CA2349517A1 - Molded running board - Google Patents
Molded running board Download PDFInfo
- Publication number
- CA2349517A1 CA2349517A1 CA002349517A CA2349517A CA2349517A1 CA 2349517 A1 CA2349517 A1 CA 2349517A1 CA 002349517 A CA002349517 A CA 002349517A CA 2349517 A CA2349517 A CA 2349517A CA 2349517 A1 CA2349517 A1 CA 2349517A1
- Authority
- CA
- Canada
- Prior art keywords
- running board
- structural support
- support portion
- molded
- top portion
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R3/00—Arrangements of steps or ladders facilitating access to or on the vehicle, e.g. running-boards
- B60R3/002—Running boards
Abstract
A molded running board provided with a structural support portion and a top portion is described herein. The structural support portion is made of plastic material and provided with reinforcing ribs and the top portion is made of a plastic material that is advantageously compatible with the plastic material forming the structural support portion. A method for the assembly a molded running board is also described herein. This method includes the welding of a top portion to a structural support portion via the use of a thin strand of plastic material compatible with material used in the top portion and the structural support portion and metallic particles in an electromagnetic press, for example.
Description
TITLE OF THE INVENTION
MOLDED RUNNING BOARD
FIELD OF THE INVENTION
The present invention is concerned with molded running boards. More specifically, the present invention relates to a molding running board having a reinforced plastic molded structure support portion to which is welded a top portion also made oi~' plastic material.
BACKGROUND OF THE INVENTION
Running boards are very well known in the art. They are usually mounted to the frames of small trucks such as pick-up trucks and Sport Utility Vehicles (SUVs) or to other vehicles to help the users to get in and out of the vehicle.
Conventionally, these running boards are made of metallic material such as steel which is chrome plated both for esthetic reasons and for protection against the elemi~nts. A drawback of these conventional steel running boards is that they are quite heavy and costly to manufacture.
More recently, running boards having a structural support portion made of coated steel but provided with a plastic top portion have been introduced in the market. These bi-material running boards are advantageous since they slightly reduce tlhe weight of conventional running boards and provide a top surface with good aesthetic tridimentional surface.
A drawback of the bi-material running boards is that the weight is still significant and the costs associated with the manufacturing and coating of the structural support portion is still important.
OBJECTS OF THE INVENTION
An object of the present invE;ntion is therefore to provide an improved running board.
Other objects, advantages and features of the present invention will become more apparent upon rE:ading of the following non-restrictive description of preferred embodiments thereof, given by way of example only with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the appended drawings:
Figure 1 is an exploded view of a molded running board according to the first embodiment of the present invention;
MOLDED RUNNING BOARD
FIELD OF THE INVENTION
The present invention is concerned with molded running boards. More specifically, the present invention relates to a molding running board having a reinforced plastic molded structure support portion to which is welded a top portion also made oi~' plastic material.
BACKGROUND OF THE INVENTION
Running boards are very well known in the art. They are usually mounted to the frames of small trucks such as pick-up trucks and Sport Utility Vehicles (SUVs) or to other vehicles to help the users to get in and out of the vehicle.
Conventionally, these running boards are made of metallic material such as steel which is chrome plated both for esthetic reasons and for protection against the elemi~nts. A drawback of these conventional steel running boards is that they are quite heavy and costly to manufacture.
More recently, running boards having a structural support portion made of coated steel but provided with a plastic top portion have been introduced in the market. These bi-material running boards are advantageous since they slightly reduce tlhe weight of conventional running boards and provide a top surface with good aesthetic tridimentional surface.
A drawback of the bi-material running boards is that the weight is still significant and the costs associated with the manufacturing and coating of the structural support portion is still important.
OBJECTS OF THE INVENTION
An object of the present invE;ntion is therefore to provide an improved running board.
