Plastic profile extruded retractable side step

Abstract

A plastic profile extruded side step (104) includes a profile extruded plastic elongated frame (202) having a first wall (204) and a second wall (206) opposite the first wall. The frame has a length. A CFRT reinforcement layer (216, 218) is laminated on a portion of the first wall and a portion of the second wall. The side step is configured to be mounted to the support (106a) and extend along the length. A vehicle rocker panel (102) area defines a step into a vehicle.

Description

Technical Field

[0001] This disclosure relates to automotive parts, and more specifically to automotive parts manufactured by extrusion of plastic profiles. Background Technology

[0002] Side steps are platforms that extend from the front wheels to the rear wheels of a car (such as a truck, SUV, pickup truck, or other vehicle). They are typically found in vehicles with relatively high ground clearance (i.e., a relatively high height above the ground), such as four-wheel drive (4WD) vehicles. Side steps can be fixed, meaning they are stationary relative to the car body. Alternatively, side steps can be retractable, meaning they can selectively move between an extended and retracted position. Retractable side steps are also known as electric side steps.

[0003] U.S. Patent No. 11,269,798 describes a horizontally movable, retractable vehicle step that can be attached to a vehicle, such as a van, that is low to the ground. The horizontal vehicle step provides access to different parts of the vehicle. The step's tread structure comprises structurally strong and / or lightweight materials.

[0004] U.S. Patent 11,180,100 describes a retractable step and side rail assembly for use in raised vehicles, such as trucks. The retractable step provides significant accessibility in its deployed position, allowing a user to enter the raised vehicle. In its stowed position, the retractable step can be located within the side rail. The vehicle components can be made of structurally strong and / or lightweight materials.

[0005] U.S. Patent 2002 / 00041087 describes a side tread plate comprising multiple light-diffusing waveguides. A reflective layer is disposed around a portion of each waveguide. A base layer receives one or more light-diffusing waveguides and the reflective layer. A transparent lens layer is disposed above the light-diffusing waveguides, the reflective layer, and the base layer. The components of the side tread plate may be formed from fiber-filled polypropylene material.

[0006] U.S. Patent No. 10,442,361 describes a vehicle side step having opposing vertical walls extending along the length of a tubular structure. The side step includes a carbon fiber component. Opposing horizontal walls extend between the opposing vertical walls and include a glass component. The opposing vertical and horizontal walls form a tubular structure having a generally rectangular cross-section. A polymer outer covering extends above the opposing vertical and horizontal walls. Summary of the Invention

[0007] This disclosure describes a plastic profile extruded retractable side pedal and a method for manufacturing the same.

[0008] Details of one or more embodiments of this disclosure are set forth in the following drawings and description. Other features, objects, and advantages of this disclosure will become apparent from the description and drawings and from the claims. Attached Figure Description

[0009] Figure 1A This is a schematic diagram of an example of a car with extruded side steps made of plastic profiles.

[0010] Figure 1B This is a schematic diagram of a retractable side pedal made of extruded plastic profile.

[0011] Figure 2 This is a schematic diagram of a cross-section of an example side pedal.

[0012] Figure 3 It shows the manufacturing process. Figure 2 A schematic diagram illustrating an example of a side pedal method.

[0013] Figure 4 It is manufacturing Figure 2 A flowchart illustrating an example of the side pedal method.

[0014] Figure 5A-5G It is used to connect to Figure 2 A schematic diagram of an example of a side pedal bracket.

[0015] Figure 6 This is a schematic diagram of a cross-section of another example of a side pedal.

[0016] Figures 7A-7F It is used to connect to Figure 6 A schematic diagram of an example of a side pedal bracket.

[0017] Figure 8 This is a schematic diagram of a cross-section of an example side pedal.

[0018] The same reference numerals in the accompanying drawings indicate the same elements. Detailed Implementation

[0019] This disclosure describes retractable side treads produced by extruding plastic profiles. The frame can be manufactured with or without reinforcements (e.g., thermoplastic composites or sheet metal, or both), which meet or increase stiffness and strength requirements. The resulting design is lightweight and serves as an alternative to metal side treads or side treads made of materials heavier than the plastics described in this disclosure. Profile extrusion allows for a closed cross-section. Such a design further increases flexural resistance due to a high moment of inertia.

[0020] The retractable side pedals described in this disclosure are alternatives to side pedals made using stamped metal (e.g., steel) components that are then welded together. The side pedals described herein are also alternatives to side pedals made from extruded aluminum profiles. By using the side pedals described in this disclosure, the need for surface treatments of the side pedals, such as corrosion prevention (steel side pedals) or anodizing / brushing (aluminum side pedals), can be avoided or reduced. Therefore, the amount of material used to manufacture the side pedals and the technical complexity associated with processing such materials can be reduced. Using lightweight plastic side pedals allows for a reduction in the size of auxiliary components such as the motor used to operate the side pedals.

