GB2471399A - A vehicle extension module support and method of adapting a vehicle - Google Patents

Abstract

An extendable module support mechanism usually stored within the body of a vehicle (figure 1a) for outwardly extending the body of the vehicle (figure 1b). The mechanism comprises: a base 30 securable within the body, to the floor or chassis of the vehicle including two spaced linear bearing members 26; a module floor member 22 including two spaced and generally parallel linear bearing slideways 24 each cooperable with a respective one of the two linear bearing members; and a powered actuator 40 for moving the floor member in the direction of the slideways and relative to the base into and out of the body. A method of adapting a vehicle for providing an extendable module is also disclosed, the method comprising the steps of: removing at least one door from the body of the vehicle; providing a body module for storing generally inside the body; re-fitting the removed door(s) to the body module; and fitting the module in a sliding manner in or on the vehicle such that the door(s) form a closure when the module is in the retracted position and forms one end of the module when the module is in the extended position.

Description

Extendable vehicle body This invention relates to an extendable vehicle body, in particular, but not exclusively, a vehicle which has a body, and an inner module which may be stored in the body and extended out of the body for use.

Vehicles, which have expandable compartments to give more space in the vehicle are known, but these suffer significant disadvantages. For example the mechanisms by which the compartment is expanded is often heavy and complex. Also these compartments are difficult to fit after the vehicle has been made. For that reason they are usually made from fabric on a frame.

The inventor has realised that there is a need for an expandable vehicle body module which can be fitted to a vehicle after it has been made, and is simple, and light weight.

According to one aspect of the invention, there is provided an extendable module support mechanism usually stored within the body of a vehicle for outwardly extending the body of the vehicle, the mechanism comprising: a base securable within the body, to the floor or chassis of the vehicle including two spaced linear bearing members; a module floor member including two spaced and generally parallel linear bearing slideways each cooperable with a respective one of the two linear bearing members; and a powered actuator for moving the floor member in the direction of the slideways and relative to the base into and out of the a body.

Thus a simple module support mechanism can be conveniently fitted to the floor of a vehicle body and is arranged for powered movement into and out of the body.

In an embodiment, said actuator is arranged for fitting substantially no lower than the lowest level of the base.

In this way no apertures need be made in the vehicle floor for the actuator.

Preferably the actuator is positioned generally centrally of the two linear slideways.

In an embodiment, the two spaced linear bearing members each comprise a pair of spaced linear bearing blocks such that the linear slideways are both supported by two spaced bearing blocks mounted to or forming part of the base.

Conveniently said actuator comprises a threaded rod rotatable about an axis substantially parallel to the plane, by means of an electric motor. The actuator may have a complementary non-rotatable threaded block which moves relative to the rod when the rod is rotated. Movement of the threaded block relative to the rod causes said movement of the module into and out of the body in the plane.

The actuator may be provided with a manually operable drive for rotating the rod, for example, operable in the event of a failure of the electrical supply to the motor, or failure of the motor.

Preferably, an electrical supply to the module and or the motor is provided by a flexible electrical conductor, for example a caterpillar track.

According to a second aspect the invention comprises a vehicle body module for storage in a body of a vehicle and extendable outwardly, having a module support mechanism as described above.

In embodiments, the module may comprise a generally flat work surface, a compartment, storage means, living accommodation, or the like.

The module my include legs which are moveable into a ground engaging position at least when said module is in the extended position.

The module may include location features, for locating with complementary location features mounted to or forming part of the vehicle for restraining the module in the retracted or extended positions.

Said location features may include tapered lugs, and/or tapered apertures.

According to a third aspect, the invention comprises a method of adapting a vehicle for providing a module stored inside the body of a vehicle which module is extendable outwardly of the vehicle from a retracted position to an extended position, the method comprising the steps, in any suitable order, of: a) removing at least one door from the body of the vehicle; b) providing a body module for storing generally inside the body c) re-fitting the removed door(s) to the body module; d) fitting the module in a sliding manner in or on the vehicle such that the door(s) form a closure when the module is in the retracted position and forms one end of the module when the module is in the extended position.

The method may further comprise any one or more of the following steps: e) removing a seal member of the door from the vehicle; f) fitting a plate to the vehicle adjacent the door or door seal, having an forward facing surface and a rearwardly facing surface; g) fitting the door seal to the module such that the door seal when so fitted forms a seal for the door on the module.

Step d) of the method may further comprise the step of: h) providing an extendable body module support mechanism as defined above.

