Patent Publication Number: US-2006001229-A1

Title: Stone guard for step bar

Description:
RELATED APPLICATIONS  
      This application is a continuation of U.S. patent application Ser. No. 10/156,506; filed on May 28, 2002, which claims priority to U.S. Provisional Application Ser. No. 60/358,762 filed on Feb. 22, 2002. 
    
    
     BACKGROUND OF THE INVENTION  
      This invention relates to a step bar for a motor vehicle and specifically for a stone guard assembly for a step bar.  
      Typically, vehicles designed for off-road use have an additional amount of ground clearance compared to other types of vehicles. The greater ground clearance increases the difficulty of getting into and out of the vehicle. For this reason, it is known to install a side step or step bar to the motor vehicle. The step bar aids a passenger or operator in entering and exiting the vehicle. Step bars can be installed as original equipment by the manufacturer or as an aftermarket item purchased and installed by the vehicle owner.  
      The increased ground clearance allows the motor vehicle to overcome obstacles and perform better in adverse road conditions such as snow or muddy terrain. However, increased ground clearance increases the amount of road debris and rocks kicked up by the motor vehicle tires and thrown against the body panels of the motor vehicle. Further, although many motor vehicles with increased ground clearance are designed for strictly work applications, off-road vehicles are popular and owned by many operators who may never drive the vehicle off road. Further, vehicles with traditional ground clearance are also susceptible to damage caused by road debris often found on deteriorated roads prevalent in large metropolitan areas. As appreciated, rock and road debris thrown up against the body and rocker panel may cause paint damage and dent the motor vehicle.  
      Typically, many vehicles include special coatings or paint applied to the rocker panel regions to protect against rock damage. These special coatings provide only a limited amount of protection and only slow the deterioration of paint on the body and rocker panels of the motor vehicle. Further, the deterioration of the rocker panel can create an unsightly cosmetic appearance that is highly undesirable to an operator or consumer who has a significant investment in the motor vehicle. In addition to the degradation of cosmetic appearance of the vehicle, chipped paint caused by rocks and road debris thrown up against the rocker panel can lead to premature corrosion of the body. Premature corrosion of the motor vehicle body and specifically the rocker panel may require significant costly repair.  
      In addition to the purely cosmetic degradation of the rocker panel of the motor vehicle, rocks and road debris, especially larger rocks encountered in off-road travel, can cause significant dents and damage to the rocker panel. Another significant problem encountered by rocks and road debris being thrown against the rocker panel is the increased amount of noise heard in the passenger compartment of the motor vehicle. As is appreciated, the popularity of such off-road type vehicles has lead to many purchasers of such vehicles using them in non-off-road applications where passenger comfort is a desired and expected characteristic of the motor vehicle. The increased noise emitted into the passenger compartment caused by road debris and rocks being thrown against the rocker panel is therefore undesirable.  
      Accordingly, it is desirable to design a device installable onto a step for a motor vehicle that substantially prevents damage to the surface coating of the motor vehicle.  
     SUMMARY OF THE INVENTION  
      An embodiment of this invention is a guard assembly for a vehicle step blocking road debris from being thrown against a vehicle body.  
      The vehicle step partially defines an opening allowing road debris to be thrown against the vehicle rocker panel. The guard assembly attaches to the step bar, blocking the opening and preventing road debris from being thrown against the rocker panel.  
      The guard assembly includes a guard portion suspended from a bottom surface of the step bar and extending inboard of the rocker panel and tires of the motor vehicle. A lip extends transverse to the guard portion preventing road debris from being thrown between the guard portion and an underside of the motor vehicle. An embodiment of this invention includes a lip extends upward from the guard providing a location for the application of decorative items such as lights, text messages, or illustrations.  
      Embodiments of the guard assembly are attached in various positions relative to the step. In one embodiment, the guard portion is attached to a bottom surface of the step and in another embodiment the guard attaches to a top surface of the step bar. In still another embodiment, the guard is mounted to an intermediate surface disposed between the top and bottom surfaces of the step bar.  
