AU2003271290B2

AU2003271290B2 - Mounting assembly for vehicle protective members

Info

Publication number: AU2003271290B2
Application number: AU2003271290A
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: 2003-12-19
Publication date: 2007-05-24
Anticipated expiration: 2023-12-19
Also published as: AU2003271290A1

Description

Our Ref: 12196871 P/00/011 Regulation 3:2

AUSTRALIA

Patents Act 1990

ORIGINAL

COMPLETE SPECIFICATION STANDARD PATENT Applicant(s): Toyota Motor Corporation Australia Limited of 2-28 Alexander Avenue Taren Point, New South Wales 2229 Australia Address for Service: DAVIES COLLISON CAVE Patent Trade Mark Attorneys Level 10, 10 Barrack Street SYDNEY NSW 2000 Invention Title: The following statement is a performing it known to me:- Mounting assembly for vehicle protective members full description of this invention, including the best method of 5020 10-05-'07 14:22 FHOM-DCC SYDNEY 626200T99 F5/3 F-0 -61292621080 T-299 P005/032 F-230 MAWPV0CGXW UpoCIcAS I2I9Ohi aadkbi s I0-t47 dao-IWALOO7 MOUNTING ASSEMBLY FOR VEHICLE PROTECTIVE MEMBERS Field of the Invention This invention relates generally to the mounting of protective members to vehicles.

The expression "protective members" includes for example bumper bars, builbars and other protective members which are adapted to protect a vehicle body in the event of impact collisions.

0 Backuronud 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 bulibar. Such bulibars 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 possible that chassis members deform, especially where the chassis member is fitted with crumple zones.

The present invention seeks to alleviate one or more of the abovementioned COMS ID No: SBMI-07325794 Received by IP Australia: Time 14:35 Date 2007-05-10 10-0~5-'07 14:22 FBOM-DCC SYDNEY 196W0T29P0/3 -3 +61292621080 T-299 P006/032 F-230 o -2- Ct disadvantages.

Summary of the Invention According to one aspect of the present invention there is provided a mounting apparatus for mounting a protective bar to a vehicle chassis, the mounting apparatus including: a collapsible member operatively connected to the vehicle chassis at one end of the collapsible member and extending generally outwardly from the vehicle and including a distal region at an outer end thereof; a head section operatively connected to the collapsible member generally adjacent the distal region, the head section being adapted for movement from a standby position, which movement causes buckling of the collapsible member, said head section including at least one collapse initiator member which as result of said movement is urged towards a wall of the collapsible member to cause deformation of a wall of the collapsible member.

Preferably the collapse initiator member includes a connector member for connecting the head section to the collapsible member at a head connection region.

Preferably two connector members are provided so that said movement causes deformation of two walls or two regions of one wall of the collapsible member.

Preferably each connector member is attached to a respective one of opposed walls of the collapsible member so as to facilitate deformnation of the opposed walls of the collapsible member.

Preferably said opposed walls are side walls of the collapsible member.

Preferably the or each connector member is urged generally laterally towards the or the respective walls of the collapsible member.

Preferably the connector member is urged towards the or the respective walls of the collapsible member from externally of the collapsible member.

COMS ID No: SBMI-07325794 Received by IP Australia: lime 14:35 Date 2007-05-10 10-05-'07 14:23 FBOM-DCC SYDNEY +61292621080 T-299 P007/032 F-230 0 3o Preferably the head section includes a connector plate laterally extending between two connector members which angle towards the wall of the connector member so that the head plate causes the connector members to be urged inwards during said movement.

Preferably the collapsible member is a hollow column.

o Preferably the collapsible member includes one or more weakened zones to provide o for a reduced buckling threshold capacity associated therewith.

Preferably one or more weakened zones are disposed adjacent a deformning region of the collapse initiator member where the collapse initiation member initially contacts the collapsible member.

Preferably the weakened zones are disposed adjacent the head connection region.

Preferably the or each weakened zone is disposed at the distal end.

Preferably the or each weakened zone includes a notch in the distal end so as to facilitate deformation of the walls of the collapsible member.

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 -240kN.

A coupling assembly suitable for connecting a mounting assembly for a vehicle protective bar to a vehicle body may be connected to the mounting assembly, the 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 COMS ID Na:SBMI-07325794 Received by IP Australia: Time 14:35 Date 2007-05-10 10-05-' 07 14:23 FBOIY-DCC SYDNEY 62610 T99P8/2F-3 +61292621080 T-299 P008/032 F-230 outboard end of the chassis member, the coupling assembly including: a connector member o 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.

