Additively manufactured heated running board and system for a motor vehicle

Abstract

A heated running board for a motor vehicle comprises a substrate formed by an additive manufacturing process and a prefabricated heating element embedded in the substrate. The prefabricated heating element is not formed by the additive manufacturing process. A system for operating a heated running board for a motor vehicle comprises the heated running board, at least one sensor, and a controller. The controller is configured to receive signals from the at least one sensor and supply power to the prefabricated heating element to control its temperature based on at least one operating characteristic from the at least one sensor.

Description

FIELD OF TECHNOLOGY

[0001] The present disclosure relates to running boards for motor vehicles and, more particularly, to a method of making and a system for operating a heated running board. GENERAL STATE OF THE ART

[0002] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.

[0003] Motor vehicles are commonly equipped with running boards that extend along an entry area of ​​the motor vehicle to assist a passenger in getting in and out of the motor vehicle. In some motor vehicles, the running boards are permanently attached to one side of the motor vehicle, and in other configurations, they can be deployed when a motor vehicle door is opened. In both cases, however, because they are located on an exterior surface of the motor vehicle, they are subject to the effects of weather and other elements. For example, they can accumulate dirt, get wet, or develop a layer of ice under certain weather conditions.

[0004] The present disclosure addresses these problems associated with running boards on which dirt, debris, or ice accumulates. SUMMARY

[0005] This section provides a general summary of the disclosure and is not a comprehensive disclosure of its full scope or all of its features.

[0006] In one form, the present disclosure provides a heated running board for a motor vehicle. The heated running board includes a substrate formed by an additive manufacturing process and a prefabricated heater embedded in the substrate. The prefabricated heater is not formed by the additive manufacturing process.

[0007] In variations of this heated footboard, which can be implemented individually or in any combination, the following applies: The substrate includes a plurality of openings, and the prefabricated heater defines a line pattern extending around the plurality of openings; the heated footboard further includes a plurality of LEDs (light-emitting diodes) embedded in the substrate and positioned over at least a portion of the plurality of openings; the prefabricated heater includes a resistive heating element surrounded by a dielectric core, the dielectric core surrounded by a protective enclosure; the prefabricated heater includes a radiant fluid channel configured to receive a heating fluid; the prefabricated heater is disposed proximate a top surface of the substrate;the heated running board further comprises an ice detector embedded in the substrate; the heated running board further comprises at least one temperature sensor embedded in the substrate; the substrate is a monolithic material; the heated running board further comprises a plurality of embedded prefabricated heaters arranged at predetermined locations along a length of the substrate; each of the plurality of prefabricated heaters is independently controlled; and the heated running board further comprises electronic circuitry embedded in the substrate.

[0008] The present disclosure further provides a heated running board for a motor vehicle. The heated running board includes a substrate formed by an additive manufacturing process, a prefabricated heater embedded in the substrate and disposed near a top surface of the substrate, and a plurality of LEDs (light-emitting diodes) embedded in the substrate. The substrate includes a plurality of openings. The prefabricated heater defines a line pattern extending around the plurality of openings. The LEDs are positioned over at least a portion of the plurality of openings.

[0009] In one form, the present disclosure provides a system for operating a heated running board for a motor vehicle. The system includes a heated running board, at least one sensor, and a controller. The heated running board includes a substrate formed by an additive manufacturing process and a prefabricated heater embedded in the substrate. The controller is configured to receive signals from the at least one sensor and supply power to the prefabricated heater to control a temperature of the prefabricated heater based on at least one operating characteristic of the at least one sensor.

[0010] In variations of this system, which may be implemented individually or in any combination, the following applies: the at least one sensor is a temperature sensor and the at least one operating characteristic is an outside air temperature (OAT); the at least one sensor is a vibration sensor and the at least one operating characteristic is ice accumulation; the at least one sensor is an exterior camera mounted on the motor vehicle and the at least one operating characteristic is foreign substance accumulation along the substrate; the at least one sensor is a resistive heating element of the prefabricated heater, the resistive heating element defining a sufficient temperature coefficient to function as both a heater and a sensor; the controller provides power to the prefabricated heater based on a predetermined schedule when the motor vehicle is started;and the controller is configured to deploy the heated running board based on the at least one operating characteristic.;

[0011] Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are for illustrative purposes only and are not intended to limit the scope of the present disclosure. DRAWINGS

[0012] In order that the disclosure may be fully understood, various forms thereof will now be described by way of example with reference to the accompanying drawings, in which: Fig. 1 is a perspective view of a motor vehicle having a heated running board constructed in accordance with the teachings of the present disclosure; Fig. 2 is a perspective top view of one form of the heated footboard of Fig. 1; Fig. 3 is a cross-sectional view taken along line 3-3 of Fig. 2 of the heated running board Fig. 1; Fig. 4 is a cutaway perspective view of a tubular heater constructed in accordance with the teachings of the present disclosure; Fig. 5 is a flow diagram illustrating a method of manufacturing the heated running board according to the teachings of the present disclosure; and Fig. 6 is a schematic diagram illustrating a system for operating the heated running board according to the teachings of the present disclosure.

