US20010015559A1 - Push bar mounting system - Google Patents

Abstract

A push bar mounting system for mounting a push bar to vehicle's bumper without significant damage to the bumper. The system comprises a front and rear bracket mounted to an inner bumper of the vehicle and having top and bottom mounting tabs that extend away from the inner bumper. The brackets are configured to attach to the inner bumper without drilling mounting holes therein. Additionally, the mounting tabs are configured to extend through a bumper fascia that surrounds the inner bumper. As such, the bottom mounting tab extends through a grille opening in the fascia, and the upper mounting tab extends through a small horizontal opening cut out of the bumper fascia's chrome trim channel. Upon removal of the push bar from the vehicle, the opening cut in the bumper fascia can be covered by replacing the chrome trim that is mounted in the trim channel.

Description

FIELD OF THE INVENTION
• The present invention generally relates to push bars for vehicles and more specifically to a mounting system for such a device that does not significantly damage the bumper of the vehicle to which the push bar is mounted.[0001]
BACKGROUND OF THE INVENTION
• Push bars are mounted on law enforcement vehicles to protect the front of the vehicle while pushing stranded vehicles off the roadway. Such devices are well known and are commonly mounted to the front bumper of such vehicles. The push bar usually comprises a generally vertical member mounted to the bumper of the vehicle. The vertical member is typically fabricated from a metallic material with the necessary strength to support the resistance of another vehicle during pushing. Typically, the vertical member will have a rubber coating or bumper applied to the surface that contacts the stranded vehicle. Usually, two push bars are mounted on either side of the vehicle's front grille in order to properly push a stranded vehicle.[0002]
• In order to further protect the front of the law enforcement vehicle, the two vertical members can be interconnected by two generally horizontal members disposed in front the vehicle's grille and configured to form a grille guard. Additionally, the push bar may comprise two generally horizontal tubular members that wrap around the front ends of the vehicle to form a wrap around brush guard that adds further protection thereto. As will be recognized to those of ordinary skill in the art, the push bar/grille guard is not limited to just law enforcement vehicles but may be mounted to any vehicle for protection thereof. As such, the push bar/grill guard may be mounted on off-road vehicles or tow trucks.[0003]
• The push bar is essential for proper law enforcement activities. It allows the law enforcement official to use his/her vehicle to push stranded or damaged vehicles during emergency situations. The push bar ensures that the grille and bumper of the law enforcement vehicle will not be damaged during such maneuvers.[0004]
• The typical law enforcement vehicle is specially outfitted with police accessories such as emergency lights, police computer, heavy duty engine and suspension. The bumper unit of a typical vehicle is formed from two members and is used for mounting the push bar thereon. The first member is an outer, purely decorative fascia that integrates the styling of the vehicle to the bumper unit. The second member is an inner metallic bumper disposed within the fascia and attached to the frame of the vehicle. The inner bumper is configured to absorb impacts and therefore has the necessary strength and rigidity to mount the push bar thereon. The bumper fascia is secured to the front of the vehicle and over the inner bumper via plastic push fasteners.[0005]
• The conventional push bar is typically mounted to the inner bumper and bumper fascia of the law enforcement vehicle. As such, mounting and/or access holes must be drilled into the bumper and the bumper fascia. Therefore, the conventional push bar is difficult to install because the holes in the bumper and bumper fascia must be perfectly positioned and aligned. Typically, installation takes about two hours and must be performed by a professional in order to insure proper installation.[0006]
