AU671557B2 - A bull-bar assembly - Google Patents

Description

1 "A BULL-BAR ASSEMBLY" This invention relatcs to a bull-bar assembly.

This invention has particular but not exclusive application to a bull-bar assembly, and for illustrative purposes reference will be made to such application.

However, it is to be understood that this invention could be used in other applications such as the construction of a roll bar assembly for a motor vehicle and the attachment of various fittings to bumper bars such as for carrying bicycles or the like.

Most bull-bars include a plurality of metal frame members welded to a bumper bar of a motor vehicle so as to form a frame assembly protecting the front of the vehicle from damage in the event of a collision. However, the S15 welding of the frame members to the bumper bar often results in unsightly welds and may adversely effect the structural integrity of the bumper bar. Furthermore, cleaning the weld eq..

and subsequently chrome plating or painting the welded area e can be very time consuming.

20 It will also be appreciated that, the construction of bull-bars of the type described above does not permit the selective removal of all or some of the frame members or the possible interchange of frame members to suit the whim of the owner of the motor vehicle.

In the case of heavy vehicles such as trucks, the bumper bar is hingedly connectE:d to the chassis of the vehicle such Sthat the bumper bar, and any bull-bar attached thereto, may 2 be tilted forward away from the front of the vehicle thereby permitting forward tilting of the cabin. Typically the bumper bar includes an aperture formed therein which provides access to a tow bar of a tow bar assembly comprising a plurality of heavy steel plates which are mounted on the chassis.

The mounting of a bumper bar to a motor vehicle typically involves the welding of mounting brackets to the bumper bar and to either the chassis of the vehicle or a chassis mounting such as an existing tow bar assembly. The mounting procedure may also involve some modification of the chassis or the chassis mounting to which the bumper bar is attached. Such alterations can be rather time consuming and wherein the method of attachment does not readily facilitate the removal or replacement of the bumper bar.

Furthermore, because the configuration of the chassis and/or the chassis mountings of a particular vehicle may differ from those pertaining to a different make and/or model of vehicle, the mounting brackets are invariably manufactured to suit the particular vehicle to which it is desirous to fit the bumper bar or bull bar. It will be appreciated that the need to manufacture mounting brackets to suit the disposition of the mountings of many different models of motor vehicle is both costly and time consuming.

The present invention aims to alleviate the above disadvantages and to provide a bull-bar assembly which will be reliable and efficient in use. Other objects and 3 advantages of this invention will hereinafter become apparent.

With the foregoing and other objects in view, this invention in one aspect resides broadly in a bull bar assembly including:a primary transverse frame member adapted for attachment to a vehicle; an auxiliary frame member pivotally connected to said primary transverse frame member and being pivotal from a raised position in which the auxiliary frame member in combination with the primary transverse frame member is adapted to at least partially protect the front end of the vehicle to a lowered position in which access to the front end of the vehicle can be gained, and 15 releasable retaining means for retaining said auxiliary frame member in said raised position, characterised in that said auxiliary frame member is an elongate tubular member and is connected to said primary frame member by hinge means including a first hinge member 20 pivotally connected to a second hinge member and said first hinge member extends into said auxiliary frame member and is secured therein and said second frame member is secured to said primary transverse member.

The bull bar assembly may also include a cover which is adapted to cover or at least partially conceal the connection between the primary transverse frame member and the auxiliary frame member.

4 The auxiliary frame member may follow or complement the contours of a motor vehicle and wherein the assembly may include a plurality of interconnected auxiliary frame members, at least one of which is connected to the primary transverse frame member.

Preferably, the primary transverse Zrame member includes a bumper member and a connecting member, the connecting member having first connecting means for connecting the connecting means to the chassis of the vehicle, and second connecting means for connecting said connecting member to said bumper member, said connecting member being 6 characterised in that said first connecting means permits transverse adjustment of the connecting member relative to the chassis. In such form of the invention it is preferred that the first connecting means is a channel which extends along at least part of the length of said connecting member, said channel being adapted to slidably receive and retain 005 .•therein the head of a bolt or a nut. Preferably, the second connecting means also permits transverse adjustment of the connecting member relative to the bumper member. In a preferred form the second connecting means is a channel which extends along at least part of the length of said connecting member, said channel being adapted to slidably receive and retain therein the head of a bolt or a nut. It is also preferred that the first connecting means and the second connecting means are provided in substantially orthogonal faces of the connecting member.

