Plastic profile extrusion retractable running board

Abstract

A plastic profile extrusion running board (104) includes a profile- extruded plasticelongate 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 running board is configured to mount to the brackets (106a) and extend along the length. The automobile rocker panel (102) area defines a step into the automobile.

Description

PLASTIC PROFILE EXTRUSION RETRACTABLE RUNNING BOARDTECHNICAL FIELD

[0001] This disclosures relates to automobile components, and more particularly to automobile components made by plastic profile extrusion.BACKGROUND

[0002] A running board of an automobile component is a platform that extends from the front wheel to the back wheel of an automobile, for example, a truck, a sport utility vehicle [SUV], pickup truck or other vehicle. In general, running boards can be found in vehicles, for example, four wheel drive [4WD] vehicles, that have a relatively high ground clearance, i.e., a relatively high elevation above the ground. The running board can be fixed, i.e., stationary relative to the automobile’s body. Alternatively, the running board can be retractable, i.e., selectively moveable between a deployed position and a retracted position. A retractable running board is also called a powered running board.

[0003] U.S. 11,269,798 describes a horizontally moving retractable vehicle step attachable to a low-to-the-ground vehicle like a van. The horizontal vehicle step can provide access to different portions of the vehicle. The stepping structure of the vehicle step includes a structurally strong and / or lightweight material.

[0004] U.S. 11,180,100 describes a retractable step and side bar assembly that can be used for raised vehicles such as trucks. The retractable step can provide for significant reach in a deployed position to allow for a user to enter the raised vehicle. In a stowed position, the retractable step can be located within the side bar. The components of the vehicle can be made from structurally strong and / or light weight material.

[0005] U.S. 2002 / 00041087 describes a running board top plate that includes multiple light-diffusing waveguides. A reflective layer is positioned around a portionof each waveguide. A base layer receives one or more of the light-diffusing waveguides and the reflective layer. A clear lens layer is positioned over the lightdiffusing waveguides, the reflective layer, and the base layer. The components of the running board can be formed of fiber-filled polypropylene material.

[0006] U.S. 10,442,361 describes a vehicle running board with opposing vertical walls extending along a length of a tubular structure. The running board 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 the tubular structure with a generally rectilinear cross-section. A polymer outer covering extends over the opposing vertical and opposing horizontal walls.SUMMARY

[0007] This disclosure describes plastic profile extrusion retractable running boards and methods of making the same.

[0008] The details of one or more implementations of the disclosure are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the disclosure will be apparent from the description and drawings, and from the claims.DESCRIPTION OF DRAWINGS

[0009] FIG. 1A is a schematic diagram of an example of an automobile having a plastic profile extrusion running board.

[0010] FIG. IB is a schematic diagram of a plastic profile extrusion retractable running board.

[0011] FIG. 2 is a schematic diagram of a cross-section of an example of a running board.

[0012] FIG. 3 is a schematic diagram showing an example of a method of making the running board of FIG. 2.

[0013] FIG. 4 is a flowchart of an example of a process of making the running board of FIG. 2.

[0014] FIGS. 5A-5G are schematic diagrams of an example of a bracket to couple to the running board of FIG. 2.

[0015] FIG. 6 is a schematic diagram of a cross-section of another example of a running board.

[0016] FIGS. 7A-7F are schematic diagrams of an example of a bracket to couple to the running board of FIG. 6.

[0017] FIG. 8 is a schematic diagram of a cross-section of an example of a running board.

[0018] Like reference symbols in the various drawings indicate like elements.DETAILED DESCRIPTION

[0019] This disclosure describes a retractable running board produced by plastic profile extrusion. The frame can be manufactured with or without reinforcements, e.g., thermoplastic composite or metal sheet or both, that satisfy or increase stiffness and strength requirements. The resulting design is light weight and serves as an alternative to metallic running boards or running boards made of materials heavier than the plastic described in this disclosure. Profile extrusion allows having a closed cross-section. Such a design further increases resistance to bending due to high Moment of Inertia.

[0020] The retractable running board described in this disclosure is an alternative to a running board made using stamped metal [e.g., steel] parts that are then welded together. The running board described here is also an alternative to one made by aluminum profile extrusion. By using the running board described in thisdisclosure, the need to surface treat running boards, for example, to avoid corrosion (steel running board) or to anodize / wire draw (aluminum running board) can be avoided or reduced. Consequently, a quantity of material used to make the running board and technological complexities associated with processing such material can be reduced. Using a lightweight plastic running board allows downsizing the auxiliary components such as the motor used to maneuver the running board.

