EXPANDABLE HOUSING STRUCTURE WITH ACCORDION WALLS

Abstract

An accordion wall structure includes three primary components, namely two linkage systems and four wall panels. The linkage systems are adeptly positioned both at the upper and lower extremities of each wall panel. The composition of the linkage system is meticulously engineered, featuring gear sets and linkage bars that work in concert to ensure seamless functionality. A hydraulic component can be used for the propulsion of the first link and the subsequent rotation of the initial wall panel. During the rotation of the wall panels, the interconnected gearsets of the linkage systems are consistently aligned generally parallel to the main mount due to their linkage connection. The direct coupling between the gears and the panel ensures synchronous rotation between them. The gearsets of the linkage systems ensure a synchronized rotation of the gears. This coordinated rotation further translates into the simultaneous rotation of the adjacent wall panel.

Claims

1. An expandable structure comprising: a main structure; a first expansion section, the first expansion section expandable outward in a first direction from the main structure; side walls of the first expansion section formed from a plurality of wall panels storable in a stacked, accordion arrangement in a retracted configuration; and a linkage system interconnecting the plurality of wall panels, the linkage system including a set of gear systems, each gear system of the set of gear systems adjoining each abutting side faces of the plurality of wall panels.

2. The expandable structure of claim 1, further comprising a second expansion section expandable outward in a second direction, different from the first direction, from the main structure, the second expansion section including a second set of side walls formed from a plurality of second wall panels storable in a stacked, accordion arrangement in a retracted configuration.

3. The expandable structure of claim 2, further comprising a second linkage system interconnecting the plurality of second wall panels, the second linkage system including a second set of gear systems, each gear system of the second set of gear systems adjoining each abutting side faces of the plurality of second wall panels.

4. The expandable structure of claim 1, wherein each gear system of the set of gear systems includes a first gear having first teeth that engage with second teeth of a second gear.

5. The expandable structure of claim 4, wherein the first gear is attached to a first one of the wall panels and the second gear is attached to a second one of the wall panels, the first one being adjacent the second one.

6. The expandable structure of claim 4, wherein the first gear and the second gear of each of the gear systems of the set of gear systems are aligned along a plurality of axial axes, each of the plurality of axial axes are parallel during movement between the retracted configuration and a fully opened configuration.

7. The expandable structure of claim 6, wherein each of the plurality of axial axes align into a single linear axis when the side wall is in the fully opened configuration.

8. The expandable structure of claim 1, further comprising linkages extending between adjacent ones of the set of gear systems.

9. The expandable structure of claim 8, wherein the linkages extend outside of the wall panels when the side walls are in a fully opened state.

10. The expandable structure of claim 8, wherein the linkages at least partially fit into recesses formed in the plurality of wall panels when the side walls are in the retracted configuration.

11. The expandable structure of claim 1, further comprising a push arm, the push arm operable to move an innermost one of the wall panels from the retracted configuration to the fully opened configuration.

12. The expandable structure of claim 11, wherein movement of the innermost one of the wall panels from the retracted configuration to the fully opened configuration causes, via the linkage system, remaining ones of the plurality of wall panels to uniformly open.

13. The expandable structure of claim 1, further comprising an insulation material disposed on one end of each of the plurality of wall panels, the insulation material filling a gap between adjacent ones of the plurality of wall panels with the side wall is in a fully opened configuration.

14. The expandable structure of claim 1, further comprising a cover operable to cover a push arm disposed in a storage region of the expandable structure, the storage region receiving the plurality of wall panels in the retracted configuration, the cover operable to cover the push arm when the plurality of wall panels are in a fully opened configuration to form the side walls of the first expansion section.

15. An expandable structure comprising: a main structure; a first expansion section, the first expansion section expandable outward in a first direction from the main structure; side walls of the first expansion section formed from a plurality of wall panels storable in a stacked, accordion arrangement in a retracted configuration; and a linkage system interconnecting the plurality of wall panels, the linkage system including a set of gear systems, each gear system of the set of gear systems adjoining each abutting side faces of the plurality of wall panels, wherein each gear system of the set of gear systems includes a first gear having first teeth that engage with second teeth of a second gear; the first gear is attached to a first one of the wall panels and the second gear is attached to a second one of the wall panels, the first one being adjacent the second one; and the first gear and the second gear of each of the gear systems of the set of gear systems are aligned along a plurality of axial axes, each of the plurality of axial axes are parallel during movement between the retracted configuration and a fully opened configuration.

