U.S. patent application number 11/306149 was filed with the patent office on 2007-06-21 for modular day/sleeper cab and interface therefor.
This patent application is currently assigned to VOLVO TRUCKS NORTH AMERICA. Invention is credited to David S. Adams, Martin Luckhaus, John M. Martin, Linton D. Myers, Nikolaus G. Racz.
Application Number | 20070138834 11/306149 |
Document ID | / |
Family ID | 38157020 |
Filed Date | 2007-06-21 |
United States Patent
Application |
20070138834 |
Kind Code |
A1 |
Racz; Nikolaus G. ; et
al. |
June 21, 2007 |
MODULAR DAY/SLEEPER CAB AND INTERFACE THEREFOR
Abstract
Method and arrangement for providing a modular tractor assembly
including a driver compartment having a rearward connecting edge
configured to slidably receive a complementary forward connecting
edge of one of a day compartment module, a sleeper compartment
module, or an inter-modular fairing connector assembly. A portion
of the rearward connecting edge of the driver compartment has a
flange portion disposed at an acute angle relative to a long axis
of the tractor for complementarily receiving a forward connecting
edge of one of the day compartment module, the sleeper compartment
module and the inter-modular fairing connector assembly. The
interface between the driver compartment and the day compartment
module, a sleeper compartment module, or an inter-modular fairing
connector assembly is substantially hidden by the doors of the
vehicle to provide an aesthetically pleasing appearance.
Inventors: |
Racz; Nikolaus G.; (Colfax,
NC) ; Adams; David S.; (Macungie, PA) ;
Luckhaus; Martin; (Goteborg, SE) ; Martin; John
M.; (Madison, NC) ; Myers; Linton D.;
(Lenhartsville, PA) |
Correspondence
Address: |
NOVAK DRUCE & QUIGG, LLP
1300 EYE STREET NW
SUITE 1000 WEST TOWER
WASHINGTON
DC
20005
US
|
Assignee: |
VOLVO TRUCKS NORTH AMERICA
7825 National Service Road One Airpark West
Greensboro
NC
|
Family ID: |
38157020 |
Appl. No.: |
11/306149 |
Filed: |
December 16, 2005 |
Current U.S.
Class: |
296/190.02 |
Current CPC
Class: |
B62D 63/025 20130101;
B62D 33/0612 20130101 |
Class at
Publication: |
296/190.02 |
International
Class: |
B62D 33/06 20060101
B62D033/06 |
Claims
1. A modular tractor assembly comprising: a driver compartment
module having a width and a rearward connecting edge; a sleeper
compartment module having a width and a forward connecting edge; an
inter-modular fairing connector assembly joining the driver
compartment module and the sleeper compartment module, the
inter-modular fairing connector assembly including a forward
connecting section arranged to establish a first width
corresponding to the width of the driver compartment module and
configured for connection with the rearward connecting edge of the
driver compartment module, a rearward connecting section arranged
to establish a second width corresponding to the width of the
sleeper compartment module and configured for connection with the
forward connecting edge of the sleeper compartment module, said
inter-modular fairing connector assembly including an intermediate
portion between the forward connecting section and the rearward
connecting section, the intermediate portion having a flared
contour providing an aerodynamic surface from the rearward
connecting edge of the driver compartment module to the forward
connecting edge of the sleeper compartment module; and a flared
modular roof covering the driver compartment, the sleeper
compartment and the inter-modular fairing connector assembly.
2. The modular tractor assembly of claim 1 wherein the
inter-modular fairing connector assembly is configured as a
predominantly square ring.
3. The modular tractor assembly of claim 2 wherein a top portion of
the inter-modular fairing connector assembly is formed by an arched
interconnection between two lateral, backwardly flared side
portions.
4. The modular tractor assembly of claim 2 wherein a bottom portion
of the inter-modular fairing connector assembly is formed by a
substantially flat interconnection between two lateral, backwardly
flared side portions that constitutes a floor section of the
inter-modular fairing connector assembly.
5. The modular tractor assembly of claim 1 wherein the sleeper
compartment module has an external width greater than that of the
driver compartment module.
6. The modular tractor of claim 1 wherein the inter-modular fairing
connector assembly is flared such that the width of the forward
connecting section is less than that of the rearward connecting
section.
7. The modular tractor of claim 1 wherein a portion of the rearward
connecting edge of the driver compartment module comprises an
angled flange extending from a B-post of the driver compartment
module.
8. The modular tractor assembly of claim 7 wherein a portion of the
forward connecting section of the inter-modular fairing connector
assembly is angled to complementarily mate with the angled flange
extending from the B-post.
9. The modular tractor of claim 8 wherein the rearward connecting
edge abuttingly receives the forward connecting section which are
configured to accommodate relative sliding therebetween and thereby
permit an adjusted fit between the driver compartment module and
the sleeper compartment module.