[0021] Moreover, certain automobiles like vans or sport utility vehicles (SUVs) deploy long running boards. Such long running boards made using metals or heavier materials can sag under the weight of the running board itself. In addition, such long running boards made using light weight alternative materials can sag under the weight of load applied to the running board during regular use. The running board described in this disclosure addresses the problem of the running board sagging under its own weight or under load. Specifically, the running board described in this disclosure can be made with a lamination process that combines plastic and composites. For example, the running board described here has a plastic frame reinforced with thermoplastic composite or metal sheets on the top or bottom (or both) of the frame of the running board. Such a construction can reduce, minimize or completely prevent sagging in the running board.

[0022] FIG. 1A is a schematic diagram showing an example of an automobile 100. The rocker panel 102 connects the front of the automobile 100 to the back of the automobile 100. In doing so, the rocker panel 102 increases rigidity of the automobile 100. Increased rigidity improves automobile handling. The automobile 100 has a plastic profile extrusion running board 104. Multiple brackets (e.g., a first bracket 106a, a second bracket 106b, or more brackets) can be mounted to the rocker panel 102. A running board 104 can be coupled to the multiple brackets 106a, 106b. The multiple brackets 106a, 106b can connect the running board 104 to the automobile 100. The running board 104 can be stationary or retractable. A stationary running board is one that remains stationary in the deployed position, i.e., extended away from the automobile 100 and available to be stepped on by an automobile user. Aretractable running board is one that can transition between a deployed state, in which the running board 112 can be stepped on to enter into the automobile 100, and a retracted state in which the running board 112 is folded and rendered unavailable to step on to enter the automobile 100.

[0023] The running board 104 can have a first end 108a and a second end 108b. A length of the running board 104 can span between the two ends 108a, 108b. The length of the running board 104 can span substantially the space between the front and rear wheels of the automobile 100. A cover 110 [e.g., a plastic or metal cover, sometimes called an endcap) can cover the first end 108a. Another cover [not shown) similarly can cover the second end 108b. The covered ends can also allow stowing the running board 104 in the limited space available in the rocker panel 102 area below the floor of the automobile 100.

[0024] FIG. IB is a schematic diagram showing a retractable running board 112. The running board 112 itself can be the same as the running board 104 [FIG. 1A). The running board 112 can be stationary or retractable. For example, the running board 112 can be in a retracted state when the automobile 100 is moving.

[0025] The running board 112 can be retractable due to the links 114a, 114b to which the running board 112 is connected. Specifically, one end of each of the links 114a, 114b can be connected to a respective bracket 106a, 106b. As described later, the brackets 106a, 106b can be connected to a frame of the running board 112. The brackets 106a, 106b are connected to the frame through fixation points 116a, 116b. In particular, the fixation points 116a, 116b form a connection between the brackets 106a, 106b and links 114a, 114b, respectively. A fixation point can be a combination of an opening formed in the bracket, an opening formed in the link and a pin or bolt or rod that passes through the two openings.

[0026] In some implementations, each link can be connected to a respective bracket by more than one fixation point. The opposite end of each link 114a, 114b can be connected to another respective bracket 118a, 118b. Both brackets 118a, 118b canbe connected to the automobile 100. For example, both brackets 118a, 118b can be connected by one or more fixation points similar to the fixation points 116a, 116b. Each end of each link can pivot about the fixation point that connects each end of each link to a respective bracket.

[0027] A motor 120 can be connected to one of the links [e.g., the link 114a). In response to receiving power, the motor 120 can induce a rotation on an end of the link 114a. The induced rotation can cause one end of the link 114a to pivot about the fixation point that can connect the link 114a to the bracket 118a. As the end of the link 114a, which is connected to the bracket 118a, pivots, the other end of the link 114a, which can be connected to the bracket 116a, also pivots. The pivoting causes a retraction of the running board 112 from a deployed state to a retracted state. The motor 120 can induce a rotation in an opposite direction to reverse the motion of the running board 112 from the retracted state to the deployed state. In this manner, the motor 120 can maneuver the running board 112 between the retracted and deployed states.

[0028] FIG. 2 is a schematic diagram of a cross-section of the running board 104. As shown in FIG. 2, the running board 104 can include a frame 202. The frame 202 has a stiffness sufficient to resist bending deflection. In particular, the stiffness of the frame 202 can be sufficient to not bend or have minimal deflection [i.e., fulfill structural requirements) under load applied on the frame 202. The load can be, for example, a person steps on the running board 104 to enter or exit the passenger compartment of the automobile 100 [FIG. 1). The frame 202 can include a first wall 204. The frame 202 can include a second wall 206 opposite the first wall 204. The two walls can extend a length of the frame 202.