• Currently, law enforcement vehicles are replaced quite often due to the wear from constant use. Therefore, after having been used, the law enforcement vehicle is re-sold at auction to the public. However, the conventional mounting of push bars necessitates the replacement of the bumper and bumper fascia when the push bar is removed prior to resale. The mounting holes drilled in the bumper weaken the bumper such that it is not safe for use. Additionally, the holes created in the bumper fascia necessitate replacement thereof because such holes detract from the vehicle's appearance. Therefore, when a law enforcement vehicle is re-sold, typically the vehicle's bumper and bumper fascia are replaced. However, this is not desirable because it adds additional expense to the cost of the used law enforcement vehicle.[0007]
• The present invention addresses the above-mentioned deficiencies in conventional push bar mounting methods by providing a mounting system that does not significantly damage the vehicle's bumper. Therefore, the present invention does not necessitate replacement of the vehicle's bumper or bumper fascia and provides a system for mounting a push bar that is quick and simple to install. Additionally, the present invention may be adapted for installation of push bars and other accessories to protect other types vehicles, not just law enforcement vehicles.[0008]
SUMMARY OF THE INVENTION
• The present invention is a push bar mounting system for a vehicle bumper having a front and rear side. The system comprises a first, generally C-shaped front bracket formed complementary in shape to the bumper and having a first mounting tab. The first front bracket is generally disposed proximate to the front side of the bumper. Additionally, the system further comprises a first, generally planar rear bracket, formed complementary in shape to the rear side of the bumper, and having a second mounting tab. The first rear bracket is disposed proximate to the rear of the bumper and attached to the first front bracket. Furthermore, in accordance with the present invention, there is provided a first generally vertical push bar member mechanically attached to the first and second mounting tabs and disposed proximate to the front of the vehicle so as to prevent damage thereto during pushing maneuvers. The first and second mounting tabs are configured to project outwardly from exit openings in a bumper fascia that covers the bumper. As such, the first mounting tab exits the fascia through an opening removed from the bumper fascia and the second mounting tab exits through a grille opening of the fascia.[0009]
• The push bar mounting system may further include a second generally vertical push bar member that is attached to a second front bracket via a third mounting tab and second rear bracket via a fourth mounting tab similar to the first push bar member. As such, the first and second vertical push bar members comprise a protective push bar system for the front of the vehicle.[0010]
• The push bar mounting system constructed in accordance with the present invention may further include a first and second horizontal grille guard member. As such, the first and second horizontal grille guard members are attached to the first and second vertical push bar members to form a protective grille guard for the front of the vehicle.[0011]
• The present invention further includes a method of mounting a push bar to a vehicle bumper having a fascia cover. The method comprises the step of first removing the fascia from the bumper. Next, a section of the fascia is removed to provide an opening therein. Front and rear brackets are attached to the bumper such that the bumper is disposed therebetween. Both brackets provide mounting tabs for attaching a generally vertical push bar thereto. Next, the bumper fascia is re-attached to the bumper such that one of the bracket mounting tabs projects through the opening formed therein and the other mounting tab projects through a grille opening of the fascia. Finally, a generally vertical push bar member is attached to the mounting tabs in order to protect the front of the vehicle from damage. It is contemplated in the present invention that a second vertical push bar member is attached to the bumper in a similar fashion as the first member. Additionally, the method of mounting the push bar to the vehicle may further comprise mounting a first and a second generally horizontal grille member between the push bar members in order to form a grille guard.[0012]
BRIEF DESCRIPTION OF THE DRAWINGS
• These as well as other features of the present invention, will become more apparent upon reference to the drawings wherein:[0013]
• FIG. 1 is a perspective view of a push bar assembly, grille guard and wraparound brush guard mounted to a law enforcement vehicle;[0014]
• FIG. 2 is a perspective view of a bumper fascia with push bar mounting tabs projecting therethrough;[0015]
• FIG. 3 is a perspective view of a set of push bar mounting brackets;[0016]
