AU2007201364A1

AU2007201364A1 - Mounting for vehicle protective members

Info

Publication number: AU2007201364A1
Application number: AU2007201364A
Authority: AU
Inventors: Mario Paul Dimech; Christopher Neil Howe
Original assignee: Toyota Motor Corp Australia Ltd
Current assignee: Toyota Motor Corp Australia Ltd
Priority date: 2002-12-23
Filing date: 2007-03-28
Publication date: 2007-04-19
Anticipated expiration: 2023-12-19
Also published as: AU2007201364B2

Description

Our Ref:20183707 P/00/011 Regulation 3:2

AUSTRALIA

Patents Act 1990

ORIGINAL

COMPLETE SPECIFICATION STANDARD PATENT Applicant(s): Address for Service: Invention Title: Toyota Motor Corporation Australia Limited 2-28 Alexander Avenue Taren Point New South Wales 2229 Australia DAVIES COLLISON CAVE Patent Trade Mark Attorneys 255 Elizabeth Street Sydney, New South Wales, Australia, 2000 Mounting for vehicle protective members The following statement is a full description of this invention, including the best method of performing it known to me:- P \WPDOCSGXS\LNM\2OO7\SpcciTOYOTA MOTOR CORPAUSTI12 Mach_121%9671_Mollling assembly for vehicle doc-.328/2007 -1- O MOUNTING FOR VEHICLE PROTECTIVE MEMBERS 0O Field of the Invention This invention relates generally to the mounting of protective members to Svehicles. The expression "protective members" includes for example bumper bars, bullbars and other protective members which are adapted to protect a vehicle body in the event of impact collisions.

Background to the Invention It is often desirable that vehicle bodies be protected from damage during relatively low impact collisions and animal strikes. These same vehicles are also often fitted with supplemental personnel restraints such as air bags to protect vehicle occupants from injury. A problem with such restraints is that they can be activated at relatively low speed, or low energy collisions which can cause occupant injury that would not otherwise have occurred.

Often where vehicles are generally used for off road purposes the protective member is in the form of a bullbar. Such bullbars are often adapted to be used with a winch to enable self recovery of the vehicle if the vehicle becomes bogged, or to allow the vehicle to be winched down or up slopes.

Thus, the protective member is exposed to longitudinally compressive loads during impact, and tensile loads during winching. Therefore the protective member and chassis must often deal with opposing loading conditions.

As a winch is generally mounted to or integral with the protective member, winching forces are generally taken by the protective member and then transferred through to the vehicle through the protective member mounting points, which are generally directly disposed at a front end of a chassis member. During winching, it is P WPDOCS'GXSUNM12OO7DSp.\TOYOTA MOTOR CORP.AUSTM2 Mach 12196 8 7 1_Moulitl a$nlbly for vhicle doc-.3128/2007 -2possible that chassis members deform, especially where the chassis member is fitted with crumple zones.

SThe present invention seeks to alleviate one or more of the abovementioned 00 5 disadvantages.

SSummary of the Invention According to one aspect of the present invention there is provided a coupling assembly suitable for connecting a protective bar mounting device to a vehicle which includes a chassis member having a plurality of weakened zones disposed proximal an outboard end of the chassis member, the coupling assembly including: a connector member which is adapted to connect the protective bar mounting device at a first connection region disposed outboard and adjacent the chassis member; the connector member also adapted to connect to the chassis at a second connection region disposed generally inboard of the weakened zones, so that tensile forces such as winching forces applied to the protective bar mounting device are transferred to the chassis member inboard of the weakened zones.

Preferably the connector member includes a pin bolt which is arranged so that in an installed position it extends generally along an axis extending between forward and rearward ends of the vehicle body.

Preferably the connector member includes a compression force bypass section disposed intermediate the first and second mounting regions so that compression forces are absorbed by the protective bar mounting device and/or the weakened zones of the chassis.

Preferably the coupling assembly includes an anchor element which includes a connector member mounting region for mounting the connector member at the second mounting region, and a chassis mounting region for mounting the anchor element to the chassis member.

Preferably the anchor element is a pin which when installed extends between the opposed walls of the chassis member and the chassis mounting region includes an operative P \WPDOCSIOXS.NM207TSpcc \TOYOTA MOTOR CORP AUST%I12 M¢h_lI19R)7 Mo-~lLgIohI bly f. vchl, dc-3/28/12007 -3connection for connecting the pin to opposed walls of the chassis member.