The cover may be integral with or attached to either the primp transverse frame member or the auxiliary frame member and wherein the cover may be a substantially solid object or it may be a shell. The cover may include attachment means for attaching of the cover to the auxiliary frame member and/or the primary transverse frame member and/or connection means for connecting the auxiliary frame member to the primary transverse frame member. In an alternative embodiment, an adhesive may be used to attach the covering means to either the primary transverse frame member or the auxiliary frame member.

The cover may provide shock absorbtion characteristics and in one embodiment may include a resilient contact portion 0 *em which may be adapted to protect the primary transverse frame 15 member from damage in the event of a minor collision.

Alternatively, the cover may be manufactured predominantly from a material having shock absorbing characteristics. For eSSS example, the cover may be molded from a resilient material such as a plastics material or a rubber material. Preferably the cover is molded from a polyurethane material.

The cover may also include a plug or cap intended to close or cover any exposed aperture or recess formed therein.

In order that this invention may be more easily understood and put into practical effect, reference will now be made to the accompanying drawings which illustrate a preferred embodiment of the invention, wherein:- FIG. 1 is a front view of a bull-bar assembly 6 constructed in accordance with the present invention; FIG. 2 is a top view of the bull-bar assembly illustrated in figure 1; FIG. 3 is a side view of the bull-bar assembly illustrated in figure 1; FIG. 4 is a sectional view of the bull-bar assembly illustrated in figure 1; FIG. 5 is a sectional view of the bull-bar assembly illustrated in figure 1; FIG. 6 is a perspective view of mounting means for mounting a primary transverse frame member to a vehicle; FIG. 7 is a front view of a portion of another bull-bar assembly constructed in accordance with the present invention; 15 FIG. 8 is a side cross-sectional view of the bull- •5 FIo bar assembly illustrated in figure 7; FIG. 9 is a side cross-sectional view of the bullbar assembly illustrated in figure 7 showing in *e detail the connection between the primary transverse frame member and the vehicle chassis; FIG. 10 is a plan view of a portion of the bullbar assembly illustrated in figure 7 showing in detail the retaining means for retaining the auxiliary frame member in an operative position, and FIG. 11 is a rear view of a hinge member.

Figures 1 to 4 illustrate a bull-bar assembly including a primary transverse frame member or bumper bar 11, and a plurality of auxiliary frame members 12 releasably attached to the bumper bar 11 and which cooperate to form a protective grid to be mounted on the front of a motor vehicle.

The bumper bar 11 has a substantially shaped transverse cross-section and includes a front wall 13 positioned intermediate a top wall 14 and a bottom wall and wherein the top wall 14 and the bottom wall 15 each include a rear peripheral flange 16 and 17 respectively. The bumper bar 11 further includes a plurality of mounting apertures 18 and 19 formed in the flanges 16 and 17 to which may be attached vehicle mounting means 20 connecting the Sbumper bar 11 and chassis mountings, not shown, of a motor 15 vehicle.

The frame members 12 include an inverted, substantially shaped central frame member 21 and two side frame members 22 each having an end 23 which is welded to an intermediate portion 24 of the central frame member so as to form a single unit. Each frame member 21 or 22 is constructed from a length of tubular steel or aluminium which has been bent such that the frame members 21 and 22 follow or enhance the contours applicable to the motor vehicle to which the bullbar 10 is to be attached to.

The free ends 26 of the frame member 21 each include a mounting notch formed therein and a mounting plate 27 welded thereto such that in an assembled state the mounting plates VTy I! ~i

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27 abut against the top wall 14 of the bumper bar 11 and the side edges 28 of the notches abut against the front wall 13 of the bumper bar 11 as illustrated in figure 4.

The central frame member 21 is secured to the bumper bar 11 by bolts 29 having threaded ends 30, and wherein the shank of each bolt extends through an aperture 31 and a threaded aperture 32 formed in the top wall 14 of the bumper bar 11 and the mounting plate 27 respectively.

The central frame member 21 is further secured to the bumper bar 11 by two shaped bolts 33 which extend about respective ends 26 of the frame member 21 and which extend through respective mounting apertures 34 formed in the front wall 13 of the bumper bar 11. The bolts 33 are retained in place by nuts 35 and washers 15 The free ends 25 of the outer frame members 22 are each closed by a mounting plate or threaded welded spigot 36 and are spaced from the top wall 14 of the bumper bar 11 by a cast cover 44. The cover 44 includes a recess 45 adapted to fit about a respective end 25 of an outer frame member 22 and 20 further includes a spigot 46 for insertion in a corresponding aperture formed in the top wall 14 of the bumper bar 11.

