U.S. patent application number 09/491092 was filed with the patent office on 2001-12-20 for injection molded componints for off-road recreational and utility vehicles.
Invention is credited to Andrews, Craig, Davis, Rhonda L., Higgins, Kenneth Terry, Johnson, Mitchell D., Johnson, Patrick, Karl, Mark Thomas, Klein, Michael A., Lowery, Robert A., Mitchell, Alton, Parks, Matthew David, Ruby, Keith D., Sajna, Jeff, Spahr, Tim.
Application Number | 20010052707 09/491092 |
Document ID | / |
Family ID | 24139812 |
Filed Date | 2001-12-20 |
United States Patent
Application |
20010052707 |
Kind Code |
A1 |
Johnson, Mitchell D. ; et
al. |
December 20, 2001 |
Injection molded componints for off-road recreational and utility
vehicles
Abstract
Injection molded components for off-road recreational and
utility vehicles such as an ATV's, snowmobiles and the like. In one
embodiment, the invention provides a rack having a fiber-filled
plastic resin body. The body has an overall thickness substantially
less than its width and length, and includes a generally flat,
horizontal top having a plurality of slots. Each of the slots is
defined by a flange extending downwardly the flange having a
thickness that is substantially less than its height to define a
downwardly extending reinforcing rib, which also provides a point
of attachment for straps such as bungee cords. Preferably the rack
includes integrally molded transverse reinforcing ribs extending
across the slots, the reinforcing ribs having a top surface which
is recessed downwardly from the top surface of the rack. In another
embodiment, the invention provides an injection molded foot rest
for an off-road recreational or utility vehicle. The foot rest is
similarly made from a fiber-filled plastic resin body having a
nominal thickness of less than about 1/4 inch. In another
embodiment, the invention provides a bumper similarly made from
such fiber-filled plastic resin.
Inventors: |
Johnson, Mitchell D.;
(Roseau, MN) ; Klein, Michael A.; (Roseau, MN)
; Parks, Matthew David; (Orono, MN) ; Karl, Mark
Thomas; (Roseau, MN) ; Johnson, Patrick;
(Winona, MN) ; Spahr, Tim; (Galesville, WI)
; Sajna, Jeff; (St Charles, IL) ; Andrews,
Craig; (Brighton, MI) ; Higgins, Kenneth Terry;
(Metamora, MI) ; Lowery, Robert A.; (Troy, MI)
; Ruby, Keith D.; (Hopkinsville, KY) ; Mitchell,
Alton; (Princeton, KY) ; Davis, Rhonda L.;
(Hopkinsville, KY) |
Correspondence
Address: |
Gregory P Kaihoi
Fredrikson & Byron PA
1100 International Centre
900 Second Avenue South
Minneapolis
MN
55402-3397
US
|
Family ID: |
24139812 |
Appl. No.: |
09/491092 |
Filed: |
January 24, 2000 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09491092 |
Jan 24, 2000 |
|
|
|
08566844 |
Dec 4, 1995 |
|
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|
6016943 |
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08566844 |
Dec 4, 1995 |
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08536754 |
Sep 29, 1995 |
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Current U.S.
Class: |
293/120 |
Current CPC
Class: |
B60R 9/00 20130101 |
Class at
Publication: |
293/120 |
International
Class: |
B60R 019/03 |
Claims
What is claimed is:
1. An injection molded bumper for an off-road recreational or
utility vehicle, comprising a fiber-filled plastic resin body
having fibers of a length of at least about 1/4 inch, the body
having an overall thickness substantially less than its width and
substantially less than its length, the body including a generally
vertically oriented front surface, the front surface having upper
and lower peripheral edges, at least a portion of such upper
peripheral edge and at least a portion of such lower peripheral
edge each having a flange extending generally horizontally away
from the front surface, such flanges having a thickness that is
substantially less than the lengths they extend from the front
surface to thereby define generally horizontally extending
reinforcing ribs.
2. The bumper of claim 1 further comprising a plurality of
integrally molded additional reinforcing ribs extending from the
upper edge flange to the lower edge flange.
3. The bumper of claim 1 wherein the front surface of the bumper
body includes side peripheral edges each having a flange extending
generally away from the front surface and connecting the upper and
lower peripheral edge flanges.
4. The bumper of claim 3 further comprising one or more integrally
molded additional reinforcing ribs extending from one of the side
peripheral edges to the other side peripheral edge.