[0021] Furthermore, some vehicles, such as vans or sport utility vehicles (SUVs), deploy long side steps. Such long side steps, made of metal or heavier materials, tend to sag under their own weight. Conversely, long side steps made of lightweight alternative materials tend to sag under the weight of the loads applied to the side steps during normal use. The side steps described in this disclosure address the problem of side steps sagging under their own weight or loads. Specifically, the side steps described in this disclosure can be manufactured using a lamination process that combines plastics and composite materials. For example, the side steps described herein have a plastic frame reinforced at the top or bottom (or both) of the side step frame with thermoplastic composite materials or metal sheets. This construction can reduce, minimize, or completely prevent sagging of the side steps.

[0022] Figure 1A This is a schematic diagram illustrating an example of a car 100. A door sill plate 102 connects the front of the car 100 to its rear. In doing so, the door sill plate 102 increases the rigidity of the car 100. This increased rigidity improves vehicle handling. The car 100 has a plastic profile extruded side pedal 104. Multiple brackets (e.g., a first bracket 106a, a second bracket 106b, or more brackets) can be mounted to the door sill plate 102. The side pedal 104 can be connected to multiple brackets 106a, 106b. The multiple brackets 106a, 106b can connect the side pedal 104 to the car 100. The side pedal 104 can be fixed or retractable. A fixed side pedal is one that remains fixed in the extended position, i.e., extends away from the car 100 and is accessible to the car user. The retractable side step is a side step that can switch between an extended state and a retracted state. In the extended state, the side step 112 can be stepped on to enter the vehicle 100. In the retracted state, the side step 112 is folded and cannot be stepped on to enter the vehicle 100.

[0023] The side step 104 may have a first end 108a and a second end 108b. The length of the side step 104 may span between the two ends 108a and 108b. The length of the side step 104 may substantially span the space between the front and rear wheels of the vehicle 100. A cover 110 (e.g., a plastic or metal cover, sometimes referred to as an end cap) may cover the first end 108a. Another cover (not shown) may similarly cover the second end 108b. The covered ends may also allow the side step 104 to be accommodated within the limited space available in the area of ​​the door sill plate 102 below the floor of the vehicle 100.

[0024] Figure 1B This is a schematic diagram showing the retractable side pedal 112. The side pedal 112 itself can be connected to the side pedal 104 ( Figure 1A The side step 112 can be fixed or retractable. For example, the side step 112 can be in a retracted state when the car 100 is moving.

[0025] Side pedal 112 can be retractable due to the connecting rods 114a and 114b to which it is connected. Specifically, one end of each of the connecting rods 114a and 114b can be connected to a corresponding bracket 106a or 106b. As described later, brackets 106a and 106b can be connected to the frame of side pedal 112. Brackets 106a and 106b are connected to the frame via fixing points 116a and 116b. In particular, fixing points 116a and 116b form connections between brackets 106a and 106b and connecting rods 114a and 114b, respectively. Fixing points can be openings formed in the brackets, openings formed in the connecting rods, and combinations of pins or bolts or rods passing through these two openings.

[0026] In some embodiments, each link can be connected to a corresponding bracket via more than one anchor point. Opposite ends of each link 114a, 114b can be connected to another corresponding bracket 118a, 118b. Both brackets 118a, 118b can be connected to the vehicle 100. For example, both brackets 118a, 118b can be connected via one or more anchor points similar to anchor points 116a, 116b. Each end of each link can pivot about the anchor point connecting each end of each link to the corresponding bracket.

[0027] Motor 120 can be connected to one of the links (e.g., link 114a). In response to receiving power, motor 120 can rotate the end of link 114a. The resulting rotation causes one end of link 114a to pivot about a fixed point where link 114a can be connected to bracket 118a. When the end of link 114a connected to bracket 118a pivots, the other end of link 114a (which can be connected to bracket 116a) also pivots. Pivoting causes side pedal 112 to retract from the deployed state to the retracted state. Motor 120 can reverse the rotation to reverse the movement of side pedal 112 from the retracted state to the deployed state. In this way, motor 120 can control side pedal 112 between the retracted and deployed states.

[0028] Figure 2 This is a schematic diagram of the cross-section of the side pedal 104. (See diagram below.) Figure 2 As shown, the side step 104 may include a frame 202. The frame 202 has sufficient stiffness to resist bending deflection. Specifically, the stiffness of the frame 202 may be sufficient to prevent bending or have minimal deflection under loads applied to the frame 202 (i.e., to meet structural requirements). The load may be, for example, a person stepping on the side step 104 to enter or exit the passenger compartment of the vehicle 100 (FIG. 1). The frame 202 may include a first wall 204. The frame 202 may include a second wall 206 opposite to the first wall 204. Both walls may extend the length of the frame 202.