10. The modular tractor of claim 8 wherein a seal is positioned
between the rearward connecting edge and the forward connecting
section.
11. The modular tractor of claim 8 wherein the rearward connecting
edge and forward connecting section are connected by at least one
releasable fastener.
12. The modular tractor of claim 8 wherein the rearward connecting
edge and forward connecting section are connected by welding.
13. The modular tractor of in claim 1 wherein at least a portion of
an exterior joint between the driver compartment module and the
inter-modular fairing connector assembly is covered by a closed
door of the driver compartment module.
14. The modular tractor of claim 1 wherein the rearward connecting
section of the inter-modular fairing connector assembly comprises
an angled flange.
15. The modular tractor assembly of claim 14 wherein a portion of
the forward connecting edge of the sleeper compartment module is
angled to complementarily mate with the angled flange extending
from the inter-module fairing.
16. The modular tractor of claim 15 wherein the rearward connecting
section of the inter-modular fairing connector assembly and a
forward connecting edge of the sleeper compartment module are
connected by a releasable fastener.
17. The modular tractor of claim 15 wherein the rearward connecting
section of the inter-modular fairing connector assembly and a
forward connecting edge of the sleeper compartment module are
connected by welding.
18. A modular tractor assembly comprising: a driver compartment
module having a rearward connecting edge configured to slidably
receive a complementary forward connecting edge of a rear mounted
module taking the form of one of (1) a day compartment module, (2)
a sleeper compartment module, and (3) an inter-modular fairing
connector assembly.
19. The modular tractor of claim 18 wherein a portion of the
rearward connecting edge of the driver compartment module comprises
a flange portion disposed at an acute angle relative to a long axis
of the tractor.
20. The modular tractor assembly of claim 19 wherein a portion of
the forward connecting edge of the rear mounted module has an
angled portion configured for complementary, face-to-face slidably
mating engagement with the flange portion of the rearward
connecting edge of the driver compartment module.
21. The modular tractor of claim 20 wherein the flange portion of
the rearward connecting edge of the driver compartment module
extends from a B-post of the driver compartment module.
22. The modular tractor assembly of claim 21 wherein the rearward
and forward connecting edges are connected by releasable
fasteners.
23. The modular tractor assembly of claim 21 wherein the rearward
and forward connecting edges are connected by welding.
24. The modular tractor assembly of claim 21 wherein a seal is
disposed between the rearward and forward connecting edges.
25. The modular tractor of claim 24 wherein at least a portion of
an exterior joint between the driver compartment module and the
inter-modular fairing connector assembly is covered by a closed
door of the driver compartment module.
26. The modular tractor of claim 25 wherein when the door is
closed, a seal between the rearward edge, forward edge and the door
is formed.
27. A method for securing one of a plurality of sleeper compartment
modules, each having a different width, to a driver compartment
module of a semi-truck having a predetermined width, the method
comprising: selecting one of the plurality of sleeper compartment
modules to be connected to the driver compartment module;
determining the width of the selected sleeper compartment module;
providing a plurality of inter-modular fairing connector
assemblies, each of the inter-modular fairing connector assemblies
having a forward connecting edge and a rearward connecting edge,
each of the forward and the rearward connecting edges having a
width; selecting one of the plurality of inter-modular fairing
connector assemblies such that the width of the forward connecting
edge corresponds with the width of the driver compartment module
and the rearward edge corresponds with the width of the sleeper
compartment module; and, securing the forward edge of the
inter-modular fairing connector assembly to the driver compartment
module and the rearward edge of the inter-modular fairing connector
assembly to the sleeper compartment module.
28. The method of claim 27 wherein the width of the sleeper
compartment module is greater than that of the driver compartment
module and the external surface of the inter-modular fairing is
flared to provide a smooth aerodynamic transition between the
driver compartment module and the sleeper compartment module.
29. The method of claim 28 wherein the inter-modular fairing
connects to a portion of a B-post of the driver compartment
module.
30. The method of claim 29 wherein the B-post includes an acutely
angled flange portion relative to a long axis of the tractor for
receiving a complementarily disposed angle portion of the forward
edge of the inter-modular fairing.
31. The method of claim 30 wherein the rearward edge of the
inter-modular fairing includes an acutely angled flange portion,
relative to a long axis of the tractor, for receiving a
complementarily disposed angle portion of the forward edge of the
sleeper compartment module.
32. The method of claim 31 wherein the inter-modular fairing is
secured to the driver compartment module and the sleeper
compartment module with releasable fasteners.
33. The method of claim 31 wherein the inter-modular fairing is
secured to the driver compartment module and the sleeper
compartment module by welding.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to semi-trucks, and more
specifically to apparatus and methods that enable the installation
of different-width sleeper cabs on a given truck and which
facilitate the conversion of a semi-truck from a sleeper
configuration to a day configuration.
