Abstract:
A running board for a vehicle such as a truck is mounted to the vehicle body using a C-shaped mounting bracket. The bracket has an open clearance area to accommodate air conditioning conduits or other similar structure adjacent the vehicle body. The running board may include pivotable end caps which may be pivoted to lie parallel with the support surface of the running board and overlying front or rear vehicle fenders. Mounting bolts for the end cap may pass through the running board body of the vehicle fender and the vehicle body.

Description:
FIELD OF THE INVENTION 
   This invention relates to a method and apparatus for securing a running board to the rocker panel of a motor vehicle. In particular, the invention relates to the method of securing such a running board to a motor vehicle bearing in mind other constraints of the support system namely the need to avoid other structure which may be part of the motor vehicle at the desired support locations. 
   Many motor vehicles which are mounted on a large wheels and tires or have raised suspension systems, have a vehicle floor which is well above the road surface on which the vehicle travels. Many such vehicles are provided with a step to facilitate entry into the vehicle. These are often referred to as a running board. Typically, running boards are used on trucks, sport utility vehicles and the like The running board provides a structural step which projects outwardly from the rocker panel area of the vehicle and gives enough supporting surface area to support the foot of a person desiring entry into the vehicle. The running board may be a separate structure from the rocker panel and requires structural support to support the load of the person standing on the running board when entering or leaving the vehicle. 
   In some cases the running board can be bolted directly to a rocker panel at a convenient flange. However, in other cases, because of other clearance requirements within the vehicle which may or may not have a frame, there is other structure which extends along the length of the vehicle running adjacent to the running board. This structure could include fluid lines for carrying different fluids such as gasoline, oil, brake fluid, air conditioning fluids and the like. Where such structure exists, there is a need to provide a mounting system for a running board so that the running board can be mounted to the truck. 
   BACKGROUND OF THE INVENTION 
   In most such vehicles, the running board extends along the length of the rocker panel. The running board typically extends the entire length of the rocker panel. For aesthetic and other reasons, it is often desired that the running boards extend forwardly of the rocker panel to overlap the front fender and in some cases, also extend rearwardly of the rocker panel to extend adjacent to the rear fender or other body structure immediately aft of the rocker panel. If the running board overlaps either the front or rear fender structure then the fender mounting assembly must be done before the running board is installed. This order of assembly may not be desirable. This means that the running board must be capable of a finished assembly to the vehicle after the front and rear fenders have been mounted to the vehicle. 
   It is generally desirable in the automotive industry to create sub assemblies which may be made by suppliers. As many parts as possible are included in the subassembly. The subassembly can then be finish-assembled as needed and the subassembly fitted to the motor vehicle as it is assembled in an automotive assembly plant. 
   While running boards have conveniently been manufactured from materials having the necessary structural strength such as steel and the like, there are manufacturing advantages to making such products from plastics and there are additional economies to be realized by using the blow molding process. Accordingly, there is a need for improved running board support structure and running board assemblies which can meet the vehicle assembly and clearance requirements as outlined above. 
   SUMMARY OF THE INVENTION 
   In accordance with this invention, there is a bracket for mounting a running board to a vehicle. The bracket has a body. The body has at least first and second mounting flanges and a third mounting flange located between the first and second mounting flange. The body of the bracket includes a substantially “C” shaped portion between the first and third mounting flanges. The “C” shaped portion defines an open clearance area. In accordance with a further embodiment of the invention, the body of the bracket includes an extension arm between the third and second mounting flanges. The extension arm may extend from the third mounting flange toward the second mounting flange away from the open clearance area. 
   In accordance with a further embodiment of the invention, the invention includes an assembly comprising a bracket as explained above in combination with a running board. The running board includes a supporting surface and a mounting surface. The mounting surface includes a first running board mounting pad, a mounting receptacle and a first fastener. The fastener extends through the second mounting flange of the bracket and into the mounting receptacle so that the second flange of the bracket contacts the first running board mounting pad. In accordance with a preferred embodiment of this aspect of the invention, the assembly includes a plurality of such brackets. 
   In accordance with a further aspect of the invention, the assembly of the running board and at least one bracket as outlined above, further includes, a running board with a central portion and at least one end cap. In a preferred embodiment of this aspect of the invention, the end cap is adapted to pivot with respect to the central portion of the running board between a non-aligned position and an aligned position. 
   In a further aspect of the invention, there is provided a motor vehicle, the motor vehicle having a rocker panel assembly, the rocker panel assembly including an inner rocker panel and an outer rocker panel and an assembly of a running board and at least one bracket as explained above. In a preferred embodiment of this aspect of the invention, the inner rocker panel includes at least a first inner rocker panel mounting pad. The running board includes a second running board mounting pad and the second running board mounting pad and the first inner rocker panel mounting pad are aligned to receive a second fastener. In a further preferred embodiment of this aspect of the invention, the outer rocker panel includes an outer rocker panel mounting pad and the outer rocker panel mounting pad is aligned with the second running board mounting pad and the first inner rocker panel mounting pad to receive the second fastener. In a further aspect of the invention, the motor vehicle includes an inner rocker panel which includes a second inner rocker panel mounting pad and the second inner rocker panel mounting pad is aligned with the first bracket mounting flange to receive a third fastener. 
