FORM 2
THE PATENTS ACT-1970
(39 of 1970)
and
The Patent Rules, 2006
COMPLETE SPECIFICATION
(See Section 10 and Rule 13)
1. TITLE OF THE INVENTION
AN IMPROVED AND MODULAR REST-KIT ASSEMBLY THAT MAXIMIZES CABIN INTERNAL SPACE
2. APPLICANT

a) Name VE Commercial Vehicles Ltd
b) Nationality Indian
c) address
VE Commercial Vehicles Ltd
102, Industrial Area No. 1
Pithampur-454775
Dist. Dhar (Madhya Pradesh), India
PREAMBLE TO THE DESCRIPTION
The following specification particularly describes the invention and the manner in vhich it is to be performed.

FIELD OF INVENTION
The present invention relates to an improved and modular rest-kit sleeper assembly that optimizes cabin internal space and is designed to be installed in cabins of day-trucks especially for the driver or the assistant driver of the truck. More particularly, the invention relates to a modular rest-kit sleeper assembly which is made with light-weight and high-strength materials and is economical to manufacture.The invention further relates to an apparatus and method for installing a modular rest kit sleeper assembly in cabins of day-trucks.
BACKGROUND AND PRIOR ART
The cabin or cab of a truck is an enclosed space in a truck where the driver is seated. Over-the-road, or long-haul, trucks are often equipped with sleeper cabs. A sleeper (or sleeper-berth or bunk) is a compartment attached to the cab where the driver or his companion (assistant driver) can rest while not driving. Sleeper cabs allow truck drivers who are on the road for several days at a time to take breaks at appropriate times. Long-haul truck vehicles are configured with sleeper units which provide sleeping accommodation for truck operators during long hauls.
There are two categories of the currently available sleeper units - Integral assemblies and Modular assemblies. Integral sleeping assemblies provide a cab and a sleeper in a single structure, thereby providing unrestricted access between the cab and sleeper. However, since the cab and the sleeper are provided in a single structure, it is impossible to remove or replace the sleeper. One such integral assembly has been described in the patent document US5083834.
The problem with integral sleeper assemblies is that the sleeper assembly is a permanent fixture in the cabin and cannot be removed or detached. The present invention overcomes this problem as there is no change in. the BIW (body in white - stage of design when the sheet metal components are welded together) and in the trim (glass, steel, upholstery, electronics etc.). It is available as a spare part and can be fixed into any day-cab.
Another prior art document US3353861 describes a bunk-type sleeping assembly for trucks. This type of arrangement suffers from the disadvantage that the bunk is very narrow and also, the limited space available within the cabin impairs comfort of the driver and his assistant. Due to shortage of space, the driver and the assistant driver cannot carry

luggage or supplies with them. Thus, the need for a sleeping assembly that can offer both a comfortable resting space and also storage space for supplies was felt.
Modular sleeping assemblies, on the other hand, consist of separate cab and sleeper structures that are individually mounted on a truck chassis or a common sub-frame. Contrary to integral sleeper assemblies, they offer the advantage of being able to be interchanged to suit various needs for different sizes and styles of the sleepers in the market.
The prior art document US5560673 illustrates a modular sleeper assembly which can be affixed into the cabin of the truck by using adhesive sealants and bolts. The drawback of such an assembly is that to remove it. the adhesive needs to be cut and the sleeper needs to be unbolted from the cabin. Because of the cumbersome nature of this fixing and removing process, the need to develop light and easy-to-detach modular resting assembly was felt.
Another prior art document US5310239 discloses a similar modular resting assembly. The invention describes a sleeper structural assembly that includes a sleeper frame network and a sleeper exterior skin portion, and the cab structural assembly includes a cab frame network and a cab exterior skin portion. The sleeper and cab structural assemblies are connected together via upper and lower brackets which are mounted on the front and back walls of the sleeper and cab structural assemblies, respectively. This results in restricted access between the sleeper and cab units. Thus, it was required to develop a modular rest-kit that allows unrestricted access between cab and sleeper unit.
US4005898 describes a foldable structure that can be removably mounted on the cab wall of the truck and can be unfolded to be used as seat/sleeper/table. This document described the sleeper assembly for only for pick-up vans and long-haul trucks. There was a need to include a sturdy but light-weight modular sleeping assembly in day-cabin trucks.
The cabin of a long-haul truck is usually equipped with at least one bunk in which the driver or an assistant driver can rest or sleep during a journey so that stops on a journey can be kept at a minimum and the driver or the assistant driver need not leave the vehicle in order to sleep overnight. But, day cabs are shorter than normal cabs (long-haul trucks) and are meant to run on shorter distances. The cabin of day cabs is small in size and does not have space to accommodate a sleeper inside. Day-trucks are put on routes that are closer to home base. Day-trucks thus generally have only 'day-cabs\ without a sleeper.

