AU2015372440B2

AU2015372440B2 - Mounting assembly

Info

Publication number: AU2015372440B2
Application number: AU2015372440A
Authority: AU
Inventors: Luke MCLOUGHLAN
Original assignee: Aeroklas Asia Pacific Group Pty Ltd
Current assignee: Aeroklas Asia Pacific Group Pty Ltd
Priority date: 2014-12-22
Filing date: 2015-12-22
Publication date: 2019-06-13
Anticipated expiration: 2035-12-22
Also published as: AU2015372440A1; WO2016101030A1

Abstract

The invention generally relates to a mounting assembly (10) for mounting a bullbar to a vehicle. The assembly comprises: an attachment member (20) that is integrally formed with or attachable to the bullbar. The attachment member (20) extends along a collision axis and is associated with a fold (25) that extends from the attachment (20) member at an angle to the collision axis. The assembly also includes a second member, to which the attachment member is movably attached. The assembly is configured such that the attachment member (20) is capable of movement in the direction of the collision axis and of absorbing impact energy from a collision with the bullbar by deforming the fold (25).

Description

Mounting assembly

Field of the invention [0001] The present invention generally relates to a mounting assembly. In particular, the invention relates to an assembly that is suitable for mounting components such as bullbars, bumper bars, towbars, sidesteps and the like to vehicles.

Background of the invention [0002] Bullbars (also known as grill guards) are components that are fitted to the front of vehicles to protect the vehicle and occupants from collisions. Bullbars are especially fitted to the types of vehicles (typically larger four wheel drives) that are used in environments where collisions with animals are not an uncommon occurrence. Without a bullbar, a high-speed collision on a rural highway with an animal (such as a kangaroo) can be catastrophic to vehicle operation and occupant safety.

[0003] Earlier generations of bullbars were directly attached to the vehicle in a rigid manner. However more recently, bullbars have been attached to vehicles with an interposed energy absorbing system. Such systems are used to reduce vehicle damage as a result of a collision by absorbing impact energy that would otherwise be transferred from the bullbar to the vehicle. Energy absorbing systems are also used with the 'bumper bar' that is invariably fitted to modem vehicles.

[0004] Various impact energy absorbing systems have been proposed in the past. For example, US 6,402,209 describes a device for interconnecting a protective bar and a vehicle. In broad terms, the device comprises a pair of spaced apart lateral walls that enclose an impact absorber in the form of a hollow crushing member.

[0005] US 4,929,008 describes an impact absorber that deploys a box-beam inflatable member as a primary shock absorber. The device described in US 4,929,008 also includes a number of secondary absorbers that are arranged in series for sequential actuation in response to an increase in impact forces.

[0006] The use of various forms of shearing bolts as impact absorbers for bumper bars is described in US 4,823,923, US 4,426,109, US 4,190,276, US 3,697,108 and US 2,811,385.

[0007] The present invention aims to provide an alternative mounting assembly that is suitable for mounting components such as bullbars, bumper bars, towbars, sidesteps and the like to vehicles.

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Summary of the invention [0008] According to a first aspect of the present invention there is provided a A mounting assembly suitable for mounting a bullbar to a vehicle, the assembly comprising:

an attachment member integrally formed with or attachable to the bullbar, the attachment member extending along a collision axis and being associated with a fold that extends from the attachment member at an angle to the collision axis; and a second member, to which the attachment member is movably attachable, wherein the assembly is configured such that the attachment member is capable of movement in the direction of the collision axis and of absorbing impact energy from a collision with the bullbar by deforming the fold.

[0009] The present invention provides a robust impact absorber that is suitable for mounting components such as bullbars, bumper bars, towbars, sidesteps and the like to vehicles. The invention utilises simple and/or progressive bending in a single plane as opposed to the complex crushing structures of the prior art, including the crushing-member-based impact energy absorbing system described above. Moreover, the use of an attachment member and an angularly extending fold allows for the direction of deformation to be very strictly controlled. This is in contrast to the crushing structures of the prior art in which deformation occurs in a random and uncontrolled manner.