[0029] The first wall 204 may be generally planar (i.e., flat) along the entire length of the frame 202. The first wall 204 may be wide enough that a person can easily step on it when entering or exiting the passenger compartment of the vehicle 100 (FIG. 1). The second wall 206 may include an arcuate portion 208. The arcuate portion 208 may be connected to the first wall 204. The second wall 206 may also include a generally planar wall portion 209. The generally planar wall portion 209 may be parallel to the first wall 204.

[0030] Multiple ribs (e.g., first rib 210a, second rib 210b, third rib 210c) may extend between and connect the first wall 204 and the second wall 206. For example, each of the multiple ribs may be perpendicular to the first wall 204. Each of the multiple ribs may also be perpendicular to the planar wall portion 209 of the second wall 206. Thus, when the frame 202 is oriented such that the first wall 204 is horizontal relative to the ground, each of the multiple ribs may be vertical relative to the first wall 204, wherein the end of each of the multiple ribs is attached to the generally planar wall portion 209 of the first wall 204 and the second wall 206.

[0031] The frame may be made of about 40 wt% to about 90 wt% of polypropylene (PP), polybutylene terephthalate (PBT), polycarbonate (PC), or polyamide (PA). The frame may also be made of about 10 wt% to about 60 wt% of fibers (e.g., long glass fibers). The frame may include about 0.0001 wt% to about 30 wt% of impact modifiers, fillers, flame retardants, antioxidants, or reinforcing agents (or any combination thereof). Other fibers such as glass, aramid, carbon, natural fibers, or any combination thereof may be used as an alternative to or in addition to long glass fibers. Each wt% is based on the weight of the frame. In the context of weight percentage, the term “about” indicates a deviation between ±2% and ±5%.

[0032] In some embodiments, an arcuate portion 208 may be formed at one end of the second wall 206. The arcuate portion 208 can connect this end of the second wall 206 to one end of the first wall 204. A support receiving structure 212 may be formed at the opposite ends of the first wall 204 and the second wall 206. Figure 2 In the illustrated embodiment, the support receiving structure 212 may include two extruded plastic rings (first ring 214a, second ring 214b). The extruded plastic rings may be arranged to form an L-shaped opening 215. The opening 215 may be configured to receive a support. Specifically, the first ring 214a may be formed and attached to the inner surface of the first wall 204 (i.e., the surface not exposed to the outside of the frame 202). The second ring 214b may be formed and attached to the rib 210a and extend away from the rib 210a. Each of the rings may extend the length of the frame 202. This configuration allows each support to be attached at any location along the length of the frame 202.

[0033] The frame 202 can be reinforced with continuous fibers or metal sheets. In the case of metal sheet reinforcement of the frame 202, the metal sheet can be used to form a cover covering the ends of the frame 202 (Figure 1).

[0034] A continuous fiber-reinforced thermoplastic (CFRT) reinforcement layer 216 may be laminated onto a portion of the first wall 204. An outer surface may be laminated onto the first wall 204 (i.e., the surface exposed to the outside of the frame 202). Layer 216 may be laminated along the width of the outer surface. Another CFRT reinforcement layer 218 may be laminated onto the second wall 206. For example, another CFRT reinforcement layer 218 may be laminated onto a generally planar portion of the second wall 206. Each CFRT reinforcement layer may be an organic sheet, a multilayer laminate (UD laminate) formed from unidirectional tape, a woven fabric composite, or a thermoplastic organic sheet, which may comprise multilayer thermoplastic prepregs or semi-prepregs (or any combination thereof) stacked and pressed into sheets. The use of unidirectional tape forming the multilayer laminate provides off-axis properties. Off-axis properties allow the laminate to be molded into complex shapes. Complex shapes can be overmolded with thermoplastics to provide localized reinforcement at specific locations. Woven fabric composites may include plain weave, twill weave, satin weave, etc. (or any combination thereof). In some embodiments, CFRT reinforcement layers may be applied by lamination or co-extrusion.

[0035] Each CFRT reinforcement layer may be made of about 10 wt% to about 60 wt% of polypropylene, PBT, PC, or PA. The CFRT reinforcement layer may be made of about 30 wt% to about 80 wt% of fibers (e.g., continuous glass fibers) and about 0.0001 wt% to about 20 wt% of impact modifiers, fillers, flame retardants, antioxidants, and reinforcing agents. Each wt% is based on the weight of the CFRT reinforcement layer. Other fibers such as glass, aramid, carbon, natural fibers, or any combination thereof may be used as an alternative to or in addition to continuous glass fibers.