Preferably the anchor element includes a threaded hole to mount the second end of the Gconnector member.

00 Preferably wherein an alignment means is provided to cooperate with the chassis member connection to align the pin with the connector member for ease of mounting the pin bolt in the threaded hole.

Preferably wherein the winching loads are distributed to a position between approximately 100mm and 400mm rearward of the mounting assembly.

Preferably wherein the compression bypass section includes a bolt head at the first connection region which is adapted to bear against a forward face of a protective bar mounting plate when installed so that the plate is released to travel inboard under compression loading.

A mounting assembly may be mounted to the coupling assembly, the mounting assembly including: a collapsible member, operatively connected between the protective member and the vehicle body, the collapsible member including a collapse initiator portion which provides a controlled preliminary absorption of impact forces by the collapsible member across a range of impact levels, commencing at a relatively low level of impact involving the protective member.

The collapsible member may include a columnar section having a longitudinal axis, which preferably when installed extends in a direction between the forward and rearward ends of the vehicle. In one preferred form, the columnar section includes a tubular portion which may be of any suitable cross sectional shape. Preferably, the tubular portion is of square or rectangular section. In one preferred form, the collapse initiator includes a weakened region in the wall of the tubular portion.

The collapsible member may further include a head section at a forward end portion of the columnar section. The head section may include an end wall which is P:\WPDOCSIGXS\LNMOO7,Spoci\TOYOTA MOTOR CORP AUST I 12 Mrch_1 2 I871_MutM-luigl nbly for vdicle doc-3/282007 -4disposed laterally with respect to the longitudinal axis of the columnar section and side O walls which extend from the end wall and are operatively connected to the columnar section. Preferably, the side walls are spaced apart and inclined with respect to the longitudinal axis of the columnar section.

00 The weakened zone may be in the form of a notch in the wall of the tubular portion.

Preferably, two notches are arranged in opposite walls of the tubular portion at a INDforward end thereof. In the case where the cross sectional shape of the tubular portion is square or rectangular the notches are formed in one pair of opposed walls and the side walls of head section are each secured to a respective side wall of the other pair of opposed walls. Preferably, the side walls of the head section are connected to the columnar section in the region of the weakened zone.

In use, the head section is adapted to transform a longitudinal impact force into a force with a transverse impact component, and impart that transverse component to the columnar member, initiating collapse before the buckling load for the column would normally be reached. In example embodiments a collapse load is within a range of about 50kN 240kN.

In one preferred form the operative connections at the ends of the columnar section include, at the forward end, a plate and at a rearward end, a second plate. Preferably, the plate is integral with the head section at the first end of the collapsible member.

Brief Description of the Drawings In order to enable a clearer understanding of the invention, drawings illustrating example embodiments are attached, and in those drawings: Figure 1 is an isometric view of the mounting assembly according to the present invention, operatively connected to a chassis rail of a suitable vehicle; Figure 2 is an isometric exploded view of the embodiment of the mounting assembly P\WPDOCSGXS\LNM\2007\Spc TOYOTA MOTOR CORP AUST\I12 Mwch_1219687t _Moutilu tswnlbly fo vhicl doc-3/282007 shown in Figure 1.

Detailed Description of the Preferred Embodiments Referring to the drawings there is shown a mounting device for operatively mounting a vehicle protective member to a vehicle, the vehicle having a chassis. The mounting device is generally indicated at 10 includes collapsible body 12 in the form of a laterally extending columnar member or bar 13 of hollow rectangular cross-section, for absorbing impacts during for example a vehicle collision. The mounting device may be fitted to a vehicle in which air bags or other supplemental restraints having impact detection are installed. The mounting assembly is adapted to absorb impact force and can thereby reduce the undesired deployment of the supplemental restraints. The hollow columnar member or bar 13 includes opposed ends, upper and lower walls 41 and 44, and lateral side walls 42 and 43.

The mounting device 10 further includes a collapse initiator 14, disposed generally at a first end 9 of the collapsible member 12. The collapse initiator 14 includes a head section 16 in the form of a saddle-shaped element 17 having a transversely-extending plate 24 and side walls 15 and 19 which incline towards columnar side walls 42 and 43 of columnar member or bar 13. The collapse initiator 14 also includes a weakened zone 18 in the form of a notch in a forward region of upper 41 and lower 44 walls of the hollow columnar member or bar 13.