BACKGROUND OF THE INVENTION
[0002] There are generally two types of semi-truck used for
transporting cargo: long haul trucks and short haul trucks. Long
haul trucks are typically equipped with sleeper compartments that
allow drivers to sleep or rest when transporting cargo over long
distances. Because of this, such long haul trucks are commonly
referred to as having sleeper cabs. Short haul trucks on the other
hand are typically only utilized for transporting cargo over short
distances and which can be completed in a single day. Short haul
trucks, thus, are commonly referred to as having day cabs.
[0003] In order to permit occupants to move between the driver and
sleeper compartments, the driver compartment is provided with a
back-side opening and the sleeper compartment is provided with a
corresponding front-side opening that when aligned and joined
together form a an occupant-passage between the two
compartments.
[0004] Generally, after an initial period of road use, long haul
truck owners and operators find it economically prudent to remove
their long haul trucks from service and utilize them as short haul
trucks and/or to sell their long haul trucks, typically for short
haul use. A problem with this, however, is that the former long
haul trucks include sleeper cabs, which are not needed for short
haul use. Additionally, the sleeper cabs tend to detrimentally
affect the resale value of the trucks. Thus, it is desirable to
convert a sleeper cab into a day cab.
[0005] Several factors can affect the ease by which a sleeper cab
can be converted into a day cab. However, perhaps the factor most
affecting the ease of conversion is whether the sleeper cab was
originally constructed to be integral with the driver compartment
of the truck, or whether it was prefabricated and subsequently
mated with the driver compartment during assembly, i.e., a modular
sleeper cab. Generally, as described and illustrated in U.S. Pat.
No. 6,883,860, the conversion of a truck from an integral sleeper
cab into a day cab requires the removal of interior components such
as seats, carpeting, insulation, and can require that structural
beams and body panels be cut. Consequently, it is generally
desirable to construct long haul trucks utilizing removable modular
sleeper cabs because the sleeper cabs can be readily removed when
the semi-truck is removed from long haul service.
[0006] A problem with constructing long haul trucks utilizing
modular sleeper cabs, however, is that the driver compartments and
sleeper cabs come in many different lengths, widths and heights,
which can make it difficult to mate various driver compartments
with different sleeper cabs. For example, the back-side opening of
one type of driver compartment may differ from the front-side
opening of a mated day or sleeper cab in such a way that the two
connected compartments are not fully "open" to one another, which
detrimentally restricts the established occupant passage
therebetween.
[0007] Another issue that arises even when the openings are
configured to mate-up with one another is that due to manufacturing
tolerances and the like there will usually not be exact matings of
the openings. Therefore, the need has been recognized to utilize
take-up devices, of sorts, that allow for the compensation of these
inexactnesses and the establishment of suitable alignment, or
accommodation of acceptable misalignment between mated
compartments.
[0008] In another respect, when a back compartment (sleeper or day
cab) has an exterior width greater than that of the driver
compartment (see FIG. 1C where the expansion to the sleeper cab is
abrupt with a flat, forward-facing surface), the transition has not
traditionally been particularly aerodynamic, with the result being
a negative impact on fuel economy for the truck.
[0009] Another problem with using today's modular sleeping cabs is
that the interface between a driver compartment and the sleeper cab
may not be as "solid" as in trucks in which the sleeper cab is
integral with the driver compartment module. Consequently, a truck
having a modular cab can experience increased vibration and road
noise when compared with that of a truck having an integral sleeper
cab. Also, the interface between a modular sleeper cab and a driver
compartment may not be as aesthetically pleasing when compared with
a truck having an integral sleeper cab. Furthermore, many modular
sleeper cabs are specifically designed to mate with certain driver
compartments, thus limiting their reuse or installation on other
trucks.
[0010] In view of the above and related deficiencies, there is
presently a need to provide an interface or adapter that can be
used for enabling access between variously configured modular
sleeper cabs and mated driver compartments, and which more
effectively and stably interconnects the sleeper cab and driver
compartment. Still further, it is preferred that these interfaces
be aerodynamic and provide an appearance that the modular sleeper
cab is integrally formed with the driver compartment of the
truck.
SUMMARY OF THE INVENTION
[0011] In an effort to address the above-identified problems, in
one embodiment the present invention takes the form of a modular
tractor assembly including a driver compartment module having a
rearward connecting edge configured to receive a complementary
forward connecting edge of either (1) a day compartment module, (2)
a sleeper compartment module, or (3) an inter-modular fairing
connector assembly (also referred to as a flared adaptor) that
facilitates the installation of a wider-width sleeper compartment
module. In some embodiments, a portion of a rearward connecting
edge around the backside opening in the driver compartment module
takes the form of a flange disposed at, for example, an acute angle
relative to a long axis of the tractor for complementarily
receiving a forward connecting edge of a compartment (sleeper or
day compartment, for instance) to be mounted therebehind, or an
inter-compartment, flared connector as will hereinafter be
described in greater detail.