5. The bumper of claim 1 wherein the flanges have a thickness of
not more than about 1/3 the distance they extend away from the
front surface of the bumper.
6. The bumper of claim 1 wherein the flanges have a thickness of
not more than about 1/6 the distance they extend away from the
front surface of the bumper.
7. The bumper of claim 1,wherein the flanges extend away from the
front surface of the bumper a distance of at least about two
inches.
8. The bumper of claim 1 wherein the flanges extend away from the
front surface of the bumper a distance not less than the vertical
distance from one such flange to the other.
9. The bumper of claim 1 wherein the flanges extend away from the
front surface of the bumper a distance not less than one half the
vertical distance from one such flange to the other.
10. The bumper of claim 1 wherein a substantial portion of the
flanges have a thickness of not more than about 1/2 inch.
11. The bumper of claim 1 wherein a substantial portion of the
flanges have a thickness of not more than about 3/8 inch.
12. The bumper of claim 1 wherein the predominant portions of the
body and the flanges have generally similar thicknesses, the ratio
of the thickest of such portions to the thinnest of such portions
being no more than about 2:1.
Description
[0001] This application is a division of application Ser. No.
08/566,844, filed Dec. 4, 1995, which is a continuation of
application Ser. No. 08/536,754, filed Sep. 29, 1995, entitled
INJECTION MOLDED RACKS AND COMPONENTS FOR OFF-ROAD RECREATIONAL AND
UTILITY VEHICLES.
TECHNICAL FIELD
[0002] The invention relates to injection molded racks and other
components for off-road recreational and utility vehicles, such as
all terrain vehicles, snowmobiles and the like.
BACKGROUND OF THE INVENTION
[0003] Off-road recreational and utility vehicles such as all
terrain vehicles ("ATV's"), snowmobiles and the like frequently
incorporate carrying racks, bumpers and similar components that
traditionally have been fabricated from tubular steel (either
square or round tube stock, though typically round), sometimes
supplemented with stamped sheet metal where flat surfaces are
desired. Although such steel construction usually provides the
structural strength required for relatively rugged service, it is
costly and labor intensive to fabricate--a typical rack for an ATV
(often with associated bumper) may contain up to a dozen or more
individual pieces, each of which must be cut to the proper length,
some of which must be bent to the proper shape, and all of which
must be welded together in the desired configuration. Because the
assembly is manual, quality control is an important function to
assure consistent assembly of the racks, bumpers, and similar
components. Once assembled, the components must be painted before
final assembly to the vehicle. Even with high quality painting
technology, such components nevertheless are subject, eventually,
to corrosion since the heavy service often required of the racks
often eventually results in denting, chipping or scratching of the
paint, giving corrosion an opportunity to set in. Moreover, design
options are significantly limited by the nature of the material
from which the components are made--any unique aesthetic nuances or
style character built into a rack or bumper typically adds
significant additional manufacturing pieces which must be
fabricated and assembled, exacerbating the problems identified
above.
[0004] While many components of vehicles have been made in recent
years from non-metal materials, the role of such materials in
general has been limited to non-structural components because they
typically do not provide the necessary strength and durability.
Alternately, certain relatively exotic non-metal structural
materials have recently become available. They typically involve
other severe drawbacks, such as very high cost, difficult handling
characteristics, limitations on the use or application of color to
the material, and the like. Accordingly, such materials have not
been considered economical or desirable for use in the manufacture
of racks, bumpers and similar structural components of recreational
and utility vehicles such as ATV's.
SUMMARY OF THE INVENTION
[0005] The invention provides injection molded structural
components for use on off-road recreational and utility vehicles
(such as ATV's, snowmobiles, and the like). In contrast to metal
fabricated components, a component of the invention is easily
injection molded in a single manufacturing step, which provides
inherent quality control for size and configuration, and allows
color to be selectively integrally molded into the component. Thus,
the component provides substantial savings in manufacturing steps
and labor, is economical to manufacture, and is not subject to
corrosion. It does not dent or chip, and scratches, to the extent
they can occur, do not affect the color of the component since the
component may be molded of a solid color material. With properly
designed structural configurations, the components provide ample
structural strength, and the addition of unique aesthetic nuances,
style character or function can be easily accommodated in many
circumstances--since such nuances can be built right into the
molding tooling, additional costs attributable to such additional
aesthetic features are insignificant with reasonable volumes of
production (and add no additional manufacturing steps). Thus,
designers may be permitted relatively broad freedom for the
creation of various "looks", both in terms of color and shape.