16. The expandable structure of claim 15, further comprising linkages extending between adjacent ones of the set of gear systems, wherein the linkages extend outside of the wall panels when the side walls are in a fully opened state and the linkages at least partially fit into recesses formed in the plurality of wall panels when the side walls are in the retracted configuration.

17. The expandable structure of claim 15, further comprising a push arm, the push arm operable to move an innermost one of the wall panels from the retracted configuration to the fully opened configuration, wherein movement of the innermost one of the wall panels from the retracted configuration to the fully opened configuration causes, via the linkage system, remaining ones of the plurality of wall panels to uniformly open.

18. The expandable structure of claim 15, further comprising an insulation material disposed on one end of each of the plurality of wall panels, the insulation material filling a gap between adjacent ones of the plurality of wall panels with the side wall is in a fully opened configuration.

19. The expandable structure of claim 15, further comprising a cover operable to cover a push arm disposed in a storage region of the expandable structure, the storage region receiving the plurality of wall panels in the retracted configuration, the cover operable to cover the push arm when the plurality of wall panels are in a fully opened configuration to form the side walls of the first expansion section.

20. An expandable structure comprising: a main structure; a first expansion section, the first expansion section expandable outward in a first direction from the main structure; side walls of the first expansion section formed from a plurality of wall panels storable in a stacked, accordion arrangement in a retracted configuration; a push arm, the push arm operable to move an innermost one of the wall panels from the retracted configuration to the fully opened configuration; and a linkage system interconnecting the plurality of wall panels, the linkage system including a set of gear systems, each gear system of the set of gear systems adjoining each abutting side faces of the plurality of wall panels, wherein: the linkage system include linkages extend between adjacent ones of the set of gear systems; the linkages extend outside of the wall panels when the side walls are in a fully opened state and the linkages at least partially fit into recesses formed in the plurality of wall panels when the side walls are in the retracted configuration; each gear system of the set of gear systems includes a first gear having first teeth that engage with second teeth of a second gear; the first gear is attached to a first one of the wall panels and the second gear is attached to a second one of the wall panels, the first one being adjacent the second one; and movement of the innermost one of the wall panels from the retracted configuration to the fully opened configuration causes, via the linkage system, remaining ones of the plurality of wall panels to uniformly open.

21. The expandable structure of claim 20, further comprising an insulation material disposed on one end of each of the plurality of wall panels, the insulation material filling a gap between adjacent ones of the plurality of wall panels with the side wall is in a fully opened configuration.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Some embodiments of the present invention are illustrated as an example and are not limited by the figures of the accompanying drawings, in which like references may indicate similar elements.

[0012] FIG. 1 illustrates a perspective view of an expandable structure in its retracted state;

[0013] FIG. 2 illustrates a perspective view of an expandable structure in its expanded state;

[0014] FIG. 3 illustrates top-down cross-sectional view of the expandable structure of FIG. 1;

[0015] FIG. 4 illustrates detailed view of an accordion wall in its folded state;

[0016] FIG. 5A illustrates a partially exploded view of an accordion wall according to an exemplary embodiment of the present invention;

[0017] FIG. 5B illustrates an assembled view of the accordion wall of FIG. 5A;

[0018] FIG. 6 illustrates an exploded view of a linkage system for the accordion wall of FIG. 5A;

[0019] FIG. 7 illustrates an assembled view of the linkage system of FIG. 6;

[0020] FIG. 8 illustrates opening of the accordion wall of FIG. 5A, from its folded state to its opened state;

[0021] FIG. 9A illustrates a cross-sectional view of the accordion wall of FIG. 5A in the folded state;

[0022] FIG. 9B illustrates a cross-sectional view of the accordion wall of FIG. 9A, in a partially opened state, showing the wall panels being pushed out of a storage region with an arm;

[0023] FIG. 9C illustrates a cross-sectional view of the accordion wall of FIG. 9A, in a further opened state, showing the innermost wall panel beginning its rotation;

[0024] FIG. 9D illustrates a cross-sectional view of the accordion wall of FIG. 9A, in a further opened state, showing the innermost wall panel nearing its fully opened state;

[0025] FIG. 9E illustrates a cross-sectional view of the accordion wall of FIG. 9A, in its fully opened state;