[0029] The first wall 204 can be substantially planar [i.e., flat) along the entire length of the frame 202. The first wall 204 can have a width sufficient for a person to conveniently step on when entering or exiting the passenger compartment of the automobile 100 [FIG. 1). The second wall 206 can include an arced portion 208. Thearced portion 208 can connect to the first wall 204. The second wall 206 can also include a substantially planar wall portion 209. The substantially planar wall portion 209 can be parallel to the first wall 204.

[0030] Multiple ribs [e.g., a first rib 210a, a second rib 210b, a third rib 210c) can extend between and connect the first wall 204 and the second wall 206. For example, each of the multiple ribs can be perpendicular to the first wall 204. Each of the multiple ribs can 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 with reference to the ground, each of the multiple ribs can be vertical with reference to the first wall 204, with ends of each of the multiple ribs attached to the first wall 204 and the substantially planar wall portion 209 of the second wall 206.

[0031] The frame can be made of about 40 weight percentage (wt %) to about 90 wt % polypropylene [PP] or polybutylene tephthalate [PBT] or polycarbonate [PC] or polyamide (PA). The frame can also be made of about 10 wt% to about 60 wt% fiber (such as long glass fiber). The frame can include about 0.0001 wt% to about 30 wt% of an impact modifier, filler, flame retardant, antioxidant or reinforcing agent (or any combination of them). As an alternative or in addition to long glass fiber or other fibers such as glass, aramid, carbon, natural fiber, or any combination of them, can be used. Each wt % is based on a weight of the frame. In the context of weight percentage, the term “about” represents a deviation between ±2% and ±5%.

[0032] In some implementations, the arced portion 208 can be formed on one end of the second wall 206. The arced portion 208 can connect that end of the second wall 206 to one end of the first wall 204. A bracket receiving structure 212 can be formed on the opposite ends of the first wall 204 and the second wall 206. In the implementation shown in FIG. 2, the bracket receiving structure 212 can include two extruded plastic loops (first loop 214a, second loop 214b). The extruded plastic loops can be arranged to form an L-shape opening 215. The opening 215 can be configured to receive a bracket. In particular, the first loop 214a can be formed and attached tothe inside surface of the first wall 204 [i.e., the surface that is not exposed to the outside of the frame 202). The second loop 214b can be formed and attached to and extend away from the rib 210a. Each of the loops can extend the length of the frame 202. Such construction allows each bracket to be attached at any location along the length of the frame 202.

[0033] The frame 202 can be reinforced with continuous fiber or metal sheets. Where metal sheets reinforce the frame 202, the metal sheets can be used to form the covers [FIG. 1) that cover the ends of the frame 202.

[0034] A continuous fiber-reinforced thermoplastic [CFRT] reinforcement layer 216 can be laminated on a portion of the first wall 204. An outside surface can be laminated on the first wall 204 [i.e., the surface that is exposed to the outside of the frame 202]. The layer 216 can be laminated along the width of the outside surface. Another CFRT reinforcement layer 218 can be laminated on the second wall 206. For example, the other CFRT reinforcement layer 218 can be laminated on the substantially planar wall portion of the second wall 206. Each CFRT reinforcement layer can be an organic sheet, multi-ply laminates formed of unidirectional tapes [a UD laminate], a woven fabric composite, or a thermoplastic organosheet that can include multiple layers of thermoplastic prepreg or semi-preg material stacked and pressed into a sheet [or any combination of them]. Using unidirectional tapes formed into multi-ply laminates can offer off-axis performance. The off-axis performance can allow molding the laminates into complex shapes. The complex shapes can be overmolded with thermoplastic to provide localized reinforcement in specific locations. The woven fabric composite can include plain weave, twill weave, satin weave, to name a few [or any combination of them]. In some implementations, the CFRT reinforcement layer can be applied by lamination or co-extrusion.

[0035] Each CFRT reinforcement layer can be made of about 10 wt % to about 60 wt % polypropylene or PBT or PC or PA. The CFRT reinforcement layer can be made of about 30 wt % to about 80 wt % fiber [such as continuous glass fiber], andabout 0.0001 wt % to about 20 wt % of an impact modifier, filler, flame retardant, antioxidant and reinforcing agent. Each wt % is based on a weight of the CFRT reinforcement layer. As an alternative or in addition to continuous glass fiber or other fibers such as glass, aramid, carbon, natural fiber, or any combination of them, can be used.