• FIG. 4 is a top plan view of the push bar mounting brackets attached to an inner bumper;[0017]
• FIG. 5 is a partial cut-away view of a push bar mounting bracket;[0018]
• FIG. 6 is a side plan view of the push bar assembly.[0019]
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
• Referring now to the drawings wherein the showings are for purposes of illustrating a preferred embodiment of the present invention only, and not for purposes of limiting the same, FIG. 1 perspectively illustrates a[0020]push bar assembly10 mounted to the front of alaw enforcement vehicle14. The mounting system described herein can be adapted for any type ofvehicle14 that is used to push other vehicles. Presently, the typical law enforcement vehicle is a Ford Crown Victoria and theassembly10 may be adapted for use on such vehicles.
• The[0021]push bar assembly10 protects the front of thelaw enforcement vehicle14 from damage that may be caused by pushing another vehicle during emergencies or mechanical breakdowns. Typically, the law enforcement vehicle will use twopush bar assemblies10 mounted on both sides of a grille16. As such, eachpush bar assembly10 comprises at least one generally verticalpush bar member18 configured to extend generally proximate the grille and/or front lights of thevehicle14. Thepush bar member18 is configured to protect the front ofvehicle14 from damage and is therefore mounted in front of adecorative bumper fascia12. Thepush bar member18 extends in a generally vertical direction such that thelaw enforcement vehicle14 may push vehicles with varying bumper heights without damage to either thelaw enforcement vehicle14 or the vehicle being pushed.
• In the preferred embodiment of the present invention, as seen in FIG. 1, two[0022]push bar assemblies10 can be interconnected by a top horizontalgrille guard member20 and a bottom horizontalgrille guard member22 in order to protect the grille16 ofvehicle14 from damage. The topgrille guard member20 is mechanically attached to the top end of eachpush bar member18, while the bottomgrille guard member22 is attached near the middle of eachpush bar member18. Thegrille guard members20 and22 are typically attached to each verticalpush bar member18 through the use of a threaded fastener in order to facilitate installation thereof or through a welded joint. The configuration of each of the verticalpush bar members18 and the top and bottomgrille guard members20,22 protect the grille area of thevehicle14 from damage. Additionally, the bottom and topgrille guard members20,22 provide a location to install lights, winches, tow hooks and any other type of emergency equipment and thepush bar member18 andgrille guard members20,22 may be pre-drilled for installation of such accessories. Furthermore, as will be recognized by those of ordinary skill in the art, the top and bottom horizontalgrille guard members20,22 may extend around the front ends of thevehicle14 to form awraparound brush guard24. As such, thegrille guard members20,22 wrap around the front of thevehicle14 and are configured to prevent damage to the lights ofvehicle14.
• In accordance with the preferred embodiment of the present invention, each[0023]push bar member18 may be formed from two generally planar sections of metallic material attached perpendicular to each other to form a generally T-shaped cross section. Therefore, as will be recognized, the two sections may be welded or attached to each other through conventional means. Arubber strip26 may be applied to a vehicle contact surface of eachpush bar member18. Thestrip26 may be attached through the use of an adhesive or slid over the T-shaped cross section as is commonly known. Therubber strip26 prevents damage to the vehicle being pushed by thelaw enforcement vehicle14. Additionally, in order to protect thepush bar assembly10 from harsh environmental conditions, all of the parts are fabricated with a rugged, black, powder coat finish.
• Referring now to FIG. 6, the[0024]push bar assembly10 comprises afront bracket28 and arear bracket30 and thepush bar member18 mounted thereto. Thefront bracket28 and therear bracket30 are attached to each other such that thebrackets28,30 compress an innermetallic bumper32 disposed behind thebumper fascia12. Thefront bracket28 is provided with atop mounting tab34 for attachment of thepush bar member18 and similarly therear bracket30 is provided with abottom mounting tab36 for attachment ofpush bar member18. Theinner bumper32 is attached to thevehicle14 in a conventional fashion and protects the front ofvehicle14 from damage. Thebumper fascia12 surrounds theinner bumper32 with enough space therebetween such that the front andrear brackets28,30 may be attached to theinner bumper32 without deforming thebumper fascia12.