[0010] Utilising a simple impact absorption means allows the assembly to be tuned for a wide variety of vehicles and components. More particularly, the characteristics of the fold deformation are dependent on a variety of factors including the starting angle, magnitude of collision forces and the materials from which the components are made. The magnitude and rate of energy absorbed can be suitably adjusted by routine design variations in order to tailor the assembly to different vehicles.

[0011] The assembly is also cost effective to manufacture, due to its utilisation of low cost components. No welding or complicated fabrications and pressings are required to manufacture the assemblies according to the invention. The design is thus easily repeatable and has manufacturing simplicity.

[0012] Typically, the fold is integrally formed with or connected to the attachment member. However, according to other embodiments, the fold is located on a separate member to which the attachment member is fixedly attached and is capable of moving in unison with the attachment member during a collision.

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PCT/AU2015/050831 [0013] The second member may also be associated with a second member fold that extends from the second member at an angle to the collision axis, wherein the assembly is configured such that the attachment member fold is capable of deforming while partially separating from the second member fold. According to some embodiments, the attachment member fold is fixedly attached to the second member fold.

[0014] Preferably, the attachment member fold and second member fold extend from the collision axis at substantially the same angle.

[0015] The mounting assembly may include deformation control means for controlling the extent of deformation of the attachment member fold. According to some embodiments, the deformation control means takes the form of a plate that is fixedly attached to the attachment member fold and second member fold. The plate can be fixedly attached to the attachment member fold at or near the end thereof distal to the vertex of the attachment member and attachment member fold. When in this location, the plate is capable of controlling the deformation of the attachment member fold during the early stages of the collision. During a collision, the attachment member fold is also capable of deforming by bending about the plate.

[0016] Preferably, the mounting member includes one or more longitudinally extending slots, the slots being suitable to facilitate movable attachment of the attachment member to the second member. More particularly, the longitudinallyextending slots are capable of movement during a collision, [0017] Typically, the assembly includes one or more fasteners that each extend through one of the longitudinal slots and are fixedly attached to the second member, wherein the longitudinal slots are capable of moving past the fastener during a collision.

[0018] Preferably, the longitudinal slots are tapered in the opposite direction of movement of the attachment member during a collision. These tapered slots provide an additional impact-absorbing mechanism, by being deformed by the fasteners during a collision.

[0019] The assembly may include a clamping member that is fixedly attached to the second member and spaced therefrom by the attachment member.

[0020] According to a second aspect of the present invention, there is provided A mounting assembly suitable for mounting a bullbar to a vehicle, the assembly comprising:

two or more laterally spaced assemblies for receiving the bullbar;

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PCT/AU2015/050831 each assembly including an attachment member integrally formed with or attachable to the bullbar along its length, the attachment member extending along a collision axis and being associated with a fold that extends from the attachment member at an angle to the collision axis; and a second member, to which the attachment member is movably attached, the assembly being configured such that the attachment member is capable of movement in the direction of the collision axis and of absorbing impact energy from a collision by deforming a fold.

[0021] According to another aspect of the present invention there is provided a system for attaching a bullbar to a vehicle, the system comprising a first member for attachment to the vehicle and a second member for connecting with the bullbar, each member having a longitudinal portion and a lateral flange portion extending at an angle to the longitudinal member, the two longitudinal portions mounted to allow constrained relative movement therebetween in the longitudinal direction, and the two flange portions fixedly connected together at a position spaced from the longitudinal portions. With this construction, on collision in the longitudinal direction there will be relative sliding movement between the longitudinal portions (in the longitudinal direction), while one or both of the flange portions will deform to absorb the energy of the collision.