The mounting device 10 is operatively connected to a protective bar at the first end 9 and to a vehicle chassis at the second end 8. The head section 16 has a plurality of holes therein through which bolts (not shown) can be passed. A mounting plate 26 is provided at the second end having holes for receiving bolts for attachment to the vehicle chassis.

In operation, a generally longitudinal impact force (essentially in a direction extending between plate 24 and second plate 26) will be imparted to a protective bar (not shown), bolted to the first end, at 20, of the support device. The collapse initiator 14, in what may be considered a first phase, then employs the head section 16 to transform the longitudinal impact force into a force with a transverse component, generally inwards. The collapse P WPDOC XS \LNM\2OTpci\TOYOTA MOTOR CORP AUSTI 2 Machl 21%971 Mo n lin g bly fo chicle do-3/28/2007 -6initiator 14 then imparts that transverse force inwards into side walls 42 and 43 of the hollow columnar member or bar 13 at an intermediate longitudinal position along the weakened zone so that controlled collapse of the hollow columnar member or bar 13 occurs. In so doing, the buckling strength of the collapsible body 12 is reduced to a O 5 generally known level by the presence of the weakened zone 18, and in operation collapse is initiated so that the largest impact force distributed through to chassis member 34 is generally below the threshold of activation of supplemental restraint systems which may IDbe fitted to the vehicle, in this case 240kN. In this manner, a generally even collapse of the hollow columnar member or bar 13 is provided, without pronounced force peaks during collapse of the collapsible body 12, reducing the likelihood of deployment of air bags or supplemental restraints during low-energy collisions.

A coupling assembly is provided which operatively connects the mounting assembly to the vehicle chassis. The assembly includes a connector member 31 in the form of a chassis pin bolt 32 which when installed extends from a first connection region at plate 26, and extends through an aperture in plate 26 and threadably connects at a second connection region to an anchor element in the form of chassis pin 30 which is itself mounted at a point on the chassis rail 34 which is inboard of chassis weakening portions 35. The chassis pin 30 extends when installed between opposed walls of the chassis member, and includes an alignment means being a square shaft to mate and correspond with a square hole in one wall of the chassis 34. The alignment region is provided so that the chassis pin bolt 32 is easily aligned with a female threaded hole in the pin 30. The coupling assembly transfers the application of winching forces from an outboard end of the chassis rail to a stronger portion of the chassis rail 34 disposed inboard of the weakening portions 35. This has the advantage that elongation of the chassis rail 34 is reduced during winching, so that the crumple characteristics of the chassis rail 34 are not substantially modified, and also weld fatigue on some welds and other connections in the region of the outboard end of chassis rail 34 is reduced.

To install the coupling assembly, the underside of the head of the chassis pin bolt 32 (and/or a washer) is tightened against the forward end of the second plate 26. In this installed position, the hollow of the columnar member or bar 13 is disposed forward of the bolt 32 head. In the event of a collision, this bolted connection provides a compression force bypass section intermediate the two ends of the chassis pin bolt 32 P:\WPDOCSGXS'LNMU007\SpeciTOYOTA MOTOR CORP AUST 12 Mach 12196871_Mounllg assnbly for vehicle doc-3/2/20)7 -7which simply allows the chassis rail 34 and collapsible member 12 to collapse, and the collapse is not excessively interfered with by the coupling/winching connection. The bolt head merely slides away from the forward end of the second plate 26.

00 5 Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated integer or step or N group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

Finally, it is to be understood that various alterations, modifications and/or additions may be incorporated into the various constructions and arrangements of parts without departing from the spirit or ambit of the invention.

Claims

1. A coupling assembly suitable for connecting a protective bar mounting device to a vehicle which includes a chassis member having a plurality of weakened zones disposed proximal an outboard end of the chassis member, the coupling assembly IO including: a connector member which is adapted to connect the protective bar mounting device at a first connection region disposed outboard and adjacent the chassis member; the connector member also adapted to connect to the chassis at a Ssecond connection region disposed generally inboard of the weakened zones, so that tensile forces such as winching forces applied to the protective bar mounting device are transferred to the chassis member inboard of the weakened zones.

2. A coupling assembly in accordance with claim 1 wherein the connector member includes a pin bolt which is arranged so that in an installed position it extends generally along an axis extending between forward and rearward ends of the vehicle body.

