RELATED DISCLOSURES

[0001] Not Applicable.

INTRODUCTION

[0002] It is often useful to be able to collapse a truck or trailer, such as a towed recreational vehicle into a more easily transportable form. Typically, in order to have a structurally stable horizontally expandable portion of the trailer, the expandable portion is received in a collapsed or retracted configuration.

[0003] Actuators are conventionally used to move the expandable portion from a retracted to an extended position by exerting an outward lateral force on an outer rail thereof. Typically, the actuator may be a motor-driven screw jack that drives a rod and piston assembly in which the rod is coupled to one of the outer rails of the expandable portion.

[0004] Accordingly, as may be seen in the prior art drawing of Figure 1 of a view from above of the undercarriage of an example trailer shown generally at 100, a plurality of actuators 110 are disposed in spaced-apart fashion along the longitudinal length of the trailer 100. In the example embodiment being shown, the trailer 100 has two expandable portions, one in each lateral direction relative to the longitudinal axis of the trailer 100. As such, the actuators 110 are disposed in pairs, and within each pair, the actuators 110 extend in opposing lateral directions, as shown by corresponding arrows.

[0005] The actuators 110 are gear driven. In the example embodiment of

Figure 1, at each pair of actuators 110 a central gear box 120 translates rotational power from a central shaft 121 driven by a motor 125 at a rear end of the trailer 100 to an offset gear box 122 corresponding to each actuator 110, which drives the screw drive in the associated actuator 110 and causes the rod (not shown) to bear outwardly against the outer rail (not shown) of the expandable portion of the trailer 100.

[0006] With screw drives, however, it is notoriously difficult to access the drive mechanism for maintenance purposes. Further, such drives are generally not weight-bearing, thus calling for supplementary extendable supports 130 to be positioned at spaced-apart intervals along and beneath the trailer 100 to extend laterally outwardly in the directions shown by the arrows and bear the weight of the expandable portion when it is being extended.

[0007] Screw drives are mechanisms that generally extend ponderously and require a motor of considerable size to drive them.

[0008] In order to ensure that there is sufficient ground clearance beneath the trailer 100, the extendable supports 130 are generally spaced-apart from the actuators 110 along the longitudinal length of the trailer 100. As a result, the lateral force imposed by the actuators 110 may be a considerable distance away from the point of resistance between the stationary and movable parts of the extendable supports 130.

[0009] Accordingly, considerable torque and resulting stress is imparted on the structural components of the trailer 100.

DRAWINGS

[0010] The embodiments of the present disclosure will now be described by reference to the following figures, in which identical reference numerals in different figures indicate identical elements and in which:

[0011] FIGURE 1 is a plan view from above of an undercarriage of a prior art expandable trailer in a retracted position;

[0012] FIGURE 2 is a perspective view from the side and rear of an example embodiment of an expandable trailer in a retracted position and having an actuator mechanism in accordance with an example embodiment of the present disclosure;

[0013] FIGURE 3 is a similar perspective view from the side and rear of the trailer of Figure 2 in an open, extended position;

[0014] FIGURE 4 is a rear elevation view of the trailer of Figure 2;

[0015] FIGURE 5 is a rear elevation view of the trailer of Figure 3;

[0016] FIGURE 6 is a side view of the actuator mechanism of the example embodiment of Figure 2 in a fully-closed position;

[0017] FIGURE 7 A and 7B are perspective views from the side and a first end of the actuator mechanism of the example embodiment of Figure 2, in a partially-opened and in a fully-closed position respectively;

[0018] FIGURE 8 is a perspective view from the side and a second end of the actuator mechanism of the example embodiment of Figure 2 in a fully- closed position;

[0019] FIGURE 9 is a plan view from above of an undercarriage of the trailer of Figure 2 in a retracted position; and

[0020] FIGURE 10 is a cross-sectional view of the actuator mechanism of

Figure 7 taken along section 10-10.

DESCRIPTION

[0021] An actuator mechanism is disclosed that incorporates a rack and pinion actuator system directly in contact with each expandable support. The drive force is accordingly directed at exactly the point of resistance between the movable and stationary portions of the expandable support in both the longitudinal and lateral directions. The rack forms part of the movable portion of the expandable support and is driven by a gear assembly mounted directly below and substantially at an extremity of the fixed portion of the expandable support.

[0022] Preferably, the various gear assemblies associated with the expandable supports on one side of the trailer are rotationally driven in a synchronous fashion by a common shaft driven by a single motor. A mitre-box gear may be incorporated to simultaneously drive a pair of shafts corresponding to each side of the trailer.

[0023] The incorporation of the rack and pinion actuator system on the expandable supports dispenses entirely with the screw drive mechanisms, with a corresponding simplicity of design and a significant reduction in overall weight and cost of the trailer. By their very nature, rack and pinion systems are generally more easily accessible for purposes of maintenance.