Other objects, advantages and features of the present invention will become more apparent upon rE:ading of the following non-restrictive description of preferred embodiments thereof, given by way of example only with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the appended drawings:
Figure 1 is an exploded view of a molded running board according to the first embodiment of the present invention;
Figure 2 is a perspective bottom view of the molded running board of Figure 1;
Figure 3 is a sectional view taken along line 3-3 of Figure 1;
Figure 4 is an exploded view of a molded running board according to a second embodiment of the present invention;
Figure 5 is a perspective bottom view of the molded running board of Figure 4;
Figure 6 is a sectional view taken along line 6-6 of Figure 4;
Figure 7 is an exploded perspective view of a molded running board according to a third embodimE:nt of the present invention and;
Figure 8 is a perspective view of the structural support portion of the running board of Figure 7;
Figure 9 is a sectional view taken along line 9-9 of Figure 7; and Figure 10 is a flow chart of the difference steps in the production of a molded running board according to an aspect of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Generally stated, the present invention is concerned with the molding of a full size running board having a structural support portion made in a moldable material having structuiral characteristics that are sufficient to provide adequate rigidity such as, for example, reinforced polypropylene, i.e. polypropylene that has been reinforced with glass fibre, and a top portion made of a moldable material such as TPO (Thermo Plastic Olefin) that is secured to the structural support portion.
The present invention is also related to a method to produce a molded running board where the structural support portion and the top board are molded separately and then welded together using, for example, an electromagnetic welding process. Indeed, it has been found that other processes to form a plastic material running board are inadequate. For example, extrusion proces,>es do not easily allow the manufacture of objects having varying cross aections or objects that are not straight and other types of plastic welding such as vibration, ultrasonic, hot plate or infra-red plastic welding process usually do not yield adequately strong bonds. Furthermore, the diameter of running boards is generally too large to allow gas assisted molding.
Turning now more specifically to Figures 1 to 3, a molded running board 10 according to a first embodiment to the present invention will be described.
The molded running board 10 includes a structural support portion 12, a top portion 14 and thin strands of a material 16 provided between the structural support portion 12 and the top portion 14.
Figure 3 is a sectional view taken along line 3-3 of Figure 1;
Figure 4 is an exploded view of a molded running board according to a second embodiment of the present invention;
Figure 5 is a perspective bottom view of the molded running board of Figure 4;
Figure 6 is a sectional view taken along line 6-6 of Figure 4;
Figure 7 is an exploded perspective view of a molded running board according to a third embodimE:nt of the present invention and;
Figure 8 is a perspective view of the structural support portion of the running board of Figure 7;
Figure 9 is a sectional view taken along line 9-9 of Figure 7; and Figure 10 is a flow chart of the difference steps in the production of a molded running board according to an aspect of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Generally stated, the present invention is concerned with the molding of a full size running board having a structural support portion made in a moldable material having structuiral characteristics that are sufficient to provide adequate rigidity such as, for example, reinforced polypropylene, i.e. polypropylene that has been reinforced with glass fibre, and a top portion made of a moldable material such as TPO (Thermo Plastic Olefin) that is secured to the structural support portion.
The present invention is also related to a method to produce a molded running board where the structural support portion and the top board are molded separately and then welded together using, for example, an electromagnetic welding process. Indeed, it has been found that other processes to form a plastic material running board are inadequate. For example, extrusion proces,>es do not easily allow the manufacture of objects having varying cross aections or objects that are not straight and other types of plastic welding such as vibration, ultrasonic, hot plate or infra-red plastic welding process usually do not yield adequately strong bonds. Furthermore, the diameter of running boards is generally too large to allow gas assisted molding.
Turning now more specifically to Figures 1 to 3, a molded running board 10 according to a first embodiment to the present invention will be described.
The molded running board 10 includes a structural support portion 12, a top portion 14 and thin strands of a material 16 provided between the structural support portion 12 and the top portion 14.
5 As can be seen from Figure 1, the structural support portion 12 is generally hollow and includes rE~inforcing ribs 18, front and rear ends 20, 22, also respectively including reinforcing ribs 24 and 26.
Three brackets 28, 30 and 32 are provided to mount the structural support portion 12 to the vehicle to which the running board is intended.