   Various other aspects and objects of the invention may be understood from reference to the following description of preferred embodiments of the invention and the following drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a side view of a bracket in accordance with a first embodiment of the invention; 
       FIG. 2  is a rear view of the bracket of  FIG. 1 ; 
       FIG. 3  is a perspective view of the bracket of  FIG. 1 ; 
       FIG. 4  is an exploded view of a first embodiment of an assembly in accordance with the invention utilizing a plurality of brackets in accordance with  FIG. 1 ; 
       FIG. 5  is a top perspective view of the assembly of  FIG. 4  in assembled condition; 
       FIG. 6  is a bottom exploded view of the assembly of  FIG. 4 ; 
       FIG. 7  is an enlarged view of the assembly of  FIG. 4  showing two brackets in accordance with  FIG. 1  ready for mounting; 
       FIG. 8  is an expanded detailed view of portions of two of the components of the assembly of  FIG. 4 ; 
       FIG. 9   a  is a cross-sectional view illustrating the interreaction of the two components shown in  FIG. 4   a  in a first preassembly condition; 
       FIG. 9   b  is similar to  FIG. 9   a  showing the two components in a non-aligned position; 
       FIG. 9   c  is similar to  FIG. 9   b  showing the two components being moved toward a second position; 
       FIG. 9   d  is similar to  FIG. 9   c  showing the two components in an aligned position; 
       FIG. 10   a  shows a portion of a vehicle with the assembly of  FIG. 4  in an initial position similar to  FIG. 9   b;    
       FIG. 10   b  is the components of  FIG. 10   a  being rotated toward a final position; 
       FIG. 10   c  shows the components of  FIG. 10   b  rotated to the final position and illustrating the placement of fasteners; 
       FIG. 10   d  illustrates the finished assembly of  FIG. 4  when assembled to the vehicle; 
       FIG. 11  is a perspective view of the assembled vehicle of  FIG. 10   d  showing a portion of the assembly, and 
       FIG. 12  is a cross-sectional view along the line  12 — 12  of  FIG. 11 . 
   

   DETAILED DESCRIPTION OF THE INVENTION 
     FIGS. 1 ,  2  and  3  illustrate a mounting bracket ( 20 ). The mounting bracket  20  includes a body  22 . The body  22  includes a C-shaped portion  24  and an extension arm  26 . The body  22  of the bracket  20  includes a first mounting flange  30  at one end, a second mounting flange  32  at the opposite end of the body. There is also a third mounting flange  34  located intermediate the first mounting flange  30  and the second mounting flange  32 . 
   The body  22  defines the C-shaped portion  24  extending between the first mounting flange  30  and the third mounting flange  34 . The open area of the C-shaped portion is shown as an open clearance area  40  indicated by the three arrows extending to the perimeter of the clamp from a central location. 
   The first mounting flange is a generally planar flange having a general plane illustrated by the dotted line  42  shown in  FIG. 1 . The second mounting flange  32  is also a substantially planar flange as illustrated by the dotted line  44  shown in  FIG. 1 . The plane  42  of the first mounting flange  30  is substantially at right angles to the plane  44  of the second mounting flange  32 . The third mounting flange  34  is also substantially planar, the plane being shown by the dotted line  46 . The plane  46  is orientated at a slight angle to the plane  42  of the first mounting flange  30 . 
     FIG. 4  illustrates an exploded running board assembly indicated generally at  50 . The running board assembly  50  includes a running board  52  having a central portion  54  and two end caps  56  and  58 . The assembly also comprises four brackets  20  which are the same as illustrated in  FIGS. 1 ,  2  and  3 .  FIG. 5  illustrates the assembly of  FIG. 4  in the assembled condition.  FIG. 6  illustrates the assembly  50  in exploded condition from the bottom.  FIG. 7  illustrates a portion of the running board  52  showing a portion of the central portion  54  of the running board and two of the brackets  20  which have been placed in place ready to be secured by first fasteners to the running board  52 . 