[0036] A thermoplastic layer 220 may be applied to the first surface 204. For example, the thermoplastic layer 220 may be applied on top of the reinforcing layer 216. The thermoplastic layer 220 may be applied by lamination or co-extrusion. The thermoplastic layer 220 may be applied to completely cover the reinforcing layer 216. The thermoplastic layer 220 may be applied to extend the entire width of the first wall 204. The outer surface of the thermoplastic layer 220 (i.e., the surface away from the reinforcing layer 216) may be formed to have a non-slip surface. For example, the outer surface of the thermoplastic layer 220 may be patterned to have steps or ribs. When a person steps on the thermoplastic layer 220 when entering or leaving the vehicle 100 (FIG. 1), the non-slip surface provides traction, thereby preventing slippage. In some embodiments, the side pedal 104 comprises only the thermoplastic layer 220. In some embodiments, in addition to the thermoplastic layer 220, a second thermoplastic layer may be laminated onto the second surface 206. For example, a second thermoplastic layer can be laminated on top of reinforcing layer 218. Layers 218 and 220 can improve the appearance of the side pedal. Layer 220 can also have scratch-resistant properties.

[0037] Figure 3 This shows the manufacturing of the side pedal 104 ( Figure 2 A schematic diagram illustrating an example of the method. Figure 4 It is for manufacturing side pedal 104 ( Figure 2 The flowchart for example of method 400 is shown below. (See reference.) Figure 3 The schematic diagram shown illustrates method 400. At 402, a plastic frame (e.g., frame 202) is extruded using a first die 302. Figure 2 The frame 202 has a first planar wall, a second planar wall opposite to the first planar wall, and a profile of the frame 202. Figure 2 Similar length. As mentioned earlier, the extruded frame may consist only of thermoplastic or thermoplastic reinforced with fiber composites or metal sheets. At 404, a reinforcing layer made of CFRT 304 (e.g., layers 216, 218) is added. Figure 2 The CFRT 304 can be heated and laminated onto the frame using a second die 306. For example, the CFRT 304 can be heated and laminated onto a portion of the first wall and a portion of the second wall. At 405, the example may optionally include a top protective layer (e.g., an anti-slip layer) co-extruded using a second die. At 406, multiple supports (e.g., supports 106a, 106b (FIG. 1)) can be attached along the length of the frame. Each support can connect the side step 104 to the body of the vehicle (e.g., vehicle 100 (FIG. 1)).

[0038] Thermoplastic layer (e.g., thermoplastic layer 220) Figure 2 A CFRT reinforcement layer (e.g., CFRT reinforcement layer 220) can be attached to the first wall of the frame. Figure 2 This attachment can be achieved through lamination or co-extrusion. To do this, the surfaces of the CFRT reinforcing layer and the thermoplastic extruded beam can be heated and melted, pressurized, and subsequently cooled to bond them together. For example, static hot pressing and double-band pressing can be used. In embodiments where metal sheets are used for structural reinforcement of the side pedals, such a metal frame can be joined to the plastic frame by an adhesive film or mechanical lock (or both), covering the inner and outer corners of the frame. As previously mentioned, an anti-slip surface can be formed on the outer surface of the thermoplastic layer attached to the CFRT reinforcing layer. The anti-slip surface can be formed by embossing on the thermoplastic layer. Alternatively or additionally, an additional layer of thermoplastic pre-formed with an anti-slip morphology can be applied to the first layer of thermoplastic. The result of performing method 400 can be having Figure 2 The frame with the cross-section shown.

[0039] Figure 5A-5G It is used for connecting to the side pedal, such as side pedal 104 ( Figure 2 ) or side pedal 112 ( Figure 1BThis is a schematic diagram of an example of a bracket 500. The bracket 500 may include a body 502. The body 502 may include a first end portion 504. The body 502 may include a second end portion 506 opposite to the first end portion 504. As described below, the first end portion 504 may connect the bracket 500 to a side sill plate. In embodiments where the side sill plate is a fixed side sill plate (e.g., side sill plate 104), the second end portion 504 may connect the bracket 500 to a door sill plate 102. The door sill plate 102 is connected to the vehicle 100 ( Figure 1A In embodiments where the side pedal is a retractable side pedal (e.g., side pedal 112), the second end portion 504 can connect the bracket 500 to a link (e.g., link 114a). The link can be connected to a bracket (e.g., bracket 118a).

[0040] like Figure 5B As shown, the first end portion 504 of the body 502 can be formed with a cantilever portion 508. The first end portion 504 can also be formed with a support portion 510. The cantilever portion 508 can be coupled to a first position on the frame (e.g., frame 202) of the side pedal 104. The first position on the frame 202 can be the bracket receiving structure 212 described above. The cantilever portion 508 can have a shape that can be inserted into the bracket receiving structure 212 and locked in place. In some embodiments, the cantilever portion 508 can be formed in an L-shape. Generally, the cantilever portion 508 can have any shape including one member being sharply deviated (e.g., 90 degrees or less) from another connected member. In this arrangement, both members can be inserted into the bracket receiving structure 212 such that the deviated member can engage a rib (e.g., rib 210a) of the frame 202 to lock the bracket 500 to the frame 202.