As can be better seen from I=figure 2, the three brackets 28, 30 and 32 are integrally formed with the structural portion 12. It is however to be noted that these brackets coulcl be formed separately from the main portion of the structural support portion 12 and assembled thereto via fasteners or by an electromagnetic welding method as will be described hereinbelow.
The brackets 28, 30 and 32 include a matrix of ribs 34 stiffening the brackets without unduly increasing the weight thereof.
Returning to Figure 1, the top portion 14 is so shaped as to be welded onto the structural portion 12 as will be more described hereinbelow.
It is to be noted that the top surface 36 of the top portion 14 includes friction producing ribs 38. The thin strands of material 16 are provided for securing the top portion 14 to the structural portion 12 as will be described hereinbelow.
The reinforcing ribs 18-26 and 34 as well as the friction producing ribs 38 may be better seen from Figure 3. It is apparent from this Figure that the height of the stiffening ribs 18 is slightly higher than the sides 19 of the support structure portion 12. This height difference causes a tension to be applied to the top portion 14 once assembled to the support structure portion 12 to thereby decrease rattling issues.
Turning now to Figure 10 of 'the appended drawings, the general steps in the manufacture of a molded running board according to an aspect of the present invention will be described.
In a first step 40, the structural support portion is molded in a conventional fashion. According to a preferred embodiment of the present invention, the structural support portion is made of reinforced polypropylene i.e. polypropylene that has been reinforced with glass fibre.
A second step 42, which can be carried out simultaneously with step 40, the top portion i;s molded. Still according to a preferred embodiment of the present invention, the top portion is made of TPO (Thermo Plastic Olefin). Of course, other suitable materials that can be welded to the structural portion, i.e. that is compatible, could be used.
In step 44, the structural support portion and the top portion are set aside to let them sufficient time to shrink. It has been found that 24 hours are sufficient for the struci;ural support portion and the top portion to reach their stable size.
In step 46, a least one piece of thin strand or string of material is provided. The thin strand or string is advantageously made of a material compatible with both the structural support portion and the top portion. According to a preferred embodiment of the present invention, the thin strand or string of material is made of polypropylene and includes metallic particles embedded in the material. A proportion of metallic particles to the polypropylene of about 50% has been found adequate. Of course, other suitable materials that are compatible with the structural and top portions could be used.
Step 48 consists in assembling the structural support portion, the thin strands of material and the top portion. In step 50, this assembly is put into an electromagnetic press (not shown) which includes copper coil surrounding the assembly. An electric generator supplies the copper coil with a current that causes the mei:allic particles embedded in the thin strand of material to heat up and melt the polypropylene forming the strand, thus welding the top portion to the structural support portion.
The resulting welded molding running board is kept into the press once the generator has been shut up to allow sufficient time for the liquified portion of the running board to solidify (step 52).
Finally, in step 54, the completed molded running board is removed from the electromagnetic press.
Three brackets 28, 30 and 32 are provided to mount the structural support portion 12 to the vehicle to which the running board is intended.
As can be better seen from I=figure 2, the three brackets 28, 30 and 32 are integrally formed with the structural portion 12. It is however to be noted that these brackets coulcl be formed separately from the main portion of the structural support portion 12 and assembled thereto via fasteners or by an electromagnetic welding method as will be described hereinbelow.
The brackets 28, 30 and 32 include a matrix of ribs 34 stiffening the brackets without unduly increasing the weight thereof.
Returning to Figure 1, the top portion 14 is so shaped as to be welded onto the structural portion 12 as will be more described hereinbelow.
It is to be noted that the top surface 36 of the top portion 14 includes friction producing ribs 38. The thin strands of material 16 are provided for securing the top portion 14 to the structural portion 12 as will be described hereinbelow.
The reinforcing ribs 18-26 and 34 as well as the friction producing ribs 38 may be better seen from Figure 3. It is apparent from this Figure that the height of the stiffening ribs 18 is slightly higher than the sides 19 of the support structure portion 12. This height difference causes a tension to be applied to the top portion 14 once assembled to the support structure portion 12 to thereby decrease rattling issues.