[0012] In some preferred embodiments, the flange portion extends
from a B-post of the driver compartment module. The rearward and
forward connecting edges of the driver compartment module and the
inter-modular fairing connector assembly, respectively, are
connected by releasable fasteners and/or a weld. In some
embodiments, a seal is disposed between the rearward and forward
connecting edges of the driver compartment module and the
inter-modular fairing connector assembly and a portion of the
exterior interface of the rearward edge and the forward edge is
hidden by a door of the driver compartment module. In a
particularly preferred embodiment, when the door is closed, a seal
between the rearward edge, the forward edge and the door is
formed.
[0013] In some versions, the invention comprises an inter-modular
fairing connector assembly and a sleeper module. The inter-modular
fairing connector assembly connects the driver compartment module
to the sleeper compartment module. In some embodiments, the sleeper
compartment module has an external width greater than that of the
driver compartment module and the inter-modular fairing connector
has a forward connecting edge connected to the driver compartment
module and a rearward connecting edge connected to the sleeper
compartment module.
[0014] In some versions, the rearward connecting edge of the
inter-modular fairing connector has an acute angled flange relative
to a long axis of the tractor for complementarily mating with the
forward connecting edge of the sleeper compartment module. In some
embodiments, the inter-modular fairing connector assembly has a
flared exterior surface for reducing drag between the driver
compartment module and the sleeper compartment module. Still
further, in some embodiments a roof module covers the driver
compartment module, the inter-modular fairing connector assembly
and the sleeper compartment module. Further still, in some
embodiments the invention comprises a day compartment module and a
roof module wherein the roof module covers the driver compartment
module and the day compartment module.
[0015] The invention also takes the form of a method for securing
one of a plurality of sleeper compartment modules, each having a
different width, to a driver compartment module of a semi-truck
having a predetermined width. The method comprises selecting one of
the plurality of sleeper compartment modules to be connected to the
driver compartment module. The width of the selected sleeper
compartment module is determined and an appropriate inter-modular
fairing connector assembly is chosen. Each connector has a forward
connecting edge and a rearward connecting edge, each with a
particular width.
[0016] An appropriate connector is chosen from the plurality of
inter-modular fairing connector assemblies such that the width of
the forward connecting edge corresponds with the width of the
driver compartment module and the rearward edge corresponds with
the width of the sleeper compartment module. The forward edge of
the fairing connector assembly is secured to the driver compartment
module and the rearward edge of the fairing connector assembly is
secured to the sleeper compartment module.
[0017] In some embodiments of the inventive method, the width of
the sleeper compartment module is greater than that of the driver
compartment module and the external surface of the inter-modular
fairing is flared to provide a smooth aerodynamic transition
between the driver compartment module and the sleeper compartment
module. In some embodiments of the method, the inter-modular
fairing connects to a portion of a B-post of the driver compartment
module. In some embodiments of the method, the B-post includes an
acutely angled flange portion (relative to a long axis of the
tractor) for receiving a complementarily disposed angled portion of
the forward edge of the inter-modular fairing. In some versions of
the inventive method, the rearward edge of the inter-modular
fairing includes an acutely angled flange portion (relative to a
long axis of the tractor) for receiving a complementarily disposed
angled portion of the forward edge of the sleeper compartment
module. In some embodiments of the method, the inter-modular
fairing is secured to the driver compartment module and the sleeper
compartment module with releasable fasteners and/or a weld.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The present invention will now be more fully described, by
way of example, with reference to the accompanying drawings in
which:
[0019] FIG. 1A is a perspective view of a currently available
semi-truck in a day cab configuration;
[0020] FIG. 1B is a perspective view of a currently available
semi-truck with an integral sleeper compartment configuration;
[0021] FIG. 1C is a perspective view of a currently available
semi-truck with a separate sleeper compartment module, which has a
width greater than the driver compartment;
[0022] FIG. 2A is a perspective view of a day cab configuration of
a semi-truck configured according to the present invention;
[0023] FIG. 2B is a perspective view of a semi-truck configured
according to the present invention and comprising a sleeper
compartment module having a width equal to that of the driver
compartment module;
[0024] FIG. 2C is a perspective view of a semi-truck configured
according to the present invention comprising a sleeper compartment
module having a width greater than that of the driver compartment
module with an inter-modular fairing connector assembly located
therebetween;
[0025] FIG. 3A is an exploded cross-sectional view of an exemplary