[0041] The support portion 510 can be formed to extend further from the first end 504 than the overhang portion 508. In this configuration, when the overhang portion 508 is inserted into the support receiving structure 212 of the frame 202, the support portion 510 can extend below the planar wall portion 210 of the second wall 206 of the frame 202. In this way, the support portion 510 can provide additional support for the bottom of the frame 202. The support portion 510 can also be further secured to the frame 202. To do this, openings (e.g., openings 512a, 512b) can be formed in the support portion 510. Figure 5C )) and with the opening formed in frame 202 (e.g., opening 516 ( Figure 5A Alignment. Fasteners 518 (e.g., pins, rods, bolts, similar fasteners) may pass through openings 512a, 512b and each of the openings formed in frame 202 to securely fasten support 510 to frame 202.

[0042] like Figure 5C ,5F As shown in 5G, the second end portion 506 of the support 500 may include two leg portions 522a, 522b. Each leg portion may be connected to the body 502 to define a space 523 between them. A link may be positioned in the space and connected to each leg portion. To do this, fixing points may be defined in each leg portion, such as fixing points 514a, 514b in leg portion 522a and fixing points 524a, 524b in leg portion 522b. The fixing points may be through holes formed in the leg portions. Corresponding through holes may be formed in the link. The through holes formed in the link may be aligned with the fixing points on the leg portions. The leg portions may then be connected to the link using fasteners similar to those described above.

[0043] Figure 5D and 5E Different views of the stent 500 are shown. The stent 500 can be made of injection-molded plastic. The stent 500 can be made of resins such as polypropylene (PP), polybutylene terephthalate (PBT), polycarbonate (PC), polyamide (PA), or any combination thereof. The stent 500 can be reinforced with fibers such as long glass fibers or other fibers such as glass, aramid, carbon, natural fibers, or any combination thereof. The amount of fiber can be between 20 wt% and 60 wt%. Each wt% is based on the weight of the stent. In the context of weight percentage, the term "about" indicates a deviation between ±2% and ±5%.

[0044] like Figure 5D and 5E As shown in each of the figures, the body 502 can be integrally formed with a ribbed design to increase bending and torsional stiffness. Each of the overhang 508 and the support 510 can extend across the entire width of the body 502. The overhang 508 can have an upper member, a lower member, and a cross-sectional member. The cross-sectional member connects the upper member to the lower member, thereby giving the overhang 508 thickness. Similarly, the support 510 can also have an upper member, a lower member, and a cross-sectional member. This cross-sectional member connects the upper member to the lower member, thereby giving the support 510 thickness.

[0045] Figure 6 This is a schematic cross-sectional view of another example of side pedal 600. Side pedal 600 can be substantially similar to side pedals 104, 112 ( Figure 1A , 1B 2). The cross-section of the side pedal 600 may differ from the cross-sections of the side pedals 104 and 112. For example... Figure 6As shown, the side step 600 may include a frame 602. The frame 602 may have sufficient stiffness to resist bending deflection. Specifically, the stiffness of the frame 602 may be sufficient to prevent bending under loads applied to the frame 602, such as when a person steps on the side step 600 to enter or leave the vehicle 100. Figure 1A , 1B When the passenger compartment is located, the frame 602 may include a first wall 604. The frame 602 may include a second wall 606 opposite to the first wall 604. The two walls may extend the length of the frame 602.

[0046] The first wall 604 may be substantially planar (i.e., flat) along the entire length of the frame 602. The first wall 604 may have sufficient dimensions to facilitate easy entry into or exit from the vehicle 100. Figure 1A , 1B The width of the footsteps in the passenger compartment. The second wall 606 may include an arcuate portion 608. The arcuate portion 608 may be connected to the first wall 604. The second wall 606 may also include a substantially planar wall portion 609. The substantially planar wall portion 609 may be parallel to the first wall 604. A plurality of ribs (e.g., first rib 610a, second rib 610b, third rib 610c, fourth rib 610d, fifth rib 610e) may extend between and connect the first wall 604 and the second wall 606. For example, each of the plurality of ribs may be perpendicular to the planar wall portion 610 of the first wall 604 and the second wall 606. Thus, when the frame 602 is oriented such that the first wall 604 is horizontal relative to the ground, each of the plurality of ribs may be vertical relative to the first wall 604, wherein the end of each of the plurality of ribs is attached to the substantially planar wall portion 610 of the first wall 604 and the second wall 606.

[0047] Frame 602 can be used in conjunction with the manufacture of frame 202 ( Figure 2 The frame 602 can be made of the same or substantially similar material. Similarly, the second wall 606 of the frame 602 can be reinforced with a CFRT reinforcement layer 612. The CFRT reinforcement layer 612 can be substantially similar to the CFRT reinforcement layer 218 (…). Figure 2 The CFRT enhancement layer 218 enhances the frame 202 ( Figure 2 The second wall 206 () Figure 2 The first wall 604 of frame 602 can also be reinforced with a combination of a CFRT reinforcing layer and a thermoplastic layer co-extruded with frame 602. This CFRT reinforcing layer and thermoplastic layer can be substantially similar to CFRT reinforcing layer 216. Figure 2 ) and thermoplastic layer 220 ( Figure 2 The CFRT reinforcing layer 216 and the thermoplastic layer 220 reinforce the frame 202. Figure 2 The first wall 204 ( Figure 2An opening (not shown) may be formed in the second wall 606 of the frame 602, at one of the multiple ribs. The opening may be configured to receive a bracket 700 attached to the vehicle 100. Figure 1A , 1B ).