[0013] The drawings described in this document are for illustrative purposes only and are not intended to limit the scope of the present disclosure in any way. DETAILED DESCRIPTION

[0014] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that corresponding reference characters indicate like or corresponding parts and features throughout the drawings.

[0015] In relation to Fig. 1-3, a heated running board 20 for an exemplary motor vehicle 10 is shown. The heated running board 20 is configured as a long, roughly rectangular surface disposed along the length of the motor vehicle 10 to assist a passenger in entering or exiting the motor vehicle 10. In one form (not shown), the heated running board 20 is configured to extend from a retracted position to an extended position and back again to provide a streamlined shape to the motor vehicle 10.

[0016] The heated footboard 20 generally includes a substrate 22 formed by an additive manufacturing process and a prefabricated heater 24 embedded in the substrate 22. As explained in more detail below, the prefabricated heater 24 is not formed by an additive manufacturing process, but is instead preformed or fabricated prior to the actual additive manufacturing process that forms the substrate 22 and embeds the prefabricated heating element 24 in the substrate 22.

[0017] The substrate 22 is formed by an additive manufacturing process, as explained in more detail below. Because the substrate 22 is formed by additive manufacturing techniques, the substrate 22 can be formed as a single integral component rather than from an assembly of individual component parts. The integral structure of the substrate 22 thus reduces potential stresses caused by welds or other joining methods, such as mechanical, and also provides the flexibility to be able to embed other components alongside the prefabricated heater 24, as explained in more detail below.

[0018] In one form, the substrate 22 is formed from a metal, such as aluminum, stainless steel, or mild steel. In another form, the substrate 22 is formed from a polymer, such as acrylonitrile butadiene styrene (ABS), polyamides, polypropylene, and the like. In yet another form, the substrate 22 may be formed from a composite or hybrid material, such as a thermosetting or thermoplastic matrix with embedded fibers. In one form, the substrate 22 is monolithic, meaning it comprises the same material throughout with the same material properties in every direction. In another form, more than one type of material may be used in forming the substrate 22, e.g., a polymer on the bottom and an aluminum material on the top. Further examples and details of various additive manufacturing processes are provided in more detail below.

[0019] With particular reference to Fig. 3, the substrate 22 includes a lower portion 26 and an upper portion 28. The upper portion 28 includes an upper surface 30 and includes, in one form, a plurality of protrusions 32. The optional protrusions 32 (or other surface shaping / structuring) provide more traction on the upper surface 30 for an operator and / or passenger. As further shown, the substrate 22 includes a plurality of openings 34 (also in Fig. 2) or apertures extending from the upper surface 30 through the substrate 22 to a lower surface 31. The apertures 34 are generally provided to reduce the weight of the entire heated running board 20 while providing drainage for any precipitation or debris that may form on the upper surface 30 of the heated running board 20. In another form not shown, the heated running board 20 does not include apertures 34.

[0020] The prefabricated heater 24 is embedded between the lower portion 26 and the upper portion 28 in the substrate 22 and, in this form, is disposed near the upper surface 30 of the substrate 22. This places the heat from the prefabricated heater 24 closer to the ice / deposit on the upper surface 30 and helps provide improved traction on the upper surface 30 of the heated running board 20. However, it should be understood that the prefabricated heater 24 may be placed in any of a number of locations in the substrate 22 depending on specific application requirements, while remaining within the scope of the present disclosure.

[0021] Furthermore, with reference to Fig. 2, the prefabricated heater 24 defines a line pattern (or line path) extending around the plurality of openings 34, as shown. The line pattern is configured to provide heat in predetermined areas of the substrate 22, and thus, the line pattern shown is merely exemplary.

[0022] In a form not shown, the heated footboard 20 includes a plurality of embedded prefabricated heaters 24 arranged at predetermined locations along a length of the substrate 22. Each of the plurality of prefabricated heaters 24 may be controlled independently, or alternatively, some of the plurality of prefabricated heaters 24 may be controlled together or simultaneously.