[0006] In one embodiment, the invention provides an injection
molded rack for an off-road recreational and utility vehicle (such
as an ATV, snowmobile or the like). The rack includes a
fiber-filled plastic resin body having fibers of a length of at
least about 1/4 inch. The body has an overall thickness
substantially less than its width and substantially less than its
length, and includes a generally flat, horizontal top surface
having a plurality of slots. Each of the slots is defined by a
flange extending downwardly about the periphery of the slot, the
flange having a thickness that is substantially less than its
height to define a downwardly extending reinforcing rib.
[0007] Preferably the rack of the invention includes a plurality of
integrally molded transverse reinforcing ribs extending across the
slots, the reinforcing ribs having a top surface which is recessed
below the generally flat, horizontal top surface of the rack.
Desirably at least one of the transverse reinforcing ribs is
comprised of two or more downwardly extending flanges spaced
laterally from one another and being joined by a common upper web
which defines the top surface of the transverse reinforcing rib. In
a particularly preferred embodiment, at least one of the transverse
reinforcing ribs is comprised of three or more of such downwardly
extending flanges.
[0008] In another embodiment, the invention provides an injection
molded foot rest for an off-road recreational or utility vehicle
(such as an ATV, snowmobile or the like), comprising a fiber-filled
plastic resin body having fibers of a length of at least about 1/4
inch. The body includes top and bottom surfaces, inner and outer
edges, and a nominal thickness of less than about 1/4 inch. The
bottom surface includes integrally molded downwardly extending
reinforcing ribs. The outer edge has an upwardly extending ridge
defining an outer boundary for the foot rest, the ridge including
an inner upwardly extending flange and an outer downwardly
extending skirt, the flange and skirt being joined by a common
upper web which defines a top surface of the ridge, the flange and
skirt thereby functioning to structurally reinforce the foot
rest.
[0009] In a preferred embodiment, the foot rest further includes an
integrally molded transverse cleat extending upwardly from the top
surface of the foot rest body and extending substantially entirely
across the foot rest body to form an integral heal cleat. The foot
rest may also include molded gripping cleats extending upwardly
from the top surface of the foot rest body. Preferably such
gripping cleats comprise upwardly extending protrusions each of
which terminate in a transversely oriented pointed edge.
[0010] In yet another embodiment, the invention provides an
injection molded bumper for an off-road recreational or utility
vehicle (such as an ATV, snowmobile or the like), comprising a
fiber-filled plastic resin body having fibers of a length of at
least about 1/4 inch. The body has an overall thickness
substantially less than its width and substantially less than its
length, and includes a generally vertically oriented front surface
having upper and lower peripheral edges. At least a portion of such
upper peripheral edge and at least a portion of such lower
peripheral edge each has a flange extending generally horizontally
away from the front surface, such flanges having a thickness that
is substantially less than the lengths they extend from the front
surface to thereby define generally horizontally extending
reinforcing ribs. Additional reinforcing ribs may also be provided
intermediate the flanges.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 depicts an ATV with the racks, bumper and foot rest
of the invention mounted thereon;
[0012] FIG. 2 is a top plan view of a rack of the invention;
[0013] FIG. 3 is a bottom plan view of the rack of FIG. 2;
[0014] FIG. 4 is a front elevational view of the rack of FIG.
2;
[0015] FIG. 5 is a side elevational view of the rack of FIG. 2;
[0016] FIG. 6 is a cross-sectional view of the rack of FIG. 2,
taken along lines 6-6 thereof;
[0017] FIG. 7 is a cross-sectional view of the rack of FIG. 2,
taken along lines 7-7 thereof;
[0018] FIG. 8 is a cross-sectional view of the rack of FIG. 2,
taken along lines 8-8 thereof;
[0019] FIG. 9 is a cross-sectional view of the rack of FIG. 2,
taken along lines 9-9 thereof;
[0020] FIG. 10 is a top plan view of an alternate rack of the
invention;
[0021] FIG. 11 is a bottom plan view of the rack of FIG. 10;
[0022] FIG. 12 is a front elevational view of the rack of FIG.
