U.S. patent application number 14/887230 was filed with the patent office on 2017-04-20 for tubular vehicle exterior accessory extrusion.
The applicant listed for this patent is Curt Manufacturing, LLC. Invention is credited to Joel D. Diller, Robert G. Fehr, Wolfe C. Parzyck.
Application Number | 20170106918 14/887230 |
Document ID | / |
Family ID | 58523520 |
Filed Date | 2017-04-20 |
United States Patent
Application |
20170106918 |
Kind Code |
A1 |
Diller; Joel D. ; et
al. |
April 20, 2017 |
Tubular Vehicle Exterior Accessory Extrusion
Abstract
A hollow tubular shape is extruded from aluminum and used as a
basic building block for one or more different truck accessories,
such as a side step, grill guard and headache rack. The outside of
the hollow tubular shape provides flat surfaces and angled edges
over most of its periphery, including a major wall and several side
walls. An attachment wall opposite the major wall includes
attachment slides that enable the extrusion to be attached in
numerous configurations, including to attachment brackets. The
interior of the extruded hollow tubular shape includes openings to
receive end caps.
Inventors: |
Diller; Joel D.; (Eau
Claire, WI) ; Fehr; Robert G.; (Colfax, WI) ;
Parzyck; Wolfe C.; (Colfax, WI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Curt Manufacturing, LLC |
Eau Claire |
WI |
US |
|
|
Family ID: |
58523520 |
Appl. No.: |
14/887230 |
Filed: |
October 19, 2015 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B60R 19/52 20130101;
B60R 21/13 20130101; C22C 21/00 20130101; B21C 23/142 20130101;
B21C 23/085 20130101; B60R 3/002 20130101 |
International
Class: |
B62D 29/00 20060101
B62D029/00; B21C 23/00 20060101 B21C023/00; B60R 21/13 20060101
B60R021/13; B62D 65/16 20060101 B62D065/16; B60R 3/00 20060101
B60R003/00; B60R 19/52 20060101 B60R019/52 |
Claims
1. A vehicle exterior accessory formed primarily from a hollow
tubular member, the hollow tubular member comprising: a major wall
having a generally planar exposed major surface running
longitudinally between two longitudinally extending edges; at least
four side walls connected to the longitudinally extending edges,
each of the side walls having a generally planar exposed side
surface running longitudinally; and an attachment wall connected
with the major wall and the side walls to complete a hollow tubular
profile, the attachment wall defining an exposed connection slide
opening running longitudinally, the connection slide opening
defining a neck for holding a connection; wherein the hollow
tubular member is formed of aluminum extruded about a longitudinal
axis within the hollow tubular profile, and wherein the extruded
hollow tubular member has ends formed by transversely cutting the
hollow tubular member at a non-perpendicular angle relative to the
longitudinal axis.
2. The vehicle exterior accessory of claim 6, wherein the hollow
tubular member is formed of extruded aluminum.
3. The vehicle exterior accessory of claim 2, wherein the hollow
tubular member is angle cut.
4. The vehicle exterior accessory of claim 1, comprising multiple
pieces of hollow tubular members welded together at the location of
the non-perpendicular cut on each of the multiple pieces, with
their major walls extending contiguously.
5. The vehicle exterior accessory of claim 1, wherein the hollow
tubular member comprises at least six side walls, wherein the major
wall, the at least six side walls and the attachment wall are
arranged in an octagon with the longitudinally extending edges
defining 45.degree. angles between the major wall and the two
adjacent side walls.
6. A vehicle exterior accessory formed primarily from a hollow
tubular member, the hollow tubular member comprising: a major wall
having a generally planar exposed major surface running
longitudinally between two longitudinally extending edges, the
major wall having a major wall thickness defined between an inside
surface and the longitudinally running exposed major surface; at
least four side walls connected to the longitudinally extending
edges, each of the side walls having a generally planar exposed
side surface running longitudinally; and an attachment wall
connected with the major wall and the side walls to complete a
hollow tubular profile, the attachment wall defining an exposed
connection slide opening running longitudinally, the connection
slide opening defining a neck for holding a connection; wherein at
least one of the side walls is directly connected to one of the two
longitudinally extending edges of the major wall and extends in a
non-perpendicular fashion relative to the major wall, wherein said
at least one of the side walls has a side wall thickness defined
between an inside surface and the longitudinally running exposed
side surface, and wherein the side wall thickness is thicker than
the major wall thickness, with the side wall being able to support
a weight placed on the major surface of the major wall as a bending
moment, such that the thicker side wall thickness better supports
the bending moment.