[0023] With further reference to Fig. 3, the heated running board 20, in one form, further includes a plurality of LEDs (light-emitting diodes) 35 embedded in the substrate 22 and positioned over at least a portion of the plurality of openings 34. The LEDs 35 illuminate the heated running board 20, thus assisting an operator or passenger in more easily locating and placing their foot on the heated running board 20. The LEDs 35 may also be located in other areas of the heated running board 20 without departing from the scope of the present disclosure, and thus, the locations illustrated herein are merely exemplary. For example, the LEDs 35 could be located on an outer edge 37 such that the heated running board 20 is visible from an exterior of the motor vehicle 10.

[0024] In an additional form, at least one sensor 62 is embedded in the substrate 22. A variety of types of sensors 62 may be used, including, among others, an ice detector or a temperature sensor. The sensors 62 are described in more detail below.

[0025] The heated running board 20 further includes an electronic circuit 36 ​​embedded in the substrate 22. The electronic circuit 36 ​​is used to provide power to the prefabricated heater 24, the LEDs 35, the sensors 62, or any other electrical components in or on the substrate 22. The electronic circuit 36 ​​can also be used to receive communication from the controllers 64 or sensors 62 on the motor vehicle 10.

[0026] As previously stated, the prefabricated heater 24 is preformed or fabricated before being embedded into the substrate 22 during the additive manufacturing process.

[0027] Thus, the prefabricated heater 24 is not manufactured by additive manufacturing at the same time as the substrate 22 is formed by additive manufacturing. In a form as in Fig. 4, the prefabricated heater 24 is a "tubular" heater construction generally comprising a resistive heating element 42 surrounded by a dielectric core 44, with the dielectric core 44 surrounded by a protective sheath 46. The resistive heating element 42 may also define a sufficient temperature coefficient of resistance (TCR) to function as both a heater 24 and a temperature sensor (i.e., changes in resistance are calibrated to the TCR characteristics of the resistive heating element 42 to calculate temperature). In another form, the prefabricated heater 24 is a radiant fluid conduit (not shown) configured to receive a heating fluid provided / circulated by the systems of the motor vehicle 10 (e.g., an engine cooling fluid).

[0028] Now with reference to Fig. Figure 5 illustrates a method for manufacturing the heated footboard 20. First, the lower portion 26 of the substrate 22 is manufactured by additive manufacturing. For example, in one mold, the lower portion of the substrate 22 is manufactured by a fused deposition process in which multiple layers of a polymer are built up until the required shape is formed. Next, the prefabricated heater 24 is placed on the lower portion 26 of the substrate 22. In one mold, a recess is left in the lower portion 26 during printing, into which the prefabricated heater 24 is placed. Finally, the upper portion 28 of the substrate 22 is manufactured by additive manufacturing, thereby embedding or encapsulating the prefabricated heater 24.In additional variations of this method, additional components, such as the electrical circuit 36, the LEDs 35, or the sensors 62, are also embedded in the substrate 22 at specific predetermined locations, similar to the prefabricated heater 24.

[0029] The substrate 22 is additively manufactured using known or yet-to-be-developed additive manufacturing techniques. In one form, for example, the substrate 22 is manufactured from a metal powder by, among other processes, selective laser melting (SLM), direct metal laser sintering (DMSL), direct metal laser melting (DMLM), and electron beam melting (EBM). In another form, the substrate 22 is manufactured from a polymer by processes such as fused filament fabrication (FFF), selective laser sintering (SLS), stereolithography (SLA), and the like.

[0030] Additive manufacturing provides flexibility in producing a heated footboard with a substrate having embedded components (e.g., the prefabricated heater 24, the LEDs 35, the sensors 62) while allowing for varying composition throughout the volume of the heated footboard 20. For example, the upper portion 28 may be a wear-resistant material, such as ABS or nylon, while the lower portion 26 may be a lower-density material, such as polypropylene, to save weight. In one form, the substrate 22 is additively manufactured to include a plurality of small voids at predetermined locations so that the density of the substrate varies throughout the volume of the heated footboard 20.

[0031] Thus, thanks to the additive manufacturing process in combination with a prefabricated heater 24, the heated running board 20 has a number of distinctive structural properties. The properties of the substrate 22, for example, are tailored to the specific application and are further adapted to the requirements of specific locations in the heated running board by varying the material and / or material properties. Additionally, the embedded components (the prefabricated heater 24, sensors 62, LEDs 35, electronic circuits 36) can be arranged anywhere in the substrate 22 in real time and without dedicated tools, further adapting the design to a specific application.The customized location of the prefabricated heater 24 also allows for precise heat delivery to specific locations of the heated footboard 20 by adjusting the path / line or distance of the prefabricated heater 24 from the top surface 30. Furthermore, because additive manufacturing produces an integrated substrate without joints or seams, the heated footboard 20 has greater strength and lower weight than conventional manufacturing techniques.