The invention extends to any novel feature described or illustrated herein, and any novel combination of features described or illustrated herein. The invention may be put into effect in numerous ways, one embodiment only being described below with reference to the drawings, wherein, Figure la shows a side view of a vehicle fitted with an extendable body module, the module being shown in the stored position; Figure lb shows a further side view of a vehicle fitted with an extendable body module, the module being shown in the extended position; Figure 2 shows a sliding module support mechanism for use in the arrangements shown in Figures la and lb; Figures 3 to 11 show further details of components used in the arrangements shown in Figures la,lb and 2.

Figures 12 to 15 shows variants of the components shown in the previous Figures.

Referring to Figure la, the rear of a vehicle 1 is shown, having an existing body 2. The body includes a hinged door 3, an internal volume 4 and a floor 5.

Where more space is required the vehicle can be fitted with an extendable body module 10 according to the invention. The body module 10 is shown in its retracted position. The body 2 has been modified to accept the module 10, although minimal modifications are required, and are explained below.

Figure lb shows the module 10 in its extended position having adjustable resilient supporting legs 11. In this position the door 3 can be seen to form one end of the module 10 and it can be seen that a formation 12 on the module 10 abuts an infill plate 14 adjacent the door to form a seal as will be described in more detail below.

In Figures la and lb the module 10 is mounted on an extendable module support mechanism 20. This mechanism 20 is shown in more detail in plan view in Figure 2. Referring additionally to Figure 2, there is shown in hatched lines, a floor 22 for the module 10, which has on its under side two spaced linear slideways 24. Each slideway is mounted for sliding movement in two spaced bearing blocks 26, sO that the two slideways can move substantially in parallel back and fore in the direction of arrow A. The bearing blocks are mounted on a base plate 30. The base plate 30 is bolted to the vehicle floor 5 using bolt holes 31 only one of which is referenced.

Thus, the module 10 when mounted to the supporting floor 20 can slide in and out of the volume 4 of the vehicle body 2, by means of the linear slideways 24.

In this embodiment the slideways are linear tracks.

The movement of the module floor 22 relative to the base 30 is controlled by an actuator 40. In this embodiment the actuator is a threaded rod 42 which is driven in rotation by a reversible 12 V electric motor 44 via a drive belt 46, and supported in rotation by support blocks 48. The rod 42 cooperates with a threaded block 50 mounted to the base 30 and when the rod is rotated, it moves with the floor 22 relative to the fixed base 30.

Movement of the floor 22 is limited by limit switches 52 mounted to the base 30 and adjustable stops 54 attached to the underside of the floor 22, to allow movement of the module between the retracted and extended positions shown respectively in Figure la and lb. As mentioned above the vehicle 1 needs to be adapted or modified for fitting the module 10. Initially, as shown in Figure 3 the door 3 needs to be removed, and a door seal 6 removed together with a metal support for the door seal 6, by cutting on cut line 7. The seal and its support are saved and attached to the rearwardly facing face of a flange 13 (Figure lb) in turn attached to the rear of module 10. The door is used to form an openable end of the module 10 by means of attaching the door 3 to the flange 13. The door can alternatively be non-moveably attached to flange 13.

An infill plate 14 is attached, for example by means of welding, to the area of the body 2 where the seal 6 has been removed. This plate is shown in Figure 4. The inner profile 15 of the plate matches the outer profile of the module 10 in this case. The rearwardly facing face of plate 14 has a new seal 6a attached thereto, for abutting and sealing to the forwardly facing face of flange 13 when the module is retracted.

Referring to Figure 5, when the module is extended as shown in Figure 1 b, a new seal 6b, mounted to the rearwardly facing face of flange 12, abuts the forwardly facing face of the plate 14.

Figure 6 shows an enlarged view of the flange 12, which is a strip of metal formed into an angle B which is generally about 90 degrees, having a rearwardly facing sealing face 13 for mounting the new seal 6a and mounting holes 17 for mounting to the module 10. Plastics material could be used for the flange 12 also.

The extendable module support 20 is fitted into the body 2 of the vehicle 1 and the module 10 is mounted to the support 20. In use when retracted (Figure la) the module 10 is sealed in the vehicle 1 by means of new seal 6a abutting the forward face of flange 13, and in the extended position, (Figure ib) the module is sealed by means of seal 6b abutting the forward face of plate 14.