10;
[0023] FIG. 13 is a cross-sectional view of the rack of FIG. 10,
taken along lines 13-13 thereof;
[0024] FIG. 14 is a cross-sectional view of the rack of FIG. 10,
taken along lines 14-14 thereof;
[0025] FIG. 15 is a cross-sectional view of the rack of FIG. 10,
taken along lines 15-15 thereof;
[0026] FIG. 16 is a front elevational view of a bumper such as is
depicted on the ATV of FIG. 1;
[0027] FIG. 17 is a top view of the bumper of FIG. 16;
[0028] FIG. 18 is a rear view of the bumper of FIG. 16;
[0029] FIG. 19 is a cross-sectional view of the bumper of FIG. 16,
taken along lines 19-19 thereof;
[0030] FIG. 20 is a right side view of the bumper of FIG. 16;
[0031] FIG. 21 is a top view of an alternate embodiment of a bumper
of the invention;
[0032] FIG. 22 is a rear view of the bumper of FIG. 21;
[0033] FIG. 23 is a cross sectional view of the bumper of FIG. 22,
taken along lines 23-23 thereof;
[0034] FIG. 24 is a front, outside perspective view of a foot rest
of the invention;
[0035] FIG. 25 is a rear, inside perspective view of the foot rest
of FIG. 24;
[0036] FIG. 26 is an outside side view of the foot rest of FIG.
24;
[0037] FIG. 27 is an inside side view of the foot rest of FIG.
24;
[0038] FIG. 28 is a bottom, rear, inside perspective view of the
foot rest of FIG. 24;
[0039] FIG. 29 is a bottom, front, inside perspective view of the
foot rest of FIG. 24;
[0040] FIG. 30 is a top view of the foot rest of FIG. 24; and
[0041] FIG. 31 is a broken away detail of the gripping cleats of
the foot rest of FIG. 24.
DETAILED DESCRIPTION OF THE INVENTION
[0042] FIG. 1 depicts an off-road recreational/utility vehicle
commonly referred to as an all-terrain vehicle (ATV) on which is
mounted the racks 20, 60, bumper 110 and foot rest 210 of the
invention. It will be appreciated that other similar types of
off-road recreational/utility vehicles could similarly utilize the
components of the invention, such as snowmobiles, etc.
[0043] FIGS. 2-9 illustrate in detail the construction of one
particular embodiment of an integrally molded rack 60 of the
invention. The rack 60, which is injection molded, includes a
generally flat, horizontal top surface 64 having a peripheral edge
and a plurality of slots 70. Each of the slots is rimmed by a
flange 66 which extends downwardly from the top surface 64, the
flange therefore defining the periphery of the slot 70. The
peripheral edge similarly includes a downwardly extending flange
78. The downwardly extending flanges 66 and 78 are integrally
molded in the rack 60, and have a thickness that is substantially
less than their height; the flanges 66 and 78 thus serve to
structurally reinforce the rack against deflection, particularly
against deflection about an axis generally perpendicular to the
longitudinal dimension of the flanges. Desirably the flanges have a
thickness of not more than about 1/3 their height, and preferably
not more than about 1/6 their height. Desirably the flanges have a
height of at least about 1/2 inch, and preferably at least about
3/4 inch. The rack depicted in the drawings has a flange height of
about one inch and flange thickness of about 1/6 inch, which has
been found to work quite well. An incidental benefit of flanges
with such heights and thicknesses is that the flanges provide ample
convenient locations for attachment of bungee cords and similar
fasteners.
[0044] The rack 60 also desirably is provided with a number of
integrally molded reinforcing ribs 74 which extend across the slots
70, thereby providing additional reinforcement against deflection
of the rack 60 in a direction generally parallel to (and, if
necessary, at acute angles to) the longitudinal dimension of the
slots 70. Desirably the ribs are made from material with a
thickness similar to the thickness of the flanges--the rack
depicted in the drawings has a rib thickness of about 1/8 inch.