      The guard includes a plurality of fasteners extending through openings within the guard and secured to the step. One embodiment of the guard includes snap features securing the guard assembly to the step bar. The snap features eliminate the need for separate fasteners for securing the guard assembly to the step bar.  
      The rock guard assembly of this invention prevents and protects the rocker panel of the motor vehicle from rock and road debris being thrown up by the wheels of the motor vehicle. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      The various features and advantages of this invention will become apparent to those skilled in the art from the following detailed description of the currently preferred embodiment. The drawings that accompany the detailed description can be briefly described as follows:  
       FIG. 1  is side view of a step bar with guard installed to a motor vehicle;  
       FIG. 2  is a sectional view of the guard installed to the step bar;  
       FIG. 3  is a sectional view of one embodiment of the guard installed to a step bar;  
       FIG. 4  is a sectional view of another embodiment of the guard installed to a step bar;  
       FIG. 5  is a sectional view of yet another embodiment of the guard installed to a step bar;  
       FIG. 6  is a side view of the step bar with the guard;  
       FIG. 7  is a top view of the guard installed to the step bar;  
       FIG. 8  is a top view of the guard with a snap fit feature;  
       FIG. 9  is a side view of a guard with the snap fit feature  
       FIG. 10A  is a top view of another embodiment of the guard;  
       FIG. 10B  is a cross section of the guard of  FIG. 10A ;  
       FIG. 11A  is a top view of another embodiment of the guard;  
       FIG. 11B  is a cross section of the guard of  FIG. 11A ;  
       FIG. 12A  is a side view of another embodiment of the guard  
       FIG. 12B  is a top view of the embodiment of  FIG. 12 A ;  
       FIG. 13  is a side view of the guard including a design applied to a lip of the guard;  
       FIG. 14  is a side view of a guard with an interlocking lip potion;  
       FIG. 15  is an enlarged view of the interlocking lip portion;  
       FIG. 16  is a side view of a lip extension member; and  
       FIG. 17  is an enlarged view of the lip extension member. 
    
    
     DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT  
      Referring to  FIGS. 1 and 2 , a motor vehicle  10  is shown including a step bar  12  supported under the motor vehicle by supports  18 . The step bar  12  eases entrance and exit from the motor vehicle  10 . Preferably, the step bar  12  is a tubular member extending from the underside of the motor vehicle  10  a distance from the motor vehicle  10  and specifically from the rocker panel  16 .  
      The step bar  12  provides a convenient step for passengers to enter and exit the motor vehicle  10 . The step bar  12  includes steps  34  to aid traction when using the step bar  12 . The tubular member  12  does not provide significant protection to the rocker panel  16  of the motor vehicle  10  from rocks or road debris thrown up by tires  14 . This is so because the step bar  12  includes only a tubular member extending from mounting points  18  underneath the motor vehicle  10 . An opening  19  between the tubular member and the rocker panel  16  allows rocks and road debris to be thrown up against the rocker panel  16 . Note that although preferably, the step bar  12  is tubular, it is within the contemplation of this invention to use any configuration of step as would be known to a worker skilled in the art.  
      A guard assembly  20  fastened to a bottom surface of the step bar  12  blocks the opening partially defined by the step bar  12 . The guard assembly  20  prevents road debris from being thrown up against the rocker panel by blocking the opening. Preferably, the guard assembly  20  is suspended from the bottom surface of the step bar  12  and extends inboard of the step bar  12  and the rocker panels  16  of the motor vehicle  10 .  
      Referring to  FIGS. 3-5 , although preferably the guard assembly  20  is attached to a bottom surface of the step bar  12  ( FIG. 3 ), other mounting configurations are within the contemplation of this invention. One embodiment includes the guard attached to an inner surface  44  toward the top of the step bar  12  ( FIG. 4 ). Preferably, the guard  20  is attached to the step bar  12  such that it does not form a load baring structure that is stepped on to gain access to the motor vehicle  12 . The guard  20  is attached to the step bar  12  such that the step bar  12  will bear any load from an occupant entering or exiting the motor vehicle  10 . Another embodiment includes mounting of the guard assembly  20  on the inner surface  44  disposed between the top and bottom surfaces  40 , 42  of the step bar  12  ( FIG. 5 ). Different mounting configurations of the guard assembly  20  provide adaptability to specific vehicle configurations. A worker skilled in the art would understand that specific mounting configurations of the guard are application dependent and would fall with the contemplation of this invention.  