7. The vehicle exterior accessory of claim 1, wherein the
attachment walls defines a second exposed connection slide opening
running longitudinally, the second connection slide opening
defining a neck for holding a connection.
8. The vehicle exterior accessory of claim 1, wherein the hollow
tubular member comprises a plurality of longitudinally extending
fastener openings on an inside of the hollow tubular profile.
9. The vehicle exterior accessory of claim 8, further comprising
end caps covering the non-perpendicular cut ends of the hollow
tubular member using fasteners extending through the end caps and
into the fastener openings.
10. The vehicle exterior accessory of claim 8, wherein the fastener
openings have a generally C-shaped cross-section.
11. A vehicle exterior accessory formed primarily from a hollow
tubular member, the hollow tubular member comprising: a major wall
having a generally planar exposed major surface running
longitudinally between two longitudinally extending edges; at least
four side walls connected to the longitudinally extending edges,
each of the side walls having a generally planar exposed side
surface running longitudinally; and an attachment wall connected
with the major wall and the side walls to complete a hollow tubular
profile, the attachment wall defining an exposed connection slide
opening running longitudinally, the connection slide opening
defining a neck for holding a connection; wherein the hollow
tubular member comprises a plurality of longitudinally extending
fastener openings on an inside of the hollow tubular profile,
wherein the fastener openings have a generally C-shaped
cross-section, and wherein the fastener openings are each connected
to side walls with a single longitudinally extending web portion,
thereby spacing the fastener openings inwardly from the side
walls.
12. The vehicle exterior accessory of claim 6 in the form of a
running board, side step or nerf bar attachable horizontally under
the door on a side of a vehicle.
13. The vehicle exterior accessory of claim 4 in the form of a
grill guard attachable on a front of a vehicle.
14. The vehicle exterior accessory of claim 4 in the form of a
headache rack attachable behind a cab of a vehicle.
15. A method of forming a vehicle exterior accessory, comprising:
extruding metal into a generally hollow extrusion, the generally
hollow extrusion comprising: a major wall having a generally planar
exposed major surface running longitudinally between two
longitudinally extending edges; and side walls connected to the
longitudinally extending edges, each of the side walls having a
generally planar exposed side surface running longitudinally, the
major wall and the side walls jointly defining a generally hollow
profile about a longitudinal axis; cutting the generally hollow
extrusion across its longitudinal axis, wherein the cut defines an
open end of longitudinally extending fastener openings on an inside
of the generally hollow profile, wherein the cutting is a planar
cut at a non-perpendicular angle to the longitudinal axis; and
fastening an end piece to the generally hollow extrusion using the
open end of the longitudinally extending fastener openings.
16. The method of claim 15, wherein the metal for extruding the
generally hollow extrusion is aluminum.
17. The method of claim 19, wherein the cutting is a planar cut at
a non-perpendicular angle to the longitudinal axis.
18. The method of claim 17, further comprising welding multiple
pieces of angle cut generally hollow extrusions together at their
planar cuts with their major walls extending contiguously.
19. A method of forming a vehicle exterior accessory, comprising:
extruding metal into a generally hollow extrusion, the generally
hollow extrusion comprising: a major wall having a generally planar
exposed major surface running longitudinally between two
longitudinally extending edges; and side walls connected to the
longitudinally extending edges, each of the side walls having a
generally planar exposed side surface running longitudinally, the
major wall and the side walls jointly defining a generally hollow
profile about a longitudinal axis; cutting the generally hollow
extrusion across its longitudinal axis, wherein the cut defines an
open end of longitudinally extending fastener openings on an inside
of the generally hollow profile; and fastening an end piece to the
generally hollow extrusion using the open end of the longitudinally
extending fastener openings; wherein the extruding creates a
generally hollow extrusion wherein at least one of the side walls
is directly connected to one of the two longitudinally extending
edges of the major wall and extends in a non-perpendicular fashion
relative to the major wall, wherein said at least one of the side
walls has a side wall thickness defined between an inside surface
and the longitudinally running exposed side surface, and wherein
the side wall thickness is thicker than the major wall thickness,
with the side wall being able to support a weight placed on the
major surface of the major wall as a bending moment, such that the
thicker side wall thickness better supports the bending moment.