[0045] As can be seen by reference to FIGS. 2, 4, 6 and 9,
typically the transverse reinforcing ribs 74 are comprised of two
or more (in many cases, three) downwardly extending flanges 76
which are spaced laterally from one another, being joined by a
common upper web which defines the top surface 75 of the transverse
reinforcing rib 74. Preferably this top surface 75 of the
transverse reinforcing rib 74 is recessed with respect to the top
surface 64 of the rack 60. Although recessing the transverse
reinforcing ribs 74 does not entirely hide them from view (since
they can nevertheless be seen through the slots 70), recessing them
slightly does make them somewhat less visible, particularly at
lower viewing angles. In a rack having overall dimensions of about
20 by 40 inches with slots about an inch wide and slot flanges
about an inch tall, desirably the tops of the reinforcing ribs 74
are recessed at least about 1/8 inch, and preferably about 1/4 inch
from the top surface 64 of the rack. In the rack depicted in the
drawings, the tops of the reinforcing ribs 74 are recessed about
1/4 inch.
[0046] The availability of recessed reinforcing ribs provides a
rack designer with a relatively large degree of latitude in
designing the aesthetic and functional characteristics of the rack.
While the flanges 66 rimming the slots 70 provide a significant
degree of structural reinforcement to the rack 60, the designer is
not necessarily constrained to any particular number, size,
configuration or orientation of the slots, since (at least within
broad limits), any necessary structural reinforcement not provided
by the slot flanges 66 can be supplied by employing recessed
reinforcing ribs 74. Thus, a rack designer is able to design the
rack slots 70 with aesthetics, and/or functionality, primarily in
mind, thereby creating the desired look and utility for the rack.
Structural rigidity can then be supplied by building in the
necessary reinforcing ribs 74. As noted above, while recessing the
portion of these ribs 74 which are exposed by the slots 70 does not
completely remove them from view, it does significantly subdue
their prominence in relation to the slots 70 and any other
topographical features on the top surface 64 of the rack,
particularly at lower viewing angles.
[0047] The rack may be provided with a plurality of accessory
mounting holes 80--in the embodiment depicted in FIG. 2, six such
accessory mounting holes are provide about the outer periphery of
the rack 60, for mounting, e.g., an accessory box or railing.
Detail regarding the configuration of these holes is illustrated in
FIG. 8. Frame mounting holes 82 may also be provided for mounting
the rack to the vehicle. Details of two of these holes are shown in
FIG. 7. In the rack 60 depicted in FIG. 2, four frame mounting
holes 82 are provided. Note that these holes are not located at the
outer extremities (i.e., the outer corners) of the rack 60. As a
result, a significant portion of the rack is cantilevered outwardly
from such frame mounting holes. Accordingly, it is desirable to
locate a number of recessed reinforcing ribs 74 such that they
extend from an area adjacent to the frame mounting holes 82 to an
area adjacent to the outer extremities of the rack 60, in this
case, that being the outer corners of the rack.
[0048] Conventional non-metallic materials generally are not strong
enough to provide the strength and durability required for a rack
of the used on ATV's and similar recreational/utility vehicles;
moreover, many systems using fiber-reinforcement do not produce a
sufficiently pleasing cosmetically clean finish--often fibers or
fiber ends are visible at the surface, a result not ordinarily
acceptable for finish parts used on ATV's and similar vehicles. It
has been found, however, that utilizing injection moldable
fiber-filled plastic resins having fibers of a length of at least
about 1/4 inch provides sufficient reinforcement to achieve the
necessary strength characteristics, while still being injection
moldable. Suitable fiber-filled resins having such desirable
characteristics and also producing the desired finish
characteristics are available commercially from Polymer Composites,
Inc. of Winona, Minn., under the trademark CELLSTRAN.RTM.. A
particularly preferred CELLSTRAN.RTM. glass filled polypropylene
resin is sold under the designation PPG 40-02-4 (this particular
resin has 40% glass fibers, and is supplied in pellet form,
preferably in pellets 11 mm in length, therefore containing glass
fibers of the same length). The Polymer Composites material is
desirable because the glass fibers are believed to be entirely
wetted by the resin; the material thus works well in injection
molding equipment, and produces a finish substantially without any
fibers showing at the surface.
[0049] As can be seen by reference to the drawings, preferred
embodiments of the invention utilize injection molded material of a
generally uniform thickness. That is, preferably the predominant
portions of the top surface of the rack, as well as the predominant
portions of the flanges and reinforcing ribs are all of a similar
thickness--desirably in the range of about {fraction (1/10)} to
about 1/3 inch, and preferably about 1/6 inch. Preferably the ratio
of the thickest of such portions to the thinnest of such portions
is no more than about 2:1.