[0048] Figures 7A to 7F It is used to connect to the side pedal 600 ( Figure 6 A schematic diagram of an example of a bracket 700. The bracket 700 can be used with a bracket 500 ( Figures 5A-5G They share some similarities. Scaffold 700 can be made of resin (e.g., polypropylene (PP), polybutylene terephthalate (PBT), polycarbonate (PC), polyamide (PA), or any combination thereof). Scaffold 500 can be reinforced with fibers such as long glass fibers or other fibers (e.g., glass, aramid, carbon, natural fibers, or any combination thereof). The amount of fiber can vary between 20 wt% and 60 wt%. Each wt% is based on the weight of the scaffold. In the context of weight percentage, "about" indicates a deviation between ±2% and ±5%.

[0049] like Figure 7A As shown, the bracket 700 may include a body 702. The body 702 may include a first end portion 704. The body 702 may include a second end portion 706 opposite to the first end portion 704. As described below, the first end portion 704 can connect the bracket 700 to the side pedal 600. Figure 6 In embodiments where the side pedal is a fixed side pedal (e.g., side pedal 104), the second end portion 704 can connect the bracket 700 to the vehicle 100 ( Figure 1A The sill plate 102 is connected to the side pedal. In embodiments where the side pedal is a retractable side pedal (e.g., side pedal 112), the second end portion 704 can connect the bracket 700 to a link (e.g., link 114a) connected to the bracket (e.g., bracket 118a).

[0050] The first end portion 704 of the body 702 may be formed with a cantilever portion 708. The first end portion 704 may also be formed with a support portion 710. The cantilever portion 708 may be formed on the support portion 710. In a side view of the body 702, the cantilever portion 708 may have a generally trapezoidal cross-section. The trapezoidal cross-section may have a longer edge 712 and a shorter edge 714. The longer edge 712 may be attached to the support portion 710. In some embodiments, when the body 702 is viewed from the side, the cantilever portion 708 may have a rectangular cross-section or a triangular cross-section. When viewed from the top, the cantilever portion 708 may have a rectangular cross-section with a first width close to the shorter edge 714. Additionally, when viewed from the top, the cantilever portion 708 may have a rectangular cross-section with a second width close to the longer edge 712 (greater than the first width). The cantilever portion 708 may be inserted into a first position on the frame 602 of the side pedal 600. For this purpose, a rectangular hole may be cut in the frame 602. The hole can have a width equal to the width of a rectangular cross-section that is close to the first width of the shorter edge 714. The rectangular cross-section close to the shorter edge 714 can be inserted into the cut hole. Specifically, a rectangular hole can be cut in the bottom portion of the frame 602, and the overhang 708 can be inserted into the frame 602 from below.

[0051] Body 702 can define shoulder 716 ( Figure 7A , Figure 7B , Figure 7C The overhang 708 may be arranged relative to the shoulder 716. This arrangement may define a space 718 between the shoulder 716 and the overhang 708. The shoulder 718 may define a plurality of openings (e.g., openings 720a, 720b). The openings may be connected to the side step 600 ( Figure 6 Multiple vertical ribs (e.g., ribs 610d, 610e) Figure 6 The corresponding multiple openings (not shown) in the diagram are aligned. For example... Figure 7E As shown, multiple fasteners (e.g., fasteners 722a, 722b) can be inserted into multiple openings (e.g., openings 720a, 720b). Openings 720a, 720b can be defined by a shoulder 708 and multiple openings formed in multiple vertical ribs to connect the body 702 to the side pedal 600. Figure 6 ).

[0052] like Figure 7C China and Figure 7D As shown in the top view of the body 702, the overhang 708 may define a plurality of seats (e.g., seats 724a, 724b). Each seat may be formed in the sidewall of the overhang 708. Each seat may be formed as a groove in which the end of a fastener may be positioned.

[0053] The suspension 708 can be attached to a first position on the frame (e.g., frame 202) of the side pedal 104. The first position on frame 202 can be the second wall 606 ( Figure 6 The wall portion 609 is substantially planar. As previously described, the overhang portion 708 has a shape (e.g., trapezoidal cross-section) that can be inserted into and locked into an opening formed in the substantially planar wall portion 609.

[0054] The area of ​​the support 710 between the shoulder 716 and the overhang 708 can be formed with a specific geometry. This geometry complements the geometry of the second wall 606 between the two ribs (e.g., ribs 610d, 610e) of the frame 602 located within space 718. In this configuration, when the overhang 708 is inserted into an opening formed in the substantially planar wall 609, the support 710 can extend below the planar wall 609 of the second wall 606 of the frame 202. In this way, the support 710 can provide additional support for the bottom of the frame 602. Fasteners 722a, 722b further secure the bracket 700 to the frame 702.