20. The method of claim 15, wherein the end piece is an end cap,
and further comprising: casting the end cap into a shape having an
interior sleeve portion sized to fit in mating engagement within
the generally hollow extrusion; positioning the end cap covering
the cut of the generally hollow extrusion with the interior sleeve
portion extending partially within the generally hollow extrusion;
and fastening the end cap to the generally hollow extrusion with
fasteners extending through the end cap and into the open end of
the longitudinally extending fastener openings.
21. The method of claim 20, wherein the fastener openings have a
generally C-shaped cross-section, and wherein the fastener openings
are each connected to side walls with a single longitudinally
extending web portion, thereby spacing the fastener openings
inwardly from the side walls.
22. A vehicle having at least two exterior accessories mounted
thereon, wherein at least one of the exterior accessories is
selected from the group consisting of grill guards and headache
racks, and wherein each of the at least two exterior accessories is
formed primarily from a hollow tubular member, the hollow tubular
member having an identical cross-sectional profile in both of the
at least two exterior accessories, the hollow tubular member
comprising: a major wall having a generally planar exposed major
surface running longitudinally between two longitudinally extending
edges; and side walls connected at a non-perpendicular angle
relative to the major wall and extending from the longitudinally
extending edges, each of the side walls having a generally planar
exposed side surface running longitudinally.
Description
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] None.
BACKGROUND OF THE INVENTION
[0002] Many different types of exterior accessory products are
known for attachment to vehicles such as trucks, sport utility
vehicles ("SUVs"), crossover utility vehicles ("CUVs"), four-wheel
drive vehicles ("4.times.4s"), jeeps, police cars, all-terrain and
other utility vehicles. Such exterior accessories can be provided
as part of a trim package offered by the original equipment
manufacturer, but more commonly are provided in the automotive and
trucking aftermarket.
[0003] For instance, exterior accessories such as grill guards,
brush guards, push bars and bull bars (collectively referred to as
"grill guards") are attached on the front end of vehicles. See U.S.
Pat. Nos. 4,469,360 and 9,108,581, for example, both incorporated
by reference. Exterior accessories known as side steps, running
boards and nerf bars are attached on the sides of vehicles running
horizontally beneath the doors. See U.S. Pat. Nos. 8,342,550 and
8,528,925, for example, both incorporated by reference. Exterior
accessories such as headache racks are attached behind the cab in
vehicles. See U.S. Pat. No. 8,668,124, for example, incorporated by
reference. These exterior accessories are commonly independently
designed, often with an attachment bracket specially designed to
fit the frame, bumper or bed of the particular vehicle with which
the exterior accessory attachment bracket will be used. Many common
designs of exterior accessory products are derived using tubular
metal (such as steel or aluminum alloy) as the primary starting
material, with the tubular metal being cut, bent and/or welded into
the shape desired for the exterior accessory product. Standard
tubular metal shapes include round, rectangular and oval, and such
standard tubular metal shapes have been used for aftermarket
exterior accessories. Attachment brackets are commonly formed from
sheet or plate metal, welded or bolted to the tubular metal at
appropriate locations.
[0004] Exterior accessory products are normally subjected to
considerable amounts of dirt and grime, and are treated very
roughly and withstand considerable impacts and loads, and exterior
accessory products should readily withstand such conditions. The
exterior accessory product and its attachment bracket must be
robust and reliable, to last for carefree operation over the life
of at least one vehicle despite being openly exposed to weather
over its years or decades of use. As much as possible, the exterior
accessory product should also have minimal cost and expense in
manufacturing and assembly. When sold into the automotive or
trucking aftermarket, the method of attachment to the vehicle
should be simple, reliable and strong, using readily available
tools. In keeping with these objectives, further improvements to
exterior accessory products are possible.