[0032] Now with reference to Fig.6, a system 60 for operating the heated running board 20 integrated into an exemplary motor vehicle 10 is shown. The system 60 includes the heated running board 20 as described above and at least one sensor 62 in communication with a controller 64. As set forth in more detail below, the controller 64 is configured to receive signals from the sensors 62 and supply power to the prefabricated heater 24 to control a temperature of the prefabricated heater 24 based on at least one operating characteristic from the sensors 62.

[0033] The at least one sensor 62 detects at least one operating characteristic. The at least one operating characteristic may include any of a variety of outside environmental conditions and / or vehicle conditions. The operating characteristics may include, for example, temperature, vibration, light, ice accumulation, or vehicle speed, among others. In one form, the sensor 62 is a temperature sensor, and the operating characteristic is the outside air temperature or a temperature of the upper surface of the heated running board 20. The resistive heating device 24 element of the prefabricated heating device 24 may function as a temperature sensor, or a separate temperature sensor may be included. In another form, the sensor 62 is a vibration sensor, and the operating characteristic is ice accumulation on the heated running board 20.If the heated running board 20 is retractable, torque sensors 62 may identify ice accumulation in addition to or instead of vibration sensors. In yet another form, the sensor 62 is a camera, and the operational characteristic is a foreign substance accumulation on the substrate 22, which may include ice or a mixture of ice and mud. The camera may also be used to identify snow or ice in the environment of the motor vehicle 10, possibly indicating ice-forming conditions. LEDs embedded in the substrate 22 may be used to assist in the visual identification of the substance accumulation. Other types of sensors 62 and operational characteristics may be utilized within the scope of the present disclosure. Additionally, the various forms may be used in any combination.The sensors 62 are located on the motor vehicle 10 and may be embedded in the substrate 22, otherwise attached to the heated running board 20, or placed elsewhere on the motor vehicle 10.

[0034] The controller 64 is coupled to the at least one sensor 62 that measures or detects external environmental conditions and vehicle conditions. In one form, the controller 64 is part of an electronic control unit (ECU) of the motor vehicle 10 that controls one or more electrical systems of the motor vehicle 10. In another form, the controller 64 is further configured to deploy or retract the heated running board 20 based on the at least one operating characteristic. The controller 64 is configured as understood in the art and, in one form, includes a processor and memory.

[0035] The controller 64 is configured to send power to the prefabricated heater 24 to apply heat to the heated footboard 20 based on the signals received from the sensors 62. In one form, the controller sends power to the prefabricated heater 24 if the input from the sensors 62 indicates that an operating characteristic meets a predetermined threshold or range. The controller may continue to send power to the prefabricated heater 24 until the operating characteristic is no longer within the predetermined range. Alternatively, the controller 64 may provide power to the prefabricated heater 24 for a period of time. In another form, the controller 64 may turn the prefabricated heater 24 on and off at predetermined intervals until the operating characteristic is no longer within the predetermined range.

[0036] In one form, the controller 64 provides power to the prefabricated heater 24 based on a predetermined schedule starting from an event, such as when the motor vehicle 10 is started or turned off. In another form, the controller 64 provides power to the prefabricated heater 24 based on a weather forecast or other additional input. These and other various control schemes may be employed depending on specific operating requirements or user preferences without departing from the scope of the present disclosure.

[0037] Unless expressly stated otherwise herein, all numerical values ​​indicating mechanical / thermal properties, composition percentages, dimensions and / or tolerances, or other characteristics are to be understood as modified by the word "about" or "approximately" when describing the scope of the present disclosure. This modification is desirable for various reasons, including industrial practice, material, manufacturing and assembly tolerances, and testability.

[0038] As used in this document, the phrase "at least one of A, B, and C" should be interpreted to mean a logical (A OR B OR C) using a non-exclusive logical OR, and should not be interpreted to mean "at least one of A, at least one of B, and at least one of C."

[0039] In this application, the terms "controller" and / or "module" may refer to, be part of, or include: an application specific integrated circuit (ASIC); a digital, analog, or mixed analog / digital discrete circuit; a digital, analog, or mixed analog / digital integrated circuit; a combinational logic circuit; a field programmable gate array (FPGA); processor circuitry (shared, dedicated, or group) that executes code; memory circuitry (shared, dedicated, or group) that stores code executed by the processor circuitry; other suitable hardware components (e.g.,an operational amplifier circuit integration circuit as part of the heat flow data module) that provide the described functionality; or a combination of some or all of the foregoing, such as in a single-chip system.

