, pivot on shafts 41, to which they are attached. Support tubes 39 also have fixed pins located, nearer the end, on the same end as shaft 41. Springs 42, are situated between support tubes 39, and frame member 44. Springs hold pin in support tubes 39, locked, into one of several holes in frame member 43. For each support, one hole is positioned, to lock the support in a maximum upward position, for travel.

Referring to FIG. 9, the ramp assemblies are shown as weldments, with aluminum rails 45. These could be of cast aluminum or molded plastic. Plates 46, 47, 48 are welded as are shafts 49. Rollers are of nylon. Shaped steel plates 50, slide over shafts 53, and are secured with a machine screw.

Operation

When the deck is in the stowed position, as in FIG. 2, the gas springs 20, FIGS. 2 & 5, are slightly compressed, securing the entire deck assembly for travel. The acme screw acts as a safety device, preventing the deck from accidentally deploying, in the event both gas springs fail. Also at the stowed position, blocks 26, FIG. 5, are seated tangent to rollers 51, FIG. 9. Also hook plates 50, FIG. 9, are engaged to shaft 27, FIG. 5. When activated to deploy, the motor 33, FIG. 6, rotates the acme screw and the platform begins outward movement. At this time hook plates 50, FIG. 9, engaged to shaft 27, FIG. 5, pull the entire carriage forward and further depress the gas springs. After short movement, the weight of the deck, begins to help in depressing the gas springs. The gas springs help prevent jerky movement and once compressed in the deployed position are ready to aid in the lifting action required during the retraction process. As the movement continues, tube 25, FIG. 5, pivots upward until reaching a fixed stop. At this point the hook plates 50, FIG. 9, have rotated out of engagement of shafts 27, FIG. 5. and rollers 28, FIG. 5, are tangent to and rolling down ramp rail 45, FIG. 9. Once the rollers leave the ramp rails, downward motion stops and the platform continues in a horizontal direction until fully deployed. The process is simply reversed for retraction, with the compressed gas springs aiding in the lifting. The ramps start the upward travel until such point as the “push arms” tubes 25, FIG. 5, have reached the proper angle to allow taking over the lifting motion.

Basic operator instructions would be:

For deployment:

Depress support shafts 41, FIG. 8, allowing supports to pivot to deployment position, release shaft allowing supports to lock into place.

Depress deployment button and hold until deployment has stopped.

Adjust supports if necessary.

For stowing:

Depress stow button and hold until retraction has stopped.

Depress support shaft, swing support to stow position, release shaft allowing support to lock into place. Happy Camping!!

Claims

1. A deck assembly for installation on a recreational vehicle with means to deploy and retract a platform in combined vertical and horizontal directions and where the vertical movement does not restrict the horizontal movement.

2. A complete deck assembly of claim 1, comprising:

Frontal and rearward adjustable mounting brackets

Left and right deployment arm assemblies

Carriage assembly with integrated drive mechanism

And a platform, being rectangular in shape, with integrated adjustable supports

Where as said frontal and rearward mounting brackets, of deck assembly of claim 2, are further defined as:

As having means of adjustment for differing types of frame members

And having means of vertical and horizontal adjustment

And where as the left and right deployment arm assemblies, opposing in nature, of deck assembly of claim 2 are further defined as comprising:

A frontal and rearward arm assembly and a link arm assembly

And where as said frontal arm assembly comprises: A first end of a first member, with means of attachment to, carriage of deck assembly of claim 2 And where as said first member has means of pivotal attachment on second end And where as a second member has first end pivotally attached to said first member And where as second member has second end pivotally attached to mounting bracket of claim 2

And where as rearward arm assembly comprises: A first member the same as aforesaid frontal arm assembly And a second member of greater length than the second member of the aforesaid frontal arm assembly And first end of said second member is pivotally attached to mounting bracket of claim 2 And where said second member is pivotally attached to first member at a distance from first end, of said second member, equal to that of aforesaid frontal arm assembly And where as the first end of a third member is pivotally attached to the second end of the said second member And where as the said third member has means of attaching rollers to provide movable tangency to, yet to be described, ramp rails of platform of claim 2

And where as the link arm assembly is further defined as a link member with first end pivotally attached to second member of aforesaid frontal arm assembly, at a point between and offset from, existing pivotal axis And second end of link arm is pivotally attached to second member of rearward arm assembly And where as the first end of a gas spring is pivotally attached to said link member at an appropriate distance from said first end of said link member And where as the second end of said gas spring is pivotally attached to the bracket of claim 2 And where as the gas spring gives means for smooth deployment operation and assists the drive mechanism in retraction operation

And where as the carriage assembly, of claim 2, is further defined as: Opposing rails perpendicularly attached to each end of a channel And where as said channel has an integrated drive system comprising: A motor, means of speed reduction, and an acme screw

And where as the platform of claim 2, is further described as comprising:

An assembled aluminum frame, a plurality of vinyl deck boards, a ramp assembly and integrated adjustable supports Where as center vinyl deck board serves to protect, stabilize and lubricate aforesaid acme screw of aforesaid drive mechanism And where as an acme nut is attached at rearward end of said center vinyl deck board And where as aforesaid ramp assembly provides means of assisting in deployment and retraction operations And where as integrated front supports are further define: The first end of a first member pivotally attached to a pad And a pin attached to said first member on second end parallel to first pivot And a shaft transversely passing through, parallel to pin, and attached to, said first member at a short distance from the said second end of first member And where aforesaid shaft, passes through a second member, being the frontal most member of the aforesaid frame And where as a spring is placed on the said shaft, between the first member and a third member, being the second most member of the afore said frame And where as depressing the end of said shaft, compresses spring, and allows first member to pivot And where as, upon release of shaft, aforesaid pin locks into one of several hoes in said second member.

3. An integral adjustable support of deck assembly of claim 2,

Where as the said support could be adapted for various uses

And where as said support could easily be adapted into a detachable support, by simply adding a mounting component, where as additional uses are possible.