      Referring to  FIG. 2 , the guard assembly  20  includes a guard portion  21  preferably comprised of a sheet member extending from an outermost point of the step bar  12  to a point inboard of the tires  14 . The motor vehicle rocker panel  16  is susceptible to rock debris thrown from the tires  14  through the opening  19  in the range indicated at  36 . The guard assembly  20  includes a plurality of attachment points  32 . Each attachment point  32  includes a threaded fastener  38  extending through the guard portion  21  into the step bar  12 . Although preferably threaded fasteners  38  are used to secure the guard assembly  20  to the step bar  12 , it is within the contemplation of this invention to use any type of fastener known to a worker skilled in the art.  
      Preferably, the guard portion  21  extends to a point inboard of the inboard portion  26  of the tire  14 . Although, preferably the guard portion  21  extends inboard of the tires  14 , it is within the contemplation of this invention that the guard portion  21  extends inboard of the step bar  12  at any point that would provide protection of the rocker panel  16  from road debris.  
      Referring to  FIGS. 6-7 , the guard assembly  20  blocks rock and road debris from being thrown between the outermost portion of the step bar  12  up and into the rocker panel  16 . Preferably, the guard assembly  20  includes the guard portion  21  that is a substantially rectangular pan suspended below the step bar  12  and extending to a point inboard of the tires  14  ( FIG. 2 ) of the motor vehicle  10 . It is within the contemplation of this invention to provide a guard portion  21  of any shape adapted to the specific configuration of the motor vehicle  10  and the step bar  12 .  
      The guard portion  21  includes a width  24  and a length  22 . Preferably, the width  24  is such that the guard portion  21  extends inboard of the vehicle tire  14  ( FIG. 2 ). The length  22  of the guard portion  21  is application specific, and a worker skilled in the art would understand that the length is configured according to the specific configuration of the motor vehicle  10  and the step bar  12 .  
      The guard  21  is preferably fabricated from a flat sheet of metal that is attached by a plurality of fasteners at attachment points  32 . It should be understood that the type of fastener used to attached the guard  21  to the step bar  12  may be of any type known to a worker skilled in the art, such as screws, rivets or bolts. Further, the guard  21  may be attached by other means such as welding, molding, snap type fits and the like. Further, referring to  FIGS. 8 and 9 , an alternate embodiment of the guard assembly  20  is shown including snap features  46 . The snap features  46  provide a temporary holding mechanism for the step bar to ease installation. The snap features  46  hold one side of the guard  20  to the step bar  12  while fasteners at attachment points  32  are secured to attach the guard to the step bar  12 . The snap features  46  shown in  FIGS. 8 and 9  are only one possible configuration of a snap feature within the contemplation of this invention, other configurations as are known to a worker skilled are within the scope of this invention.  
      Although a flat sheet of non-corrosive material such as stainless steel is preferable, it is within the contemplation of this invention that the guard  20  may be fabricated from any materials such as plastics, fiberglass, steel grate, powder coated sheet steel or other such materials as one skilled in the art would understand is applicable to such applications. The flat sheet comprising the guard portion  21  may includes various strengthening features as are known to a worker skilled in the art, including grooved, ribs, channels, groove, along with the addition of strengthening members attached to the guard  20  to provide the desired additional strength.  
      Referring to FIGS.  10 A-B, an alternate embodiment of the guard portion  21  is shown including a plurality of grooves  48 . The grooves  48  provide additional traction and strength to the guard portion  21 .  FIG. 8B  illustrates a cross-section of the guard portion  21  including grooves  48 . It should by understood that any groove configuration as is known to a worker skilled in the art is within the contemplation of this invention.  
