Vehicle Running Board Assembly with Extruded Body and Die Cast Ends

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Solution Overview

Problem

Existing running board assemblies for vehicles lack a robust and versatile design that combines effective structural integrity with ease of manufacturing, particularly in the formation of body and end members.

Innovation Solution

A running board assembly comprising a body member formed by extrusion and end members formed by die casting, where the body member has a unique configuration with extended lower and upper walls to facilitate connection with the end members, enhancing structural rigidity and manufacturing flexibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the body member and end members are formed by the same process, then manufacturing simplicity is improved, but manufacturing flexibility and design freedom deteriorate

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoiddesign freedom

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The running board assembly is divided into three separate components: a body member formed by extrusion and two end members formed by die casting. This segmentation allows each component to be manufactured using the most appropriate process for its specific requirements, combining the simplicity of extrusion for the main body with the design flexibility of die casting for the end members.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent combines multiple manufacturing processes (extrusion and die casting) within a single assembly. The body member is produced by extrusion while the end members are produced by die casting, and these different manufacturing approaches are merged into one integrated running board assembly through welding connections.

Inventive Principle:

Principle #5Merging (Combining)

2Productivity

If the body member is formed by extrusion, then manufacturing efficiency is improved, but shape complexity deteriorates

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidshape complexity

Core Design Contradiction:

ProductivityVSShape

Solution Approach 1:

The running board is segmented into a body member suitable for extrusion and end members suitable for die casting. The body member with its relatively simple cross-sectional profile is efficiently produced by extrusion, while the more complexly shaped end members are manufactured by die casting.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different parts of the assembly have different quality requirements. The body member requires efficient production with consistent cross-section, while the end members require complex geometries and localized features. This principle allows each part to be manufactured with the quality characteristics appropriate to its specific function and shape requirements.

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If the end members are formed by die casting, then shape versatility is improved, but manufacturing cost deteriorates

Engineering Contradiction:

Improveshape versatilityVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

Die casting is applied locally only to the end members where complex shapes are required, rather than to the entire assembly. This localized application of the more expensive die casting process minimizes costs while still achieving the necessary shape versatility for the end members.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The assembly is segmented so that only the portions requiring complex geometry (the end members) are manufactured by die casting, while the majority of the structure (the body member) is produced by the more cost-effective extrusion process.

Inventive Principle:

Principle #1Segmentation

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The proposed assembly provides improved structural rigidity and durability while allowing for a wide range of shapes and designs for the end members, enhancing the overall performance and aesthetic appeal of the running board.

Implementation Method 1

The body member is formed by extrusion

Methodology Applied

Scientific EffectExtrusion: Extrusion

Implementation Method 2

The first and second end members are formed by die casting

Methodology Applied

Scientific EffectDie casting:

Implementation Method 3

A body member is provided having an upper wall and a lower wall, each extending between opposite sides of the body member

Methodology Applied

Scientific EffectGeometric structure: Geometry

Data Source

PatentUS20250136000A1Running board assembly for a vehicle

Publication Date: 2025.05.01 NISSAN NORTH AMERICA INC

AI summary

A running board assembly for a vehicle includes a body member, a first end member, and a second end member. The body member has a first end and a second end. The first end member is connected to the first end of the body member. The second end member is connected to the second end of the body member. The body member is formed by extrusion. The first and second end members are formed by die casting.