interface between a driver compartment and day cab, with the door
of the driver compartment slightly open away from a sealing gasket
carried on the forward-most edge of the day cab;
[0026] FIG. 3B is a partially assembled, cross-sectional view
showing matable flanges of the driver compartment and day cab of
FIG. 3A in abutting, slidable, face-to-face engagement with one
another, but not yet completely aligned with each other;
[0027] FIG. 3C is a fully assembled, cross-sectional view showing
the flanges of the driver compartment and day cab of FIGS. 3A and
3B in adjusted and fixed engagement with one another;
[0028] FIG. 3D is a fully assembled, cross-sectional view showing
inclined, engagement flanges of a driver compartment and a sleeper
cab in adjusted and fixed engagement with one another;
[0029] FIG. 3E is a fully assembled, cross-sectional view showing
inclined, engagement flanges of a driver compartment and a sleeper
cab in adjusted and fixed engagement with respect to one another,
via a flared inter-modular connector;
[0030] FIG. 4A is a partial perspective view of a semi-truck
configured according to the present invention comprising a day cab
configuration with a driver compartment door that is in a closed
position to illustrate the fact that the exterior joint of the
interface between the driver compartment and the back-cab
compartment module is hidden behind the closed door;
[0031] FIG. 4B is a partial perspective view of the semi-truck of
FIG. 4A with the driver compartment door open revealing the
exterior joint between the driver compartment and the wide sleeper
cab module which is preferably obscured from view when the driver
compartment door is closed as in FIG. 4A;
[0032] FIGS. 5A-5C are exploded perspective views illustrating the
conversion of each of a semi-truck with a similar-width sleeper cab
(FIG. 5A) and a semi-truck with a wider-width sleeper cab utilizing
an inter-modular fairing connector assembly (FIG. 5B) to a day cab
configuration (FIG. 5C);
[0033] FIG. 6 is a perspective view of the inter-modular fairing
connector assembly of FIG. 5B;
[0034] FIG. 7 is a perspective view of an alternative embodiment of
an inter-modular fairing connector assembly comprising a pair of
side panel pieces; and
[0035] FIGS. 8A-8B are exploded perspective views illustrating
conversion from a day cab configuration (FIG. 8A) to a semi-truck
with a wider-width sleeper cab (FIG. 8B).
DETAILED DESCRIPTION
[0036] The present invention will now be described and disclosed in
greater detail. It is to be understood, however, that the disclosed
embodiments are merely exemplary of the invention and that the
invention may be embodied in various and alternative forms. It
should also be understood that the accompanying figures are not
necessarily to scale and some features may be exaggerated, or
minimized, to show details of particular components. Therefore,
specific structural and functional details disclosed herein are not
to be interpreted as limiting the scope of the claims, but are
merely provided as an example to teach one having ordinary skill in
the art to make and use the invention. It should also be
appreciated that in the following detailed description, like
reference numerals on different drawing views are intended to
identify like structural elements. The phrase "sleeper cab" may be
used to refer to both an actual sleeper compartment of a
semi-truck, as well as a semi-truck having a sleeper compartment
connected thereto. The terms tractor, truck, semi-truck and the
like are intended to refer to the tractor portion of a
tractor-trailer type truck.
[0037] Referring now to the drawings, FIGS. 1A-1C illustrate
semi-trucks in day cab 10, integral sleeper cab 12 and modular
sleeper cab 14 configurations, respectively. Each of the cab
configurations (10, 12, 14) comprises a hood 16, a driver
compartment 18, and a trailer-receiving area 20. The sleeper cab 12
configuration of FIG. 1B includes an integral sleeper compartment
22 and the modular sleeper cab 14 configuration of FIG. 1C has a
separable modular sleeper compartment 24. As previously discussed,
day cab 10 configurations (FIG. 1A) are generally utilized for
performing local deliveries that are completed in a day.
Consequently, day cab configurations 10 do not have a sleeper
compartment.
[0038] Integral and modular sleeper cabs are each employed upon
semi-trucks used for transporting cargo over long distances. The
integral sleeper cab 12 of FIG. 1B is rigidly connected with the
driver compartment 18 by common frame components. Consequently, it
is difficult to convert integral-type sleeper cabs 12 into day
cabs. As shown in FIG. 1C, while the separable modular sleeper cab
14 may be more easily modified into a day cab configuration, access
between the driver compartment 18 and the sleeper compartment 24
can be restricted. Additionally, because the separable modular
sleeper compartment 24 often has an exterior width and height that
is greater than that of the driver compartment 18, the exterior
interface between the driver compartment and the modular sleeper
cabin is not as aerodynamic as an integral sleeper cab.
Additionally, the interconnection between the driver compartment 18
and the separable modular sleeper compartment 24 is not as solid
because the sleeper compartment is not formed from the same
structural framework as the driver compartment. Thus, the separable
modular sleeper cab 14 has a tendency to experience increased
vibration and road noise when compared with that of the integral
sleeper cab configuration 12.