[0026] FIG. 10 illustrates a cross-sectional view of the accordion wall of FIG. 9A, showing a selected pair of wall panels;

[0027] FIG. 11A illustrates a detailed view of the selected pair of wall panels of FIG. 10;

[0028] FIG. 11B illustrates a detailed view taken about the circle drawn in FIG. 11A;

[0029] FIG. 12A illustrates a detailed view of the selected pair of wall panels of FIG. 11A, in a partially opened state;

[0030] FIG. 12B illustrates a detailed view taken about the circle drawn in FIG. 12A;

[0031] FIG. 13A illustrates a detailed view of the selected pair of wall panels of FIG. 11A, in a fully opened state;

[0032] FIG. 13B illustrates a detailed view taken about the circle drawn in FIG. 13A;

[0033] FIG. 14A illustrates a perspective view of a hydraulic system cover;

[0034] FIG. 14B illustrates a cross-sectional view of the accordion wall in a fully opened state, with the hydraulic system uncovered; and

[0035] FIG. 14C illustrates a cross-sectional view of the accordion wall in a fully opened state, with the hydraulic system covered with the cover of FIG. 14A.

[0036] The illustrations in the figures may not necessarily be drawn to scale.

[0037] The invention and its various embodiments can now be better understood by turning to the following detailed description wherein illustrated embodiments are described. It is to be expressly understood that the illustrated embodiments are set forth as examples and not by way of limitations on the invention as ultimately defined in the claims.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS AND BEST MODE OF INVENTION

[0038] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the term and/or includes any and all combinations of one or more of the associated listed items. As used herein, the singular forms a, an, and the are intended to include the plural forms as well as the singular forms, unless the context clearly indicates otherwise. It will be further understood that the terms comprises and/or comprising, when used in this specification, specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof.

[0039] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one having ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0040] In describing the invention, it will be understood that a number of techniques and steps are disclosed. Each of these has individual benefit and each can also be used in conjunction with one or more, or in some cases all, of the other disclosed techniques. Accordingly, for the sake of clarity, this description will refrain from repeating every possible combination of the individual steps in an unnecessary fashion. Nevertheless, the specification and claims should be read with the understanding that such combinations are entirely within the scope of the invention and the claims.

[0041] In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be evident, however, to one skilled in the art that the present invention may be practiced without these specific details.

[0042] The present disclosure is to be considered as an exemplification of the invention and is not intended to limit the invention to the specific embodiments illustrated by the figures or description below.

[0043] As is well known to those skilled in the art, many careful considerations and compromises typically must be made when designing for the optimal configuration of a commercial implementation of any system, and in particular, the embodiments of the present invention. A commercial implementation in accordance with the spirit and teachings of the present invention may be configured according to the needs of the particular application, whereby any aspect(s), feature(s), function(s), result(s), component(s), approach(es), or step(s) of the teachings related to any described embodiment of the present invention may be suitably omitted, included, adapted, mixed and matched, or improved and/or optimized by those skilled in the art, using their average skills and known techniques, to achieve the desired implementation that addresses the needs of the particular application.

[0044] Broadly, embodiments of the present invention provide an accordion wall structure that includes three primary components, namely two linkage systems and four wall panels. The linkage systems are adeptly positioned both at the upper and lower extremities of each wall panel. The composition of the linkage system is meticulously engineered, featuring gear sets and linkage bars that work in concert to ensure seamless functionality. The primary driving force behind the wall module is a hydraulic component that is responsible for the propulsion of the first link and the subsequent rotation of the initial wall panel. Notably, during the rotation of the wall panels, the interconnected gearsets are consistently aligned generally parallel to the main mount due to their linkage connection. The direct coupling between the gears and the panel ensures synchronous rotation between them.

[0045] As discussed in greater detail below, in reference to the figures, as the wall panel executes its rotational movement, the gearsets maintain their substantially parallel orientation, resulting in a synchronized rotation of the gears. This coordinated rotation further translates into the simultaneous rotation of the adjacent wall panel.

[0046] When the wall panels are in their fully extended position, they form a seamless, flat surface, effectively creating a complete wall. However, due to the nature of individual panels aligning together, there can be a minute gap between them. These gaps, though small, have the potential to allow water or wind to infiltrate the cabin.

