Multi-Piece Vehicle Side Step Assembly for Flexible Surface Finishing
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Solution Overview
Problem
Conventional side step assemblies are limited by their single-piece, closed cross-sectional design, which restricts manufacturing methods and requires unnecessary chrome-plating of non-visible surfaces, increasing production costs and complexity.
Innovation Solution
A side step assembly formed by two separate elongated body parts connected using a hinge feature, allowing for easier manufacturing, reduced plating costs, and flexible assembly, with the option to apply different surface treatments to each part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single-piece extrusion design is used, then structural integrity is maintained, but manufacturing flexibility and surface treatment options are limited
Solution Approach 1:
The side step assembly is divided into multiple separate extrusions (first extrusion, second extrusion, third extrusion) that are connected together. Each extrusion can be manufactured independently with different surface treatments, then assembled using joining mechanisms such as interlocking features, fasteners, or adhesives. This segmentation resolves the contradiction by enabling manufacturing flexibility and surface treatment options while maintaining overall structural integrity through the connected assembly.
2Reliability
If the entire body is chrome-plated, then all surfaces are protected and aesthetically finished, but production costs increase unnecessarily for non-visible surfaces
Solution Approach 1:
Different surface treatments are applied to different extrusions based on their specific requirements and visibility. For example, the first extrusion (visible stepping surface) may receive chrome-plating for protection and aesthetics, while the third extrusion (non-visible support structure) may receive a simpler, less expensive coating or no plating at all. This local quality approach reduces production costs by applying expensive surface treatments only where necessary while maintaining adequate protection for all surfaces.
3Strength
If a closed cross-sectional shape is used, then structural strength is maintained, but the methods to form surface features are restricted
Solution Approach 1:
The side step assembly is segmented into multiple separate extrusions, each with open cross-sectional shapes that allow for easier formation of surface features such as openings, recesses, and mounting locations. These individually manufactured extrusions are then connected to form the complete assembly, achieving both the desired surface features and overall structural strength without the constraints of a single-piece closed cross-section design.
Data Source
AI summary
A side step assembly includes a side step assembly including a step body having an elongated length that extends in a vehicle longitudinal direction. The step body includes a first elongated body part having a first exterior facing surface that defines a stepping area and a second elongated body part having a second exterior facing surface that faces away from the first exterior surface. The first and second elongated body parts being formed as separate parts and connected together forming a divide that extends the elongated length of the step body.