Patent Publication Number: US-11046252-B1

Title: Vehicle side rail having one or more steps with a braced front end and a non-braced back end

Description:
CROSS-REFERENCE TO CO-PENDING APPLICATIONS 
     This application is a continuation application which claims priority to U.S. patent application Ser. No. 15/638,944, filed Jun. 30, 2017, which claimed priority to and the benefit of U.S. 62/415,213 filed Oct. 31, 2016, U.S. 62/417,821 filed Nov. 4, 2016, and U.S. 62/458,931 filed Feb. 14, 2017. 
    
    
     BACKGROUND 
     This disclosure is in the field of vehicle side or step rails made of a decorative tube or channel with steps connected to the tube or channel at vehicle entry points. These prior art rails include steps that are either formed as part of the rail itself or steps that connect at each end to the rail or the vehicle frame. 
     SUMMARY 
     Embodiments of a vehicle side or step rail includes a longitudinal extending vehicle side rail having a vehicle frame-facing side arranged to mount to the frame of a motor vehicle and an outward-facing side to which a leading end of one or more steps is connected to the rail but the trailing end is not. The connection may be in the form of a brace. Depending on where the vehicle mounting points are located relative to the leading end of the step, one or more additional braces can be added. Regardless of whether additional braces are used, the trailing end of the step is not braced or connected to the rail and always extends past the brace. The step surface of the step is always spaced apart from the rail, leaving a gap between it and the outward-facing side of the rail. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front elevation view of an embodiment of a vehicle side or step rail having only one end connected to the rail. 
         FIG. 2  is a top plan view of the rail and step of  FIG. 1 . 
         FIG. 3  is a left side elevation view of the rail and step of  FIG. 1 . The step has a circular-shaped cross section. 
         FIG. 4  is a right side elevation view of the rail and step of  FIG. 1 . 
         FIG. 5  is an embodiment of the step having an oval-shaped cross section. 
         FIG. 6  is an embodiment of the step having a semi-circular shaped cross section. 
         FIG. 7  is an embodiment of the step having a square-shaped cross section. 
         FIG. 8  is a front elevation view of another embodiment of a vehicle side or step rail having only one end connected to the rail. 
         FIG. 9  is a top plan view of the rail and step of  FIG. 8 . 
         FIG. 10  is a left side elevation view of the rail and step of  FIG. 8 . The step has a circular-shaped cross section. 
         FIG. 11  is a right side elevation view of the rail and step of  FIG. 8 . 
         FIG. 12  is an embodiment of the step having an oval-shaped cross section. 
         FIG. 13  is an embodiment of the step having a semi-circular shaped cross section. 
         FIG. 14  is an embodiment of the step having a square-shaped cross section. 
         FIG. 15  is a top plan view of an embodiment of the step having a step pad. 
         FIG. 16  is a side elevation view of the step of  FIG. 15 . 
         FIG. 17  is a top plan view of an embodiment of the vehicle rail and step that includes a brace for connection to the rail. 
         FIG. 18  is a side elevation view of the step of  FIG. 17 . 
         FIG. 19  is a top plan view of an embodiment of the vehicle rail and step that includes an additional brace. 
         FIGS. 20 to 27  are perspective views in sketch form of other embodiments of the vehicle rail and step. The rail may be extended lengthwise, and additional steps added. 
         FIG. 20  is an embodiment of the step having angled surfaces and connected to a rail having an open channel shape. 
         FIG. 21  is an embodiment of the step having a curving wing-like shape. 
         FIG. 22  is an embodiment of the step having a semi-circular shaped cross section and a tread plate design on its upper surface. 
         FIG. 23  is an embodiment of the step having a circular-shaped cross section. 
         FIG. 24  is an embodiment of the step having an oval-shaped cross section with a tread plate design on its upper surface. 
         FIG. 25  is an embodiment of the step having an angled shape similar to that of the rail and illustrating how the step may be adjustable and mounted to the brace using fasteners. 
         FIG. 26  is an embodiment of the step illustrating how the step may be adjustable and mounted to the rail with fasteners. 
         FIG. 27  is an embodiment of the step including an open channel shape. 
         FIG. 28  is a front elevation view of another embodiment of the step. 
         FIG. 29  is a top plan view of the step of  FIG. 28 . 
         FIG. 30  is a left side elevation view of the step of  FIG. 28 . 
         FIG. 31  is a right side elevation view of the step of  FIG. 28 . 
         FIG. 32  is a perspective view of the step of  FIG. 28 . 
         FIG. 33  is a perspective view of another embodiment of the vehicle step rail and step. 
         FIG. 34  is a perspective view of yet another embodiment. 
         FIG. 35  is a left-side elevation view of an embodiment. 
     