[0055] like Figure 7D and Figure 7F As shown, the second end portion 706 of the support 700 may include two leg portions 728a and 728b. Each leg portion can be connected to the body 702. The connection between each leg portion and the body 702 defines a space 730 between them. A connecting rod can be positioned in this space. The connecting rod can be connected to each leg portion. For this purpose, fixing points can be defined in each leg portion, for example, fixing points 732a and 732b in leg portion 728a and fixing points 732ca and 732db in leg portion 728b. The fixing points are through holes formed in the leg portions. Corresponding through holes formed in the connecting rods are aligned with the fixing points on the leg portions, and the leg portions are connected to the connecting rods using fasteners similar to those described above.

[0056] Figure 7E and Figure 7F The top and bottom views of the bracket 700 are shown respectively. The bracket 700 can be made of injection-molded plastic. Figures 7A to 7F As shown, the main body 702 can be integrally formed with a ribbed design to increase bending and torsional stiffness. Each of the overhang 708 and the support 710 can extend across the entire width of the main body 702. The overhang 708 has an upper member, a lower member, and a cross-sectional member. The cross-sectional member connects the upper member to the lower member, thereby providing thickness to the overhang 708. Similarly, the support 710 can also have an upper member, a lower member, and a cross-sectional member. This cross-sectional member connects the upper member to the lower member, thereby providing thickness to the support 710.

[0057] Figure 8 This is a schematic cross-sectional view of another example of a side pedal 800. The side pedal 800 can be substantially similar to side pedals 104, 112 (…). Figure 1A , Figure 1B , Figure 2 The cross-section of side pedal 800 may differ from the cross-sections of side pedals 104 and 112. For example... Figure 8 As shown, the side step 800 may include a frame 802. The frame 802 may have sufficient stiffness to resist bending deflection. Specifically, the stiffness of the frame 802 may be sufficient to prevent bending under loads applied to the frame 802, such as when a person steps on the side step 800 to enter or exit the vehicle 100. Figure 1A , Figure 1B When the passenger compartment is located, the frame 802 may include a first wall 804. The frame 802 may include a second wall 806 opposite to the first wall 804. The two walls may extend along the length of the frame 802.

[0058] The first wall 804 may be substantially planar (i.e., flat) along the entire length of the frame 802. The first wall 804 may have sufficient dimensions to facilitate easy entry into or exit from the vehicle 100. Figure 1A , Figure 1B The width of the passenger compartment when standing on it. The second wall 806 may include an arcuate portion 808. The arcuate portion 808 may be connected to the first wall 804. The second wall 806 may also include a substantially planar wall portion 809. The substantially planar wall portion 809 may be parallel to the first wall 804. A plurality of ribs (e.g., first rib 810a, second rib 810b, third rib 810c, fourth rib 810d, fifth rib 810e) may extend between and connect the first wall 804 and the second wall 806. For example, each of the plurality of ribs may be perpendicular to the planar wall portion 810 of the first wall 804 and the second wall 806. Thus, when the frame 802 is oriented such that the first wall 804 is horizontal relative to the ground, each of the plurality of ribs may be vertical relative to the first wall 804, wherein the end of each of the plurality of ribs is attached to the substantially planar wall portion 810 of the first wall 804 and the second wall 806.

[0059] Frame 802 can be used in conjunction with the manufacture of frame 202 ( Figure 2 The frame 802 can be made of the same or substantially similar material as the frame 202. Similarly, the second wall 806 of the frame 802 can be reinforced with a CFRT reinforcement layer 812. The CFRT reinforcement layer 812 can be substantially similar to that used to reinforce the frame 202. Figure 2 The second wall 206 ( Figure 2 CFRT enhancement layer 218 ( Figure 2The first wall 804 of frame 802 can also be reinforced with a combination of a CFRT reinforcing layer and a thermoplastic layer co-extruded with frame 802. This CFRT reinforcing layer and thermoplastic layer can be substantially similar to those used to reinforce frame 202. Figure 2 The first wall 204 ( Figure 2 CFRT enhancement layer 216 ( Figure 2 ) and thermoplastic layer 220 ( Figure 2 An opening (not shown) may be formed in the second wall 806 of the frame 802, within one of the multiple ribs. The opening may be configured to accommodate attachments to the vehicle 100. Figure 1A , Figure 1B ) 700 bracket.

[0060] Figure 8 The illustrated embodiment includes a finger 818 for connecting the side pedal 800 to the bracket 701. The finger may be sized to snap into the side pedal 800. It may include features that allow the side pedal 800 to slide onto the finger 818. The finger may include a stop 820 to resist removal.