[0047] To address this issue, a distinctive solution is proposed involving specialized insulation along the edges of the wall panels. This insulation material can be affixed to the curved edge of each wall panel. As one wall panel pivots, the adjoining edge of the neighboring panel applies pressure to the insulation material. This compression action effectively seals the wall, preventing the ingress of water or wind, and ensuring optimal environmental control within the cabin.

[0048] The expansion of the slide-out area is facilitated by a pair of accordion wall modules. In this configuration, the wall panels are extended and seamlessly incorporated into a unified whole on either side of the structure.

[0049] An integral component of this mechanism is the hydraulic cylinder, serving as the link between the primary cabin structure and the accordion wall module. The wall module itself establishes a connection between the main cabin structure and the side wall. The hydraulic system is tasked with two primary functions: firstly, it propels the initial link of the wall module to achieve full extension, and secondly, it orchestrates the outward movement of the entire system from within the cabin.

[0050] Referring to FIGS. 1 through 3, an expandable structure 10 can include at least one expansion section, such as a first expansion section 13 (also referred to as a side expansion section) and a second expansion section 15 (also referred to as a rear expansion section) that extends out from a main structure 11. The side expansion section 13 can include a side outer wall 12 and, similarly, the rear expansion section 15 can include a rear outer wall 14. The outer walls 12, 14 may move outward, away from the main structure 11, when the expansion sections 13, 15 are moved from their retracted state to their expanded state.

[0051] An accordion wall 16 can form the side walls of the expansion sections 13, 15, when the expansion sections 13, 15 are in their expanded state, as shown in FIG. 2. The accordion wall 16 may be in its folded state when the expansion sections 13, 15 are fully retracted, as shown in FIG. 3. As shown in FIG. 4, a storage region 18 can house the wall panels 22 of the accordion wall 16 when the wall is in its folded state. A floor section 20 may be attached to the side outer wall 12, as shown in FIG. 4, and may expand outward from the floor of the main structure 11 during expansion of the side outer wall 12. A roof structure (not shown) may expand similarly from the roof of the main structure 11 during expansion of the expansion section 13.

[0052] Referring to FIGS. 5A and 5B, a linkage system 24 may interconnect the wall panels 22 of the accordion wall 16. An inner wall panel 22A of the wall panels 22 can be adjacent the main structure 11 when the accordion wall is fully opened, as shown in FIGS. 5A and 5B. An outer wall panel 22B of the wall panels 22 can be adjacent the side outer wall 12. Of course, a similar arrangement can be provided for the expansion section 15.

[0053] Referring to FIGS. 6 and 7, the linkage system 24 can include a plurality of gear systems 26A, 26B, 26C. Each of the gear systems 26A, 26B, 26C can include first and second gears 36A, 36B that mesh with each other. Each gear 36A, 36B has a pivot axis 27 that aligns with and shares a pivot shaft with a pivot axis 29 formed on the top and bottom of each wall panel 22. Each gear system, such as gear system 26A, can have its first gear 36A attached/fixed to one of the wall panels 22 and its second gear 36B attached/fixed to an adjacent one of the wall panels 22. One linkage system 24 may be attached near a top end of the wall panels 22 and another linkage system 24 may be attached near a bottom end of the wall panels.

[0054] Linkages 28A, 28B, 28C may interconnect adjacent ones of the gear systems. For example, linkage 28A can connect gear system 26A to gear system 26B, linkage 28B can connect gear system 26B to gear system 26C, and linkage 28C can connect gear system 28C to an end linkage 30 and a push arm 50 (see FIG. 9B, for example).

[0055] The outer wall panel 22B can attach to gear system 26A, which can include fixed arm 38 and pivot hole 40. The pivot hole 40 can align with the pivot hole 32 on the linkage 28A. Similarly, gear system 26B can include fixed arms 42 and pivot holes 44, where the pivot hold 44 can align with the pivot hole 32 on linkages 28A and 28B. An opening 34 can be formed in the linkages 28A, 28B to help in providing an accordion wall 16 that can be folded flat (with the wall panels 22 substantially parallel with each other), where the gears 36A, 36B can fit into the openings 34.

[0056] As shown in FIG. 7, the gears 36A, 36B of the gear systems 26A, 26B, 26C can align along a linear axis 46. Axis 46 also defines the axis of the wall panels 22 when the accordion wall 16 is fully opened.