BRIEF SUMMARY OF THE INVENTION
[0005] The present invention is a vehicle exterior accessory, such
as a side step, bull bar or headache rack or combinations thereof,
formed from a hollow tubular member which can be extruded aluminum.
The hollow tubular member has a shape making it particularly
applicable for this use. The shape of the hollow tubular member
includes a major wall having a generally planar exposed major
surface running longitudinally, and at least four further side
walls providing planar exposed surfaces. Opposite the major wall,
an attachment wall completes the hollow tubular profile. The
attachment wall has a necked connection slide which is exposed and
runs longitudinally, which can be used in connecting the vehicle
exterior accessory to the vehicle using a bracket. In one aspect,
the interior of the hollow tubular member is configured for
attachment to end caps.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a perspective view of a pickup truck outfitted
with preferred side bars, a bull bar and a headache rack all in
accordance with the present invention.
[0007] FIG. 2 is a perspective view from below showing attachment
of the support bracket to the side bar of FIG. 1.
[0008] FIG. 3 is an exploded perspective view of the side bar of
FIG. 1.
[0009] FIG. 4 is a partial perspective view, from below of the
basic extrusion used in the side bar of FIG. 2.
[0010] FIG. 5 is a cross-sectional view of the extrusion of FIG.
4.
[0011] FIGS. 6 and 7 are perspective views of the end caps used in
the side bar of FIG. 2.
[0012] FIG. 8 is an end view of the end caps of FIGS. 3, 6 and
7.
[0013] FIG. 9 is a cross-sectional view of the end cap, taken along
lines 9-9 in FIG. 8.
[0014] FIG. 10 is a cross-sectional view of the end cap, taken
along lines 10-10 in FIG. 9.
[0015] FIG. 11 is an exploded perspective view of the bull bar type
of grill guard of FIG. 1.
[0016] FIG. 12 is a front view of the bull bar of FIGS. 1 and
11.
[0017] FIG. 13 is a side view of the bull bar of FIGS. 1, 11 and
12.
[0018] FIG. 14 is a perspective view of the headache rack of FIG.
1.
[0019] While the above-identified drawing figures set forth
preferred embodiments, other embodiments of the present invention
are also contemplated, some of which are noted in the discussion.
In all cases, this disclosure presents the illustrated embodiments
of the present invention by way of representation and not
limitation. Numerous other minor modifications and embodiments can
be devised by those skilled in the art which fall within the scope
and spirit of the principles of this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] As an example vehicle for showing usage of the present
invention, FIG. 1 shows a pickup truck 10. Characteristic of most
pickup trucks, the truck 10 shown includes a front bumper 12 and
headlights 14, a cab 16 with doors 18, and a box or bed 20, all
supported on a frame (not separately shown) for moving on four
wheels 22. The truck 10 shown in FIG. 1 has been outfitted with
three types of exterior accessories designed in accordance with the
present invention, namely, a bull bar 24 type of grill guard, two
side bars 26 (one on the driver's side and one (not separately
shown) on the passenger's side of the truck 10), and a headache
rack 28.
[0021] As better shown in the assembly view of FIG. 2 and the
exploded view of FIG. 3, the components which make up each of the
side bars 26 include two frame brackets 30, two end caps 32 and a
tread 34, each mounted with respect to the primary running board
36. The end caps 32 are mounted to the side bar 26 using two bolts
or screws 38 per end cap 32, but could in some embodiments be
mounted by other means, such as clips or adhesive. Each of the
frame brackets 30 are mounted to the underside of the running board
36 with bolts 40 and nuts 42 (shown in FIG. 2). Similar bolts 44
(shown in FIG. 2) are used to mount each of the frame brackets 30
to the frame (not separately shown) of the truck 10.