Referring additionally to Figures 7 and 8, a hold-down 56 is fitted to the floor 5 of the vehicle. The hold-down 56 cooperates with a key 58 on the under side of the floor 20, to guide the module into place, to support the weight of the module when retracted, and to prevent the module from moving sideways when the module 10 is in its retracted position and the vehicle is underway. A securing pin or screw 64 may be fitted to stop the key 58 from jumping out of the hold-down 56.

Referring to Figure 9, and 9a which is an enlarged view of Figure 9, further movement restraint when the module 10 is retracted can be provided by one or more locating lugs 66 mounted to the door 3, which each cooperate with a tapered location aperture in plate 14.

Figure 10 shows a manual override mechanism for the motor 44. In the event of failure of the motor 44, or failure of the power supply, a socket 61 can be inserted in aperture 62 and fitted over a bolt head 60 attached to the end of the rod 42. The socket can be used to turn the rod 42 by hand if required, from outside or outside of the vehicle 1 depending on which end of the support 30 the bolt head 60 is located.

Figure 11 shows the underside 21 of the floor 22 of the module 10. In order to supply motor 44 as well as other electrical services need in the module 10, a caterpillar type electrical supply 70 is provided which doubles back on itself, as the floor 22 moves relative to the base 30 on the slideways mentioned above. Other services like a gas supply can be routed in this manner.

The embodiment described provides a relatively simple but aesthetically pleasing conversion of the vehicle, like a camper van, into an extendable vehicle for extra space. The use of linear slideways means that the overall thickness of the module support 20 (that is dimension X in Figure 1) is minimised and can be mm or less. The actuator 40 can be located in this space, so no additional apertures need be formed for the actuator 40 in the floor 5. Using the existing door, in this case the rear door, and re-using the door seals, saves time and costs, as well as providing an aesthetically pleasing finish. The vehicle chassis can be used without the need to weld additional plates etc. The use of a hold-down 56 and lugs 66 locates the module 10 in the correct position each time the module is retracted. Additionally the module is restrained securely when the vehicle is underway.

Figures 12, 13 and 14 show modifications to the embodiment described above.

In Figure 12 leg 11 is shown, which is motorised for raising and lowering about a pivot 70 in the directions of arrow R, and includes an electric motor 72 for driving a clutch 74 which can slip at an adjustable torque threshold. In practice the threshold is preset according to the load carried by the module 10 so that the legs do not jack the module, but rather stop extending downwardly when they touch the ground. The leg 11 further includes a threaded leadscrew 76 which moves a threaded follower 78 in the direction of arrows X depending on the rotational direction of the motor 72. The follower 78 moves linearly in a slot 75 in the floor 22. The follower 78 drives the leg stay 71 and leg member 73 about pivot 70 in the direction of arrows R so that a foot 77 mounted to the end of the leg member 73 moves up and down to provide support for the extended module 10.

Referring to Figures 13 and 14, a seal arrangement as an alternative to the seal arrangement shown in Figures 3,4, 5 and 6 is shown.

Figure 15 shows a modified module 10, showing a recess 90 which is formed in one or both sides of the inner end of the module 10 SO that a side door S can be used to allow access into the interior of the vehicle 1. A similar side door could be used on the opposite side of the vehicle if a recess is formed on both sides of the module 10.

In this variant, the door 3 of the donor vehicle is removed, along with the door seal 6 and its metal support. A plate 80 is welded in place of the seal 6 and its metal support. The plate 80 includes a wiping seal 82 which is in generally resilient contact at least at with the top and sides of the module 10 when the module is being extended or retracted. This resilient contact wipes away debris or rain water, particularly when the module 10 is retracted. In this variant the a new metal door seal support can be fabricated to fit on the distal end of the module and the existing door seal 6 can be fitted to the newly fabricated support.

The existing door is then hingedly fitted to the distal end of the module which includes the existing door seal shaped to seal the door on the module.

Various modifications, alternatives and variants which do not depart from the scope of the invention or are embraced thereby will be apparent to the skilled addressee. For example, a module has been described and illustrated as a compartment for example for living accommodation, but the module could be a generally flat work surface, a storage means, an advertising or display area or the like.

The motor 44, if a heavy module is used, may protrude above the floor 22, or may be fixed above the floor 22. The actuator is located centrally in the drawings and that position is preferred, but it may be offset, or multiple actuators may be employed.

Linear (bearing) slideways, linear bearing members and like terms have been described and illustrated, which term is intended to encompass any arrangement where an element, the linear bearing element, moves, slides or rolls, not necessarily including balls or rollers but encompassing plane bearing blocks, along a track, groove, or rail or like linear slideway.