[0036] A thermoplastic layer 220 can be applied on the first surface 204. For example, the thermoplastic layer 220 can be applied on top of the reinforcement layer 216. The thermoplastic layer 220 can be applied by lamination or co-extrusion. The thermoplastic layer 220 can be applied to completely cover the reinforcement layer 216. The thermoplastic layer 220 can be applied to extend an entire width of the first wall 204. The outside surface of the thermoplastic layer 220 [i.e., the surface facing away from the reinforcement layer 216) can be formed to have an anti-skid surface. For example, the outside surface of the thermoplastic layer 220 can be patterned to have steps or ribs. The anti-skid surface can provide traction when a person steps on the thermoplastic layer 220 when entering or exiting the automobile 100 [FIG. 1), thereby preventing slipping. In some implementations, the running board 104 includes only the thermoplastic layer 220. In some implementations, in addition to the thermoplastic layer 220, a second thermoplastic layer can be laminated on the second surface 206. For example, the second thermoplastic layer can be laminated on top of the reinforcement layer 218. The layers 218 and 220 can improve an aesthetic of the running board. The layer 220 can additionally have anti-scratch properties.

[0037] FIG. 3 is a schematic diagram showing an example of a method of making the running board 104 [FIG. 2). FIG. 4 is a flowchart of an example of a process 400 of making the running board 104 [FIG. 2). The process 400 is described with reference to the schematic diagram shown in FIG. 3. At 402, a profile of the plastic frame [e.g., the frame 202 [FIG. 2)) is extruded using a first die 302. The frame 202 has a first planar wall, a second planar wall opposite the first planar wall, and a length similar to the frame 202 [FIG. 2). As described earlier, the extruded frame can include only thermoplastic or thermoplastic reinforced with fiber composites or metal sheets.At 404, a reinforcement layer (e.g., the layers 216, 218 (FIG. 2)) made of CFRT 304 can be heated and laminated on the frame using a second die 306. For example, the CFRT 304 can be heated and laminated on a portion of the first wall and a portion of the second wall. At 405, examples can optionally include the co-extrusion of top protective layer (e.g. an anti-skid layer) using a second die. At 406, multiple brackets (e.g., brackets 106a, 106b (FIG. 1)) can be attached along the length of the frame. Each bracket can connect the running board 104 to the body of an automobile (e.g., the automobile 100 (FIG. 1)).

[0038] A thermoplastic layer (e.g., the thermoplastic layer 220 (FIG. 2)) can be attached to the CFRT reinforcement layer on the first wall of the frame (e.g., the CFRT reinforcement layer 220 (FIG. 2)). Such attachment can be implemented either by lamination or co-extrusion. To do so, the surfaces of the CFRT reinforcement layer and the thermoplastic extruded beam can be heated and melted, pressurized and subsequently cooled for bonding. For example, static hot press and double belt press can be used. In implementations in which metal sheets are used for structural reinforcement of the running board, such metal frames can be joined to the plastic frame through adhesive film or mechanical locks (or both), covering the inside and outside corners of the frame. As described earlier, anti-skid surface can be formed on the outside surface of the thermoplastic layer attached to the CFRT reinforcement layer. The anti-skid surface can be formed by embossing treatment on the thermoplastic layer. Alternatively or in addition, an additional layer of thermoplastic, pre-formed with the anti-skid morphology, can be applied to the first layer of thermoplastic. A result of implementing the process 400 can be a frame with the cross-section shown in FIG. 2.

[0039] FIGS. 5A-5G are schematic diagrams of an example of a bracket 500 to couple to the running board, for example, the running board 104 (FIG. 2) or the running board 112 (FIG. IB). The bracket 500 can include a body 502. The body 502 can include a first end portion 504. The body 502 can include a second end portion 506 opposite the first end portion 504. As described below, the first end portion 504can couple the bracket 500 to the running board. In implementations in which the running board is a stationary running board (for example, the running board 104), the second end portion 504 can couple the bracket 500 to the rocker panel 102. The rocker panel 102 couples to the automobile 100 (FIG. 1A). In implementations in which the running board is a retractable running board (for example, the running board 112), the second 504 portion can couple the bracket 500 to a link (for example, the link 114a). The link can couple to the bracket (for example, the bracket 118a).