[0022] The tread 34 is mounted to a top surface of the running
board 36 with bolts or screws 45, but could alternatively be
mounted with clips, adhesive or rivets. Also sometimes called a
step pad, the purpose of the tread 34 is to minimize slipping with
the user's shoes or boots (which may occasionally be wet or caked
in mud or other slippery substances) when the user stands on the
side bar 26 or climbs in and out of the cab 16 using the side bar
26. Openings 46 in the tread 34 help to keep mud or other
substances from causing slippage. The openings 46 can be in the
shape of a trademark or can define other words or images. In the
preferred embodiment shown, the openings 46 define both the mark
ARIES and a repeating octagon shape mark similar to the overall
octagonal shape of the running board 36. While the tread 34 could
be molded from a polymer material, the preferred tread 34 is
punched out of a 3 mm thick sheet of 5052 aluminum. The tread 34
could cover only the top face 48 of the running board 36, but more
preferably is bent to cover not only the top face 48 but also one
of the side faces 50 of the running board 36.
[0023] In contrast to the tubes used for most prior art side bars,
the running board 36 of the present invention is formed from an
extrusion 52 best shown in FIG. 4. Instead of being round, oval or
rectangular, the outside cross-sectional shape of the extrusion 52
is, in the preferred embodiment, octagonal. Of the octagonal shape,
the top face 48 of the running board 36 is a major face, i.e., is
wider than the size of the side walls 54, 56. For instance, the
preferred octagonal embodiment includes a top surface 48 which is
flat and planar, with edges 58 of the top face 48 being linear and
being about 100 mm apart. The 100 mm wide planar major face 48
provides an appropriately sized flat surface to serve as a step on
the vehicle 10. There are three side walls 54, 56 on one side of
the top wall 60 toward the vehicle 10 and three side walls on the
other side of the top wall 60 away from the vehicle 10, each
presenting a planar face running longitudinally which is at
45.degree. to adjacent faces. The side faces 50, 62 are smaller
than the top face 48. For instance, the preferred embodiment
includes vertical side walls 54 which are about 25 mm wide (i.e.,
about one quarter the size of the top face 48). The angled side
walls 56 in the preferred embodiment are all equally sized, with
the preferred size having the width and height profile of the
running board 36 be 140.times.65 mm, so each of the angled side
walls 56 are about 28 mm wide. Each of the side walls 54, 56
provides a generally planar exposed side surface 50, 62 running
longitudinally. Many other shapes could alternatively be used
instead of the preferred octagon. As one example, the running board
36 could be formed as a hexagonal extrusion. The exterior surface
of any of the walls 54, 56, 60 could have an exterior profile which
was curved instead of planar. However, with six side walls 54, 56
and the top wall 60 all having planar outer surfaces 50, 62, 48,
the running board 36 is strong and appropriately sized and shaped
to receive the user's footwear, while simultaneously presents a
pleasing and unique non-rectangular angular look.
[0024] The frame brackets 30 support the running board 36 so the
top surface 48 extends horizontally. When thus supported, two of
the side walls 54 extend vertically, while four of the side walls
56 extend at an angle to vertical, with the preferred angle being
45.degree.. When the user steps on the running board 36, the four
angled side walls 56 absorb the majority of the weight of the user
as a bending moment, while the vertical side walls 54 and the top
wall 60 support the weight much more in compression. To better
withstand the bending moments and resist deformation of the side
bar 26 during use, the preferred extrusion 52 includes a thicker
wall thickness for the four angled side walls 56 than for the
vertical side walls 54 and thicker than for the top wall 60. When
extruded from 6063-T5 aluminum, the preferred embodiment includes a
top wall thickness of 2 mm, and vertical side wall thicknesses of 2
mm, as compared to angled side wall thicknesses of 3 mm.
Alternatively, the dimensions can be changed or the side bars 26
formed of a different metal material to withstand the forces and
moments which will be encountered during use. For instance, the
running boards could alternatively be formed of steel, including a
steel sheet material which was bent into the desired octagonal (or
hexagonal, or other non-rectangular polygonal) shape.