[0057] As shown in FIG. 8, during unfolding, a first axis 46A can be defined as passing through gear systems 26A, 26C. This first axis 46A remains a linear axis during unfolding. Similarly, a second axis 46B can be defined as passing through gear system 26B, as well as through the proximal end of the inner wall panel 22A and the distal end of the outer wall panel 22B. This second axis also remains a linear axis during unfolding of the accordion wall 16. Once fully unfolded, the first and second axes 46A, 46B align along the axis 46 (see FIG. 7). When fully folded, a recess 66 formed in the wall panels 22 can contain at least a portion of the linkages 28A, 28B, 28C, thus permitting a flat folding (with the wall panels 22 generally parallel with each other) of the accordion wall system.

[0058] As can be seen from the transition between FIGS. 9A and 9B, a push arm 50 can move the accordion wall 16 out from the storage region 18. Once out of the storage region 18, as shown in FIG. 9B, the push arm 50 can push on the inner wall panel 22A to rotate the inner wall panel on axis 30A (which is part of the end connector 30). During opening of the accordion wall 16, as shown in the transitions between FIGS. 9B and 9E, rotation of the inner wall panel 22A, caused by the push arm 50, can cause the same rotations in the other wall panels 22 via the gear systems 26A, 26B, 26C. In some embodiments, the push arm 50 can be a hydraulic push arm. In other embodiments, the push arm 50 may be a motor drive arm.

[0059] Referring now to FIGS. 10 through 13B, detailed views of a portion 60 of the accordion wall 16 is illustrated. The portion 60 can include wall panels 22 (two adjacent wall panels), along with gear system 26B. A specialized insulation 62 can be disposed along the edges of one of the wall panel 22. The insulation 62 can be affixed to the curved edge of one side of each wall panel 22. As one wall panel pivots, the adjoining edge of the neighboring panel applies pressure to the insulation 62. This compression action effectively seals the accordion wall once fully opened, preventing the ingress of water or wind, and ensuring optimal environmental control within the structure.

[0060] Referring now to FIGS. 14A through 14C, a panel 70 serves as a cover for the accordion wall's opening. When the accordion wall achieves full extension, the storage region 18 for both the wall panels 22 and the hydraulic cylinder 50 (also referred to as push arm 50) becomes visible. To optimize the available cabin space, the panel 70 can seal off the hydraulic cylinder 50 to prevent damage thereof, while still permitting the user to access the storage region 18. A user can manually apply and remove the panel 70 after extending the accordion wall and before retracting the accordion wall.

[0061] All the features disclosed in this specification, including any accompanying abstract and drawings, may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

[0062] Claim elements and steps herein may have been numbered and/or lettered solely as an aid in readability and understanding. Any such numbering and lettering in itself is not intended to and should not be taken to indicate the ordering of elements and/or steps in the claims.

[0063] Many alterations and modifications may be made by those having ordinary skill in the art without departing from the spirit and scope of the invention. Therefore, it must be understood that the illustrated embodiments have been set forth only for the purposes of examples and that they should not be taken as limiting the invention as defined by the following claims. For example, notwithstanding the fact that the elements of a claim are set forth below in a certain combination, it must be expressly understood that the invention includes other combinations of fewer, more or different ones of the disclosed elements.

[0064] The words used in this specification to describe the invention and its various embodiments are to be understood not only in the sense of their commonly defined meanings, but to include by special definition in this specification the generic structure, material or acts of which they represent a single species.

[0065] The definitions of the words or elements of the following claims are, therefore, defined in this specification to not only include the combination of elements which are literally set forth. In this sense it is therefore contemplated that an equivalent substitution of two or more elements may be made for any one of the elements in the claims below or that a single element may be substituted for two or more elements in a claim. Although elements may be described above as acting in certain combinations and even initially claimed as such, it is to be expressly understood that one or more elements from a claimed combination can in some cases be excised from the combination and that the claimed combination may be directed to a subcombination or variation of a subcombination.

[0066] Insubstantial changes from the claimed subject matter as viewed by a person with ordinary skill in the art, now known or later devised, are expressly contemplated as being equivalently within the scope of the claims. Therefore, obvious substitutions now or later known to one with ordinary skill in the art are defined to be within the scope of the defined elements.

[0067] The claims are thus to be understood to include what is specifically illustrated and described above, what is conceptually equivalent, what can be obviously substituted and also what incorporates the essential idea of the invention.