However, sometimes it happens that travelling time increases for day trucks due to change in route i.e. different than the actual route, malfunctioning in the machinery. natural calamity at the road, or any other unforeseen circumstances leading to breakdowns. In such situations, the driver usually looks for nearby lodges to stay. Such accommodation arrangements prove to be expensive for drivers especially in India. Also. truck driver spends most of his time in the cabin and treats it like his second home due to long journey durations while travelling from one place to another. Keeping this in mind, the need of different living feature such as storage space, sleeping space etc. in a truck cab for different use of the driver is increasing day by day. To accommodate the features is easy when a sufficient space is available like sleeper cabin but on the other side, it is challenging to provide the same feature in a day cab due to space limitations. Providing a new feature in the day cab is a challenging task as it requires the study of cabin internal free space which can accommodate new feature with minimal changes and investment in the existing cabin and without affecting functionality.
An important living feature which is missing in day cab is the sleeping or resting space which can allow the driver to take rest in the cabin itself during night or day time instead of finding the place for rest somewhere outside.Therefore it is desired to provide modular rest kit sleeper assembly in a day cabin by effectively utilizing the available space without changing the dimensions of the day cabin.
Modular assembly in the invention has been preferred over integral assembly as the latter arrangement provides a cab and sleeper in a single structure, thereby making it impossible to remove or replace the sleeper. However, separate cab and sleeper assemblies are highly desirable since these configurations are capable of being constructed independent of one another, thus fostering configuration flexibility. These units are capable of different cab and sleeper configurations to suit customer needs and specifications.
Modular assemblies consist of separate cab and sleeper structures that are individually mounted to a truck chassis or a common sub frame. Access to the sleeper is provided by pulling the top portion of the seat while holding the lever down. The seat back will lower the level with the floor-board when driver wants to take rest. The modular assembly has the advantage of allowing the sleeper to easily be removed or replaced.

One problem faced with the usage of sleeper assemblies is that they cover partially or entirely the rear sliding window which hinders rear visibility for the driver. The present invention solves this problem by providing a modular apparatus that can be kept folded when not in use, and thus will not hinder rear visibility.
The prior art described above lacks modularity in left-hand drive (LHD) and right-hand drive (RHD). There is also the disadvantage of limited stretching and discomfort in currently available modular sleeper assemblies. Both these problems are overcome in the present invention as it provides modularity in LHD and RHD and ensures comfort for the
driver.
The present invention provides a modular rest kit sleeper assembly which is made up of light-weight but high strength materials and is durable, compact, easy to maintain, has a minimum number of components and is easy to use by unskilled personnel. The invention ensures best utilization of space in the small cabin of day-trucks, and ensures ease of mounting and removing the rest-kit assembly. The cost of manufacturing the said apparatus is also relatively low.
OBJECTIVES OF THE INVENTION
It is an object of the present invention to provide an improved and modular rest-kit sleeper assembly that that maximizes the utilization of cabin internal space.
It is another object of the present invention to provide a modular sleeper structure assembly for day cabin trucks which is made up of light-weight, economical and high-strength materials.
Yet another object of the present invention is to provide a modular rest-kit assembly which also provides storage space for emergency travelling supplies.
Yet another object of the present invention is to provide a coupling assembly which may be retro-fit to most modular cab and sleeper units without requiring substantial modification to the basic form of separate units.
It is a further object of the invention to provide sleeper structure assembly in day cabin trucks which is durable, compact, easy to maintain, has a minimum number of components, is easy to use by unskilled personnel, and is economical to manufacture.