The frame members 22 are each secured to the bumper bar 11 by bolts 37 each having a threaded shank 38 and wherein the shank of each bolt extends through a mounting aperture 39 formed in the spigot 46 and a threaded aperture 40 formed in the mounting plate 36. The head of the bolt 37 is shown spaced from the top wall 14 of the bumper bar 11 by a tapered '2)

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r 9 washer 47.

It will be appreciated that other constructions may be employed to bolt the frame member to the bumper bar including the replacement of the welded spigot with a split spigot having an inwardly converging recess in which is seated the head of a bolt used to connect the frame member to the bumper bar and wherein the expanded spigot is retained within the frame member as a consequence of a load applied to the bolt.

The connections securing the central frame member 21 to the bumper bar 11 are each shielded from view by a cover 41 adapted to cover same. Each cover 41 is cast from a plastics or rubber material and includes an intermediate portion of bolt 33 and a base plate 42 cast therein. The base plate 42 S• is positioned intermediate the top wall 14 of the bumper bar 15 11 and the mounting plate 27 and includes an aperture 43 through which the shank of bolt 33 may pass.

In use, covers 41 are positioned on the bumper bar 11 such that the ends of bolts 33 extend through apertures 34 and apertures 31 and 32 are suitably aligned.

20 The free ends 26 of the central frame member are placed within the recess defined by the covers 41 and the bumper bar 11 and are secured to the bumper bar by tightening nuts and by threading bolts 29 through apertures 31, 32 and 43.

Similarly, the outer frame members 22 are secured to the bumper bar 11 by threading bolts 37 through apertures 39 and When the frame members 21 and 22 are not attached to the 'N bumper bar, plugs, not illustrated, may be placed in or over any mounting apertures formed therein.

A skirt 50 if desired may be secured to the base wall of the bumper bar using a plurality of bolts and/or other fasteners, not shown, and wherein the bottom wall of the bumper bar includes a lip 51 against which an edge of the skirt 50 may abut. An additional skirt 52, if desired, may be secured to the base 53 of skirt 51.

Figure 6 illustrates mounting means 20 for mounting a bumper bar 11 to a motor vehicle, not shown, including a bumper bar mounting bracket 61 and a vehicle mounting bracket 62.

The bumper bar mounting bracket 6. includes a bumper bar mounting flange 64 and a web 65 positioned intermediate the 15 bumper bar mounting flange and the front wall 13 of the bumper bar 11. The bumper bar mounting flange 64 includes 'pper and lower, horizontally orientated, slotted mounting apertures 62 and 63. The web includes a plurality of mounting apertures 20 The bumper bar mounting flange may be secured to the rear flanges 16 and 17 of the bumper bar 11 using bolts, not shown, adapted to extend through a selected aperture 18 and a slotted aperture 62 and through a selected aperture 19 and slotted aperture 63 respectively.

The vehicle mounting bracket when viewed in plan is substantially shaped and includes a bracket mounting portion 66, having a plurality of vertically orientated

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3.1 slotted apertures 69, and a vehicle mounting portion 67 having a plurality of horizontally orientated, slotted apertures 71, separated by an intermediate portion 68.

In use bolts, not shown, may be passed through aligned apertures 69 and 70 and subsequently tightened so as to connect the vehicle mounting bracket and the bumper bar mounting bracket together. Similarly, bolts may be passed through apertures formed in the chassis mountings and a selected aperture 71 and subsequently tightened so as to connect the vehicle mounting bracket to the vehicle.

It will be appreciated that the disposition of the mounting means 20 relative to the chassis mountings may be altered by selecting appropriate apertures 18 and 19 and by 0 sliding the bumper bar mounting bracket in a lateral direction as indicated by arrows 80, and/or by sliding the vehicle mounting bracket in a vertical direction, as indicated by arrows 81, relative to the bumper bai mounting bracket, and/or by selecting an appropriate aperture 71 and by sliding the vehicle mounting bracket in a horizontal 20 direction, as indicated by arrows 82, relative to the chassis mounting.

Figures 7 to 10 illustrate yet another bull-bar assembly 100 comprising a primary transverse freme member or bumper bar 101, a pair of vertically disposed frame members 102,.

(only one of which is shown), being of hollow const'uction and each extending upwardly and forwardly from the transverse i. frame member 101. The bull-bar assembly also includes a 12 second or intermediate transverse frame member 103 which is connected to the two frame members 102.