[0040] As shown in FIG. 5B, the first end portion 504 of the body 502 can be formed to have an overhang portion 508. The first end portion 504 can be formed to also have a supporting portion 510. The overhang portion 508 can couple to a first location on the frame (for example, the frame 202) of the running board 104. The first location on the frame 202 can be the bracket receiving structure 212 described earlier. The overhang portion 508 can have a shape that can be inserted into the bracket receiving structure 212 and locked in place. In some implementations, the overhang portion 508 can be formed in an L-shape. In general, the overhang portion 508 can have any shape that includes one member deviating sharply from another, connected member (for example, by 90 degrees or less). In this arrangement, both members can be inserted into the bracket receiving structure 212 such that the deviated member can engage a rib (for example, the rib 210a) of the frame 202 to lock the bracket 500 to the frame 202.

[0041] The supporting portion 510 can be formed to extend farther from the first end 504 than the overhang portion 508. Under this construction, when the overhang portion 508 is inserted into the bracket receiving structure 212 of the frame 202, the supporting portion 510 can extend below the planar wall portion 210 of the second wall 206 of the frame 202. In this manner, the supporting portion 510 can provide additional support to the bottom of the frame 202. The supporting portion 510 can further be fastened to the frame 202. To do so, openings (for example, openings 512a, 512b (FIG. 50)) can be formed in the supporting portion 510 and aligned with openings (for example, opening 516 (FIG. 5AJ) formed in the frame 202.A fastener 518 [e.g., a pin, a rod, a bolt, similar fastener) can be passed through each of the openings 512a, 512b and the openings formed in the frame 202 to securely fasten the supporting portion 510 to the frame 202.

[0042] As shown in FIGS. 5C, 5F and 5G, the second end portion 506 of the bracket 500 can include two leg portions 522a, 522b. Each leg portion can be connected to the body 502 so as to define a space 523 in between. A link can be positioned in the space and coupled to each leg portion. To do so, fixation points can be defined in each leg portion, for example, fixation points 514a, 514b in the leg portion 522a and fixation points 524a, 524b in the leg portion 522b. A fixation point can be a through hole formed in a leg portion. Corresponding through holes can be formed in the link. The through holes formed in the link can be aligned with the fixation points on the leg portions. Then, the leg portions can be connected to the link using fasteners similar to those described above.

[0043] FIGS. 5D and 5E each show different views of the bracket 500. The bracket 500 can be made from injection-molded plastic. The bracket 500 can be made from a resin such as polypropylene [PP], polybutylene tephthalate [PBT], polycarbonate [PC], polyamide [PA] or any combinations of them. The bracket 500 can be reinforced with fibers such as long glass fiber or other fibers such as glass, aramid, carbon, natural fiber, or any combination of them, can be used. The quantity of fiber can range between 20 wt % to 60 wt%. Each wt % is based on a weight of the bracket. In the context of weight percentage, the term “about” represents a deviation between ±2% and ±5%.

[0044] As shown in each of FIGS. 5D and 5E, the body 502 can be formed with ribbing design throughout to add bending and torsional stiffness. Each of the overhang portion 508 and the supporting portion 510 can extend across an entire width of the body 502. The overhang portion 508 can have an upper member, a lower member and a cross-sectional member. The cross-sectional member can connect the upper member to the lower member, thereby giving the overhang portion 508 athickness. Similarly, the supporting portion 510 can also have an upper member, a lower member and a cross-sectional member. That cross-sectional member can connect the upper member to the lower member, thereby giving the supporting portion 510 a thickness.

[0045] FIG. 6 is a schematic diagram of a cross-section of another example of a running board 600. The running board 600 can be substantially similar to the running boards 104, 112 [FIGS. 1A, IB, 2). A cross-section of the running board 600 can be different from that of the running boards 104, 112. As shown in FIG. 6, the running board 600 can include a frame 602. The frame 602 can have a stiffness sufficient to resist bending deflection. In particular, the stiffness of the frame 602 can be sufficient to not bend under load applied on the frame 602, e.g., when a person steps on the running board 600 to enter or exit the passenger compartment of the automobile 100 [FIGS. 1A, IB). The frame 602 can include a first wall 604. The frame 602 can include a second wall 606 opposite the first wall 604. The two walls can extend a length of the frame 602.

[0046] The first wall 604 can be substantially planar [i.e., flat) along the entire length of the frame 602. The first wall 604 can have a width sufficient for a person to conveniently step on when entering or exiting the passenger compartment of the automobile 100 [FIGS. 1A, IB). The second wall 606 can include an arced portion 608. The arced portion 608 can connect to the first wall 604. The second wall 606 can also include a substantially planar wall portion 609. The substantially planar wall portion 609 can be parallel to the first wall 604. Multiple ribs [e.g., a first rib 610a, a second rib 610b, a third rib 610c, a fourth rib 610d, a fifth rib 610e) can extend between and connect the first wall 604 and the second wall 606. For example, each of the multiple ribs can be perpendicular to the first wall 604 and the planar wall portion 610 of the second wall 606. Thus, when the frame 602 is oriented such that the first wall 604 is horizontal with reference to the ground, each of the multiple ribs can be vertical with reference to the first wall 604, with ends of each of the multiple ribs attached to the first wall 604 and the substantially planar wall 610 of the second wall 606.