Still another object of the invention is to provide an apparatus and method for installing a modular rest kit sleeper assembly in day-cabin trucks.
SUMMARY OF THE INVENTION
In the presently preferred and illustrative embodiment of the invention, the modular rest kit sleeper assembly includes sleeper frame network, sleeper exterior skin portion comprising plywood and cushion assembly, sleeper storage and locking system.
Sleeper exterior skin portion is made of foam covered with a cover and is constructed in two equal parts hinged together in a way both portions arefoldable upon each other. Frame is also made in two parts such that half of the frame is fixed and is installed at the cabin length in the back side of the cabinand half of the frame is kept inside the fixed frame. Half of the portion that is kept inside the frame is again divided in two parts hinged together. When this half portion is pulled out from fixed frame, hinged portion is unfolded first to make wider-width frame. All three portions then make complete frame to hold sleeper beside cabin seats. Locking system comprises of locking pin to lock the pulled out portion of frame so that both portions of the frame lay together as one for structural integrity. Locking system provides increased structural strength and rigidity at discrete coupling points between portions of frame without structural compromise therebetween.
The modular rest-kit assembly for day trucks is floor mounted and affixed using bolts.
STATEMENT OF THE INVENTION
Accordingly the present invention provides a modular sleeping assembly for cabin of day trucks, the said assembly comprising of sleeper framework, sleeper exterior skin portion comprising sleeper plywood assembly and cushion assembly, sleeper storage and locking system. There is also provided a method for assembling and using the said invention.
BRIEF DESCRIPTION OF THE INVENTION
The modular rest-kit assembly for the cabin of day trucks comprises of sleeper framework, sleeper exterior skin portion, sleeper storage and locking system. The said assembly is designed for maximum optimization of the cabin internal space, as it can be

folded and removably mounted on the floor of the cabin. Thus, there is no need to change the B1W (body-in-white) and trim of the truck. The resting assembly is comfortable for the driver, and ensures unobstructed view of the rear window.The assembly is floor mounted and affixed using bolts.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 shows a schematic three-dimensional view of the modular rest-kit assembly for cabin of day trucks according to the first embodiment, in folded position
Fig. 2 shows a schematic representation of the sleeper framework, which provides structural support for the rest-kit assembly
Fig. 3 shows a three-dimensional view of the sleeper framework, clearly showing all its parts
Fig. 4 shows a side-view of the steps involved in unfolding of the sleeper berth
Fig, 5 shows a schematic representation of the sleeper plywood assembly
Fig. 6 shows a schematic representation of the cushion assembly comprising of folded
and fixed cushion
Fig. 7 shows a side-view of locking system of the modular rest-kit assembly
Fig. 8 shows a schematic representation of the slider frame assembly
Fig. 9 shows a schematic representation of the stay rod which holds the unfolded assembly in place
Fig. 10 shows a schematic representation of the front ABS cover of the modular rest-kit assembly
DETAILED DESCRIPTION OF THE DRAWINGS
Referring to the drawing in Fig. 1, the applicant's improved modular rest-kit assembly is made up of a sleeper frame network 1. sliding frame assembly 2, sleeper plywood assembly 3, front ABS cover 4, locking system 5, cushion assembly 6 and stay rod 7. The figure represents the basic modular rest-kit assembly and can be affixed on to the floor of the cabin using bolts. The modular rest-kit assembly would be complete and ready-to-use