Turning now to Figure 10 of 'the appended drawings, the general steps in the manufacture of a molded running board according to an aspect of the present invention will be described.
In a first step 40, the structural support portion is molded in a conventional fashion. According to a preferred embodiment of the present invention, the structural support portion is made of reinforced polypropylene i.e. polypropylene that has been reinforced with glass fibre.
A second step 42, which can be carried out simultaneously with step 40, the top portion i;s molded. Still according to a preferred embodiment of the present invention, the top portion is made of TPO (Thermo Plastic Olefin). Of course, other suitable materials that can be welded to the structural portion, i.e. that is compatible, could be used.
In step 44, the structural support portion and the top portion are set aside to let them sufficient time to shrink. It has been found that 24 hours are sufficient for the struci;ural support portion and the top portion to reach their stable size.
In step 46, a least one piece of thin strand or string of material is provided. The thin strand or string is advantageously made of a material compatible with both the structural support portion and the top portion. According to a preferred embodiment of the present invention, the thin strand or string of material is made of polypropylene and includes metallic particles embedded in the material. A proportion of metallic particles to the polypropylene of about 50% has been found adequate. Of course, other suitable materials that are compatible with the structural and top portions could be used.
Step 48 consists in assembling the structural support portion, the thin strands of material and the top portion. In step 50, this assembly is put into an electromagnetic press (not shown) which includes copper coil surrounding the assembly. An electric generator supplies the copper coil with a current that causes the mei:allic particles embedded in the thin strand of material to heat up and melt the polypropylene forming the strand, thus welding the top portion to the structural support portion.
The resulting welded molding running board is kept into the press once the generator has been shut up to allow sufficient time for the liquified portion of the running board to solidify (step 52).
Finally, in step 54, the completed molded running board is removed from the electromagnetic press.
Turning now to Figures 4 to 6, a molded running board according to a second embodiment of the present invention will be described. Since the molded running boarcl 100 is very similar to the molded running board 10 illustrated in Figures 1 to 3, only the difference therebetween will be discussed in detail hereinbelow.
The molded running board 100 includes a structural portion 102, a top portion 104 and thin strands of material 106. These three elements being substantially as described hereinabove.
The major difference between the molded running board 100 and the molded running boards 10 can be better seen in Figure 5 and 6 where it is clearly shown that the bottom portion of the structural support portion 102 includes apertures 108 which acre advantageous both for reducing the weight of the support structure portion 102 and to allow the draining of any liquid that could enter the molded running board 100.
It is to be noted that the longiitudinal ends of the running board 100 are narrower than the ends of the running board 10 to further reduce the weight thereof.
The steps of manufacture of the running board 100 are very similar to steps of manufacture of the molded running board 10, described hereinabove.
Turning now to Figures 7 to 9 of the appended drawings, a molded running board 200 according to a~ third embodiment of the present invention will now be described.
The molded running board 100 includes a structural portion 102, a top portion 104 and thin strands of material 106. These three elements being substantially as described hereinabove.
The major difference between the molded running board 100 and the molded running boards 10 can be better seen in Figure 5 and 6 where it is clearly shown that the bottom portion of the structural support portion 102 includes apertures 108 which acre advantageous both for reducing the weight of the support structure portion 102 and to allow the draining of any liquid that could enter the molded running board 100.
It is to be noted that the longiitudinal ends of the running board 100 are narrower than the ends of the running board 10 to further reduce the weight thereof.
The steps of manufacture of the running board 100 are very similar to steps of manufacture of the molded running board 10, described hereinabove.
Turning now to Figures 7 to 9 of the appended drawings, a molded running board 200 according to a~ third embodiment of the present invention will now be described.
As can be better seen from Figure 9, the molded running board 200 includes a generally U shaped cross-section structural support portion 202, a corresponding top portion 204, a string of material 206 and a step pad 208 that can be mounted to the 'top portion 204. Again, the structural support 202 includes three bracket; 210, 212 and 214 (Figures 7 and 8) that allow the molded running board to be mounted to a vehicle.
The support structure 202 includes reinforcing ribs 216 and edge portions 218 provided with a rectangular channel 220 therein.