M Preferably the connector member includes a pin bolt which is arranged so that in ainstalled 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 connection 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 connector member.

Preferably 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.

COMS ID No: SBMI-07325794 Received by IP Australia: Time 14:35 Date 2007-05-10 10-05-' 07 14:23 FPOM-DCC SYDNEY +622200T29 P0/3 -3 +61292621080 T-299 P009/032 F-230 o Preferably wherein the winching loads are distributed to a position between approximately 100mm and 400mm rearward of the mounting assembly.

Brief Description of tbe Drawings In order to eniable a clearer understanding of the invention, drawings illustrating example embodiments are attached, and in those drawings: 0 Figure 1 is an isometric view of the mounting assembly according to the present invention 3 operatively connected to a chassis rail of a suitable vehicle' Figure 2 is an isometric exploded view of the embodiment of the mounting assembly shown in Figure 1.

Detailed Description of the Preferred Embodiments Referring to the drawings there is shown a mounting apparatus for operatively mounting a vehicle protective member to a vehicle, the vehicle having a chassis including chassis rail 34. The mounting apparatus is generally inidicated at 10 in a standby position and includes a collapsible member 12 in the form of a longitudinally extending columnar member or bar 13 of hollow rectangular cross-section, for absorbing impacts during for example a vehicle collision. The mounting apparatus 10 may be fitted to a vehicle in which air bags or other supplemental restraints having impact detection are installed. The mounting apparatus 10 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 apparatus 10 further includes a head 14 to initiate collapse and to mount the protective member, disposed generally at a distal end 9 of the collapsible member 12 distal the chassis rail 34. The head 14 includes a saddle-shaped element 17 having a transversely-extending connector plate 24 and side walls or connector members COMS ID No: SBMI-07325794 Received by IP Australia: lime 14:35 Date 2007-05-10 10-05-'07 14:23 EHOM-DOC SYDNEY +6222~0T29 P1/3 -3 -61292621080 T-299 P010/032 F-230 o -6and 19 which incline towards colunmar side walls 42 and 43 of columnar member or o bar 13. The collapsible member 12 also includes a weakened zone 18 in the fonn of a notch adjacent the distal end 9 of upper 41 and lower 44 walls of the hollow columnar member or bar 13 so as to facilitate deformation of walls 42 and 43 during collapse initiation.

The mounting apparatus 10 in use is operatively connected to a protective bar adjacent the distal end 9 and to a vehicle chassis at a proximal end 8 proximal the chassis o rail 34. The head 14 has a plurality of holes therein through which mounting bolts (not shown) can be passed to mount the protective member. A mounting plate 26 is provided at the second end having holes for receiving bolts far attachment to the vehicle chassis.

In operation, during a crash a generally longitudinal impact force (essentially in a direction extending between plate 24 and second plate 26) is imparted to a protective bar (not shown), bolted to the distal end, at 20, of the support device. The head 14, in what may be considered a first phase, then moves from the standby position and in so moving employs the one or more of collapse initiator members or side walls 15 and/or 19 to transform the longitudinal impact force into a force with a transverse component, generally inwards. The side walls 15 and 19 or collapse initiator members then are urged inwards into side walls 42 and 43 of the hollow columnar member or bar 13 at an intermediate longitudinal position along the notch 51 or weakened zone 18 to deform walls 42 and 43 so that buckling and subsequent controlled collapse of the hollow columnar member or bar 13 occurs. In so doing, the buckling capacity of the collapsible body 12 is reduced to a generally known and lower level in part because of the presence of the weakened zone 18, and in operation buckling 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 be 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 member 12, reducing the likelihood of deployment of air bags or supplemental restraints during low-energy collisions.

COMS ID No: SBMI-07325794 Received by IP Australia: Time 14:35 Date 2007-05-10 10-05-' 07 14:24 FBO[1-DCC SYDNEY +622200T29 P1/3 -3 +61292621080 T-299 P011/032 F-230 o-7- A coupling assembly is provided which operatively connects the mounting o 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 hale 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 conniections. 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 which 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.

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 amnbit of the invention.