[0024] Furthermore, the rack and pinion actuator system extends more quickly than a screw drive mechanism and may be driven with a smaller motor because of the concomitant reduction in the size of the gear.

[0025] The present disclosure will now be described in detail for the purposes of illustration only, in conjunction with certain embodiments shown in the enclosed drawings.

[0026] For convenience of explanation only, reference will be made to

Canadian Patent Application No. 2,533,682 filed January 23, 2006 by Peel Truck & Trailer Ltd., naming Benito Di Franco as the inventor and incorporated by reference in its entirety herein.

[0027] Referring first to Figures 2 and 4, there is shown, from a side and rear perspective view and from a rear view respectively, an example embodiment of an expandable trailer shown generally at 100 in a retracted position. Figures 3 and 5 illustrate the expandable trailer 100 in an open position from the same views. The expandable trailer 100 illustrated in Figures 2 through 5 comprises a chassis 212 having a central longitudinal axis 214 and at least one pair of extendable supports 600 (Figure 6). The extendable supports 600 are extendable laterally outwardly from the chassis 212.

[0028] The extendable supports 600 support at least one pair of rectangular floor sections 216. Each floor section 216 of the pair is spaced laterally with respect to the other floor section 216 of the pair to either side of the central longitudinal axis 214 of the chassis 212 and adjacent floor elements 222, shown in an open and extended position in Figure 3. Each of the floor sections 216 has an inner longitudinal edge 218 and an outer rail 220, the outer rail 220 being coupled to an outer end of a corresponding one of the at least one pair of extendable supports 600.

[0029] The floor sections 216 may each comprise a planar member supported by a frame having a plurality of lateral support bars, as shown in the cut-away portions of Figures 2 and 3. This frame does not have to be in direct contact with the extendable supports 600.

[0030] At least two rectangular floor elements 222 are pivotally coupled together along respective first longitudinal edges (indicated generally by reference number 224). Each floor element 222 is pivotally coupled at a second longitudinal edge (indicated generally by reference number 226) to a corresponding inner longitudinal edge 218 of one of the at least two floor sections. Like the floor sections 216, the floor elements 222 may each comprise a planar member supported by a frame having a plurality of support bars (not shown).

[0031] Upon extension of the extendable supports 600 from a retracted position to an open, extended position, the horizontal floor sections 216 move laterally outwardly to extend from the chassis 212 and the floor elements 222 move from a retracted position where the floor elements 222 are in an upright vertical arrangement (as in Figures 2 and 4) to an open, extended position where the floor elements 222 lie in horizontal alignment with the floor section 216, positioned over and supported on the extendible supports 600 (as in Figures 3 and 5).

[0032] When in the open position, there may be a small clearance

(approximately ³ A") between the second longitudinal edge 226 of each floor element 222 and the inner longitudinal edge 218 of the corresponding horizontal floor section 216. Likewise, when in the open position, there may be a small clearance (approximately ³ A") between the first longitudinal edges 224 of the floor elements 222. In the open position, each of the floor elements 222 may be supported on a lip extending from the corresponding floor section 216 (not shown).

[0033] Preferably, as can be seen in Figures 2 and 4, the floor elements

222 extend upwardly from a lateral center of the chassis 212 (in line with longitudinal axis 214) when in the retracted position. It should be understood, however, that the floor elements 222 may extend upwardly from any suitable part of the chassis 212.

[0034] At least two side walls may extend upwardly from outer edge portions of respective ones of the floor sections 216. These walls may be supported by the vertical supports 238 shown clearly in Figures 2 through 5. Alternatively, these side walls may be implemented without vertical supports

238. At least two roof sections 239, shown in phantom in Figures 2 and 3, are attached to the upper edges of the at least two side walls. The roof sections

239, are supported by roof supports 240. Each of the side walls may comprise at least one removable panel (not shown) for the purposes of, for example, interchanging different types of panel (e.g. with window, without window).

[0035] When the extendable supports 600 are in the retracted position, the roof section 239 on one side lies beneath the roof section 239 of the other side of the trailer, as shown in Figures 2 and 4. Preferably the chassis 212 comprises a central static roof section 242 and the roof sections 239 both lie beneath the static roof section 242 of the chassis 212 when the extendable supports 600 are in the retracted position. The static roof portion 242 may be supported by additional vertical supports 238 at each corner, as shown in Figures 2 through 5. The side walls on opposite sides of the trailer may be different heights so that the first and second roof sections 239 may lie beneath the static roof portion 242 as shown in Figures 4 and 5.

[0036] A platform 244 may extend from a back end of the chassis 212.

The platform 244 may be pivotally mounted to fold up into a vertical arrangement when the trailer 100 is in motion. This platform 244 may be used for any suitable purpose, for example, additional storage.