As can be seen from Figure 9, the string of material 206 is inserted in the channel 220.
The top portion 204 includes a generally flat surfiace 222 configured in size to contact the free end of i:he ribs 216. As discussed hereinabove, the top and support structure portions are so designed that the free ends of the ribs 216 will exert a press>ure on the top portion 204, therefore strengthening the running boards 2~D0.
The edges 224 of the top portion 204 also configured and size as to enter the channels 220 of the structural support 202.
Furthermore, each edge 224 is provided with a projection 225 provided on the external surface thereof. The contact befiNeen these projections 225 and the internal surface of the channel 220 en:;ures that should the plastic material that liquifies during the electromagnEaic welding process has to overflow, it will overflow towards the inside of the running board 200, leaving the external surface of the running board 200 without unsightly marks.
It is to be noted that both the structural support portion 202 and the portion 204 are advantageously made of reinforced plastic material such as for example polypropylene reinforced with glass fibres.
5 It will be easily understood by one skilled in the art that once the support structure portion and the top portion are welded together using an electromagnetic welding process as described hereinabove and illustrated in Figure 10, a strong molded running board will be formed.
The support structure 202 includes reinforcing ribs 216 and edge portions 218 provided with a rectangular channel 220 therein.
As can be seen from Figure 9, the string of material 206 is inserted in the channel 220.
The top portion 204 includes a generally flat surfiace 222 configured in size to contact the free end of i:he ribs 216. As discussed hereinabove, the top and support structure portions are so designed that the free ends of the ribs 216 will exert a press>ure on the top portion 204, therefore strengthening the running boards 2~D0.
The edges 224 of the top portion 204 also configured and size as to enter the channels 220 of the structural support 202.
Furthermore, each edge 224 is provided with a projection 225 provided on the external surface thereof. The contact befiNeen these projections 225 and the internal surface of the channel 220 en:;ures that should the plastic material that liquifies during the electromagnEaic welding process has to overflow, it will overflow towards the inside of the running board 200, leaving the external surface of the running board 200 without unsightly marks.
It is to be noted that both the structural support portion 202 and the portion 204 are advantageously made of reinforced plastic material such as for example polypropylene reinforced with glass fibres.
5 It will be easily understood by one skilled in the art that once the support structure portion and the top portion are welded together using an electromagnetic welding process as described hereinabove and illustrated in Figure 10, a strong molded running board will be formed.
10 The step pad 208 is advantageously made of TPO and may be mounted to the top portion 204 using tabs 226 and corresponding apertures 228 or by any other suitable mean:.. Alternatively, friction ribs (not shown) could be made on the top surface of the element 204 instead of using a hind element as the step pad 208.
As will be easily understood by one skilled in the art, an advantage of using such a thin strand or string of material provided with metallic particles is that it is possible to weld together even the internal contacting surfaces of the structural support portion and of the top portion.
Other advantages of a molded running board according to the present invention include:
~ the production costs are significantly reduced;
~ the weight is significantly reduced;
~ the running board is 100°~o recyclable;
~ it is possible to paint the running board or to leave it as is;
As will be easily understood by one skilled in the art, an advantage of using such a thin strand or string of material provided with metallic particles is that it is possible to weld together even the internal contacting surfaces of the structural support portion and of the top portion.
Other advantages of a molded running board according to the present invention include:
~ the production costs are significantly reduced;
~ the weight is significantly reduced;
~ the running board is 100°~o recyclable;
~ it is possible to paint the running board or to leave it as is;
~ the running board can bE: molded using a plastic of an appropriate colour;
~ a nice surface finish is provided;
~ it is possible to customize reinforcement ribs of the structural support portion to obtain the desired stiffness before the electromagnetic welding process.
Although the present invention has been described hereinabove by way of preferred embodiments. thereof, it can be modified, without departing from the spirit and nature of the subject invention as defined in the appended claims.
~ a nice surface finish is provided;
~ it is possible to customize reinforcement ribs of the structural support portion to obtain the desired stiffness before the electromagnetic welding process.