[0047] The frame 602 can be made using the same or substantially similar materials as those using which the frame 202 [FIG. 2) is made. 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 [FIG. 2) that reinforces the second wall 206 [FIG. 2) of the frame 202 [FIG. 2). The first wall 604 of the frame 602 can also be reinforced with a combination of a CFRT reinforcement layer and a thermoplastic layer co-extruded with the frame 602. This CFRT reinforcement layer and thermoplastic layer can be substantially similar to the CFRT reinforcement layer 216 [FIG. 2) and the thermoplastic layer 220 [FIG. 2) that reinforce the first wall 204 [FIG. 2) of the frame 202 [FIG. 2). Openings [not shown) can be formed in one of the multiple ribs and in the second wall 606 of the frame 602. The openings can be configured to receive a bracket 700 that attach to the automobile 100 [FIGS. 1A, IB).

[0048] FIGS. 7A-7F are schematic diagrams of an example of the bracket 700 to couple to the running board 600 [FIG. 6). The bracket 700 can share some similarities with the bracket 500 [FIGS. 5A-5G). The bracket 700 can be made from a resin such as polypropylene [PP], polybutylene tephthalate [PBT , polycarbonate [PC), polyamide [PA) or any combinations of them. The bracket 500 can be reinforced with fibers such as long glass fiber or other fibers such as glass, aramid, carbon, natural fiber, or any combination of them, can be used. The quantity of fiber can range between 20 wt % to 60 wt%. Each wt % is based on a weight of the bracket. In the context of weight percentage, the term “about” represents a deviation between ±2% and ±5%.

[0049] As shown in FIG. 7A, the bracket 700 can include a body 702. The body 702 can include a first end portion 704. The body 702 can include a second end portion 706 opposite the first end portion 504. As described below, the first end portion 704 can couple the bracket 700 to the running board 600 [FIG. 6). In implementations in which the running board is a stationary running board [for example, the running board 104), the second end portion 704 can couple the bracket700 to the rocker panel 102 that couples to the automobile 100 (FIG. 1A). In implementations in which the running board is a retractable running board (for example, the running board 112), the second 704 portion can couple the bracket 700 to a link (for example, the link 114a) that couples to the bracket (for example, the bracket 118a).

[0050] The first end portion 704 of the body 702 can be formed to have an overhang portion 708. The first end portion 704 can be formed to also have a supporting portion 710. The overhang portion 708 can be formed on the supporting portion 710. In a side view of the body 702, the overhang portion 708 can have a substantially trapezoidal cross-section. The trapezoidal cross-section can have a longer edge 712 and a shorter edge 714. The longer edge 712 can be attached to the supporting portion 710. In some implementations, the overhang portion 708 can have a rectangular cross-section or a triangular cross-section when the body 702 is viewed from the side. When viewed from the top, the overhang portion 708 can have a rectangular cross-section of a first width near the shorter edge 714. Also, when viewed from the top, the overhang portion 708 can have a rectangular cross-section of a second width (greater than the first width) near the longer edge 712. The overhang portion 708 can be inserted into a first location on the frame 602 of the running board 600. To do so, a rectangular hole can be cut into the frame 602. The hole can have a width equal to a width of the rectangular cross-section of first width near the shorter edge 714. The rectangular cross-section near the shorter edge 714 can be inserted into the cut hole. In particular, the rectangular hole can be cut in the bottom portion of the frame 602 and the overhang portion 708 is inserted into the frame 602 from below the frame 602.

[0051] The body 702 can define a shoulder 716 (FIGS. 7A, 7B, 70). The overhang portion 708 can be arranged relative to the shoulder 716. The arrangement can define a space 718 between the shoulder 716 and the overhang portion 708. The shoulder 718 can define multiple openings (for example, openings 720a, 720b). The openings can align with corresponding multiple openings (not shown) in multiplevertical ribs (for example, the ribs 610d, 610e (FIG. 6)) of the running board 600 (FIG. 6). As shown in FIG. 7E, multiple fasteners (for example, fasteners 722a, 722b) can be inserted into the multiple openings (for example, openings 720a, 720b). The openings 720a, 720b can be defined by the shoulder 708 and the multiple openings formed in the multiple vertical ribs to couple the body 702 to the running board 600 (FIG. 6).