[0037] When the expandable trailer 100 is parked, a plurality of conventional levelling jacks 246 can be used to level the trailer 100.

[0038] According to another embodiment of the disclosure, a plurality of expandable trailers similar to the expandable trailer described previously may be connected together by a suitable coupling means 248. This connection may be facilitated by using respective levelling jacks to horizontally align respective floor sections 216 of adjacent expandable trailers.

[0039] Referring now to Figure 6, each of the extendable supports 600 comprises an inner member 630 and an outer member 632. The outer member 632 has an inner opening that extends along the length of the outer member 632 for receiving the inner member 630. The inner member 630 lies substantially within the outer member 632 when in the retracted position (as shown in Figure 4) and extends telescopically from the outer member 632 when in the extended position (as shown in Figure 7).

[0040] A rack 640 extends along the length of an outer bottom surface of the inner member 630. The rack 640 is adapted to engage a gear drive 650 affixed to the bottom of the outer member 632 at a first end. The gear drive 650 is fastened so that a portion of the gear drive 650 lies within the inner opening of the outer member 632. The rack 640 is supported as it is driven out of the outer member 632 to the extended position by impingement of the gear drive 650 against the teeth of the rack 640. The portion of the gear drive 650 that lies within the inner opening can be increased and decreased.

[0041] The inner member 630 may be tubular and generally square in cross-section. Preferably, however, a vertical fin 636 may extend upwardly from at least a portion of the inner member 630 from its second end toward the first end. The fin 636 serves as an alignment guide for the extension and retraction of the inner member 630 within the outer member 632. Additionally, the fin 636 may serve as a weight-bearing point of contact between the inner member 630 and the outer rail 220. Preferably, the inner member 632 is welded to a top surface of the fin 636 so that the horizontal floor sections 216 move laterally outwardly as the outer member 632 is extended.

[0042] Likewise, the outer member 632 may be generally square in cross-section, with a small keyway 637 extending downwardly from the bottom surface thereof to accommodate the rack 640, as may be more clearly seen in Figures 7 and 8. The outer member 632 may comprise a planar plate 638 at its second end having a slit extending partly therealong from the second end toward the first end and adapted to engage the fin 636 and ensure proper alignment between the inner member 630 and the outer member 632.

[0043] As may be better seen in Figure 8, each of the extendable supports 600 further comprises a roller 634 fastened to a second end distal to the first end of the inner member 630, a diameter of the first roller 634 being slightly smaller than the width of the outer member 632. The first roller 634 rolls along a bottom surface of the inner opening of the outer member 632. The roller 634 serves to reduce frictional forces between the inner member 630 and outer member 632 as the inner member 630 is driven out of the outer member 632.

[0044] Turning now to Figure 9, it may now be seen that the actuators

110 of the prior art embodiment in Figure 1 have been dispensed with and the extendable supports 130 have been replaced with the actuator mechanisms 600.

[0045] In Figure 9, the drive shaft mechanism has been modified from the central longitudinal alignment of Figure 1 to a parallel longitudinal alignment. The central gear box 120 is replaced with a mitre gear box 920, that converts the rotational motion of the motor 125 to drive a rotating lateral shaft 921 disposed at right angles thereto. A pair of angle gear boxes 922 links the lateral shaft 921 with corresponding longitudinal shafts 923 that extend along the length of the trailer 100. The longitudinal shafts 923 extend along the periphery of the non-extendable portion of the extendable supports 600 to drive each gear drive 650 at the point of resistance indicated by the fins 636. The fins 636 support from below the outer rail 220 of the expandable portion of the trailer 100.

[0046] Figure 10 shows a cross-sectional view of the inner member 630, the outer member 632 and the gear drive 650, taken along section 10-10 in Figure 7.

[0047] Those having ordinary skill in the relevant art will readily appreciate that while the use of the term "trailer" conventionally connotes an unpowered vehicle that is towed by or otherwise propelled by a second vehicle, the concepts disclosed in the present description could be easily made applicable to a single vehicle, such as a unitary self-propelled recreational vehicle, having expandable portions, without departing from the spirit and scope of the present description. Accordingly, for the purposes of this description, the term "trailer" is intended to include such unitary self-propelled recreational vehicles and should not necessarily be understood to be limited to unpowered vehicles towed by a second vehicle.

[0048] Those having ordinary skill in this art will also readily appreciate that the concepts disclosed in the present description may be equally applicable to expandable portions that are located along only a single side of the trailer 100 or are oriented in a different direction relative to the longitudinal axis of the trailer 100, such as along the back of the trailer 100.

[0049] Further, the expandable portion may be of any configuration and in particular, may not have a rectangular floor section with a vertically folding rectangular floor element pivotally coupled thereto at a longitudinal edge thereof.