One arrangement of seals has been described and illustrated but other arrangements could be used, for example the door seal 6 removed from the vehicle 1 could be fitted to another part of the module or vehicle.

The module is preferably fabricated from aluminium sheet material, although other materials could be employed. It will ne noted that support for the module is present only at the floor of the module, and this arrangement makes fitting of the module much simpler and quick. Also a better finished appearance is obtained. The use of a wiping seal, for example seal 82 across surfaces free from tracks provides an more aesthetically pleasing module and more efficient wiping off of water etc in use.

Claims (19)

1. Claims 1. An extendable module support mechanism usually stored within the body of a vehicle for outwardly extending the body of the vehicle, characterised in that the mechanism comprises: a base securable within the body, to the floor or chassis of the vehicle including two spaced linear bearing members; a module floor member including two spaced and generally parallel linear slideways each cooperable with a respective one of the two linear bearing members; and a powered actuator for moving the floor member in the direction of the slideways and relative to the base, into and out of the a body.
2. 2. A mechanism as claimed in 1, wherein said actuator is arranged for fitting substantially no lower than the lowest level of the base.
3. 3. A mechanism as claimed in 1 or 2, wherein said actuator is positioned generally centrally of the two slideways.
4. 4. A mechanism as claimed in any one of the preceding claims, wherein the two spaced linear members each comprise a pair of spaced linear bearing blocks such that the linear slideways are both supported by two spaced bearing blocks mounted to or forming part of the base.
5. 5. A mechanism as claimed in any one of the preceding claims, wherein said actuator comprises a threaded rod rotatable about an axis substantially parallel to the floor member, by means of an electric motor.
6. 6. A mechanism as claimed in claim 5, wherein the actuator has a complementary non-rotatable threaded block which moves relative to the rod when the rod is rotated.
7. 7. A mechanism as claimed in 6, wherein movement of the threaded block relative to the rod causes said movement of the module into and out of the body.
8. 8. A mechanism as claimed in any one of the preceding claims, wherein the actuator is provided with a manually operable drive for rotating the rod
9. 9. A mechanism as claimed in any one of the preceding claims, wherein, an electrical supply to the module and or the motor is provided by a flexible electrical conductor, optionally in the form of a caterpillar track.
10. 10. A vehicle body module for storage in a body of a vehicle and extendable outwardly to an extended position, having a module support mechanism as claimed in any one of the claims 1 to 9.
11. 11. A vehicle body module as claimed in claim 10, the module comprising either a generally flat work surface, a compartment, storage means, living accommodation, or the like.
12. 12. A vehicle body module as claimed in claim 10 or 11, wherein the module further includes legs which are moveable into a ground engaging position at least when said module is in the extended position.
13. 13. A vehicle body module as claimed in claim 12, wherein said legs raise and lower by means of electrical power.
14. 14. A vehicle body module as claimed in any one of claims 10 to 13, wherein, the module further includes location features, for locating with complementary location features mounted to or forming part of the vehicle for restraining the module in the retracted or extended positions.
15. 15. A vehicle body module as claimed in claim 14, wherein said location features include tapered lugs, and/or tapered apertures.
16. 16. A vehicle body module as claimed in claim 10, or as claimed in any one of claims 12 to 15, wherein, wherein said module includes a door removed from said vehicle and refitted to said module, for use with said module.
17. 17. A method of adapting a vehicle for providing a vehicle module stored inside the body of a vehicle which module is extendable outwardly of the vehicle from a retracted position to an extended position, the method comprising the steps, in any suitable order, of: a) removing at least one door from the body of the vehicle; b) providing a body module for storing generally inside the body c) re-fitting the removed door(s) to the body module; d) fitting the module in a sliding manner in or on the vehicle such that the door(s) form an openable closure when the module is in the retracted position and forms one end of the module when the module is in the extended position.
18. 18. A method according to claim 17, further comprising any one or more of the following steps: e) removing a seal member of the door from the vehicle; f) fitting a plate to the vehicle adjacent the door or removed door seal, having an forward facing surface and a rearwardly facing surface; g) refitting the door seal to the module such that the door seal when so fitted forms a seal for the door mounted on the module.
19. 19. A method according to claim 17, wherein step d) further comprises the step of: h) providing an extendable body module support mechanism as claimed in any one of the claims 1 to 9 or a module as claimed in any one of claims 10 to 16.