after cushion assembly has been mounted over it. On being mounted, the assembly stays in folded position. In order to use it. the slider frame assembly 2 needs to be pulled out. followed by the sleeper plywood assembly 3, over which the cushion may be unfolded. The slider frame assembly 2. when pulled out. stays in place due to the locking system 5 and the stay rod 6 that keep it firmly in the unfolded position. There is also provided storage space for the driver to keep emergency supplies and tools that he might need during travels. This storage space is made by covering the front side of the sleeper frame network 1 with a cover, preferably an ABS (Acrylonitrile butadiene styrene) plastic cover 4. Several materials may be employed to act as a cover for the front part of sleeper frame network 1, tike metal net, metal sheet, metal tubes or perforated sheets, but ABS Sheet was chosen as it reduces the manufacturing cost of the assembly, and renders it lightweight.
Referring to the drawing in Fig. 2 and Fig. 3, the sleeper frame network may be divided into several parts -the front square tube 8, rear square tube 9, side square tube 10, inner channel mounting bracket ] 1, angle for berth support 12, leg bending tube 13, leg support tube 14, front side mounting bracket for berth 15, rear side mounting bracket for berth 16, mounting angle for berth 17, bending tube middle 18, hinge assembly 19, nuts 20, bush for locking mechanism 21, locking bracket for sliding 22, stay rod 7, stay rod mounting 23 and stay rod locking bracket 24. It must be noted that the material used for making front square tube 8, rear square tube 9, side square tube 10, leg bending tube 11, leg support tube 14 and bending tube middle 18, is steel of grade IS:3074 ERW-1. The material used for making inner channel mounting bracket 11, angle for berth support 12, front side mounting bracket for berth 15, rear side mounting bracket for berth 16, locking bracket for sliding 22 and stay rod locking bracket 24 is steel of grade HR IS: 1079 St34. The Hot Rolled (HR: IS) steel has high yield strength and is thus suitable for use as mounting brackets in the modular rest-kit assembly.The sleeper frame network provides the necessary structural support for the modular rest-kit. The choice of materials may vary as per strength requirements.
Referring to the drawing in Fig. 4, the steps involved in unfolding of the sleeper berth may be observed. The figure shows the side view of the modular rest-kit assembly and the sleeper framework, the locking system 5 and the cushion assembly 6. The Step 1 shows the assembly in folded condition, wherein thesliding frame assembly 2, the sleeper plywood assembly 3 and the cushionassembly 6 remain in folded condition. The sliding

frame assembly 2 is pulled out and the sleeper plywood assembly 3 is stretched over it, as shown in Step 2. The unfolded assembly is kept in place by the locking system 5. The cushion assembly 6 is then unfolded and spread over the sleeper plywood assembly 3.
The drawing in Fig. 5 describes the sleeper plywood assembly of the modular rest-kit assembly. The sleeper plywood assembly 3 is stretchedover the pulled-out sliding frame assembly while unfolding the berth. The sleeper plywood assembly 3 is divided into three parts -one centre plank 27 and two side planks 28.The centre plank 27 is can be opened. but the side planks 28 remain fixed. The sleeper plywood assembly may be preferably covered using a carpet cover. The grade of plywood used preferably in this case is IS: 303-1989 FR.
Referring to the drawing in Fig. 6. the cushion assembly is divided into two parts wherein one foldable part 25 rests over a fixed part 26 in folded condition. Both the parts of the cushion assembly are made up of Polyurethane (PU) foam, the density and hardness of which can be changed according to the level of comfort desired by the user.The PU foam can be covered with materials which may be chosen from but are not restricted to the following - Polyvinyl chloride (PVC) sheet, rexine, fabric, any other upholstery material.
The locking system as shown in Fig. 7 comprises of locking pin to lock the pulled out portion of frame so that both portions of the frame lay together as one for structural integrity. Locking system provides increased structural strength and rigidity at discrete coupling points between portions of frame without structural compromise there between,
Fig. 8 shows a schematic representation of the sliding frame assembly. It is made up of a front square tube 29 and slider mounting brackets 30. The front square tube 29 is preferably made of steel of grade IS: 3074 ERW-1 and slider mounting brackets 30 are preferably made of steel of grade HR IS: 1079 St-34. The sliding frame assembly also houses holes for the locking after it has been pulled out for use.
The stay rod 7 that has been used to keep the opened rest-kit assembly in place, is shown is Fig. 9. The stay rod 7 is made up of bright bar grade of steel. It has a loop on one end and a bent tail on the other.
Referring to the drawing in the Fig. 10, the front cover of the modular rest-kit assembly is shown. This cover, preferably made of ABS (Acrylonitrile butadiene styrene) plastic is used to cover the storage space from the front. Other materials that can alternatively be