[0040] The term "memory" is a subset of the term "computer-readable medium." As used in this document, the term "computer-readable medium" does not include transitory electrical or electromagnetic signals propagating through a medium (such as a carrier wave); therefore, the term "computer-readable medium" can be considered tangible and non-transitory.Non-limiting examples of a non-transitory, tangible computer-readable medium include non-volatile memory circuits (such as a flash memory circuit, an erasable programmable read-only memory circuit, or a mask read-only memory circuit), volatile memory circuits (such as a static random access memory circuit or a dynamic random access memory circuit), magnetic storage media (such as an analog or digital magnetic tape or a hard disk drive), and optical storage media (such as a CD, a DVD, or a Blu-ray Disc).

[0041] The devices and methods described in this application may be implemented in part or in whole by a special-purpose computer created by configuring a general-purpose computer to perform one or more specific functions embodied in computer programs. The functional blocks, flowchart components, and other elements described above serve as software specifications that can be translated into computer programs through the routine work of a skilled technician or programmer.

[0042] The description of the disclosure is purely exemplary in nature, and thus, examples that do not depart from the substance of the disclosure are intended to be within the scope of the disclosure. Such variations should not be considered a departure from the spirit and scope of the disclosure.

[0043] According to one embodiment of the present invention, the invention is further characterized by an ice detector embedded in the substrate.

[0044] According to one embodiment of the present invention, the invention is further characterized by at least one temperature sensor embedded in the substrate.

[0045] According to the present invention, there is provided a heated running board for a motor vehicle, the heated running board comprising: a substrate formed by an additive manufacturing process; a prefabricated heater embedded in the substrate, wherein the prefabricated heater is disposed proximate a top surface of the substrate; and a plurality of LEDs (light-emitting diodes) embedded in the substrate, wherein the substrate includes a plurality of openings and the prefabricated heater defines a line pattern extending around the plurality of openings, and wherein the LEDs are positioned over at least a portion of the plurality of openings.

[0046] According to one embodiment, the at least one sensor is a resistance heating element of the prefabricated heating device, wherein the resistance heating element defines a sufficient resistance temperature coefficient to function as a heater and as a sensor.

[0047] According to one embodiment, the controller is configured to deploy the running board based on the at least one operating characteristic.

Claims

[1] Heated running board for a motor vehicle, the heated running board comprising: a substrate formed by an additive manufacturing process; and a prefabricated heater embedded in the substrate, wherein the prefabricated heater is not formed by the additive manufacturing process. [2] The heated footboard of claim 1, wherein the substrate comprises a plurality of openings and the prefabricated heater defines a line pattern extending around the plurality of openings. [3] The heated footboard of claim 2, further comprising a plurality of light-emitting diodes (LEDs) embedded in the substrate and positioned over at least a portion of the plurality of openings. [4] A heated footboard according to any one of claims 1-3, wherein the prefabricated heating device comprises a resistive heating element surrounded by a dielectric core, the dielectric core being surrounded by a protective sheath. [5] A heated footboard according to any one of claims 1-3, wherein the prefabricated heating device comprises a radiant fluid channel configured to receive a heating fluid. [6] A heated footboard according to any one of claims 1-3, wherein the prefabricated heating device is arranged near an upper surface of the substrate. [7] The heated footboard of claim 1, wherein the substrate is a monolithic material. [8] The heated footboard of claim 1, further comprising a plurality of embedded prefabricated heaters disposed at predetermined locations along a length of the substrate. [9] A heated footboard according to claim 8, wherein each of the plurality of prefabricated heaters is independently controlled. [10] The heated footboard of claim 1, further comprising an electronic circuit embedded in the substrate. [11] A system for heating a running board for a motor vehicle, the system comprising: the heated running board according to claim 1; at least one sensor; and a controller, the controller configured to receive signals from the at least one sensor and supply power to the prefabricated heater to control a temperature of the prefabricated heater based on at least one operating characteristic of the at least one sensor. [12] The system of claim 11, wherein the at least one sensor is a temperature sensor and the at least one operating characteristic is an outside air temperature (OAT). [13] The system of claim 11, wherein the at least one sensor is a vibration sensor and the at least one operating characteristic is ice accumulation. [14] The system of claim 11, wherein the at least one sensor is an exterior camera mounted on the vehicle and the at least one operational characteristic is a foreign substance accumulation along the substrate. [15] The system of claim 11, wherein the controller provides power to the prefabricated heater based on a predetermined schedule when the motor vehicle is started.

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