    
    
     ELEMENTS AND NUMBERING USED IN THE DRAWINGS AND DETAILED DESCRIPTION 
     
         
         
           
               11  Vehicle side rail 
               13  Leading (first or connected) end of  15   
               15  Step 
               17  Outward-facing side of  11   
               19  Trailing (second or free) end of  15   
               21  Step surface 
               23  Lower or bottom end of  11   
               25  Vehicle frame-facing side of  11   
               27  Bracket 
               29  Open channel 
               31  First leg 
               32  Opposing end 
               33  Second leg 
               35  Cap 
               37  Gap 
               39  Midline of  11  (top-to-bottom) 
               41  Interior of  15   
               47  Exterior profile 
               49  Longitudinal centerline of  11  (left-to-right) 
               51  Step pad 
               53  Tread plating 
           
         
       
    
     DETAILED DESCRIPTION 
     Embodiments of a vehicle side rail include at least one step that has a step surface spaced apart from an outward-facing side of the vehicle side rail, with the at least one step having one end only connected to the vehicle rail and another end not connected to the vehicle rail by any structure extending from that end to the vehicle rail. The step is a separate structure apart from the rail. In some embodiments, the step may be connected to the vehicle frame and given the appearance that its leading end is connected to the rail, the other end remaining a free end. 
     In other embodiments of the vehicle side rail the step includes two legs in contact with one another, the first leg having one end connected to the vehicle side rail and extending outwardly from the vehicle side rail and the second leg providing the step surface and extending away from the first leg, with the second leg including a free end not connected to the vehicle rail by any structure extending from the free end to the vehicle side rail. The free end can be capped. 
     The first leg may also extend in a downward direction, a rearward direction, or a downward and rearward direction from the vehicle side rail. Although not as aesthetically pleasing, the first leg may extend in the forward direction rather than the rearward direction. 
     In some embodiments, the step includes a brace extending between the vehicle side rail and the second leg, with the free end of the second leg extending past the brace. The brace can be located in a first two-thirds of the second leg as measured from where the second leg connects to the first leg. 
     The first and second legs can form a single-piece or can be connected as separate pieces. In embodiments, the legs form a weldment. The legs may be identical to, or different from, one another in length, width, or shape (or some combination thereof). The first and second legs may include a curved exterior profile or an angled exterior profile. 
     In yet other embodiments, the vehicle side rail includes at least one step having a connected end in contact with and extending outwardly from the vehicle side rail, a free end not connected by any structure extending from the free end to the vehicle side rail, and a step surface located between the connected end and the free end. At least one brace may be located in a first two-thirds of the horizontal distance or spacing between the connected end and the free end as measured from the free end. 
     Referring to the drawing figures, embodiments of a vehicle side rail  11  of this disclosure includes at least one step  15  with a leading (first) end  13  of the step  15  connected to an outward-facing side  17  of the rail  11  but the trailing (second) end  19  of step  15  is not. The leading end  13  of the step may be centered at or below a midline  39  of the rail  11 . The end  13  can be welded to the rail  11 , forming a weldment with the rail, fastened to the rail  11 , or welded and fastened. In all cases, the trailing end  19  is a free-end, with no structure connected to and extending from it to rail  11 . 
     The step  15  also may include a step pad  51 , tread plating  53 , or other step coverings on the step surface  21  that provide traction or improved aesthetics (see e.g.  FIGS. 15-19, 22 &amp; 24 ). In some embodiments, the step  15  may include a hollow interior  41  and an end cap  35  on the trailing end  19 . The cap  35  may have a same or similar surface finish to that of step  15  or may be a different material with a different surface finish as that of the step  15  (see e.g.  FIGS. 15 &amp; 29 ). Persons of skill in the art would recognize that other embodiments not shown with an end cap  35  may include a cap. In other embodiments, the step  15  may include a solid interior  41  with trailing end  19  having a same or similar surface finish as that of the step  15 . 
     A vehicle frame-facing side  25  of the rail  11  is arranged to connect to one or more mounting brackets  27 , see e.g.  FIG. 15 , that connect the rail  11  to the vehicle frame so that the rail  11  resides below the vehicle&#39;s rocker panels. The rail  11  may extend longitudinally along an entire length of the motor vehicle between the front and rear wheel wells or it may extend longitudinally along an entire length of one door or entry point to the vehicle. Regardless of rail length, the step  15  is arranged so that, when the rail  11  is mounted to a motor vehicle, the step surface  21  is below the vehicle entry point. 
     The mounting points on the frame-facing side  25  of the rail  11  can be fixed or adjustable. If adjustable, the rail  11  typically includes an open channel  29  facing the frame, see e.g.  FIG. 20 , that is sized to receive a mounting clip or plate (not shown). Rails sold by Iron Cross Automotive (Tulsa, Okla.) are examples of this type of adjustable mounting. The rail  11  itself may be generally cylindrical-shaped or polygonal-shaped, at least on the outward-facing side  17  of the rail  17 . 