[0025] As best shown in FIG. 2, the frame brackets 30 mate with an
attachment wall 64 of the running board extrusion 52. The preferred
attachment wall 64 includes two attachment slides 66. As best shown
in FIGS. 4 and 5, each of the attachment slides 66 includes a
longitudinally running recess 68 with a neck 70. In the preferred
embodiment, the recess 68 is a 13.5.times.6.5 mm rectangular recess
with a 8.5 mm wide neck 70. With rectangular attachment slides 66,
standard bolts 40 can be used with nuts 42 to attach the frame
brackets 30 to the attachment wall 64. As shown in FIG. 2, openings
72, which are at least the size of the heads of the bolts 40 used
for attachment, are preferably machined in after the extrusion 52
is formed to provide a convenient location to attach and remove the
bolts 40 from the slides 66. In the preferred embodiment, the
openings 72 are circular and 20 mm in diameter, but only as deep as
the face of the slide 66. Alternatively, the bolts 40 could be slid
into the attachment slides 66 from the end of the running board
extrusion 52 with the end caps 32 removed. In either embodiment,
the bolts 40 can then be slid to any desired longitudinal position
so as to match up with the positioning of the frame brackets 30
where the frame brackets 30 can be appropriately attached to the
frame of the vehicle 10. The sliding of the bolts 40 in the
attachment slides 66 thus permits great flexibility in being able
to use the same running board 36 and frame brackets 30 with many
different models of vehicles. The wall thickness forming the neck
70 is preferably thicker than the wall thickness of the rest of the
attachment wall 64, to better withstand the stress of the bolt
heads. In the preferred embodiment, the wall thickness at the neck
70 is 4 mm, while the wall thickness of the rest of the attachment
wall 64 is 2 mm.
[0026] In manufacturing, the extrusion 52 is formed of
indeterminate length, and is cut to the desired length for the side
bar 26. For instance, the depicted side bar 26 has a length of 1905
mm, using a running board 36 of a length of 1826 mm. Other side
bars can be offered in other lengths, with preferred side bar
lengths being 1346 mm, 2159 mm and 2312 mm. By stocking these four
lengths of side bars and with the flexibility of the attachment
slides 66, an appropriate length of side bar can be readily
attached to any of hundreds of different model vehicles.
[0027] In the preferred embodiment, the cuts which form the ends 74
of the running board 36 are at an angle to the longitudinal axis,
with the preferred angle being 30.degree.. The end caps 32 are
formed to match the cut angle and cover the cut ends 74 of the
running board 36. The end caps 32 are preferably formed of the same
material as the running board 36, but alternatively could be formed
of a different material. In the preferred embodiment, the end caps
32 are cast from aluminum. The casting includes six ejection pads
76 on a recessed interior 78 of the end caps 32.
[0028] The preferred extrusion profile is symmetrical about a
vertical longitudinally extending mid-plane, and the same extrusion
profile is used for both right and left running boards 36. Front
and rear, left and right end caps are identical to reduce
manufacturing complexity. The preferred end caps 32 include one or
more sleeve portions 80 which mate on the inside of the extrusion
profile to assist in aligning during assembly and to assist in
holding the end caps 32 in alignment during use. Screws or bolts 38
are used to fasten the end caps 32 to the running board 36. In the
preferred embodiment, the end caps 32 include recessed openings 82
for the threaded fasteners 38.
[0029] The threaded fasteners 38 for the end caps 32 seat into two
fastener openings 84 on the extrusion 52. The preferred extrusion
52 includes two sets of longitudinally extending webs 86 and
C-shaped fastener openings 84. The web 86 enables the fastener
openings 84 to be spaced inwardly from the side walls 54, 56, with
the preferred web 86 being 3 mm wide and spacing the center of the
C-shaped fastener openings 84 about 10 mm inward from the outer
planar face 62 of the vertical side walls 54. The C-shape 84
extends for about 315.degree. cylindrically around the fastener
opening axis. By using a C-shape 84 rather than a complete
cylinder, the tool used for forming the extrusion 52 is simpler.
The 315.degree. fastener opening profile still provides enough
purchase for the threaded fasteners 38 in holding on the end caps
32. By having the fastener openings 84 and webs 86 extend
continuously in the longitudinal direction on the interior of the
extrusion 52, the fastener openings 84 are exposed at any location
that the extrusion 52 is cut, making manufacturing and assembly
simple for any length of side bar and for any angle of cut 74. The
preferred sleeve portions 80 on the end caps 32 extend around only
a portion of the periphery of the ends caps 32 so as to avoid
interference with the web 86. Other locations or numbers of
fastener openings could be included in the extrusion profile using
the same concepts.