3. A coupling assembly in accordance with claim 1 or 2 wherein the connector member includes a compression force bypass section disposed intermediate the first and second mounting regions so that compression forces are absorbed by the protective bar mounting device and/or the weakened zones of the chassis.

4. A coupling assembly in accordance with any one of claims 1 3 wherein the coupling assembly includes an anchor element which includes a connector member mounting region for mounting the connector member at the second mounting region, and a chassis mounting region for mounting the anchor element to the chassis member. A coupling assembly in accordance with claim 4 wherein the anchor element is a pin which when installed extends between the opposed walls of the chassis member and the chassis mounting region includes an operative connection for connecting the pin to opposed walls of the chassis member.

P:\WPDOCS XS\LNM\2007'Sp.TOYOTA MOTOR CORPAUSTII2 Mrch_12196871_Monling 8slobly fo vehicle doc-3128/2007 -9-

6. A coupling assembly in accordance with claim 4 or 5 wherein the anchor element includes a threaded hole to mount the second end of the connector member. 00

7. A coupling assembly in accordance with claim 6 wherein an alignment means is provided to cooperate with the chassis member operative connection to align the \pin with the connector member for ease of mounting the pin bolt in the threaded hole.

8. A coupling assembly in accordance with any previous claim wherein the winching loads are distributed to a position between approximately 100mm and 400mm rearward of the mounting assembly.

9. A coupling assembly in accordance with claim 3 wherein the compression bypass section includes a bolt head at the first connection region which is adapted to bear against a forward face of a protective bar mounting plate when installed so that the plate is released to travel inboard under compression loading.

A method of connecting a protective bar mounting device to a vehicle which includes a chassis member having a plurality of weakened zones disposed proximal an outboard end of the chassis member, the method including the steps of: connecting a connector member to the protective bar mounting device at a first connecting region disposed outboard and adjacent the chassis member; and connecting the connector member to the chassis member at a second connection region disposed generally inboard of the weakened zones so that tensile forces such as winching forces applied to the protective bar mounting device are transferred to the chassis away from the weakened zones.

11. A method in accordance with claim 10, the method including the step of connecting an anchor element to the connector member; and connecting the anchor element to opposed walls of the chassis member.

12. A method in accordance with claim 10, the method including the step of P:\WPDOCS'GXS\LNM\200TSpcci\TOYOTA MOTOR CORP AUST\12 Mch_ 12196871 _Mounlng unlbly for vchicle doc.3/28/2007 connecting the connecting member to a front face of a mounting plate of the protective bar mounting device, so that the mounting plate is released when compression forces are applied to the protective bar mounting device. 00 5

13. A vehicle including: a chassis member having a plurality of weakened zones disposed proximal an outboard end of the chassis member; a protective bar mounting device attached to the chassis member; and a coupling device for IN coupling the mounting device to the chassis member, the coupling device including a connector member connected to the protective bar mounting device at a first connection region disposed outboard and adjacent the chassis member, the connector member also connected to the chassis at a second connection region disposed generally inboard of the weakened zones, so that tensile forces such as winching forces applied to the protective bar mounting device are transferred to the chassis member inboard of the weakened zones.

14. A vehicle in accordance with claim 13 wherein the coupling device includes an anchor element which comprises a connector member mounting region for mounting the connector member at the second mounting region, and a chassis mounting region for mounting the anchor element to the chassis member.

A vehicle in accordance with claim 14 wherein the anchor element is in the form of a pin which when installed extends between opposed walls of the chassis member and the chassis mounting region includes an operative connection for connecting the pin to the opposed walls of the chassis member.

16. A vehicle in accordance with any one of claims 13 15 wherein the connector member includes a compression force bypass section disposed intermediate the first and second mounting regions so that compression forces are absorbed by the protective bar mounting device and/or the weakened zones of the chassis.

17. A vehicle in accordance with claim 14, 15 or 16 wherein the anchor element includes an alignment means to cooperate with the chassis member operative connection to align the pin with the connector member for ease of mounting the connector member in the anchor element. 00 P \WPDOCSOXS\LNM\2007 SpcdiXTOYOTA MOTOR COPPAUST\12 Mxch_12196371_Mmnm~g dssoblym tovchick c. 2f2007 -11 I-

18. A coupling assembly substantially as hereinbefore described with reference to the drawings. 5

19. A vehicle substantially as hereinibefore described with reference to the drawings.