[0050] Using conventional non-metallic materials, one ordinarily
would not conclude that a rack of sufficient strength and
durability could be successfully molded with such thinness. Molding
the above-mentioned fiber-filled resins into the configuration
shown in the drawings (i.e., with the reinforcing flanges and
ribs), however, produces a remarkably strong, durable rack with
excellent finish characteristics. Moreover, selected colors can be
integrally molded into the part, so that painting is not necessary,
thereby reducing manufacturing steps, complexity and cost; any
scratches or other incidental damage to the component also are less
noticeable since the part is of uniform color throughout its
thickness. Since the part is not metallic, it is not subject to
corrosion.
[0051] An upwardly protruding lip 86 may be provided along a
portion of the periphery of the rack to assist in retaining gear on
the rack. Recesses 61 may also be provided along the side edges for
flush mounting of reflectors 62 (the reflectors are depicted in
FIG. 1).
[0052] FIGS. 10-15 depict in detail the rack 20 mounted to the
front of the ATV shown in FIG. 1. The front rack 20 for this
particular vehicle is somewhat smaller than the rear rack 60, with
the result that fewer reinforcing ribs are needed to obtain the
structural strength required. Most of the other structural features
of this embodiment of the invention are otherwise the same as the
rack depicted in FIG. 2.
[0053] FIGS. 16-20 depict a bumper 110 of the invention
manufactured using the process and materials described above with
respect to the rack of the invention. The bumper includes a front
face 112 having upper and lower peripheral edges 113 and 114, each
of the edges in turn having a flange 115, 116, respectively,
extending generally horizontally rearwardly away from the front
surface 112. The left and right ends or sides of the bumper 110
similarly have rearwardly extending flanges which are joined with
the upper and lower flanges 115 and 116. Together the flanges
define generally rearwardly extending reinforcing ribs. One or more
additional generally horizontal reinforcing ribs 119 may also be
provided, along with vertical reinforcing ribs 120.
[0054] The particular bumper 110 depicted in FIGS. 16-20 includes
an optional upwardly extending central member 121 which, as
depicted in FIG. 1, is designed to mate with the front rack 20
described above. For this purpose, the central section includes a
series of tabs 122 which are received in complementary recesses in
the bottom front portion of the front rack 20. Additional
rearwardly extending ribs may be provided in this upwardly
extending central section to further reinforce the entire
structure. A plurality of mounting holes 124 may be provided for
mounting the bumper to the vehicle. FIGS. 19-20 illustrate
additional rearwardly extending reinforcing cylinders formed about
the mounting holes 124 for adding further structural strength to
this portion of the bumper.
[0055] Note that the outer left and right ends 117 and 118 extend a
significant distance outwardly of the mounting holes 124--i.e., the
outer ends are significantly cantilevered in relation to the
overall length of the bumper. Conventional non-metallic materials
generally were not considered to be strong enough to provide the
strength and durability required for a bumper of the type used on
ATV's and similar recreational/utility vehicles, particularly given
the cantilevered design depicted in the drawings. It has been
found, however, that utilizing injection moldable fiber-filled
plastic resins as noted above provides sufficient reinforcement and
durability to achieve the necessary strength characteristics, while
still being injection moldable. As noted above, suitable
fiber-filled resins having such desirable characteristics and also
producing the desired finish characteristics are available
commercially from Polymer Composites, Inc. of Winona, Minn., under
the trademark CELLSTRAN.RTM.. A particularly preferred
CELLSTRAN.RTM. glass filled polypropylene resin is sold under the
designation PPG 40-02-4 (this particular resin has 40% glass
fibers, and is supplied in pellet form, preferably in pellets 11 mm
in length, therefore containing glass fibers of the same
length).
[0056] As can be seen by reference to the drawings, preferred
embodiments of the invention utilize injection molded material of a
generally uniform thickness. That is, preferably the predominant
portions of the bumper, including the flanges and reinforcing ribs,
are all of a similar thickness--desirably in the range of about 1/8
to about 3/4 inch, and preferably about 1/6 to about 1/2 inch.
Preferably the ratio of the thickest of such portions to the
thinnest of such portions is no more than about 2:1.