Brief description of the drawings [0022] Embodiments of the present invention will now be further explained and illustrated by reference to the accompanying drawings in which:

Figure 1 is a plan view of a mounting assembly in accordance with an embodiment of the present invention;

Figure 2 is a plan view of a mounting assembly with optional load plates omitted;

Figure 3 is a perspective view of the mounting assembly illustrated in Figure 1;

Figure 4 is a side view of the mounting assembly illustrated in Figures 1 and 3;

Figures 5(a), 5(b), 5(c) and 5(d) are views illustrating the progressive deformation of the folds of the mounting assembly illustrated in Figures 1,3 and 4;

Figure 6 is a perspective view of a mounting assembly illustrated in Figures 1 to 5 showing a washer plate;

Figure 7 is a perspective view of the mounting assembly illustrated in Figures 1 to 6 showing the slots in the support frame;

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Figure 8 is a side view of a mounting assembly illustrated in Figure 7 showing the slots in the support frame;

Figure 9 is a plan and side view of the mounting assembly illustrated in Figures 1 to 8 shown mounted to a vehicle chassis and bullbar;

Figure 10 is a plan view and side view of a second embodiment of a mounting assembly shown mounted to a vehicle chassis and bullbar;

Figures 11 and 12 are plan views of other embodiments of mounting assemblies having folds extending from the attachment member at differing angles; and

Figure 13 is a perspective view of a pair of the mounting assemblies illustrated in Figure 10, shown supporting a bullbar.

Detailed description of the drawings [0023] A first embodiment of a mounting assembly 10 is illustrated in Figures 1 and 3-9. Mounting assembly 10 is a versatile apparatus that is suitable for attaching a variety of components to vehicles, including bullbars, bumper bars, sidesteps and towbars.

[0024] Mounting assembly 10 includes a planar attachment member 20, with an integrally formed portion, tab or flange 25 that is formed by laterally bending or folding the attachment member about a fold line. In this specification, including the claims, such a portion, tab or flange is known as a 'fold'. Fold 25 extends at an angle from attachment member 20. A second member (in the form of a support frame 30) is provided adjacent to attachment member 20. The support frame 30 also includes an integrally formed angularly extending fold 35.

[0025] The exact size and shape of attachment member 20 and support frame 30 is dictated by the dimensions of the particular vehicle to which it is attached, and by the site of its attachment.

[0026] Folds 25 and 35 extend from their respective attachment member 20/ support frame 30 at generally the same angle and are thus substantially in register with each other. As described in more detail below, fold 25 and/or 35, by being deformed during a collision, serve to absorb the collision's impact energy.

[0027] In the embodiments illustrated in Figures 1 and 3-9, folds 25 and 35 extend from their respective attachment member 20/support frame 35 at an acute angle. Alternative embodiments are illustrated in Figures 11 and 12, which respectively show folds 25 and 35 extending at right and obtuse angles from their respective attachment member 20/support frame 35.

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PCT/AU2015/050831 [0028] Returning to Figures 1 to 4, a series (in the illustrated embodiment three) of vertically spaced fasteners 37 (typically bolts) are driven through folds 25 and 35 so as to secure the two components together. A washer plate 38 is provided adjacent to fold 25 on the opposite side to fold 35.

[0029] An elongated and planar mounting plate 40 is provided adjacent to attachment member 20 on the opposite side to support frame 30. The trailing end (relative to the bullbar 70) of mounting plate 40 extends out beyond both the attachment member 20 and support frame 30 and (as shown most clearly in Figure 9) is suitably attached to the vehicle's chassis 60. The component to be attached (which in the illustrated embodiment is a bullbar 70) is attached to the leading end of attachment member 20. The skilled addressee would realise that attachment member 20 and bullbar 70 could also be integrally formed as a unitary component. Furthermore, support frame 30 will vary in size, material and geometry depending on vehicle design and product required.

[0030] An alternative embodiment is shown in Figures 10 and 13, in which the leading end (relative to bullbar 70) of mounting plate 40 is attached to the bullbar 70 and the leading end of attachment member 20 is attached to the vehicle chassis 60. Figure 13 also illustrates the use of a pair of mounting assemblies with one on each of the opposite lateral sides of the vehicle. In this embodiment, the mounting plate 40 of each assembly is attached to the opposite ends of the bullbar 70.

[0031] Figures 1 and 3 to 13 illustrate a mounting assembly that includes a load plate 50 provided adjacent to mounting plate 40 opposite the attachment member 20. Load plate 50 is used to provide additional stiffening to the joint between mounting plate 40 and support frame 30. An alternative embodiment is shown in Figure 2, in which the load plate 50 and washer plate 38 are omitted.