• As seen in FIG. 5, the[0025]front bracket28 wraps around afront side38, abottom wall40 and atop wall42 of theinner bumper32 in a generally C-shaped configuration. As such, thefront bracket28 is fabricated from a generally planar section of metallic material and is formed to be complementary to the exterior shape of theinner bumper32. Thetop mounting tab34 is a generally horizontal section of material attached to the front mountingbracket28 such that the top mountingtab34 projects outwardly from thefront side38 of theinner bumper32 at a prescribed location. Thetop mounting tab34 is formed with at least one mounting hole for attachment of thepush bar member18. Thefront bracket28 additionally comprises atop attachment portion46 that projects rearward from thetop wall42 ofinner bumper32, and abottom attachment portion48 that projects downwardly from thebottom wall40 ofinner bumper32. Both the top andbottom attachment portions46,48 comprise mounting holes formed therein for mounting thefront bracket28 to therear bracket30.
• The[0026]rear bracket30 is formed from a generally planar section of metallic material such that it can abut arear side50 of theinner bumper32. Therear bracket30 comprises atop attachment portion52 for mounting therear bracket30 to thetop attachment portion46 of thefront bracket28. Thebottom mounting tab36 ofrear bracket30 is generally vertical and formed such that it projects away from thefront side38 of thebumper32 at a prescribed height below thebottom wall40. Thebottom mounting tab36 is formed with at least one mounting hole drilled therein for attachment of the verticalpush bar member18. Furthermore, therear bracket30 is formed with abottom attachment portion54 for mounting therear bracket30 to thefront bracket28.
• As best seen in FIG. 3, the[0027]front bracket28 is attached to therear bracket30 through the use of threaded fasteners. As such thetop attachment portion46 of thefront bracket28 is attached through the use of abolt56,washer58 andnut60 to the correspondingtop attachment portion52 of therear bracket30. Similarly, thebottom attachment portion48 of thefront bracket30 is attached to the correspondingbottom attachment portion54 of therear bracket30. This attachment method allows thebrackets28,30 to be rigidly attached to theinner bumper32 at a prescribed location without having to remove nor drill suchinner bumper32. Therefore installation of thebrackets28,30 can be easily accomplished.
• The[0028]inner bumper32 of the illustratedvehicle14 is curved such that afront portion62 projects forward of the the ends64. As such, when afront bracket28 and arear bracket30 are mounted thereon, thetop mounting tab34 and thebottom mounting tab36 must be angled so that thepush bar member18 is parallel to the front of thevehicle14. Therefore, as seen in FIG. 4, the top andbottom mounting tabs34 and36 are angled such that they are parallel to a longitudinal axis of thevehicle14. As such, by angling the top and thebottom mounting tabs34,36, two bracket sets66,68 are created for corresponding sides of the vehicle. As seen in FIGS. 3 and 4, the passenger or right-hand-side bracket set66 is created and a driver or left-hand-side bracket set68 is created by angling the mountingtabs36,34 toward thecenter portion62 of theinner bumper32. Thebottom mounting tab36 ofrear bracket30 is attached to an edge of therear bracket30 closest to thecenter portion62 of theinner bumper32. However, as will be recognized by those skilled in the art, thebottom mounting tab36 may be attached to any edge of therear bracket30 so long as thebottom mounting tab36 projects forward from theinner bumper32 at a prescribed location for mounting the verticalpush bar member18 as will be explained in greater detail below.
• In order to mount the[0029]push bar assembly10 to thevehicle14 without substantial modification or damage thereto, the top andbottom mounting tabs34,36 are configured to exit thebumper fascia12 through openings therein. Therefore as seen in FIG. 2, thebottom mounting tab36 is configured to exit the bumper fascia at a prescribed location whereat agrille opening76 is formed in thefascia12. As such, thefascia12 does not need to be modified for thebottom mounting tab36. However, thebumper fascia12 will need to be slightly modified to provide an opening for the top mountingtab34. A smallhorizontal exit opening70 is created in thefascia12 in order for the top mountingtab34 to project outwardly from theinner bumper32 when thefascia12 is placed thereover. As such thetop mounting tab34 is configured to exit thebumper fascia12 at a location whereat theexit opening70 is formed in ahorizontal channel72 for chrome trim74 of thebumper fascia12. Therefore, as seen in FIG. 2, a small section of thechrome trim74 is removed, as well as an underlying section of thebumper fascia12. Removal of these sections allows thetop mounting tab34 to project outwardly from thebumper fascia12 through theexit opening70 created thereby. With the top andbottom mounting tabs34,36 projecting outwardly from thebumper fascia12, the verticalpush bar member18 may be installed thereon.
