FORM 2
THE PATENT ACT, 1970
(39 of 1970)
&
THE PATENTES RULES, 2005
COMPLETE SPECIFICATION
(See section 10, rule 13)
1. TITLE OF THE INVENTION
Running Board Assembly
2. APPLICANT(S)
(a) Name : MAHINDRA & MAHINDRA LIMITED
(b) Nationality : Indian Company registered under the provisions
of the Companies Act, 1956
(c) Address : R&D Center, Automotive Sector,
89, M.I.D.C, Satpur, NASHIK - 422 007 Maharashtra State, India
3. PREAMBLE OF THE DESCRIPTION
COMPLETE
The following specification particularly describes the invention and the manner in which it is to be performed.

Running Board Assembly Field of the invention
The present invention relates to a polymer molded composite running board for automobile. More specifically, the present invention relates to a running board assembly made up of reinforced thermoplastic material useful as a standard part between different types of vehicle.
Background of the invention
Manufacturers and vehicle users add running boards to vehicles for both aesthetic appeal and functionality. A person entering or exiting a vehicle may step onto the running board to more easily facilitate vehicle entry, particularly with respect to vehicles riding high off the ground, such as trucks. In state of art automobile manufacturing process, the manufactures use light weight components to reduce the weight of components aimed to achieve better fuel economy.
Running boards are a popular accessory for motor vehicles having a high ground clearance, such as sport-utility vehicles, pick-up trucks, and minivans. The running boards assist individuals in entering and exiting the motor vehicle by allowing individuals to use the running board as a step. Typically, running boards are assemblies made up of multiple components. Previous running boards were made exclusively from metal in order to resist downward forces applied to the stepping platform. More recently, with the advent of composite materials, manufacturing part of the running board from plastic has become common. Running boards having at least one component molded from a composite material are lighter in weight and are more cost-effective compared to running boards made exclusively from metal. Another issue faced by the running board of the prior art is heavy weight due to use of a multi-piece concept which usually causes gap, flush and more vibration noise issue during

automobile use. Metal running boards of the art when subjected to low speed side impact or abuse load at outer edge generally tend to bend.
Due to recent developments in reinforced plastic, use of plastic is becoming more famous in composite running board manufacturing. Use of plastic as composite material has various issues such as high production investment and tendency to crack when subjected to low speed impact and abuse load on the outer edge of the running board.
Hence, there is a need of a running board that is light weight in composite and has standard components shared across different vehicles in order to reduce investment cost. Also there is a need of the running board that takes care of abuse load during side impact thereby overcoming drawbacks of the prior art.
Objects of the invention
An object of the present invention is to use light weight composite material that provides cost-effective manufacturing process and also resolves the cracking or breaking issues of components due to overuse.
Another object of the present invention is to allow transfer of load of a passenger towards an automobile body without affecting the integrity of components.
Yet another object of the present invention is to act as an impact protector bar that absorbs energy from side impact or any impact sustained from obstacles on the ground.
Still another object of the present invention is to facilitate effective damping effect.

Summary of the invention
Accordingly, the present invention provides a running board assembly for an automobile. The running board assembly includes a board, an insert body and a plurality of brackets. The board is made up of a composite material having a platform with a plurality of grooves configured thereon. The insert body is configured with one side of the board using a fixing mean .The insert body includes an insert assembled to a pin therewith. Each bracket of the plurality of brackets has a first end secured to the pin of the insert body and a second end capable of engaging with the automobile body. Upon stepping of a passenger on the board, the board transfers load on the insert body which subsequently transfers the load to the plurality of brackets thus facilitating even distribution of the load on the automobile body.
Brief description of drawings
Figure 1 illustrates a running board assembly with mounting features and basic components, in accordance with the present invention;
Figure 2 illustrates a perspective view of an insert, a pin and an insert assembly used in the running board;
Figure 3 illustrates a perspective view of the insert assembly placed in a tool and composite material before over molding;
Figure 4 explains a molding feasibility of the running board and the insert assembly using a side core in a mold;
Figure 5 illustrates a sectional view of the molded part of figure 4 with the pin and the insert, in accordance with a first embodiment of the present invention;

