Method of fabricating a motorhome

• US 6,807,735 B2
• Filed: 09/26/2001
• Issued: 10/26/2004
• Est. Priority Date: 12/01/2000
• Status: Expired due to Fees

• Current Assignee: Alfa Leisure Inc
• Original Assignee: Alfa Leisure Inc
• Inventors: Crean, Johnnie
• Primary Examiner(s): Cuda-Rosenbaum, I
• Assistant Examiner(s): JIMENEZ, MARC QUEMUEL
• Application Number:
  US09/965,463
• Publication Number:
  US 20020066184A1
• Time in Patent Office: 1,126 Days
• Field of Search: 298/972, 294/69, 294/62, 296/204, 296/183, 296/182, 296/37.6, 296/37.1, 296/164, 296/165, 296/175, 296/176, 296/26.13, 296/156
• US Class Current: 29/897.2
• CPC Class Codes: B60P 3/34 the living accommodation being expansible, collapsible or capable of rearrangement B60P3/38 takes precedence; tents supported at least partially by vehicles E04H15/06
• CPC Class Codes: B60P 3/36 Auxiliary arrangements; Arrangements of living accommodation toilet or washing arrangements B60R15/00; Details
• CPC Class Codes: B62D 21/02 comprising longitudinally or transversely arranged frame members
• CPC Class Codes: B62D 31/02 for carrying large numbers of passengers, e.g. omnibus
• CPC Class Codes: B62D 33/046 built up with flat self-supporting panels; Fixed connections between panels B62D29/045, B62D33/048 take precedence
• CPC Class Codes: B62D 65/00 Designing, manufacturing, e.g. assembling, facilitating disassembly, or structurally modifying motor vehicles or trailers, not otherwise provided for
• CPC Class Codes: Y10T 29/49616 Structural member making
• CPC Class Codes: Y10T 29/49622 Vehicular structural member making
• CPC Class Codes: Y10T 29/49826 Assembling or joining
• CPC Class Codes: Y10T 29/49904 Assembling a subassembly, then assembling with a second subassembly

Abstract

A method of fabricating a motorhome, wherein the motorhome comprises a chassis, a vehicle frame, and a coach body. In one embodiment, the method begins by prefabricating the frame by joining a plurality of parallel elongate members with cross-tie members. The frame is prefabricated separate from the chassis, and in one embodiment, the frame is prefabricated upside down such that the underside of the frame is accessible for attachment of a plurality of bulkheads. Then, the frame is rotated upright and positioned atop the chassis. In one embodiment, the rails of the chassis lie inside a channel defined by the plurality of bulkheads. Next, additional bulkheads are joined to the frame and chassis to further interconnect the frame and chassis. Preferably, the additional bulkheads comprise an opening such that the additional bulkheads can surround the chassis on all sides. Finally, the coach body is assembled on the frame.

Claims

1. A method of manufacturing a motorhome comprising the steps of:

assembling a three-dimensional space frame wherein the space frame defines a generally planar floor area having a first surface and a second surface with a plurality of reinforcing generally planar bulkheads extending upward from the first surface wherein the reinforcing generally planar bulkheads are spaced along the first surface and define a longitudinally extending recess;

interconnecting the space frame with a vehicle chassis having two parallel longitudinal extending rails by inverting the assembled three dimensional space frame and lowering the three dimensional space frame such that the two parallel extending rails are positioned within the recess; and

attaching living structure to the interconnected space frame and vehicle chassis so as to define an interior living area.

2. The method of claim 1, wherein assembling the three-dimensional space frame comprises:

assembling a planar ladder frame; and

attaching planar bulkheads to the ladder frame.

3. The method of claim 2, wherein interconnecting the space frame with the vehicle chassis comprises attaching the ladder frame to the vehicle chassis along first horizontal regions of the vehicle chassis and attaching the bulkheads along second vertical regions of the vehicle chassis.

4. The method of claim 1, further comprising installing a heating, ventilation, and air conditioning (HVAC) system such that the majority of the weight of the HVAC system is positioned below the floor area.

5. The method of claim 4, further comprising installing the HVAC system such that the heating and air-conditioning portions of the HVAC system share a common air return.

6. The method of claim 4, wherein the HVAC system is installed such that a furnace and an air-conditioning portions of the HVAC system are positioned outside the living area.

7. The method of claim 1, wherein the living structure is assembled such that an outside roof structure has a convex exterior contour.

8. The method of claim 1, further comprising attaching an extensible slide-out structure to the interconnected space frame and vehicle chassis wherein the slide-out is constructed such that an adult of above-average height can stand upright inside the slide-out.

9. The method of claim 1, wherein the space frame is assembled in an upside-down orientation and inverted to a right-side-up orientation prior to attachment to the chassis.