• As seen in FIGS. 1 and 6, the vertical[0030]push bar member18 is attached to the top andbottom mounting tabs34,36 via threaded fasteners. As such, verticalpush bar member18 comprises a horizontal, top mountingflange78 that attaches to the horizontaltop mounting tab34. Thetop mounting flange78 comprises mounting holes positioned in a location corresponding to the mounting holes in thetop mounting tab34. The verticalpush bar member18 also comprises abottom mounting hole80 corresponding to the mounting hole in thebottom mounting tab36. Therefore, thevertical member18 is mounted to the top andbottom mounting tabs34,36 at the top mountingflange78 and thebottom mounting hole80 with threaded fasteners. As will be recognized by those of ordinary skill in the art, the top andbottom mounting tabs34,36 may be configured to mount the verticalpush bar member18 in varying ways as long as thepush bar member18 comprises a corresponding attachment member.
• The removal of a section of[0031]chrome trim74 andbumper fascia12 are the only permanent modifications made to thevehicle14 during installation of thepush bar member18. As such, upon removal of thepush bar member18, and the front andrear brackets28,30 for resale of thevehicle14, thebumper fascia12 will not need to be replaced. Since theopening70 is formed in thechannel72 for thechrome trim74, theopening70 can be covered by replacing thechrome trim74. Thebumper fascia12 is not structurally integral for the performance of theinner bumper32, such that theexit opening70 can be covered withtrim74 without detriment to the safety ofvehicle14. Therefore, the only part that will need replacement upon removal of the pushbar mounting system10 and resale of thevehicle14 is thechrome trim74. The cost of replacing thechrome trim74 is far less than replacing theinner bumper32 and thebumper fascia12 and therefore is more economical upon resale of thevehicle14.
• The push[0032]bar mounting system10 is very simple to install in under twenty-five minutes. First thebumper fascia12 is removed from thevehicle14 by detaching the plastic push fasteners securing thefascia12 tovehicle14. Next, the front and rear mountingbrackets28,30 are rigidly fastened to theinner bumper32 using the threadedfastener56, and correspondingwasher58 andnut60. Both a right-hand-side66 and a left-hand-side68 set of brackets are installed on corresponding sides of theinner bumper32. The front28 and rear30 brackets fit over theinner bumper32 such that thebumper32 does not need to be removed. The location where each of the top mountingtabs34 exit thebumper fascia12 is determined and theexit opening70 is formed therein for each left and right hand set ofbrackets66,68. Theexit opening70 is formed by first cutting away about three inches of the chrome trim74 at the prescribed location with a utility knife and then cutting away theunderlying fascia12 in thetrim channel72. Theexit opening70 must be formed within thetrim channel72 so that theopening70 is not noticeable when the trim74 is replaced for resale ofvehicle14. Theopening70 must be formed on both the left-hand-side and the right-hand-side ofbumper fascia12 if two pushbar mounting systems10 are being used. Thefascia12 is then reinstalled on thevehicle14 with thelower mounting tab36 projecting through agrille opening76 and the upper mountingtab34 projecting through theexit opening70 formed in thefascia12. Next, the verticalpush bar member18 is installed to thetop mounting tab34 and thebottom mounting tab36 for each set of mountingbrackets66,68.
• Additional modifications and improvements of the present invention may also be apparent to those of ordinary skill in the art such as adapting the push[0033]bar mounting system10 for use on other types of vehicles and with other types of accessories. Thus, the particular combination of parts described and illustrated herein is intended to represent only certain embodiments of the present invention, and is not intended to serve as limitations of alternative devices within the spirit and scope of the invention.