Figure 6 shows a sectional view of the molded part of figure 4 with the pin and a structural foam insert, in accordance with a second embodiment of the present invention;
Figure 7 illustrates a sectional view of the molded part of figure 4 having the pin without the insert, in accordance with a third embodiment of the present invention;
Figure 8 illustrates a plurality of grooves on the running board, in accordance with the present invention;
Figure 9 illustrates a box structure with a plurality of ribs, in accordance with the present invention;
Figure 10 illustrates the running board assembly having a plurality of brackets and the inserts assembly, in accordance with the present invention;
Figure 11 illustrates a front perspective view of a gap and a flush with an automobile body;
Figure 12 illustrates a rear perspective view of the running board assembly with the automobile body;
Figure 13 illustrates a cross sectional view of the running board assembly with the automobile body;
Figure 14 illustrates a front view of the pins used in the first, second and third embodiments of the present invention;
Figure 15 explains a standardization concept used in present invention; and

Figure 16 illustrates a schematic view of a single part manufacturing using a single mold concept.
Detailed description of the invention
The foregoing objects of the invention are accomplished and the problems and shortcomings associated with the prior art techniques and approaches are overcome by the present invention as described below in the preferred embodiment.
Accordingly, the present invention provides a running board assembly designed to transfer the passenger weight load evenly at each mounting location on an automobile body. The present invention acts as an impact protector bar that absorbs energy from side impact or any impact sustained from obstacles on the ground.
For a thorough understanding of the present invention, reference is to be made to the following detailed description, including the appended claims, in connection with the above-described drawings. Although the present invention is described in connection with exemplary embodiments, the present invention is not intended to be limited to the specific forms set forth herein. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but these are intended to cover the application or implementation without departing from the spirit or scope of the claims of the present invention. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The present invention is illustrated with reference to the accompanying drawings, throughout which reference numbers indicate corresponding parts in the various figures. These reference numbers are shown in bracket in the following description.

Referring to figures 1 and 2, the details of an insert over molded running board assembly 200 (herein after referred as "running board assembly 200") for an automobile in accordance with the present invention is shown. The running board assembly 200 comprises a running board 10 (herein after referred as "board 10"), an insert body 20 and a plurality of brackets 30 (herein after referred as "brackets 30"). The board 10 of the present invention is a flat board made up of a composite material. The board 10 includes a platform 07 with a plurality of grooves 06 configured thereon. The plurality of grooves 06 on the platform 07 provides an. anti-skidding feature to the board 10.
The insert body 20 of the present invention is configured on one side of the board 10 using a fixing mean. In an embodiment of the present invention, the insert body 20 is insert / over molded to secure with the board 10. The fixing mean in another embodiment of the present invention uses nut/screws and bolts to secure the insert body 20 with the board 10. The insert body 20 includes an insert 12 adaptably assembled with a pin 14 therewith. The pin 14 of the insert body 20 acts as a cantilever supporting the insert 12 at one end and other free end to connect with an automobile body.
Each bracket of the plurality of brackets 30 includes a first end 32 having a hole 31 secured with the pin 14 of the insert body 20 using a securing means and a second end 36 capable of engaging with the automobile body. The second end 36 configures a plurality of holes 34 secured with another fixing mean for selectively engaging with a plurality of holes on the automobile body. Another fixing mean of the present invention includes using nut/screws and bolts and the like.
In the present invention, the plurality of holes 34 of the second end 36 comprises a first hole 34a, a second hole 34b and a slot 34c. The first holes 34a are vertically mounting holes adaptably aligned to engage with the automobile body holes. The second holes 34b are horizontal mounting holes adaptably aligned to

engage with the automobile body holes. The slots 34c are horizontal mounting locators adaptably aligned to engage with the automobile body holes. The brackets 30 of the present invention are made up of solid material like metal, plastic and the like. The brackets 30 of the present invention are preferably made up of steel. The brackets 30 of the present invention are designed to transfer load of passengers evenly at each mounting location on the automobile body.
Referring to figure 2, details of the insert body 20 that is over molded in composite part in accordance with the present invention is shown. In the present embodiment, the insert 12 is a pultruded thermoset, extruded thermoplastic or rigid foam part and the like. The pin 14 is a steel pin/ insert pin that is assembled with the insert 12 preferably by the use of an adhesive in cases where the insert 12 is of pultruded thermoset or extruded thermoplastic part. When the insert 12 is a rigid foam part, the pin 14 is assembled with the insert 12 preferably by insert over molding.
Now referring to figure 3, the insert body 20 is shown before placing it in a mold 38. The board 10 is formed by injecting glass filled resin in the mold 38 by using a composite material. The composite material in the present invention is a long glass filled polypropylene, a long / short glass filled nylon and the like. The board 10 of the present invention is manufactured by melting a pallet using an injection molding technology and is further compressed using a compression molding technology. A reinforced reaction injection process with molded PU or epoxy resin is also used to manufacture the board 10.
Referring to figure 4, an arrangement and a tooling layout for manufacturing of the board 10 is described. The insert body 20 including the insert 12 and the pin 14 is placed in the mold 38. In the present embodiment, the mold 38 has at least four sliding cores 38a that operate along an arrow 35 direction for the ejection of