[0039] Concepts and characterizing features of the present
invention are exemplified in FIGS. 2-5. Referring to FIGS. 2A-2C, a
semi-truck 30 according to the present invention is shown in a day
cab configuration 32, a sleeper cab configuration 34, and a wide
sleeper cab configuration 36, respectively. Each of the several
semi-truck 30 variations of FIGS. 2A-2C includes a hood 38, a
driver compartment 40, and a trailer-receiving area 42.
[0040] In the day cab configuration 32 of FIG. 2A (also see FIG. 4A
for greater detail), the semi-truck 30 includes a day cab module 44
and a day cab roof module 46. The day cab module 44 is generally
provided for forming the rear wall of the driver compartment 40. In
the embodiment illustrated, the day cab module 44 broadly comprises
a pair of side walls 45 and a rear wall 47. The side walls 45 of
the day cab module 44 secure to side walls 48 of the driver
compartment such that the rear wall 47 of the day cab module 44 is
generally disposed behind the driver and passenger seats of the
truck. Basically, the day cab module 44 acts as a cap over the
large opening in the backside of the driver compartment 40 that
otherwise enables occupant access to a rear-mounted sleeper cab
when installed.
[0041] The side walls 48 of the driver compartment 40 and the side
walls 45 of the day cab module comprise complementarily angled
surfaces configured to engage one another in a face-to-face
orientation. The use of such complementary angled surfaces is an
important feature of several of the presently disclosed inventive
arrangements. In its most frequent implementation, the concept is
to provide terminal end surfaces of two abutting wall sections of
interconnected compartment walls with complementarily angled
surfaces as exemplified in FIG. 3A where details of one such
wall-to-wall interconnection is exemplified in cross-section. As
will be appreciated from additional descriptions that are also
later included, the same concept can be used for providing an
adjustable interface connection between compartment wall-ends and
an inter-modular flared fairing connector (FIG. 3E) or between
peripheral edges of a roof module and top wall edges of the driver
and sleeper compartments which the roof covers.
[0042] Returning to FIG. 3A, an exploded view is shown of a portion
of a driver compartment wall 48 that backwardly terminates in a
bent flange 78. A forwardly directed wall-end surface of an
abbreviated day cab module 44 is positioned to be moved into
engagement with the bent flange 78 of the driver compartment wall
48. Because the two wall-end portions can nest, or conformance-fit
with one another when mated together, the relationship is described
herein as complementary.
[0043] Among other reasons, the large size of the two compartments
(driver's cab 18, and for example, a rear-mount sleeper cab 22)
that are being joined, and variations in their manufacture, often
result in something less than perfect alignment between the
end-wall surfaces when the compartments are brought together for
interconnection as shown in FIG. 3B. For this reason, one of the
angled wall ends (the driver compartment wall 48 in the
illustration) is exemplarily provided with through slots 82 that
act as means for allowing adjustable positioning of one wall with
respect to the other before being fixed together using fasteners
(exemplified as threaded bolts 87 in the illustration).
[0044] In a first situation, the imperfect alignment is merely
accommodated and the two wall ends are fastened together, albeit
slightly offset from a perfectly mated fit, and as is depicted in
FIG. 3B. The inclined or angled surfaces of the two wall ends,
however, also accommodate relative sliding of the two engaged
surfaces, one upon the other. The most likely situation in the
illustrated example is that the position of the sleeper cab 44 is
adjusted relative to the driver's cab 40 until a "best fit" is
achieved between the two cabin modules and the fasteners (bolts 87,
for example) are tightened down. Another possibility is that the
wall 45 of the sleeper cab 44 is slightly flexible. In that case
the wall 45 can be biased from the misaligned orientation of FIG.
3B into the properly mated orientation of FIG. 3C, in accordance
with the double-headed arrow of FIG. 3B, and then fastened down.
Again, such fixation is exemplified in FIG. 3C where the bolts 87
have been screwed down tight, and the walls 45, 48 are fixed
together.
[0045] Returning to the preferred embodiment of FIGS. 2A and 4A, a
day cab roof module 46 generally extends from a location proximate
the top of the windshield 56 to the rear wall 47 of the day cab
module 44. The top exterior surface of the day cab roof module 46
preferably has a smooth, generally elevated and arced aerodynamic
surface for reducing vehicle drag. A periphery of the day cab roof
module 46 is provided at an edge thereof with a downwardly directed
inclined surface (similar to that described above with respect to
the inclined or angled end-wall treatments of FIGS. 3A-3C) for
mating engagement with complementary inclined surface(s) positioned
at top edges of walls of the driver's cab. The day cab roof module
46 can then be secured upon the driver compartment 40 and day cab
module 44, forming a sort of cap thereover.