[0057] Using conventional non-metallic materials, one ordinarily
would not conclude that a bumper of sufficient strength and
durability could be successfully molded with such thinness. Molding
the above-mentioned fiber-filled resins into the configuration
shown in the drawings (i.e., with the reinforcing flanges and
ribs), however, produces a remarkably strong, durable bumper with
excellent finish characteristics. Moreover, selected colors can be
integrally molded into the part, so that painting is not necessary,
thereby reducing manufacturing steps, complexity and cost; any
scratches or other incidental damage to the component also are less
noticeable since the part is of uniform color throughout its
thickness. Since the part is not metallic, it is not subject to
corrosion.
[0058] FIGS. 21-23 illustrate an alternate embodiment of a bumper
of the invention. This bumper 130 has a shape slightly different
from the bumper 110 of FIGS. 16-20, in that it does not utilize the
upwardly extending central member 121, and in that the internal
rearwardly extending reinforcing ribs 132 are oriented at a variety
of obtuse and acute angles to the general longitudinal length of
the bumper 130. Because of the number and orientation of the
various internal ribs 132, these internal ribs 132 do not need to
extend as far rearwardly as the upper and lower flanges 134 and
136.
[0059] FIGS. 24-30 depict a foot rest 150 of the invention which is
injection molded for use on off-road recreational or utility
vehicles such as the ATV depicted in FIG. 1. Like the racks and
bumpers described above, the foot rest or foot well 150 is
injection molded from a fiber-filled plastic resin to give it the
strength, durability and resilience desired for such an
application.
[0060] The foot rest includes an inner edge 156, and an outer ridge
158 defining an outer boundary for the foot rest. The outer ridge
158 is desirably comprised of an inner, upwardly extending flange
162 and an outer downwardly extending skirt 164, the flange 162 and
skirt 164 being joined by a common upper web 166 which defines a
top surface of the ridge, the flange and skirt thereby functioning
to structurally reinforce the foot rest. Preferably the foot rest
also includes an integrally molded transverse cleat 170 extending
upwardly from the top surface of the foot rest body 152. Preferably
the cleat 170 extends substantially entirely across the foot rest
body to form an integral heal cleat against which the vehicle
operator may grip with the heal of his shoe or boot.
[0061] Preferably the upper surface of the foot rest body 152 also
includes integrally molded gripping cleats 172 dispersed over a
substantial portion of the generally flat upper surface of the foot
rest. In the particularly preferred embodiment shown in the
drawings, the gripping cleats 172 comprise upwardly extending
protrusions, each of which terminate in a transversely oriented
pointed edge (shown in detail in FIG. 31). Also, preferably these
gripping cleats 172 are arranged in a plurality of generally
parallel longitudinal rows of ribs, the ribs being scalloped with
the scallops terminating in transversely oriented pointed edges.
These pointed edges make an excellent gripping surface for the
rider's shoes or boots.
[0062] As is shown in particular detail in FIGS. 28-30, desirably
the foot rest 150 also includes reinforcing ribs 160 integrally
molded to extend downwardly from the bottom of the foot rest. The
size and depth of these ribs can be selected based on the desired
rigidity requirements of the particular application.
[0063] Suitable fiber-filled resins having desirable
characteristics for this component and also producing the desired
finish characteristics are available commercially from Polymer
Composites, Inc. of Winona, Minn. A particularly preferred glass
filled nylon resin is sold under the designation N6G50-01-4. This
resin includes about 50% glass fiber. The polypropylene resin
material used for the bumpers and racks, sold under the designation
PPG 40-02-4, is also suitable, although it has been found that
reduction of the percentage of glass fibers from 40% to 20% (by
adding in compatible polypropylene) yields a less rigid foot rest
which is less likely to fracture, e.g., if the foot rest strikes a
rock, stump, etc. Both of these materials are supplied in pellet
form, preferably in pellets 11 mm in length, therefore containing
glass fibers of the same length.
[0064] As can be seen by reference to the drawings, preferred
embodiments of the invention utilize injection molded material of a
generally uniform thickness. That is, preferably the predominant
portions of the foot rest, including the predominant portions of
the flanges and reinforcing ribs are all of a similar
thickness--desirably in the range of about {fraction (1/10)} to
about 1/3 inch, and preferably about 1/6 inch. Preferably the ratio
of the thickest of such portions to the thinnest of such portions
is no more than about 2:1.
[0065] While a preferred embodiment of the present invention has
been described, it should be understood that various changes,
adaptations and modifications may be made therein without departing
from the spirit of the invention and the scope of the appended
claims.
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