[0052] As shown in FIG. 70 and in the top view of the body 702 in FIG. 7D, the overhang portion 708 can define multiple seats (for example, seats 724a, 724b). Each seat can be formed in a sidewall of the overhang portion 708. Each seat can be formed as a recess into which an end of a fastener can be positioned.

[0053] The overhang portion 708 can couple to a first location on the frame (for example, the frame 202) of the running board 104. The first location on the frame 202 can be the substantially planar wall portion 609 of the second wall 606 (FIG. 6). As described earlier, the overhang portion 708 has a shape (for example, a trapezoidal cross-section) that can be inserted into an opening formed in the substantially planar wall portion 609 and locked in place.

[0054] The region of the supporting portion 710 between the shoulder 716 and the overhang portion 708 can be formed to have a particular geometry. That geometry can complement the geometry of the second wall 606 between the two ribs (for example, the ribs 610d, 610e) of the frame 602 that reside within the space 718. Under this construction, when the overhang portion 708 is inserted into the opening formed in the substantially planar wall portion 609, the supporting portion 710 can extend below the planar wall portion 609 of the second wall 606 of the frame 202. In this manner, the supporting portion 710 can provide additional support to the bottom of the frame 602. The fasteners 722a, 722b further fasten the bracket 700 to the frame 702.

[0055] As shown in FIGS. 7D and 7F, the second end portion 706 of the bracket 700 can include two leg portions 728a, 728b. Each leg portion can be connected to the body 702. The connection of each leg portion to the body 702 can define a space730 in between. A link can be positioned in the space. The link can couple to each leg portion. To do so, fixation points can be defined in each leg portion, for example, fixation points 732a, 732b in the leg portion 728a and fixation points 732ca, 732db in the leg portion 728b. A fixation point is a through hole formed in a leg portion. Corresponding through holes formed in the link are aligned with the fixation points on the leg portions, and the leg portions are connected to the link using fasteners similar to those described above.

[0056] FIGS. 7E and 7F show a top view and a bottom view, respectively, of the bracket 700. The bracket 700 can be made from injection-molded plastic. As shown in FIGS. 7A-7F, the body 702 can be formed with ribbing design throughout to add bending and torsional stiffness. Each of the overhang portion 708 and the supporting portion 710 can extend across an entire width of the body 702. The overhang portion 708 has an upper member, a lower member and a cross-sectional member. The cross- sectional member can connect the upper member to the lower member, thereby giving the overhang portion 708 a thickness. Similarly, the supporting portion 710 can also have an upper member, a lower member and a cross-sectional member. That cross-sectional member can connect the upper member to the lower member, thereby giving the supporting portion 710 a thickness.

[0057] FIG. 8 is a schematic diagram of a cross-section of another example of a running board 800. The running board 800 can be substantially similar to the running boards 104, 112 [FIGS. 1A, IB, 2). A cross-section of the running board 800 can be different from that of the running boards 104, 112. As shown in FIG. 8, the running board 800 can include a frame 802. The frame 802 can have a stiffness sufficient to resist bending deflection. In particular, the stiffness of the frame 802 can be sufficient to not bend under load applied on the frame 802, e.g., when a person steps on the running board 800 to enter or exit the passenger compartment of the automobile 100 [FIGS. 1A, IB). The frame 802 can include a first wall 804. The frame 802 can include a second wall 806 opposite the first wall 804. The two walls can extend a length of the frame 802.

[0058] The first wall 804 can be substantially planar [i.e., flat) along the entire length of the frame 802. The first wall 804 can have a width sufficient for a person to conveniently step on when entering or exiting the passenger compartment of the automobile 100 [FIGS. 1A, IB). The second wall 806 can include an arced portion 808. The arced portion 808 can connect to the first wall 804. The second wall 806 can also include a substantially planar wall portion 809. The substantially planar wall portion 809 can be parallel to the first wall 804. Multiple ribs [e.g., a first rib 810a, a second rib 810b, a third rib 810c, a fourth rib 810d, a fifth rib 810e) can extend between and connect the first wall 804 and the second wall 806. For example, each of the multiple ribs can be perpendicular to the first wall 804 and the planar wall portion 810 of the second wall 806. Thus, when the frame 802 is oriented such that the first wall 804 is horizontal with reference to the ground, each of the multiple ribs can be vertical with reference to the first wall 804, with ends of each of the multiple ribs attached to the first wall 804 and the substantially planar wall 810 of the second wall 806.