[0046] In the sleeper cab configuration 34 of FIG. 2B, the
semi-truck 30 is seen as further comprising a sleeper cab module 58
and a sleeper cab roof module 60. In the embodiment illustrated,
the sleeper cab module 58 broadly comprises a pair of side walls 62
and a rear wall 64 having a width that generally corresponds with
the width of the driver compartment 40. The side walls 62 of the
sleeper cab module 58 are secured to the side walls 48 of the
driver compartment as shown in detail in FIG. 3D. There, the
exposed surficial joint between the side walls 48, 62 is
substantially hidden behind the closed driver door 52 thereby
lending an aesthetically pleasing appearance to the side of the
truck cab.
[0047] As depicted in FIGS. 2B and 5A, the sleeper cab roof module
60 generally extends from a location proximate the top of the
windshield 56 to the rear wall 64 of the sleeper cab module 58. The
top exterior surface of the sleeper cab roof module 60 preferably
has a smooth, generally elevated and arced aerodynamic surface for
reducing vehicle drag. The sleeper cab roof module 60 fits on top
of the compartment walls 48, 62, and 64 in a cap-like manner and
can be fastened thereto utilizing the previously described inclined
or angled-surface method.
[0048] In the wide-width sleeper cab configuration 36 of FIGS. 2C
and 4B, the semi-truck 30 is seen as comprising an inter-modular
fairing connector assembly 66, a wide sleeper cab module 68 and a
flared sleeper cab roof module 74. In the embodiment illustrated,
the wide sleeper cab module 68 broadly comprises a pair of side
walls 70 and a rear wall 72, which has a width that is greater than
the width of the driver compartment 40. The end-edges of side walls
48 of the driver compartment are configured with inclined or angled
surfaces as described in greater detail hereinabove to mate with a
forward connecting edge of inter-modular fairing connector assembly
66 (FIG. 3E). Rearward angled edges of the inter-modular fairing
connector assembly 66 are configured to abut forward angled
connecting edges of the wide sleeper cab module 68. Lateral
portions or members 66a of the inter-modular connecting member 66,
thus, are flared from front to back such that their forward
connecting edges complementarily mate with the driver compartment
and rearward connecting edges complementarily mate with the wider
sleeping compartment 68.
[0049] The lateral exterior side surfaces of the inter-modular
fairing connector assembly 66 preferably have a front-to-back (with
respect to a long axis of the semi-truck 30), smooth and generally
outwardly flared and arced aerodynamic surface. As described above,
the exteriorly exposed joints 50 of the inter-modular fairing
connector assembly 66 and the side walls 48 of the driver
compartment 40 are respectively hidden behind the driver and
passenger doors for aesthetic reasons, including giving the
appearance that the wide sleeper cab module 68 is integrally
constructed with the driver compartment. The rearward connecting
edges of the inter-modular fairing connector assemblies 66 and the
side walls 70 of the wide sleeper cab module also comprise
complementarily angled surfaces according to the teachings
above.
[0050] The flared sleeper cab roof module 74 generally extends from
the top of the windshield 56 to the rear wall 72 of the wide
sleeper cab module 74 to cover both the driver compartment and the
sleeping compartment. The top exterior surface of the flared
sleeper cab roof module 74 preferably has a smooth, generally
elevated and arced aerodynamic surface for reducing vehicle drag.
Peripheral under-edges of the roof module 74 and top wall edges of
the driver and sleeper compartments which the roof 74 covers are
provided with complementarily angled mating surfaces as described
hereinabove. Generally, in the wide sleeper cab configuration, the
rearward opening of the driver compartment is open to the
inter-module connectors 66 and the rearward opening of the
inter-module connectors 66 is open to the forward opening of the
wide sleeper cab module. Consequently, access between the driver
compartment, the inter-module connectors and the wide sleeper cab
module is relatively unobstructed and unrestricted.
[0051] As previously discussed, FIGS. 3A-3E depict interface
arrangements, also referred to as interfaces 50, between a driver
compartment and alternatively a day cab module 44 (FIGS. 3A-3C), a
sleeper cab module 58 (FIGS. 3D), and an inter-modular fairing
connector assembly 66 (FIG. 3E). The interface 50 is generally
provided for accomplishing a transition of a semi-truck between
sleeper cab and day cab configurations. The interface is also
provided for allowing a number of differently sized modules (day
cab, sleeper cab) to be attached to the driver compartment and
aligned and adjusted to provide a factory appearance. Interface 50
is also provided, and disposed, such that the connected modules
appear to be integrally formed with the driver compartment.
[0052] The interface arrangement 50 broadly comprises driver
compartment rear connecting edge 76 exemplarily comprising an
acutely angled flange 78 (relative to a long axis of the tractor)
extending from B-post 80. B-post 80 may also be referred to as a
door post and generally comprises a frame member of the side walls
48. Angled flange 78 can include one or more of the elongate slots
82 provided for insertibly receiving fasteners such as threaded
bolts 87. The angled flange 78 defines a space 89 (FIG. 3B) which
provides access for assembly tools and the like so that the modules
can be easily attached and removed. An angled portion 84 of a
forward connecting edge 86 of whichever one of the cab modules 44,
58 or the inter-modular fairing connector assembly 66 is provided
for complementarily mating with the angled flange 78.