     FIGS. 8 ,  9  and  10  illustrate a particular feature of the running board  52 . As shown in  FIG. 8 , the central portion  54  of the running board  52  includes a mounting axle  60  at an end. The end cap  58  includes a mounting groove  62  for receiving the mounting axle  60 .  FIG. 8  is a bottom view. The mounting axle  60  is supported on a pair of studs  64  and further supported by a pair of gussets  66 . The mounting groove  62  of the end cap  58  includes a pair of longitudinally extending sections  70 . With respect to  FIGS. 9   a  through  9   d , it will be appreciated that the end cap  58  can be assembled to the central portion  54  to form the running board  52  by passing the end cap  58  toward the mounting axle  60  so that the mounting axle  60  is received within the mounting groove  62 . The mounting groove  62  includes a recess  72 . The recess  72  extends around just over 180° and is a part circular recess. Thus, the mounting axle  60  is received within the recess  72  in a snap fit. Once the snap fit assembly has been performed, the end cap  58  is retained as shown in  FIG. 9   b . As shown in  FIG. 9   b , the end cap is in a first or non-aligned position. 
   When desired, as will be more fully explained below, the end cap  58  may be rotated about the amounting axle  60  as shown in  FIG. 9   c . Rotation continues for 90° until the end cap  58  is in a second or aligned position as shown in  FIG. 9   d . In the case of the end cap  58  as shown in  FIG. 8 , the end cap  58  can be maintained in the aligned position shown in  FIG. 9   d  by passing a fastener through one of the gussets  66  where the fastener can be received into a hole within the end cap. The fastener prevents any rotation of the end cap back to the non-aligned position. End cap  56  is similar to end cap  58  but has additional features discussed below. 
   One of the features of this structure is illustrated by reference to  FIGS. 10   a  through  10   d .  FIG. 10   a  shows a portion of a truck body  80 . The truck body  80  includes a front fender  82  and a rear fender  84 . Extending between the front fender  82  and the rear fender  84  there is a rocker panel assembly  86 . In  FIG. 10   a , the vehicle includes the running board assembly  50 . The end caps  56  and  58  have been mounted to the central portion  54  of the running board  52  in the non-aligned position corresponding to  FIG. 9   b .  FIG. 10   b  shows the rotation of the two end caps from the non-aligned position toward the aligned position. This figure is similar to  FIG. 9   c .  FIG. 10   c  shows the two end caps  56  and  58  having been rotated to the aligned position similar to the view shown in  FIG. 9   d . As shown in  FIG. 10   c  a fastener  74  may be used to hold the rear end cap  56  in place. In the case of the front fender, a fastener  74  and a second fastener  88 , explained more fully below, are used to hold the front end cap  56  in place. 
   Reference is now made to  FIG. 11 .  FIG. 11  shows a portion of the vehicle  80  with the running board assembly  50  including the running board  52  and brackets  80  held in place by brackets  20 . The vehicle includes a plurality of fluid lines shown at  90 . The fluid lines  90  extend along the rocker panel of the vehicle  80  and may be used to convey fluids such as air conditioning fluids, or any other fluids typically used in a vehicle. In securing the running board to the vehicle, there is a need to ensure that the running board is secured and supported without obstructing or imposing any loads on the fluid lines  90 . With respect to  FIG. 11 , it will be noted there is a section line  12 — 12  through one of the mounting holes of one bracket  20 . With reference to  FIG. 12 , it will be observed how the bracket  20  attaches the running board assembly  50  to the vehicle  80  without interfering with the conduits  90 . 
   The running board  52  includes a supporting surface  100  for supporting a vehicle occupant and a mounting surface  102 . The mounting surface  102  includes a first running board mounting pad  104 . The running board  52  also includes a second running board mounting pad  106 . The mounting surface  102  of the running board  52  also defines a mounting receptacle  108 . The mounting receptacle includes a metal insert  110 . 
   The running board  52 , including the central portion  54 , and the two end caps  56 ,  58  may conveniently be manufactured in blow molding operations. Each piece is made individually and can be made from suitable parisons expanded in typical blow molding molds. The metal insert  110  includes self-tapping threads on the external surface. The external self-tapping threads cut their way into the mounting receptacle  108  so that the metal insert  110  is received permanently within the central portion  54  of the running board. The metal insert  110  includes internal threads for receiving a first fastener  112 . Fastener  112  is conveniently in the form of a bolt with threads matching the internal threads of the metal insert  110 . In order to create the assembly as shown in  FIG. 5 , four mounting brackets  20  are assembled to the central portion  54  of the running board  52 . The brackets are assembled by placing the brackets in place as shown in  FIG. 7 . Once the brackets are in place, the fastener  112  is inserted through the second mounting flange  32 , through the first running board mounting pad and into the metal insert  110 . When the end caps  56  and  58  are positioned as previously explained, this then creates the assembly as shown in  FIG. 5 . As shown in  FIG. 5 , the end caps  56  and  58  are in the aligned position. However, the bolt  74  as shown in  FIG. 8  is not installed to maintain the end caps in the aligned position until the assembly has been assembled to the truck body as discussed with reference to  FIG. 10 . However the snap fit of the axle  60  in the groove  62 . The assembly may be done at the vehicle manufacturing plant or assembly by a supplier as a completed subassembly. 