the pin 14 and at least two siding cores 38b that operates along the arrow 35 direction for the ejection of an end cap feature of the board 10.
Referring to figure 5, a sectional view taken along 4-4 axis of figure 4 located at the pin 14 in accordance with a first embodiment of the present invention is illustrated. In the present embodiment, a board lO.a that is a composite running board with over molded steel pins and pultruded / extruded insert is shown. The section shows a pultruded thermoset or extruded thermoplastic first insert 12.1 covered by the composite material. A first pin 14.1 is adhesively bonded with the first insert 12.1 and extended along the arrow 35 outside the composite part to serve the board lO.a mounting on the bracket 30. In this one embodiment, the sliding core 38a is in the direction of the arrow 35 for the ejection of the part. A line C shows a parting line consideration. A line D shows a tooling direction for part ejection. The grooves 06 are present as an antiskid feature in the board lO.a. The insert arrangement of the board lO.a in accordance with the first embodiment avoids a sink mark on the platform 07 surface and also reduces the need of an extra cap part to cover the sink mark.
Now referring to figure 6, a section taken along 4-4 axis of figure 4 located at the pin 14 in accordance with a second embodiment of the present invention is illustrated. In the present embodiment, a board lO.b that is a composite running board with over molded insert that is steel pins and rigid foam insert is shown. The section shows a second insert 12.2 made up of rigid foam covered by the composite material. The first pin 14.1 is over molded in the second insert 12.2 and extended along the arrow 35 outside the composite part to serve the part mounting on the bracket 30. In this one embodiment, the sliding core 38a is in the direction of the arrow 35 for the ejection of the board lO.b. The line C shows a parting line consideration. The line D shows a tooling direction for the board lO.b ejection. The grooves 06 are present as an antiskid feature in the board lO.b. The insert arrangement of the board lO.b is in accordance with the second

embodiment that avoids the sink mark on the platform 07 surface and also reduces the need of the extra cap part to cover the sink mark. The insert defined in first and second embodiment 12.1 and 12.2 acts as an impact protector bar by absorbing energy from side impact as well as any impact from the ground due to obstacles. Thus reduces the velocity of impacting object before it gets impacted on the automobile body.
Referring to figure 7, a section taken along 4-4 axis of figure 4 located at the pin 14 in accordance with a third embodiment of the present invention is illustrated. In the present embodiment, a board lO.c that is a composite running board with over molded steel pins is shown. A second pin 14.2 is over molded in the board lO.c directly with composite material and extended along the arrow 35 outside the composite part to serve the part mounting on the bracket 30. In this one embodiment, the sliding core 38a is in the direction of the arrow 35 for the ejection of the part. The line C shows parting line consideration. The line D shows a tooling direction for board lO.c ejection. The grooves 06 are present as an antiskid feature in the board lO.c. The insert arrangement of the board lO.c is in accordance with the third embodiment that avoids the sink mark on the platform 07 surface and also reduces the need of extra cap part to cover the sink mark.
An outer flange 39 is rusticated according to easy ejection of the board lO.c in tool. Slight increase in the local thickness of the outer flange 39 is done to increase strength at an outer edge of the board lO.c. In certain cases, it has been observed when the passenger places a foot on the board 10 results in to abuse on the outer edge surface and the outer flange 39 of the board 10. The insert molded part at the outer flange 39 area acts as load bearing member of the board 10c. Simultaneously, the outer flange 39 facilitates the transfer of the load to the pin 14.2 molded parts of the outer flange 39 area.