The bull-bar assembly 100 is connected to a vertically disposed wall 104 of a chassis member 105 by connecting means 106 which includes a shaped extruded connecting member 107 made of aluminium. The connecting member 107 includes an upper mounting flange 108 and a lower mounting flange 109 separats3d by an intermediate mounting flange 110.

The mounting flanges 108, 109 and 110 each include a pair of channel shaped recesses 111 formed therein which extend along the length thereof. The recesses 111 are each "e :substantially shaped and are each adapted to receive slidably therein the head of a bolt 112, each bolt being retained within the respective recess by opposing inwardly 15 directed lips 113.

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The intermediate mounting flange 110 is releasably securer the chassis member 105 by a plurality of bolts 112a which extend through apertures formed in the wall 104 and which are retained in place by nuts 114.

The connecting means 106 also includes a pair of upper and a pair of lower shaped mounting brackets 116 each having a horizontally disposed mounting flange 117, which is releasably attached to either the upper or the lower flange 108 or 109 respectively by bolts 112, and a vertically disposed mounting flange 118, each of which includes a pair mounting apertures formed therein.

v The rear of the bumper bar 101 is provided with a pair of upper mountings 119 and a pair of lower mountings 120 which have been welded thereto. The upper mountings 119, located at opposite ends of the bumper bar 101, are releasably secured to respective abutting mounting flanges 118 by bolts 121. Similarly, the lower mountings 120, also located at opposite ends of the bumper bar, are releasably secured to respective abutting mounting flanges 118.

The rear wall of the bumper bar 101 is also supported by the abutting end portions 122 and 123 of the upper and lower flanges 108 and 109 respectively.

The bumper bar 101 may also include an aperture 125 formed in the front wall thereof and which provides access to %so a vertically disposed, cylindrical, toe bar 126. The toe bar includes an enlarged head portion 127 which rests upon a 15 horizontally disposed plate 128 supported at opposite ends by opposing mounting flanges 116, and a dependant shank 129, which extends through aligned apertures formed in the plate 127 and flanges 108 and 109.

The bumper bar 101 also includes a separate lower skirt 130. Tne skirt includes an upper mounting portion 131 which is receivable within, and may be welded to, a complementary shaped recess formed in a lower wall of the bumper bar 101.

The skirt also includes a plurality of rearwardly directed ribs 132 which abut against corresponding ribs of a skirt supporting member 133 which is welded to the lower edges of mounting brackets 116a and is supported from beh.nd by lugs 134 dependent from respective flanges 120.

14 The lower end 136 of each auxiliary frame member 102 is hingedly connected to the bumper bar 101 such that each auxiliary frame member may rotate relative to the bumper bar 101 about an axis containing pins 138.

The pins 138 are each rotatably supported by a yoke 140 and wherein each yoke includes a pair of opposing flanges 139 sep,rated by a respective web. The web is releasably secured to a flange 141 dependent from flange 109 by a bolt 142.

The pins 138 are each connected to a respective cast arm member 143 having a plurality of circular ribs 143a which are each welded to the internal wall of a respective auxiliary frame member 102, access thereto being provided by the removal of a portion of the rear wall thereof, not shown.

The bull-bar assembly is also provide, with two covers 15 145 made from a polyurethane material and each being adapted to at least partially conceal the hinged connections ;e connecting the frame members 102 to the bumper bar 101. The covers each include a bore which is adapted to receive the lower portion of a respective frame member 102 and wherein 20 each cover is also adapted to conceal the cutaway formed in each of the respective frame members for the purposes of welding the arm members thereto. The colvers 145 are each connected to respectivoe a arm member 143 using threaded fasteners 175.

The bull-bar assembly also includes a pair of locking assemblies 150 for retaining the auxiliary frame members in an operative upstanding position as shown in figure 9. Each o0 o ee, oe~ ooe o locking assembly includes a hinge comprising two shaped hinge members 151 and 152 which are pivotally connected by a pin 153 and which are adapted to close from either side about auxiliary frame member 103.

Each hinge member 152 is supported by and spaced from the bumper bar 101 by a chrome spacing member 154 and a polyurethane washer 155. Furthermore, each hinge member 152 is secured to a base plate 156 which is welded to plate 128 by two bolts 157, each havihg a shank 159 which extends through a respective sleeve 160 welded to hinge member 152 at 161. The ends of each shank are threaded and are also retained within respective threaded apertures formed in the plates 156.