[0032] As most clearly illustrated in Figures 7-9, attachment member 20 is attached to support frame 30 in a way that permits attachment member 20 to move relative to support frame 30. In particular, attachment member 20 includes a matrix of four longitudinally-extending tapered guide slots 22. Support frame 30 is shown transparently in Figures 7-9 in order to illustrate the guide slots 22. The guide slots 22 are obscured in Figure 6 by the presence of support frame 30 and mounting plate 40.

[0033] Two pairs (or other suitable number) of vertically spaced fasteners 34 (typically bolts) extend from support frame 30, through attachment member 20 and mounting plate 40, to exit the assembly 10 through load plate 50. When traversing attachment member 20, the fasteners 30 pass through the guides slots 22. During

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PCT/AU2015/050831 normal operation of the vehicle, bullbar 70 is supported on the attachment member 20 by the clamping forces applied by support frame 30, mounting member 40 and load plate 50.

[0034] It will be apparent to the skilled addressee that various construction approaches are possible to facilitate movement of the attachment member 20 relative to support frame 30. For example, suitably positioned slots could be provided in support frame 30, mounting plate 40 and load plate 50, with rigidly-attached fasteners being provided in attachment member 20. According to this embodiment, the fasteners are free to move about the slots.

[0035] The lateral clamping force that is applied to attachment member 20 by mounting plate 40 and support frame 30 needs to be carefully controlled. Too high a clamping force results in attachment member 20 being completely restrained from movement even during collision conditions. Too low a clamping force can result in a sub-optimal connection of the assembly to the vehicle.

[0036] The behaviour of the mounting assembly 10 during a collision of an object with the bullbar 70 is illustrated in Figure 5. Figure 5(a) shows the assembly 10 before the collision occurs. Immediately after the collision, as shown in Figure 5(b), the impact on the bullbar 70 (particularly from a front-on collision) causes the attachment member 20 to move in a direction substantially parallel to its longitudinal axis (hereinafter referred to, including in the claim as the 'collision axis'). This movement in turn causes fold 25 to deform, first in the region of the vertex between the trailing end of attachment member 20 and fold 25. More specifically, the force applied to fold 25 in the direction of the collision axis causes the fold 25 to bend and partially separate from fold 35 in a wave-like manner. Moving along fold 25 from the vertex to the distal end, the direction of separation of fold 25 from fold 35 is substantially parallel to the collision axis.

[0037] Figure 5(c) shows the assembly after a further elapse of time from Figure 5(b). As attachment member 20 moves further along the collision axis, fold 25 becomes further separated from fold 35. The characteristic 'separation wave' pattern increases in amplitude as the medial region of fold 25 commences bending about washer plate 38. As shown in Figure 5(c), if collision forces of sufficient magnitude are involved, washer plate 38 can be bent upwardly by fold 35. The washer plate 38 serves to control the fold-deformation area and maintain contact between the folds during the early stages of the impact.

[0038] Figure 5(d) shows the final result of the object colliding with the bullbar 70. At this time, the impact energy from the collision has caused the amplitude of

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PCT/AU2015/050831 fold 35's separation wave to be at a maximum, and the crest of the wave to approach washer plate 38. The impact energy from the collision has been absorbed by the deforming of the fold 35.

[0039] A supplementary impact-energy-absorption mechanism can optionally be built into assembly 10 in the form of the tapering of guide slots 22 as shown. More specifically, as attachment member 20 moves along the collision axis, each guide slot 22 moves past one of the bolts 34. As the width of the guide slots 22 reduces in the direction opposite to the direction of travel of mounting member 20, the bolts 34 engage with the edges of the guide slots and plastically deform them in the reduced-width region. This deformation provides an additional source of impactenergy absorption.

[0040] The characteristics of the fold deformation, such as the final shape, are dependent on a variety of factors including the starting angle (i.e whether it is acute, right or obtuse), magnitude of collision forces and the materials from which the components are made. In this regard, the magnitude and rate of energy absorbed can be suitably adjusted by routine design variations in order to tailor the assembly to different vehicles. In this regard, the degree of energy absorption can be varied by altering the properties of materials, thicknesses and grades, as well as component sizes and shapes.