Referring to figure 8, top view of the board 10 and the grooves 06 is shown. The grooves 06 of the present invention act as an antiskid feature in the board 10. In certain situation where upon stepping of the passenger on the board 10, the board 10 transfers load on the insert body 20. The insert body 20 subsequently transfers the load to the brackets 30 facilitating even distribution of the load on the automobile body.
Now referring to figure 9, illustrates the structural design for even distribution of load transfer. If the board 10 is subjected to stepping load of 115 kg then at a centre of each door of the automobile, load gets transferred through specifically spaced rib structure to a steel pin molded feature box structure 40 (herein after referred as "box structure 40"). A plurality of cross ribs (herein after referred as "ribs") is placed in the centre of the box structure 40. The ribs 42, 48 and 55 are kept at the centre of box structure 40 and are subjected to direct loading. A horizontal rib 43 passing through all the parts and connecting the box sections to the loading area is subjected to direct loading. The ribs 44, 44', 45, 45', 49, 49', 50,50' transfer the load to the box structure 40. The ribs 44, 45,44', 45', 49, 50, 49', 50' support the horizontal rib 43 at a junction of the ribs 52-52' and 47-47' to support the loading at the door centre area of the automobile. A good reinforcing rib structure at other area of the board 10 is required as the stepping area is not always at the door centre.
Accordingly, the rib 55 is positioned at the centre of the box structure 40. The ribs 56 and 56' are paced at the centre of the box structure 40 and the rib 55 at each side respectively. The ribs 61, 62 and 61', 62' connects ribs 56 and 56' to the box structure 40 and forms a junction point at 63 and 63' at the inner flange of the board 10. The ribs 57, 58 and 57', 58' connect the ribs 56 and 56' to the central rib 55 at a junction 60. The ribs 57, 57', 58, 58', 61, 61', 62, 62' supports the horizontal rib 43 at a junction of the ribs 59, 59' and 64, 64' to support the loading at the centre area of the board 10.

Referring to figure 10, the running board assembly 200 including the board 10 with the brackets 30 and the box structure 40 accommodating the pin 14 is shown. The pins 14 of the board 10 is adaptably engages with a hole 31 of the bracket 30 and is fixed by using a fixing means that is tightened over the thread on the pin 14. The fixing means in the present invention includes threaded nut, and the like.
The box structure 40 includes a boss 71 to accommodate the pin 14. The boss 71 passes through a bottom wall 72. The bottom wall 72 is equally spaced on both side of the boss 71. A pair of opposed walls 73 and 73' are vertical side wall of the box structure 40 that supports the load bearing area and also supports the rib structure. A rib 74 is placed at the centre of the opposed wall 73 and 73' that passes through the boss 71, directly transferring the load from load bearing area to the pin 14. A pair of ribs 75-75' connects the end of wall 73 and 73' to the intersection of the rib 74 and the boss 71 at respective side. The ribs 75-75' facilitates the transfer of the load to the boss 71 and further to the pin 14.
In this one embodiment, the box structure 40 facilitates even distribution of a force from the horizontal platform 07 of the board 10 to the insert 12 which is further translated to the pin 14. The pin 14 acts as a cantilever by supporting the insert 12 at one end and mounting the bracket 30 on other end thereby connecting with the automobile body. The box structure 40 thus reduces the stress on the board 10.
The platform 07 is supported by the insert 12 at a front edge that significantly contributes in the reduction of frequency excitation mode. The frequency excitation mode is observed to be higher in the front edge area. The rigid foam inserts 12.2 of the second embodiment is more effective in facilitating the damping effect. Similarly, the platform 07 supported by the insert 12.1 of the

first embodiment and the insert 12.2 of the second embodiment acts as a energy absorbing element when the load of passenger weight comes on the board lO.a and the board lO.b. This results in reducing energy of impact to reach to the pins 14. Upon release of load of passenger the board 10 returns to the original position.
Referring to figure 11, a gap 80 between an automobile body 81 and the running board assembly 200 is shown. The gap 80 is created when the running board assembly 200 is mounted on the automobile. The gap 80 is even throughout as it is in Z direction and is prominently visible from outside due to body color and foot step color difference.
Now referring to figures 12 and 13, the running board assembly with the automobile body is illustrated. In a first step, the board 10 is adaptably secured through the pin 14 with the bracket 30 using the fixing means at each mounting location. In a next step, the running board assembly 200 is then mounted on the automobile body 81 by first locating it on the slot 34c that results in unevenness in the gap 80. In next step, the running board assembly 200 is tightened at the first hole 34a and the second hole 34b by tightening a bolt (not shown) with one weld nut 90 and another weld nut 92 respectively. Each bracket 30 transfers required load at each mounting location on the automobile body 81.
Referring to figure 14, a detailed design of the pin 14 for different embodiments of the present invention is described. The pin 14.1 is used in the first embodiment and the second embodiment for the insert 12.1 and 12.2. The pin 14.1 includes a rod 95, a disk 96 and a threaded portion 97. The rod 95 represents the complete length of the rod used in the pin 14.1. The disk 96 is a disc shaped feature adaptably placed on the rod 95 such that it leaves some length for the insertion in the insert 12. The disk 96 surface area in contact with