Each hinge member 152 is also provided with a threaded 15 sleeve 163 which is adapted to receive the threaded end of a respective locking member 164 and a polyurethane cover 165 intended to at least partially conceal the means by which the hinge member 152 is connected to the bumper bar. The hinge members 151 each also include an outer cover made from polyurethane and each include an aperture formed therein through which the threaded end of a respective locking member may extend.

In use, a suitable length of the extruded connecting member 107 may be attached to the wall 104 of a chassis member using a plurality of bolts 112 so as to facilitate the subsequent connection thereto of a bumper bar as described below or a bull-bar assembly of the type illustrated in r

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figures 7 to For example, pairs of upper and lower brackets 116 and 116a may be attached to the connecting member 107 at appropriate positions along the length thereof which will permit the mounting brackets 119 and 120 previously welded to a bumper bar to be subsequently attached thereto using bolts 121.

Furthermore, in use, the auxiliary frame member 102 may be released from it's operative upstanding position by unscrewing the locking member 164 thereby enabling the upper hinge member 151 may be released from its clamping position about frame member 103 as illustrated by arrow 170 in figure 8. This then permits the forward rotation of the auxiliary frame member about an axis containing pin 138 as illustrated by arrow 171 thereby permitting the user to tilt the cabin of the vehicle, not shown.

Similarly, the auxiliary frame member 102 may be retained in an operative position as shown in figure 8 by clamping hinge members 151 and 152 about frame member 103 and by the subsequent engagement of the locking member 164 with the sleeve 163.

It will of course be realised that while the above has been given by way of illustrative example of this invention, all such and other modifications and variations thereto as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of this invention as is herein defined in the appended claims.

Claims (12)

1. A bull bar assembly including:- a primary transverse frame member adapted for attachment to a vehicle; an auxiliary frame member pivotally connected to said primary transverse frame member and being pivotal from a raised-position in which the auxilliary frame member in combination with the primary transverse frame member is adapted to at least partially protect the front end of the vehicle to a lowered position in which access to the front end of the vehicle can be gained, and releasable retaining means for retaining said auxiliary frame member in said raised position, characterised in that said auxiliary frame member is an elongate tubular member and is connected to said primary frame member by hinge means including a first hinge member pivotally connected to a second hinge member and said first hinge member extends into said auxilliary frame memeber and is secured therein and said second frame member is secured to said primary transverse member.

2. A bull-bar assembly as claimed in Claim 1, wherein the auxilliary frame member is connected to said primary transverse frame member by hinge means at both ends.

3. A bull-bar assembly as claimed in Claim 1 or claim 2, 'w~ 18 and including a cover having shock absorbing characteristics adapted to at least partially conceal said hinge means and at least a portion of said cover extends forwardly of said primary transverse frame member.

4. A bull-bar assembly as claimed in Claim 3, wherein said hinge means when viewed from the forward direction is concealed by said cover.

A bull bar assembly as claimed in Claim 3 or Claim 4, wherein said cover includes a top portion having a passageway through which said auxiliary frame member extends.

6. A bull bar assembly as claimed in any one of the preceding claims, wherein the primary transverse frame member includes a bumper member and a connecting member, the connecting member having first connecting means for connecting the connecting member to the chassis of the vehicle, and second connecting means for connecting said connecting member to said bumper member, said connecting member being characterised in that said first connecting means permits transverse adjustment of the connecting member relative to the chassis.

7. A bull bar assembly as claimed in claim 6, wherein said first connecting means is a channel which extends along at z least part of the length of said connecting member, said U hannel being adapted to slidably receive and retain therein OF I I 19 the head of a bolt or a nut.

8. A bull bar assembly as claimed in claim 6 or claim 7, wherein said second connecting means permits transverse adjustment of the connecting member relative to the bumper member.

9. A-bull bar assembly as claimed in claim 6 or claim 7, wherein said second connecting means is a channel which extends along at least part of the length of said connecting member, said channel being adapted to slidably receive and retain therein the head of a bolt or a nut.

10. A bull bar assembly as claimed in claim 9, wherein said first connecting means and said second connecting means are provided in substantially orthogonal faces of said connecting member.

11. A bull bar assembly as claimed in any one of claims 6 to wherein said connecting member includes a towing member.

12. A bull bar assembly substantially as heeinbefore described with reference to figures 7 to DATED THIS Twelfth DAY OF February, HENRI BAUMANN S j by tZZEY AND COMPANY PATENT ATTORNEYS O

1996.