[0059] The frame 802 can be made using the same or substantially similar materials as those using which the frame 202 [FIG. 2) is made. 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 the CFRT reinforcement layer 218 [FIG. 2) that reinforces the second wall 206 [FIG. 2) of the frame 202 [FIG. 2). The first wall 804 of the frame 802 can also be reinforced with a combination of a CFRT reinforcement layer and a thermoplastic layer co-extruded with the frame 802. This CFRT reinforcement layer and thermoplastic layer can be substantially similar to the CFRT reinforcement layer 216 [FIG. 2) and the thermoplastic layer 220 [FIG. 2) that reinforce the first wall 204 [FIG. 2) of the frame 202 [FIG. 2). Openings [not shown) can be formed in one of the multiple ribs and in the second wall 806 of the frame 802. The openings can be configured to receive a bracket 700 that attach to the automobile 100 [FIGS. 1A, IB).

[0060] The embodiment illustrated in FIG. 8 includes one finger 818 for coupling the running board 800 with a bracket 701. The finger can be sized to snap-fit into the running board 800. It can include features enabling the running board 800 to slide onto the finger 818. The finger can include a detent 820 to resist removal.

[0061] An anti-skid layer 816 can be coupled to the running board 800. The anti-skid layer 816 can be molded to the running board 800. The anti-skid layer 816 can be co-extruded with other materials of the running board 800 such that they are molded and / or adhered together. The anti-skid layer 816 can be adhered to the running board 800, such as with a PSA or thermoset. The anti-skid layer 800 can comprise rubber, a UV-protectant, some combination thereof and other materials. The ant-skid layer 816 can include abrasives.

[0062] A number of implementations of the disclosure have been described.Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure.

Claims

CLAIMS1. An apparatus for coupling brackets (118a, 118b) mounted to an automobile (100) rocker panel (102) area, the apparatus comprising: a running board (104, 112, 600) comprising: a profile-extruded plastic elongate frame (202, 602, 702) having a first wall (204, 604), a second wall (206, 606) opposite the first wall (204, 604), the frame (202, 602, 702) having a length; and a continuous fiber-reinforced thermoplastic (CFRT) reinforcement layer (216) laminated on a portion of the first wall (204, 604) and a portion of the second wall (206, 606), wherein the running board (104, 112, 600) is configured to mount to the brackets (118a, 118b) and extend along the length, the automobile (100) rocker panel (102) area defining a step into the automobile (100).

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

3. The apparatus of claims 1 or 2, comprising a co-extruded thermoplastic layer (220) applied on the portion of the first wall (204, 604), the co-extruded thermoplastic layer (220) comprising an anti-skid surface.

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

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

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

7. The apparatus of any one of claims 1 to 6, wherein the metal sheets are joined with the frame (202, 602, 702) through adhesive film or mechanical locks.

8. The apparatus of any one of claims 1 to 7, wherein the metal sheets cover corners on a first end and a second end of the frame (202, 602, 702).

9. The apparatus of any one of claims 1 to 8, wherein the second wall comprises an arced portion (208, 608), wherein the apparatus comprises 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 of any one of claims 1 to 9, wherein the frame (202, 602, 702) comprises about 40 weight percentage (wt %) to about 90 wt % polypropylene (PP) or polybutylene tephthalate (PBT) or polycarbonate (PC) or polyamide (PA), about 10 wt% to about 60 wt% fiber and about 0.0001 wt% to about 30 wt% of an impact modifier, filler, flame retardant, antioxidant or reinforcing agent, wherein each wt % is based on a weight of the frame (202, 602, 702).

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

12. The apparatus of any one of claims 1 to 11, wherein the CFRT reinforcement layer comprises multi-ply laminates formed of unidirectional tapes, a woven fabric composite, or a thermoplastic organosheet comprising a plurality of layers of thermoplastic prepreg or semi-preg material stacked and pressed into a sheet.

13. A method of making an automobile (100) running board (104, 112, 600), the method comprising: extruding, using a first die (302), a profile of a plastic frame (202, 602, 702) having a first wall and a second wall opposite the first wall, the plastic frame (202, 602, 702) having a length; laminating, using a second (504, 704) die, a continuous fiber-reinforced thermoplastic (CFRT) reinforcement layer on a portion of the first wall and a portion of the second wall; and attaching a plurality of brackets along the length of the plastic frame (202, 602, 702), each bracket configured to connect the automobile (100) running board (104, 112, 600) to an automobile (100) body.

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

15. The method of claims 13 or 14, comprising co-extruding a thermoplastic layer (220) on the portion of the first wall, the co-extruded thermoplastic layer (220) comprising an anti-skid surface.

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