      Referring to  FIGS. 11A and 11B , another embodiment of the guard portion  21  includes a series of alternating channels  50  forming a corrugated guard portion  21 . The alternating channels  50  are strengthening features that reinforce the guard portion  21 .  FIG. 11B  is a cross-section of the guard portion  21  with the alternating channels  50 . As appreciated, any configuration of a corrugated or alternating channel guard portion  21  is within the contemplation of this invention.  
      Preferably, the guard  21  includes only the mounting openings at each of the attachment points  32 , however, it is within the conteinplation of this invention to use a guard  20  including openings throughout the guard  20  to facilitate mounting and water drainage. Further, the guard  20  is adaptable to the specific applications of the step bar and motor vehicle. As would be understood by a person skilled in the art, the exact length and width of the guard  20  is determined on an application specific basis.  
      Referring to FIGS.  12 A-B, another embodiment of a guard assembly is shown and generally indicated at  60 . In this embodiment, the guard portion  64  includes a flexible sheet of flexible material. The flexible material is preferably a vinyl composite including a plurality of snap members  62 . The snap members  62  snap fit the vinyl material to the bottom of the step bar to block the opening between the step bar  12  and the motor vehicle  10 . Further, any type of flexible material as is known to a worker skilled in the art is within the contemplation of this invention. Such material can include tarp, canvas, cloth or other like materials secured to the bottom portion of the step bar  12 .  
      Referring to  FIG. 2 , preferably, the guard assembly  20  includes a lip  30  substantially transverse to the guard portion  21 . The lip  30  extends upward on an inboard portion of the guard  20 . The lip  30  aids in protection of the rocker panel  16  of the motor vehicle  10  by preventing rocks and road debris from being thrown between the guard portion  21  and the bottom of the motor vehicle  10 . The distance at which the lip  30  extends from the guard  20  may be of any length designed to protect the rocker panel  16 .  
      Referring to  FIG. 4 , the lip  30  may also extend downwardly from the guard portion  21  to prevent road debris from being thrown up against the rocker panel  16 . In the embodiment shown in  FIG. 4 , the guard portion  21  is mounted to the top surface of the step bar  21 . The lip  30  corresponding to this mounting configuration extends downward to protect against road debris being thrown up into the rocker panel  16 . The specific configuration of the lip  30  is application specific and all configurations as is known to a worker skilled in the art are within the contemplation of this invention.  
      Referring to  FIG. 13 , another embodiment of the lip  30  extend further upward from the guard  30  to provide a location for the application of a decorative item  38  such as lights, text messages, or illustrations according to the desire of the owner of the motor vehicle  10 .  
      Referring to  FIGS. 14-15 , another embodiment of the guard is generally indicated at  66  and includes a guard portion  68  with an interlocking portion  74 . The interlocking portion  74  includes a “V” shaped section  74  with a ridge  73 . The lip portion  70  includes a corresponding interlocking section  70 . The interlocking section  70  is also “V” shaped and fits within the interlocking portion  74  of the guard  68  and retained by the ridge  73 . The lip  72  is assembled separately to provide for differing motor vehicle configurations. Different motor vehicle and step bar combinations will require lips  72  if differing lengths. The length  76  can be of any length desired and according to the specific applications. Further, the lip  72  is assembled separately from the guard  68  to allow lips  72  of differing lengths  76  to tailor to each specific application.  
      Referring to  FIGS. 16-17 , another embodiment of the guard assembly is generally indicated at  78  and includes a guard  84  with a lip  80  of a standard length  87 . Attached to the lip  87  is an extension member  82 . The extension member is generally “J” shaped with a clip portion  869 . The clip portion  86  clamps onto the lip  80  of the guard  84 . The extension member  82  provides for an overall length  88  to provide for the desired height of the guard  84  according to application specific requirements. Note that the it is within the contemplation of this invention to use any type of attachment configuration as is known to a worker skilled in the art to attach the separate lip to the guard portion, such as threaded fasteners, clamps, rivets  
      The foregoing description is exemplary and not just a material specification. The invention has been described in an illustrative manner and should be understood that the terminology used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present invention are possible in light of the above teachings. The preferred embodiments of this invention have been disclosed. However, one of ordinary skill in the art would recognize that certain modifications are within the scope of this invention.