used include - like metal net, metal sheet, metal tubes or perforated sheets. However, since the ABS sheet is made from vacuum forming process instead of the more expensive injection moulding, it was chosen as it reduces the manufacturing cost of the assembly, and renders it light-weight. The grade chosen for ABS sheet should preferably be IS: 15061. The ABS sheet can optionally be given designs, patterns or handle for opening the storage space in the modular rest-kit assembly.
The modular rest-kit assembly can be mounted on to the floor of the cabin of the day truck using bolts and mounting brackets of desired strengths. Once mounted, the assembly stays in folded condition when not in use. During emergency breakdowns, when the driver or his assistant need to rest, the modular rest-kit assembly may be opened. The back of the driver's seat needs to be folded down in order to open the modular rest-kit assembly. The modular rest-kit assembly gives best results when operated by following the steps mentioned below -
Step 1 - The sliding frame assembly 2 is pulled out which acts as the base for sleeper plywood assembly 3 and the cushion assembly 6.
Step 2 - The sleeper plywood assembly 3 is pulled out and spread over the sliding frame assembly 2.
Step 3 - The folded part of the cushion assembly 6 is unfolded over the sleeper plywood assembly 3 to make the modular rest-kit assembly ready for use.
ADVANTAGES OF THE INVENTION
The modular rest-kit assembly offers several advantages like -
• It is the best space utilisation of day cabin without changing orientation of available arrangement inside day cabin.
• The modular rest-kit sleeper assembly unit is of relatively light weight and relatively high strength as compared with units described in the prior art.
• The modular rest-kit sleeper assembly is easy to assemble and mount on to the cabin of day trucks.
• The modular rest-kit sleeper assembly allows 100% rear window visibility as its structure does not obstruct the view of the driver.

• The usage of modular rest-kit assembly does not incur any change in BIW and trim.
• Maintenance problems have been reduced, appearance has been substantially improved and comfort has been greatly increased resulting in less fatigue to the driver and improved safety.
• The modular rest-kit assembly also provides substantial storage space for essential travelling supplies like clothes, mats, utensils and medicines.

CLAIMS We claim,
1. A modular rest-kit or sleeping assembly for cabin of day trucks
comprising:
a sleeper frame network (1),
a sliding frame assembly (2).
a sleeper plywood assembly (3),
a cushion assembly (6).
sleeper storage,
front ABS cover (4);
stay rod (7) and
a locking system (5) wherein the said modular rest-kit assembly is divided along its length into a first and a second part connected by means of a hinge and the said modular rest-kit assembly remains folded when not in use, in such a way that the second part lies over the first part.
2. A modular rest-kit or sleeping assembly for cabin of day trucks as defined in claim 1, comprising the sleeper frame network 1 which includes front, rear and side square tubes, inner channel mounting bracket, angle for berth support, leg bending tube, leg support tube, front and rear side mounting bracket for berth, mounting angle for berth, bending tube middle, hinge assembly and nuts, wherein the material used for making front, rear and side square tubes, leg bending tube, leg support tube and bending tube middle is preferably steel of grade IS:3074 ERW-1 and the materia] used for making inner channel mounting bracket, angle for berth support, front and rear side mounting bracket for berth is preferably steel ofgradeHR!S:1079St34.
3. A modular rest-kit or sleeping assembly for cabin of day trucks as defined in claim 1, comprising a sleeper plywood assembly 3, the said assembly further comprising of one centre plank and to side planks, wherein both the centre and side planks are preferably manufactured using plywood of grade IS: 303-1989.
4. A modular rest-kit or sleeping assembly for cabin of day trucks as defined in claim 1, comprising a front cover for the sleeper frame network

which is preferably manufactured using ABS (Acrylonitrile butadiene styrene) plastic.
5. A modular rest-kit or sleeping assembly for cabin of day trucks as defined in claim 1. comprising a cushion assembly 6, which is divided into two parts wherein the foldable part rests over the fixed part in folded condition and the said cushion assembly if manufactured using preferably Polyurethane (PU) foam, the density and hardness of which may be changed according to the level of comfort desired by the user.
6. A modular rest-kit or sleeping assembly for cabin of day trucks as defined in claim 1, comprising a locking system 5, which further comprises of a locking pin used for locking the pulled out portion of frame such that both portions of the frame lay together as one for structural integrity, and a bush in the sleeper frame work in which the locking pin rests.
7. A method for mounting the modular rest-kit assembly on the floor of the cabin of the day truck which comprises of fixing the sleeper frame network 1 to the floor of the cabin using bolts and mounting brackets.
8. A method for operating the modular rest-kit assembly comprising the steps of-
Step 1 - Pulling out the sliding frame assembly 2 which acts as the base for sleeper plywood assembly 3 and the cushion assembly 6. Step 2 - Pulling out the sleeper plywood assembly 3 and spreading the said assembly over the sliding frame assembly 2 as described in Stepl.
Step 3 - Unfolding of the folded part of the cushion assembly 6 over the sleeper plywood assembly 3 thereby making the modular rest-kit assembly ready for use.