   When it is desired to install the assembly  50  to the vehicle  80  this is done as shown in  FIG. 12 . The rocker panel assembly  86  of the vehicle  80  includes an inner rocker panel  120  and an outer rocker panel  122 . The inner rocker panel  120  includes a first inner rocker panel mounting pad  124  and a second inner rocker panel mounting pad  126 . The outer rocker panel  122  includes an outer rocker panel mounting pad  128 . 
   When the inner rocker panel  120  is manufactured, it may conveniently be provided with a first pierce nut  130  at the first inner rocker panel mounting pad and a second pierce nut  132  at the second inner rocker panel mounting pad  126 . The installation hardware includes a second bolt  140  and a third bolt  142  which are received in the first and second pierce nuts respectively. 
   By reference to  FIG. 12 , it will be noted that the third mounting flange  34  of the mounting bracket  20 , the second running board mounting pad  106 , the outer rocker panel mounting pad  128  and the first inner rocker panel mounting pad form a multi-layer sandwich. The second bolt  140  extends through this multi-layer sandwich and is received in the first pierce nut  130 . Similarly, the second inner rocker panel mounting pad  126  is adjacent to and bears against the first mounting flange  30  of the mounting bracket  20 . The third fastener  142  extends through the first mounting flange  30  and through the second inner rocker panel mounting pad  126  into the second pierce nut  132 . 
   While the second and third bolts may be installed in any order, once the bolts are installed, they provide a unique mounting and support system for the running board  52 . With respect to  FIGS. 12 and 1 , it will be noted that the open clearance area  40  designated by the point  40  in  FIG. 12  locates the mounting bracket  20  surrounding the plurality of conduits  90 . Thus, the mounting bracket  20  mounts the running board  52  to the rocker panel  86  of the truck  80  while not interfering with or applying any forces to, the plurality of conduits  90  that are within the open clearance area  40  of the bracket  20 . 
   Also from reference to  FIG. 12 , it will be noted that the distance between the plane  42  of the first mounting flange  30  of the bracket  20  and the general area where the weight of an occupant stepping on the running board  52 , designated by the arrow F 1  in  FIG. 2 , is the distance L 1 . The bracket  20  with its C-shaped portion and with its extension arm  26  is a generally L-shaped. The vertically downward force F 1  representing the weight of an occupant boarding the vehicle is resisted by the tensile strength of the second bolt  140 . Because of the lever arm L 1 , the force F 1 , exerted on the running board and thus on the mounting brackets  20 , would tend to twist the mounting bracket in the counterclockwise direction as shown in  FIG. 12  about the multi-layer sandwich between second bolts  140  and the pierce nut  130 . With this arrangement, the third bolt  142 , which would be tightened and thus under tension, would actually be partially relieved from that tension as the first mounting flange  30  of the mounting bracket  20  attempts to move to the left in  FIG. 12  and is restrained by the second rocker panel mounting pad  126 . As shown in  FIG. 12 , the force F 3  in the second bolt  140  can be vertically upward if the third mounting flange  34  and the associated components of the multi-layer sandwich are horizontal when installed. With a slight angle to vertical as shown, the bolt  140  is still stressed mainly in tension to carry the load, but there will, in addition, be some shear load in the second bolt  140 . 
   Turning now to  FIG. 11 , there is shown the front end cap  56 . As illustrated in  FIG. 8 , the fastener  74  can hold the end cap  56  in the aligned position relative to the central portion  54  of the running board  52 .  FIG. 11  however, illustrates the need for the end cap  56  which can move from the non-aligned position to the aligned position. Because of the design of the vehicle, there is intended to be a fastener between the vehicle front fender  82 , the inner rocker panel  120  and the outer panel  122 . In most cases, the running board will be assembled to the vehicle before the front fenders are assembled to the vehicle. Thus, if the front end cap  56  were in the aligned position, it would not be possible to make the required connection between the vehicle fender  82  and the rocker panel assembly. As shown in  FIG. 11 , a connector clip  150  can be slid from the inboard direction of the vehicle toward the outboard direction. The connector clip  150  includes a U-shaped opening  152  with a formed nut  154  on one side. The U-shaped opening  152  receives and surrounds the inner rocker panel  120 , the outer rocker panel  122  and the vehicle fender  82 . The formed nut of the connector clip  150  then aligns with a hole in the end cap  56 . The fastener  88 , as shown in  FIG. 10   c , may then be passed upwardly through the end cap  56  and into the retaining clip  150  so that the appropriate connection is made between the vehicle fender  82  and the rocker panel assembly  86  as well as additionally securing the end cap  56  in place with the end cap extending beyond the rocker panel assembly and along the fender as needed. This is also shown in  FIGS. 10   a  through  10   d.