Abstract:
An accessory mounting system for on-road and off-road passenger vehicles, such as light-duty trucks and SUV&#39;s is provided. The system attaches to a vehicle to serve as an extension of the vehicle frame to provide a secure mounting location for vehicle accessories, such as a winch, grille guards, headlamp guards, and lights. The system provides for the attachment of numerous accessory components without modification or replacement of an original equipment bumper.

Description:
FIELD 
       [0001]    The present disclosure relates generally to vehicle accessories for enhancing the styling and functionality of vehicles, and more particularly, to an accessory mounting system that provides secure attachment for a winch or other vehicle accessories. 
       BACKGROUND AND SUMMARY 
       [0002]    This section provides background information related to the present disclosure, which is not necessarily prior art. This section also provides a general summary of the disclosure but not a comprehensive disclosure of its full scope or all of its features. 
         [0003]    Grille guards, also known as brush guards, are common accessories for larger, on-road and off-road passenger vehicles, such as light-duty trucks and SUV&#39;s. Such accessories may add to the aesthetic appearance of the vehicle, serve to protect the front of the vehicle from damage, and provide attachment for other accessory components. 
         [0004]    A winch is another common truck and SUV accessory. A winch is a mechanical device that winds in or lets out a rope, belt, or cable. In light truck and SUV applications, an operator often uses a winch as a pulling device to free a stuck vehicle, such as when operating a vehicle off-road. Typically, the operator attaches an end of a winch cable to a secure object, such as a tree or other vehicle, and engages the winch to draw in the cable. As the winch draws in the cable, it pulls the vehicle toward the secure object, thus freeing the vehicle. 
         [0005]    A winch must attach properly to a vehicle frame to distribute the pulling load and avoid structural damage to the vehicle. Attaching a winch directly to a vehicle frame may not always be possible or desirable, as with most on-road and off-road passenger vehicles, the vehicle frame is not exposed to the outside of the vehicle. In such situations, a winch may attach indirectly to the vehicle frame with mounting brackets or may attach to a bumper or grille guard that is already attached to the vehicle frame. Adding a grille guard may not be possible, such as when a winch is already mounted to a vehicle; the winch mounting hardware and the grille guard often use the same attachment locations on the vehicle frame. 
         [0006]    The system of the present disclosure provides a secure winch mounting attachment to the vehicle frame via a winch carrier and allows for the subsequent addition of a grille guard and other accessories without further attachment to the vehicle frame. 
         [0007]    Bumper replacement systems, often called winch-mount bumpers, can serve as a platform to securely mount vehicle accessories, such as winches, grille guards, lights, and headlamp guards. To install such systems on a vehicle, a factory-installed bumper is removed and replaced with the bumper replacement system. A bumper replacement system can drastically change the aesthetic appearance of the vehicle as the most common bumper replacement systems are steel weldments that do not conform to the more-rounded-shapes of late-model vehicles. 
         [0008]    The system of the present disclosure provides a secure winch mounting attachment to the vehicle frame and allows for the subsequent addition of a grille guard and other accessories without permanently removing the factory-installed bumper. The system of the present disclosure can provide many of the features of bumper replacement systems, while providing a less dramatic change to a vehicle&#39;s aesthetic appearance. 
         [0009]    The system of the present disclosure also provides a removable grille guard, while maintaining the installed winch carrier. While the grille guard may permanently attach to the winch carrier, the system also allows the grille guard to removably attach to the winch carrier. One may choose to remove the grille guard to service the front end of the vehicle or to change the appearance of the vehicle. 
         [0010]    Grille guards that mount to the vehicle frame often comprise two vertical side members and at least one horizontal cross member. Such grille guards are often a multi-piece design to balance manufacturing and shipping costs with often-complex vehicle frame mounting brackets. Flat, vertical side members are a common component of multi-piece, bolt-on grille guards. 
         [0011]    The system of the present disclosure also provides a one-piece grille guard. Because the winch carrier mounts to the vehicle frame the grille guard does not need to provide an interface to the vehicle frame. The interface of the grille guard to the winch carrier can be simple, when compared to mounting the grille guard to the vehicle frame. Because the grille guard of the present disclosure mounts to the winch carrier using a simple interface, more options are available for the design and shape of the grille guard. The system of the present disclosure is not limited to a one-piece grille guard and can accept multi-piece grille guards. 
         [0012]    The system also provides a grille guard that can have a rounded (tubular) cross-sectional appearance. Grille guards of a rounded cross-sectional appearance are often incorporated into bumper replacement systems but are not easily incorporated into bolt-on, grille guard systems. As a one-piece grille guard is a less-complex assembly, rounded materials are easier to incorporate in a design. The system is not limited to a rounded grille guard and can accept grille guards of other cross-sectional shapes. 
         [0013]    The system also provides for attachment of other accessory components to the winch carrier and grille guard. Examples of such accessory components are fairleads, lights, light bars, headlamp guards, and receivers. 
         [0014]    The present disclosure describes the system mounted to light-duty trucks and SUV&#39;s. The system is not limited to use on such vehicles and may apply to vans, sedans, all-terrain vehicles (ATV&#39;s), and tractors, among other vehicle types. 
         [0015]    Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]    The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in anyway. 
           [0017]      FIG. 1A  is an exploded perspective view of a prior art grille guard assembly; 
           [0018]      FIG. 1B  is an exploded perspective view of a prior art grille guard and a winch mount system; 
           [0019]      FIG. 2A  is an exploded perspective view of a winch mounting system, according to the principles of the present disclosure; 
           [0020]      FIG. 2B  is an exploded perspective view of a winch mounting and grille guard system, according to the principles of the present disclosure; 
           [0021]      FIG. 3  is a rear perspective view of a winch mounting and grille guard system, according to the principles of the present disclosure; 
           [0022]      FIG. 4  is an exploded perspective view of a winch mounting and grille guard system having additional accessories shown therewith; and 
           [0023]      FIG. 5  is a perspective view of a winch mounting and grille guard system, according to the principles of the present disclosure, shown installed on a vehicle with additional accessories mounted thereon; and 
       