[0041] Furthermore, it will be apparent to those skilled in the art that in tuning energy-absorbing rates, there are likely to be variances in material types and thicknesses. The number of slots and fasteners can vary, as can the slot lengths and widths and the ratio of tapered to constant-width regions.

[0042] The behaviour of the mounting assembly shown in Figures 10 and 13 during a collision is broadly similar to the assembly illustrated in the remaining Figures. As discussed above, in the embodiment of Figures 10 and 13, the bullbar 70 is attached to the trailing end of mounting plate 40, with the leading end of attachment member 20 being attached to the vehicle chassis 60. During a collision, bullbar 70 and mounting plate 40 move in the direction of the collision axis. Due to the fact of mounting plate 40 and support frame 30 being bolted together through the guide slots 34 in the attachment member 20, the support frame 30 moves in unison with the mounting plate 40 along the collision axis. This movement of the support frame 30 causes the fold 25 (which, like fold 35 extends at an angle to the collision axis) to deform as it is separated from the fold 35.

[0043] The word ‘comprising’ and forms of the word ‘comprising’ as used in this description do not limit the invention claimed to exclude any variants or additions.

Claims

Claims

1. A mounting assembly suitable for mounting a bullbar to a vehicle, the assembly comprising:

an attachment member integrally formed with or attachable to the bullbar, the attachment member extending along a collision axis and being associated with a fold that extends from the attachment member at an angle to the collision axis;

a mounting plate provided adjacent the attachment member; and a second member, to which the attachment member is movably attachable, wherein the assembly is configured such that the attachment member is capable of movement in the direction of the collision axis and of absorbing impact energy from a collision with the bullbar by deforming the fold.
2. A mounting assembly according to claim 1, wherein the fold is integrally formed with or connected to the attachment member.
3. A mounting assembly according to claim 1 or claim 2, wherein the second member is associated with a fold that extends from the second member at an angle to the collision axis, wherein the assembly is configured such that the attachment member fold is capable of deforming while partially separating from the second member fold.
4. A mounting assembly according to claim 3, wherein the attachment member fold is movably attachable to the second member fold.
5. A mounting assembly according to claim 3 or claim 4, wherein the attachment member fold and second member fold extend from the collision axis at substantially the same angle.
6. A mounting assembly according to any preceding claim, further including deformation control means for controlling the extent of deformation of the attachment member fold.
7. A mounting assembly according to claim 6, when dependent on claim 3, wherein the deformation control means includes a plate that is fixedly attached to the attachment member fold and second memberfold.
8. A mounting assembly according to claim 7, wherein the plate is fixedly attached to the attachment member fold at or near the end thereof distal to the vertex of the attachment member and attachment member fold.

2015372440 21 May 2019
9. A mounting assembly according to claim 7 or claim 8, wherein the assembly is configured such that the attachment member fold is capable of deforming by bending about the plate.
10. A mounting assembly according to any preceding claim, wherein the attachment member includes one or more longitudinally extending slots, the slots being suitable to facilitate movable attachment of the attachment member to the second member
11. A mounting assembly according to claim 10, further including a fastener that extends through one of the longitudinal slots and is fixedly attached to the second member, the assembly being configured such that the longitudinal slot is capable of moving past the fastener
12. A mounting assembly according to claim 10 or claim 11, wherein the longitudinal slots are tapered.
13. A mounting assembly according to any preceding claim, further including a clamping member that is fixedly attached to the second member and spaced therefrom by the attachment member.
14. A mounting assembly according to any preceding claim, wherein the attachment member and/or second member are substantially planar.
15. A mounting assembly suitable for mounting a bullbar to a vehicle, the assembly comprising:

two or more laterally spaced assemblies for receiving the bullbar;

each assembly including an attachment member integrally formed with or attachable to the bullbar along its length, the attachment member extending along a collision axis and being associated with a fold that extends from the attachment member at an angle to the collision axis;

a mounting plate provided adjacent the attachment member; and a second member, to which the attachment member is movably attachable, the assembly being configured such that the attachment member is capable of movement in the direction of the collision axis and of absorbing impact energy from a collision by deforming a fold.