Method of fabricating a motorhome

• US 7,082,685 B2
• Filed: 05/28/2004
• Issued: 08/01/2006
• 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): Nguyen, George
• Assistant Examiner(s): Afzali, Sarang
• Application Number:
  US10/857,408
• Publication Number:
  US 20040261267A1
• Time in Patent Office: 795 Days
• Field of Search: 298/972, 294/69, 298/96, 294/011, 298/97, 296/204, 296/37.1, 296/37.6, 296/164, 296/165, 296/175, 296/176, 296/156, 296/26.13
• 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. The method of lowering the center of mass of a motorhome comprising the steps of:

assembling a planar ladder frame wherein the ladder frame defines a floor plane;

attaching planar structural members to the ladder frame so as to define an assembled three-dimensional space frame such that, in an assembled configuration the planar structural members extend downward from the ladder frame;

attaching the assembled three-dimensional space frame to a chassis of an unfinished vehicle along an attachment plane wherein the chassis includes at least two parallel rails and wherein the planar ladder frame is attached to the chassis such that the floor plane is adjacent the attachment plane and so as to create a three-dimensional space frame wherein the space frame extends below the floor plane.

2. 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 plane.

3. The method of claim 2, comprising installing the HVAC system such that a heating and an air-conditioning portion of the HVAC system share a common air return.

4. The method of claim 1, wherein the planar structural members form storage areas positioned below the attachment plane.

5. 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 unfinished vehicle.