pultruded and extruded plastic insert 12 is useful for adhesive bonding of the pin 14.1.
The pin 14.2 used in the third embodiment where there is no insert. The pin 14.2 includes a rod 95' and the disk 96. The rod 95' represents the complete length of rod used in the pin 14.2. The disk 96 is a disc shaped feature adaptably placed at one end the rod 95'. The threaded portion 97 is same on both the pins 14.1 and 14.2. The threaded portion 97 acts as a locking feature for the board 10 during passenger load bearing. The disk 96 acts as a locking feature to facilitate the pins 14.1 and 14.2 to be an integrated part of the board 10 during load bearing and overload abuse by the passenger. The disk 96 and the threaded portion 97 acts as a locking feature in composite part. The threaded portion of feature 97 is used to attach composite part to the pin 14.2 with the help of nut.
Referring to figure 15, a standardization proposal of the board 10 used for two different automobiles in accordance with the present invention is shown. The board 10.1 is useful for a double cap pick up type automobile requiring large running board length. The board 10.2 is useful for sport utility type of automobile requiring moderate running board length. A cap 100 is a separate part for automobiles with the board 10.2. Both the running boards share identical geometrical features up to the length 101 as represented.
Referring to figure 16, a schematic view for standardization proposal of the board 10 used for two different automobiles by manufacturing it in a single tool is shown. The application of single tool in manufacturing process for different platform of the two different automobiles increases the cost effectiveness. A mold used has a single core 110 and a single cavity ill. Two different molds insert 112 and 113 used for manufacturing process for different boards of two different automobiles is shown. The mold insert 112 is preferably used for

manufacturing of the board 10.1 and mold insert 113 is preferably used for the manufacturing of the board 10.2. The present invention uses an insert molded board and standardization for certain vehicles and requires added part as a cap to cover the exterior visible sink mark caused due to insert placement in the component.
Advantages of the present invention
1. The running board assembly 200 of the present invention provides cost-effective manufacturing process and also resolves the cracking or breaking issues of components due to overuse.
2. The insert 12 of the running board assembly 200 act as an impact protector bar that absorbs energy from side impact or any impact sustained from obstacles on the ground, thus reducing the velocity of impacting object before it gets impacted on the automobile body.
3. The rigid foam inserts 21.2 in one of the embodiment of the present invention is designed to provide effective damping effect.
The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the present invention and its practical application, to thereby enable others skilled in the art to best utilize the present invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omission and substitutions of equivalents are contemplated as circumstance may suggest or render expedient,

but such are intended to cover the application or implementation without departing from the spirit or scope of the present invention.

We Claim
1. A running board assembly 200 for an automobile, the running
board assembly 200 comprising:
a board 10 made up of a composite material, the board 10 having a platform 07 with a plurality of grooves 06 configured thereon;
an insert body 20 configured with one side of the board 10 using a fixing mean, the insert body 20 having an insert 12 assembled to a pin 14 therewith;
a plurality of brackets 30, each bracket of the plurality of brackets 30 having a first end 32 secured to the pin 14 of the insert body 20 and a second end 36 capable of engaging with the automobile body,
wherein upon stepping of a passenger on the board 10, the board 10 transfers load on the insert body 20 which subsequently transfer the load to the plurality of brackets 30 thereby facilitating even distribution of the load on the automobile body.
2. The running board assembly 200 as claimed in claim 1, wherein the board 10 is being formed by injecting glass filled resin in a mold.
3. The running board assembly 200 as claimed in claim 2, wherein the composite material is a long glass filled polypropylene, a long glass filled nylon, and /or a short glass filled nylon.
4. The running board assembly 200 as claimed in claim 1, wherein the board 10 is manufactured by melting pallet using an injection molding technology and compressed using a compression molding technology.
5. The running board assembly 200 as claimed in claim 1, wherein the plurality of grooves 06 facilitates an anti-skidding feature.

6. The running board assembly 200 as claimed in claim 1, wherein the insert 12 is made up of any one of a pultruded thermoset, extruded thermoplastic and rigid foam part.
7. The running board assembly 200 as claimed in claim 1, wherein the pin 14 is assembled with the insert 12 using an adhesive.
8. The running board assembly 200 as claimed in claim 1, wherein the pin 14 is assembled with the insert 12 using an insert over molding method.