[0053] A seal 88 is disposed between the angled flange 78 and the
angled portion 84 as a moisture and particulate barrier. A door
seal 90 forms a seal between the rearward connecting edge of the
driver compartment and the forward connecting edge of either the
cab module 44, 58 or the inter-modular fairing connector assembly
66 when the driver compartment doors 52 are closed.
[0054] The detailed illustration of FIG. 3E demonstrates that the
rearward connecting edge 92 of the inter-modular fairing connector
assembly comprises an acutely angled flange 94 (relative to a long
axis of the tractor) extending therefrom for receiving an angled
portion 96 of a forward connecting edge 98 of a sleeper cab module.
The angled flange 94 also allows modules being attached to the
inter-modular fairing connector assembly 66 to slide along its face
such that the modules may be readily aligned and adjusted. The
angled flange 94 forms a working space similar to the space 89
established by flange 78 for installation tools during assembly.
The angled flange 94 can also comprise one or more elongate slots
for receiving fasteners such as threaded bolts.
[0055] Referring now to FIGS. 5A-5C, the process according to the
present invention by which a semi-truck may be advantageously
converted from a sleeper cab configuration to a day cab
configuration is illustrated. As demonstrated by FIG. 5A, removal
of a sleeper cab module 58 may be accomplished by disengaging the
fastener assemblies securing the sleeper cab roof module 60 to the
driver compartment 40 and sleeper cab module 58. Thereafter, the
sleeper cab roof module 60 is removed. Once the sleeper cab roof
module 60 has been removed, the sleeper cab module 58 is then also
taken away. Then, and as illustrated in FIG. 5C, a day cab module
44 can be moved into place and mated with the side walls of the
driver compartment module 40 and a day cab roof module 46 secured
thereon. Alternatively, and as illustrated in FIG. 5B (see FIG. 4B
for an assembled, non-exploded configuration), removal of a wide
sleeper cab module 68 may be accomplished by removing the fastener
assemblies securing the flared sleeper cab roof module 74 to the
driver compartment 40, inter-module connectors 66 and wide sleeper
cab module 68. Thereafter, the flared sleeper cab roof module 74 is
removed. Once the flared sleeper cab roof module 74 has been
removed, the inter-module connectors 66 and wide sleeper cab module
68 may then be taken away in a similar manner as described
immediately above. Then, and again as illustrated in FIG. 5C, day
cab module 44 can be moved into place and mated with the side walls
48 of the driver compartment module 40 and a day cab roof module 46
secured thereon. A reverse conversion from a day cab configuration
to a sleeper cab configuration is depicted in FIGS. 8A to 8B which
constitutes yet another alternative embodiment of the presently
disclosed invention(s).
[0056] FIGS. 6 and 7 show alternative configurations for
interconnecting flared, fairing assemblies or adaptors 66. In FIG.
6, the flared fairing 66 is generally formed as a predominantly
squared ring. The two lateral sides 66a are flared from front to
back, while the interconnecting top bridge 66b is generally
arch-shaped and configured to fit underneath the flared roof module
74 (FIG. 5B). The lower section 66c of the adaptor 66 is
substantially flat and provides a floor spanning from the driver
compartment to the sleeper compartment when the adaptor 66 is
connected therebetween.
[0057] In an alternative configuration, the adaptor 66 is
constituted by a pair of independent lateral flared fairings 66a as
depicted in FIG. 7. Top ends of these fairings 66a can be
interconnected by an installed roof module and a floor section must
be separately provided. In an alternative embodiment, a pair of
lateral flared fairings 66a are joined together by an
interconnecting bridge portion 66b, which is preferably
arch-shaped, and thereby forms a basically inverted U-shaped
adaptor 66.
[0058] As will readily be appreciated by those persons skilled in
these arts, one embodiment of the present invention entails the
provision (or at least an availability made) of an array of
differently configured inter-modular fairing connector assemblies
66 (or sets of connectors) that can be utilized for securing
differently sized sleeper cab modules to different semi-trucks.
From the available array of connectors, an appropriately configured
connector 66 (or set of connectors 66a) can be chosen for
interconnecting a particular wider-width sleeper cab 68 to a
particular driver compartment 18.
[0059] From this description it should become clear that the
present invention provides methods and arrangements for readily
converting a semi-truck having a sleeper compartment module into a
semi-truck having a day compartment module, and though less
frequent, from a day cab configuration to a sleeper cab
configuration. It should be appreciated by those having ordinary
skill in these arts that while the present invention has been
illustrated and described in what is deemed to be the preferred
embodiments, various changes and modifications may be made to the
invention without departing from the spirit and scope of the
invention. Therefore, it should be understood that the present
invention is not limited to the particular embodiments disclosed
herein.
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