COMS ID No: SBMI-07325794 Received by IP Australia: Time 14:35 Date 2007-05-10

Claims

10-05-' 07 14:24 FEOII-DCC SYDNEY +622200T29 P1/3 -3 -61292621080 T-299 P012/032 F-230 Clai The claims defining the invention are as follows: I. A mounting apparatus for mounting a protective bar to a vehicle chassis, the mounting apparatus including: a collapsible member operatively connected to the vehicle chassis at one end of the collapsible member and extending generally outwardly from the vehicle and including a distal region at an outer end thereof;, a head section operatively connected to the collapsible member generally adjacent the distal region, the head section being adapted for movement from a standby position, which movement causes buckling of the collapsible member, said head section including at least one collapse initiator member which as result of said movement is urged towards a wall of the collapsible member to cause deformation of a wall of the collapsible member. 2. A mounting apparatus for mounting a protective bar to a vehicle chassis in accordance with claim 1, wherein the collapse initiator member includes a connector member for connecting the head section to the collapsible member at a head connection region. 3. A mounting apparatus for mounting a protective bar to a vehicle chassis according to claim I or 2, wherein two connector members are provided so that said movement causes deformation of two walls or two regions of' one wall of the collapsible member. 4. A mounting apparatus for mounting a protective bar to a vehicle chassis according to claim 3, wherein each connector member is attached to a respective one of opposed walls of the collapsible member so as to facilitate defornation of the opposed walls of the collapsible member. A mounting apparatus for mounting a protective bar to a vehicle chassis according to claim 4, wherein said opposed walls are side walls of the collapsible member. COMB ID No: SBMI-07325794 Received by IP Australia: Time 14:35 Date 2007-05-10 10-05-'07 14:24 FBOM-DCC SYDNEY +62220 T29P1/3 -3 +61292621080 T-299 P013/032 F-230 o -9- 6. A mounting apparatus for mounting a protective bar to a vehicle chassis according to any one of the previous claims, wherein the or each connector member is urged generally laterally towards the or the respective walls of the collapsible member. 7. A mounting apparatus for mounting a protective bar to a vehicle chassis according to claim 6, wherein the connector member is urged towards the or the respective walls of the collapsible member from externally of the collapsible member. o8. A mounting apparatus for mounting a protective bar to a vehicle chassis according to any one of claims 3 to 7, wherein the head section includes a connector plate laterally extending between two connector members which angle towards the wall of the connector member so that the head plate causes the connector members to be urged inwards during said movement. 9. A mounting apparatus for mounting a protective bar to a vehicle chassis according to any one of the previous claims, wherein the collapsible member is a hollow column. A mounting apparatus for mounting a protective bar to a vehicle chassis according to any one of the previous claims, wherein the collapsible member includes one or more weakened zones to provide for a reduced buckling threshold capacity associated therewith.

11. A mounting apparatus for mounting a protective bar to a vehicle chassis according to claim 10, wherein one or more weakened zones are disposed adjacent a defonning region of the collapse initiator member where the collapse initiation member initially contacts the collapsible member.

12. A mounting apparatus for mounting a protective bar to a vehicle chassis according to claim 10 or 11, wherein the weakened zones are disposed adjacent the head connection region. COMS ID No: SBMI-07325794 Received by IP Australia: Time 14:35 Date 2007-05-10 10-05-' 07 14:25 FHOM-DCC SYDNEY+6195130T29P1/2F-3 +61292621080 T-299 P014/032 F-230 0

13. A mounting apparatus for mounting a protective bar to a vehicle chassis according o to any one of claim 10 to 12, wherein the or each weakened zone is disposed at the distal end.

14. A mounting apparatus for mounting a protective bar to a vehicle chassis according to any one of claims 10 to 13, wherein the or each weakened zone includes a notch in the distal end so as to facilitate deformation of the walls of the collapsible member. A mounting apparatus in accordance with any previous claim wherein a coupling device is provided 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.

16. A mounting apparatus in accordance with claim 15 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.

17. A mounting apparatus in accordance with claim 15 or 16 wherein the connector member includes a compression force bypass sectioin 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.

18. A mounting apparatus in accordance with claim 15, 16 or 17 wherein the coupling assembly includes an anchor element which includes a connector member mounting region COMS ID No: SBMI-07325794 Received by IP Australia: Time 14:35 Date 2007-05-10 10-05-'07 14:25 FROM-DCC SYDNEY +61292621080 T-299 P015/032 F-230 0 for mounting the connector member at the second mounting region, and a chassis mounting region for mounting the anchor element to the chassis member.

19. A mounting apparatus in accordance with claim 15, 16, 17 or 18 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. A mounting apparatus for mounting a protective bar to a vehicle chassis, as substantially hereinbefore described with reference to the accompanying drawings. COMS ID No: SBMI-07325794 Received by IP Australia: Time 14:35 Date 2007-05-10