Claims (14)

What is claimed is:

1. A push bar mounting system for a bumper of a vehicle, said bumper having a front exterior and a rear exterior, said system comprising:

a first front bracket formed complementary in shape to the front exterior and having a first mounting tab;

a first rear bracket formed complementary in shape to the rear exterior and having a second mounting tab, the first rear bracket attached to the first front bracket such that the bumper is disposed therebetween; and

a first elongate push bar member attached to the first and the second mounting tabs, the first push bar member disposed generally vertically in front of the vehicle to prevent damage thereto.

2. The push bar mounting system of

claim 1

wherein the first and second mounting tabs are configured to extend through a respective exit opening situated in a fascia associated with the bumper.

3. The push bar mounting system of

claim 2

wherein:

the first front bracket is generally C-shaped; and

the first rear bracket is generally planar.

4. The push bar mounting system of

claim 1

further comprising:

a second front bracket formed complementary in shape to the front exterior and having a third mounting tab;

a second rear bracket formed complementary in shape to the rear exterior and having a fourth mounting tab, the second rear bracket attached to the second front bracket such that the bumper is disposed therebetween; and

a second elongate push bar member attached to the third and the fourth mounting tabs, the second push bar member disposed generally vertically in front of the vehicle.

5. The push bar mounting system of

claim 4

wherein:

the second front bracket is generally C-shaped; and

the second rear bracket is generally planar.

6. The push bar mounting system of

claim 4

further comprising a first generally horizontal grille guard member attached to the first and the second push bar members.

7. The push bar mounting system of

claim 6

further comprising a second generally horizontal grille guard member attached to the first and the second push bar members.

8. The push bar mounting system of

claim 7

wherein the first and second push bar members and the first and second horizontal grille guard members are configured to form a grille guard.

9. The push bar mounting system of

claim 4

wherein the first, second, third and the fourth mounting tabs are configured to extend through a respective exit opening situated in a fascia associated with the bumper.

10. A method of mounting a push bar to a vehicle bumper having a fascia cover, comprising the steps:

a) removing the fascia cover from the bumper;

b) removing a section of the fascia to provide an opening therein;

c) attaching a first front mounting bracket with a first mounting tab to a first rear mounting bracket with a second mounting tab such that the bumper is disposed between the first front and first rear brackets;

d) attaching the fascia to the bumper such that the first mounting tab projects through the fascia opening and the second mounting tab projects through a grille opening of the fascia; and

e) attaching a first generally vertical push bar member to the first and second mounting tabs.

11. The method of

claim 10

wherein:

step (b) further comprises removing a second section of the fascia to provide a second opening therein;

step (c) further comprises attaching a second front mounting bracket with a third mounting tab to a second rear mounting bracket with a fourth mounting tab such that the bumper is disposed between the second front and second rear brackets;

step (d) further comprises attaching the fascia to the bumper such that the third mounting tab projects through the second opening and the fourth mounting tab projects through a grille opening of the fascia; and

step (e) further comprises attaching a second generally vertical push bar member to the third and fourth mounting tabs.

12. The method of

claim 11

further comprising the step of:

f) attaching a first generally horizontal grille guard member to the first and second vertical push bar members.

13. The method of

claim 12

further comprising the step of:

g) attaching a second generally horizontal grille guard member to the first and second vertical push bar members.

14. The method of

claim 10

wherein said fascia of step (b) comprises a section of a fascia trim channel.

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