[0030] As best shown in FIGS. 1 and 11-14, the extrusion 52 of the
present invention is used not only in the side bars 26, but also in
other exterior accessories including a bull bar 24 and a headache
rack 28. When used to form the bull bar 24 and the headache rack
28, the extrusion 52 is cut at angles, and the angled cuts are
welded together to create a desired angular shape. Having the
extrusion profile bi-laterally symmetrical allows the cutting to
occur and the cuts to be aligned for welding with little or no
waste of the extrusion 52.
[0031] On the bull bar 24, the top wall 60 of the extrusion 52 is
turned to generally face forward. For instance, the preferred bull
bar 24 includes cuts 87, 88 of about .+-.22.5.degree. (on a front
view) to the longitudinal axis, which can be cut with no waste and
joined (welded) in the configuration shown in FIG. 1 to form the
bull bar 24. The preferred bull bar 24 also has some curvature
around the bumper, such as by having cuts 88 be at about 7.degree.
(on a side view) to the longitudinal axis and by having cuts 90 be
at about 15.degree. (on a side view) to the longitudinal axis. This
curvature around the bumper does introduce some waste because the
total exposed surface of the top wall 60 is greater than the total
exposed surface of the attachment wall 64. The preferred bull bar
24 utilizes identical 30.degree. end caps 32 as used on the side
bars 26. The preferred bull bar 24 also includes a center support
flange 90, which can be formed from bent aluminum sheet material,
and is preferably attached to the extrusion 52 using screws 92. A
step pad 94 with openings 46 can be attached over the front faces
of the center support flange 90, creating a complimentary look to
the bull bar 24 as to the side bars 26.
[0032] As best shown in FIG. 14, the headache rack 28 includes
uprights 96 in which the top wall 60 of the extrusion 52 is turned
to generally face outward. Angled cuts 98 of the extrusion 52 are
again used to select the length of the various pieces of the
headache rack 28, which are then welded together. Like the side
view curving of the bull bar 24, the cuts 98 of the headache rack
28 introduce some waste because the total exposed surface of the
top wall 60 is greater than the total exposed surface of the
attachment wall 64. On the tops of the uprights 96, the preferred
headache rack 28 utilizes identical 30.degree. end caps 32 as used
on the side bars 26. The bottoms of the uprights 96 mate into stake
openings (not separately shown) in the box 20 of the truck 10. A
grate 100 is used in the center of the headache rack 28, and
openings 46 in the grate 100 can echo the shapes of openings 46 in
the step pad 94 and openings 46 in the tread 34, furthering the
complimentary look to the headache rack 28 as to the bull bar 24
and side bars 26. The openings 46 in the grate 100 also allow some
viewing through the grate 100. The grate 100 can be welded the
extrusion 52 such as to the attachment wall 64 of the uprights 96
between the recesses 68 (called out in FIG. 5), or could
alternatively be attached by other means. By having bull bars 24,
other types of grill guards (not shown), headache racks 28, side
bars 26, etc. all formed from the same basic extrusion 52,
consumers can purchase multiple different exterior accessories for
their vehicle 10 with all of the exterior accessories having the
same look and feel.
[0033] The present invention thus provides a hollow tubular shape
which can be used as a basic extrusion 52 in creating any of
several different exterior accessories for a vehicle 10. The
outside of the hollow tubular shape provides flat surfaces and
angled edges over most of its periphery (i.e., except for the
attachment wall 64). The attachment wall 64 provides attachment
slides 66 that enable the extrusion 52 to be attached in numerous
configurations, including to attachment brackets for use as
configured for that particular exterior accessory. The interior of
the hollow tubular shape is particularly configured to receive end
caps 32, which can also be used in multiple different types of
exterior accessories.
[0034] Although the present invention has been described with
reference to preferred embodiments, workers skilled in the art will
recognize that changes may be made in form and detail without
departing from the spirit and scope of the invention.
* * * * *