[0061] Anti-slip layer 816 can be attached to side pedal 800. Anti-slip layer 816 can be molded to side pedal 800. Anti-slip layer 816 can be co-extruded with other materials of side pedal 800, such that they are molded and / or bonded together. Anti-slip layer 816 can be bonded to side pedal 800, for example using PSA or thermosetting resin. Anti-slip layer 800 can contain rubber, UV protectant, some combination thereof, and other materials. Anti-slip layer 816 may include abrasives.

[0062] Various embodiments of this disclosure have been described. However, it should be understood that various modifications can be made without departing from the spirit and scope of this disclosure.

Claims

1. A device for connecting brackets (118a, 118b) mounted to a door sill (102) area of ​​a vehicle (100), the device comprising: Side pedals (104, 112, 600), the side pedals comprising: An extruded plastic elongated frame (202, 602, 702) having a first wall (204, 604) and a second wall (206, 606) opposite to the first wall (204, 604), the frame (202, 602, 702) having a length; and A continuous fiber-reinforced thermoplastic (CFRT) reinforcing layer (216) laminated on a portion of the first wall (204, 604) and a portion of the second wall (206, 606), The side steps (104, 112, 600) are configured to be mounted to the brackets (118a, 118b) and extend along the length, and the vehicle (100) door sill plate (102) area defines the step for entering the vehicle (100).

2. The apparatus according to claim 1, wherein the first wall (204, 604) comprises a first planar wall.

3. The apparatus according to claim 1 or 2, comprising: A co-extruded thermoplastic layer (220) is applied to said portion of the first wall (204, 604), the co-extruded thermoplastic layer (220) including an anti-slip surface.

4. The apparatus according to any one of claims 1 to 3, wherein the co-thermoplastic layer (220) is a first co-extruded thermoplastic layer (220), wherein the apparatus includes a second co-extruded thermoplastic layer applied to the portion of the second wall.

5. The device according to any one of claims 1 to 4, wherein the frame (202, 602, 702) is reinforced with continuous fibers.

6. The device according to any one of claims 1 to 5, wherein the frame (202, 602, 702) is reinforced with metal sheet.

7. The apparatus according to any one of claims 1 to 6, wherein the metal sheet is joined to the frame (202, 602, 702) by an adhesive film or a mechanical lock.

8. The apparatus according to any one of claims 1 to 7, wherein, The metal sheet covers the corners of the first and second ends of the frame (202, 602, 702).

9. The device according to any one of claims 1 to 8, wherein the second wall includes an arcuate portion (208, 608), wherein the device includes a plurality of ribs (610d, 610e) extending between and connecting the first wall and the second wall, the plurality of ribs (610d, 610e) spanning the length of the frame (202, 602, 702), wherein each bracket is connected to at least two of the plurality of ribs (610d, 610e).

10. The apparatus according to any one of claims 1 to 9, wherein the frame (202, 602, 702) comprises about 40 wt% to about 90 wt% of polypropylene (PP) or polybutylene terephthalate (PBT) or polycarbonate (PC) or polyamide (PA), about 10 wt% to about 60 wt% of fiber, and about 0.0001 wt% to about 30 wt% of impact modifier, filler, flame retardant, antioxidant or reinforcing agent, wherein each wt% is based on the weight of the frame (202, 602, 702).

11. The apparatus according to any one of claims 1 to 10, wherein the CFRT reinforcing layer comprises about 10 wt% to about 60 wt% of polypropylene or PBT or PC or PA, about 30 wt% to about 80 wt% of fiber, and about 0.0001 wt% to about 20 wt% of impact modifier, filler, flame retardant, antioxidant, or reinforcing agent, wherein each wt% is based on the weight of the CFRT reinforcing layer.

12. The apparatus according to any one of claims 1 to 11, wherein the CFRT reinforcing layer comprises a multilayer laminate formed of unidirectional tape, woven fabric composite material or thermoplastic organic sheet, wherein the thermoplastic organic sheet comprises a plurality of thermoplastic prepreg or semi-prepreg material layers stacked and pressed into a sheet.

13. A method for manufacturing a side step (104, 112, 600) for an automobile (100), said method comprising: Using a first die (302), profiles of plastic frames (202, 602, 702) are extruded, the plastic frames having a first wall and a second wall opposite to the first wall, and the plastic frames (202, 602, 702) having a length; Using a second (504, 704) die, a continuous fiber-reinforced thermoplastic (CFRT) reinforcement layer is laminated onto a portion of the first wall and a portion of the second wall; as well as Multiple brackets are attached along the length of the plastic frame (202, 602, 702), each bracket being configured to connect the side steps (104, 112, 600) of the vehicle (100) to the body of the vehicle (100).

14. The method of claim 13, wherein the first wall (204, 604) comprises a first planar wall.

15. The method according to claim 13 or 14, comprising co-extruded a thermoplastic layer (220) on the portion of the first wall, the co-extruded thermoplastic layer (220) comprising an anti-slip surface.

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