Although the present invention has been described hereinabove by way of preferred embodiments. thereof, it can be modified, without departing from the spirit and nature of the subject invention as defined in the appended claims.
Claims (2)
1. A molded running board comprising:
a structural support portion provided with reinforcing ribs;
and a top portion fixedly mounted to said structural support.
a structural support portion provided with reinforcing ribs;
and a top portion fixedly mounted to said structural support.
2. A method for making a molded running board comprising the steps of:
molding a structural support portion;
molding a top portion;
assembling the top portion to the structural support portion;
welding said top portion to said structural support portion.
molding a structural support portion;
molding a top portion;
assembling the top portion to the structural support portion;
welding said top portion to said structural support portion.
Priority Applications (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002349517A CA2349517A1 (en) | 2001-06-04 | 2001-06-04 | Molded running board |
| CA 2388717 CA2388717A1 (en) | 2001-06-04 | 2002-06-03 | Molded running board |
| US10/163,446 US6997469B2 (en) | 2001-06-04 | 2002-06-04 | Molded running board |
| US11/337,342 US20060119065A1 (en) | 2001-06-04 | 2006-01-23 | Molded running board |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002349517A CA2349517A1 (en) | 2001-06-04 | 2001-06-04 | Molded running board |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2349517A1 true CA2349517A1 (en) | 2002-12-04 |
Family
ID=4169193
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002349517A Abandoned CA2349517A1 (en) | 2001-06-04 | 2001-06-04 | Molded running board |
Country Status (2)
| Country | Link |
|---|---|
| US (2) | US6997469B2 (en) |
| CA (1) | CA2349517A1 (en) |
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| US7131655B2 (en) * | 2002-04-02 | 2006-11-07 | Lund International, Inc. | Running board, motor vehicle including a running board, and methods for manufacturing and using a running board |
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| US10518727B1 (en) * | 2018-09-28 | 2019-12-31 | GM Global Technology Operations LLC | Step assembly for energy absorption |
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| WO2020177186A1 (en) | 2019-03-05 | 2020-09-10 | 杭州天铭科技股份有限公司 | Vehicle step bar device and vehicle |
| WO2020181617A1 (en) | 2019-03-11 | 2020-09-17 | 杭州天铭科技股份有限公司 | Adjustment apparatus, adjuster, and shock absorber |
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| US4710539A (en) * | 1981-11-02 | 1987-12-01 | W. R. Grace & Co. | Heat activatable adhesive or sealant compositions |
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| US6709137B1 (en) * | 1999-07-02 | 2004-03-23 | Decoma International Corporation | Assembly including illuminated step pad |
| US6692064B1 (en) * | 1999-08-13 | 2004-02-17 | Conix Corporation | Reinforced blow-molded bumpers |
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| US6581946B2 (en) * | 2001-02-01 | 2003-06-24 | Lund International, Inc. | Running board for use with motor vehicle and method for installing a running board on a motor vehicle |
| CA2369309C (en) * | 2001-07-13 | 2009-12-29 | Terry Coomber | Running boards and methods of constructing a running board |
-
2001
- 2001-06-04 CA CA002349517A patent/CA2349517A1/en not_active Abandoned
-
2002
- 2002-06-04 US US10/163,446 patent/US6997469B2/en not_active Expired - Fee Related
-
2006
- 2006-01-23 US US11/337,342 patent/US20060119065A1/en not_active Abandoned
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US7131655B2 (en) * | 2002-04-02 | 2006-11-07 | Lund International, Inc. | Running board, motor vehicle including a running board, and methods for manufacturing and using a running board |
| CN107599336A (en) * | 2016-07-11 | 2018-01-19 | 福特全球技术公司 | Extrude multi-layer forming foot pedal |
Also Published As
| Publication number | Publication date |
|---|---|
| US20060119065A1 (en) | 2006-06-08 |
| US6997469B2 (en) | 2006-02-14 |
| US20030006576A1 (en) | 2003-01-09 |
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Legal Events
| Date | Code | Title | Description |
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| FZDE | Discontinued |