[0050] In the foregoing description, for purposes of explanation and not limitation, specific details are set forth in order to provide a thorough understanding of the present disclosure. However, it will be apparent to those having ordinary skill in this art that the present disclosure may be practised in other embodiments that depart from these specific details.

[0051] In some instances, detailed descriptions of well-known devices and methods are omitted so as not to obscure the description of the present disclosure with unnecessary detail. All statements herein reciting principles, aspects and embodiments of the disclosure, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future, i.e., any elements developed that perform the same function, regardless of structure.

[0052] Thus, for example, it will be appreciated by those having ordinary skill in this art that block diagrams reproduced herein can represent conceptual views of illustrative components embodying the principles of the technology.

[0053] It will be apparent to those having ordinary skill in this art that various modifications and variations may be made to the embodiments disclosed herein, consistent with the present disclosure, without departing from the spirit and scope of the present disclosure. [0054] While preferred embodiments are disclosed, this is not intended to be limiting. Rather, the general principles set forth herein are considered to be merely illustrative of the scope of the present disclosure and it is to be further understood that numerous changes covering alternatives, modifications and equivalents may be made without straying from the scope of the present disclosure, as defined by the appended claims.

[0055] Also, the term "couple" in any form is intended to mean either an direct or indirect connection through other devices and connections.

[0056] Moreover, all dimensions described herein are intended solely to be exemplary for purposes of illustrating certain embodiments and are not intended to limit the scope of the invention to any embodiments that may depart from such dimensions as may be specified.

[0057] Directional terms such as "upward", "downward", "left" and "right" are used to refer to directions in the drawings to which reference is made unless otherwise stated. Similarly, words such as "inward" and "outward" are used to refer to directions toward and away from, respectively, the geometric centre of a device, area and/or volume and/or designated parts thereof.

[0058] References in the singular form include the plural and vice versa, unless otherwise noted.

[0059] The terms "including" and "comprising" are used in an open-ended fashion, and thus should be interpreted to mean "including, but not limited to". The terms "example" and "exemplary" are used simply to identify instances for illustrative purposes and should not be interpreted as limiting the scope of the invention to the stated instances.

[0060] Certain terms are used throughout to refer to particular components. As one skilled in the art will appreciate, manufacturers may refer to a component by different names. It is not intended to distinguish between components that differ in name but not in function.

[0061] The purpose of the Abstract is to enable the relevant patent office and/or the public generally, and especially persons having ordinary skill in the art who are not familiar with patent or legal terms or phraseology, to quickly determine from a cursory inspection the nature of the technical disclosure. The Abstract is neither intended to define the invention of this disclosure, which is measured by its claims, nor is it intended to be limiting as to the scope of this disclosure in any way.

[0062] According to a first broad aspect of an embodiment of the present disclosure there is disclosed an actuator system for an extendable compartment of an enclosure, the compartment having a chassis defined by an inner rail, an outer rail and at least one side rail, the compartment being movable between a closed position in which at least the inner rail and a portion of each side rail lies within a perimeter defined by the enclosure and an extended position in which at least the outer rail and a portion of each side rail extend beyond the perimeter defined by the enclosure, the actuator system comprising an expandable support, comprising an inner longitudinal member and an outer longitudinal member, the inner member having an outer cross-section adapted to fit inside and to move in and out of a first end of a longitudinal bore of the outer member, the outer member adapted to be attached to the enclosure and an end of the inner member adapted to be attached to the outer rail such that the inner member supports the chassis, a rack attached to a surface of the inner member and accessible at the first end of the outer member; and a gear drive attached to the outer member proximate to the first end thereof and adapted to engage the rack to extend or retract the inner member relative to the outer member.

[0063] According to a further broad aspect of an embodiment of the present disclosure there is disclosed an enclosure having a compartment with a floor structure defined by an inner rail, an outer rail and at least one side rail, the compartment being movable between a closed position in which at least the inner rail and a portion of each side rail lies within a perimeter defined by the enclosure and an extended position in which at least the outer rail and a portion of each side rail extend beyond the perimeter defined by the enclosure, the enclosure comprising at least one actuator system each comprising an expandable support, comprising an inner longitudinal member and an outer longitudinal member, the inner member having an outer cross-section adapted to fit inside and to move in and out of a first end of a longitudinal bore of the outer member, the outer member adapted to be attached to the enclosure and an end of the inner member adapted to be attached to the outer rail such that the inner member supports the floor structure, a rack attached to a surface of the inner member and accessible at the first end of the outer member, and a gear drive attached to the outer member proximate to the first end thereof and adapted to engage the rack to move extend or retract the inner member relative to the outer member.

[0064] Other embodiments consistent with the present application will become apparent from consideration of the specification and the practice of the disclosure disclosed herein.

[0065] Accordingly, the specification and the embodiments disclosed therein are to be considered exemplary only, with a true scope and spirit of the invention being disclosed by the following claims.