     In some embodiments the step  15  is a single-piece, generally L-shaped step when viewed looking directly down on the step, having a first leg  31  serving as a brace for the step  15  and a second leg  33  forming the step surface  21 . In these single-piece embodiments, the legs  31 ,  33  merge into one another. In other embodiments, the step  15  is a two-piece step, again with the first leg  31  serving as a brace and the second leg  33  forming the step surface  21 . When arranged as a two-piece step, the legs  31 ,  33  include opposing ends  32 A,  32 B where they connect one to the other (see e.g.  FIG. 17 ). This connection may be a welded connection (thereby forming a weldment), a fastened connection, or some combination of a welded and fastened connection. 
     Regardless of single- or two-piece (or more) construction, to improve aesthetics the exterior profile  47  of the step  15  should generally match that of the rail  11 , at least on the rail&#39;s outward-facing side  17 . The step  15  can be circular-shaped, elliptical- or oval-shaped, semi-circular-shaped, triangular-shaped, square-shaped, or rectangular-shaped in cross section. In some embodiments, the step  15  includes one or more angled surfaces on the first leg  31 , the second leg  33 , or on both legs  31 ,  33 . By way of example, a cylindrical-shaped step  15  may be used on a cylindrical-shaped rail  11  or a polygonal-shaped (angled) step  15  can be used on a polygonal-shaped (angled) rail  11 . 
     In embodiments, the first leg  31  extends outwardly from the rail  11  to create a gap  37  between the second leg  33  and the outward-facing side  17  of the rail. The second leg  33  may run parallel to the longitudinal centerline of the rail  11 , with the step surface  21  being horizontal. The length, width, or shape of the legs  31 ,  33 —or some combination of length, width, and shape—may be the same as or different than one another (see e.g.  FIGS. 19-34 ). For example, the leading end  13  of the first leg  31  may match that of, or be wider than, the width or diameter of end  32 B of the second leg  33 . The first leg  31  may also taper toward the second leg  33  to match that of the second leg  33  at its opposing end  32 B. In some embodiments, first leg  31  is triangular-shaped and second leg  33  is cylindrical- or rectangular-shaped in cross-section (see e.g.  FIG. 19 ). In other embodiments, first leg  33  is wedge-shaped and second leg  31  is semi-cylindrical in cross-section (see e.g.  FIG. 22 ). In yet other embodiments, first leg  31  is triangular-, rectangular- or square-shaped and second leg  33  is elliptical- or oval shaped in cross-section. In still other embodiments, the second leg  33  is hexagonal-shaped in cross section. Other shapes and combinations of shapes can be arranged depending on aesthetics. 
     The step  15  may be arranged relative to the rail  11  so that the first leg  31  is at an angle α relative to vertical and at an angle β relative to horizontal, with the first leg  31  and second leg  33  being at an angle γ relative to one another. Depending in part on the angle α selected, the step surface  21  may be located above, even with, or below the lower (ground-facing) side  23  of the rail  11 . The first leg  31  may also extend past this lower ground-facing side  23  of the rail. Angle α relative to vertical may be about 90°, 105°, 120°, 135°, or 150° from vertical or at some other angle α in a range of 90° to 150°. Angle β may be 15°, 22.5°, 30°, 45°, 60°, 75°, or 90° from horizontal or at some other angle β in a range of 15° to 90°. Angle γ, that is the angle formed between the legs  31 ,  33 , may be 90°, 105°, 120°, 135°, or 150° or at some other angle γ in a range of 90° to 150°. 
     Depending on where the mounting points are to the motor vehicle relative to the leading end  13  of the step  15 , one or more additional braces  45  can be added, spaced-apart from this end  13 , to add strength, to minimize or eliminate flexing when under load, or for aesthetic purposes (see e.g.  FIG. 19 ). The additional brace  45  may be at a same or different angle α or β as the first leg  31  to the rail  11  and may have a same, similar, or different exterior profile as the first leg  31 . Regardless of whether one, two, or more braces  45  are used, the leading end  13  of the step  15  is connected to the rail  11  and the trailing end  19  always extends past the last brace  45  and is not connected to the rail. Similarly, a brace  45  can be used on steps  15  where the step is a single-piece step. The exterior profile of any additional brace  45  can match that, be similar to, or different from the first leg  31 . 
     Routine experimentation may be applied to determine step material, size, and mounting location for particular vehicle applications to provide the desired strength and minimize or eliminate unwanted flexing. In embodiments of the step  15 , a 200-pound load on the step surface  21  produces no flex in a horizontal plane at the trailing end  19  of the step. In other embodiments, a 200-pound load produces a ¼ inch or less of flex, a ½ inch or less of flex, ¾ inch or less of flex, 1 inch or less of flex, 1¼ inches or less of flex, or 1½ inches or less of flex. 
     While this disclosure describes embodiments of a vehicle side rail having one or more steps with a braced front end and a non-braced back end, the embodiments may be subject to certain modifications by those skilled in the art without departing from the scope of this disclosure or the following claims.