    
    
     DETAILED DESCRIPTION 
       [0024]    Example embodiments will now be described more fully with reference to the accompanying drawings. 
         [0025]    With reference to  FIGS. 1A and 1B , a prior-art, vehicle grille guard and winch mount system  10  for mounting to a forward end of a vehicle will be described. The vehicle grille guard and winch mount system  10  includes a pair of mounting brackets  12 . Rear mounting flanges  14  of mounting brackets  12  are adapted to securely attach to a vehicle frame  16 . Further reference to the vehicle frame can also include a sub-frame, mounting brackets, or any adaptive mounting feature installed on the vehicle. A plurality of holes  18  incorporated into rear mounting flanges  14  receives fasteners to attach mounting brackets  12  to the vehicle frame  16 . Mounting brackets  12  may take advantage of existing threaded holes on vehicle frame  16  or additional threaded holes may need to be added to vehicle frame  16  to secure mounting brackets  12  to vehicle frame  16 . Forward mounting flanges  20  of mounting brackets  12  are adapted to attach to vertical side members  21 . Vertical side members  21  are often substantially flat components with a plurality of through-holes  22  for attaching to mounting brackets  12  and through-holes  23  for attaching to other components in the grille guard and winch mount assembly  10 . A plurality of holes  24  incorporated into forward mounting flanges  20  receive fasteners to attach mounting brackets  12  to vertical side members  21  using through-holes  22 . At least one horizontal cross-member  30  mounts between vertical side members  21 . Typically, a horizontal cross member  30  is comprised of a tubular component  32  and a pair of mounting inserts  34  each with a threaded hole  36 . A pair of threaded fasteners  37  passes through holes  23  of vertical side members  21  and thread into holes  36  of inserts  34 . The vertical side members  21 , horizontal cross members  30 , and mounting brackets  12  form the grille guard assembly  28 . 
         [0026]    The grille guard assembly  28  serves as an extension of the vehicle frame  16 , upon which additional accessories may mount. One such accessory is a winch carrier  44 , as shown in  FIG. 1B . Winch carrier  44  may comprise mounting holes  46  and a mounting surface  48 . The winch carrier  44  may attach between vertical side members  21  of the grille guard assembly  28 . Typically, fasteners  49  are inserted through holes  23  of the vertical side members  21  and into holes  46  of the winch carrier  44 . Additional accessory components may mount to the grille guard system. An accessory component such as a winch may mount to a surface  48  of winch carrier  44 . Headlamp guards  50  may mount to the vertical side members  21 . Other examples of accessory components will subsequently be described with respect to the present disclosure. 
         [0027]    With reference to  FIGS. 2A ,  2 B, and  3 , a winch mounting and grille guard system  60  will now be described, according to the principles of the present disclosure. The winch mounting and grille guard system  60  includes a pair of mounting brackets  62 . Rear mounting flanges  64  of mounting brackets  62  are adapted to securely attach to a vehicle frame  16 . A plurality of holes  66  incorporated into rear mounting flanges  64  receive fasteners to attach mounting brackets  62  to the vehicle frame  16 . Mounting brackets  62  may take advantage of existing threaded holes on vehicle frame  16  or additional threaded holes may need to be added to vehicle frame  16  to secure mounting brackets  62  to vehicle frame  16 . Forward mounting flanges  68  of mounting brackets  62  are adapted to attach to a winch carrier  70 . A plurality of holes  72  incorporated into forward mounting flanges  68  receive fasteners  73  to attach mounting brackets  62  to holes  74  of winch carrier  70 . Winch carrier  70  and mounting brackets  62  form a winch mounting system  76 . 
         [0028]    The winch mounting system  76  of  FIG. 2A  is comparable to the prior art, grille guard assembly  28  of  FIG. 1A . Both are foundations to mount accessory components. An advantage the winch mounting system  76  offers over the grille guard assembly  28  is only the winch carrier  70  needs to be installed on a vehicle to mount accessory components, such as a winch and auxiliary lights. A grille guard accessory component could optionally be added later, as will be described. The grille guard assembly  28  requires installation of side members  21  and horizontal cross members  30  (forming a grille guard) to be installed on a vehicle before accessory components can be installed. 
         [0029]    The winch carrier  70  may be a welded assembly or a single-piece design that is comprised of three main sections. A first, substantially vertical section  80  forms the frontal section  80   a  and two side sections  80   b . Frontal section  80   a  of vertical section  80  provide for a mounting surface  82 , fairlead passage  83 , accessory mounting holes  84 , and cutouts  86  for weigh reduction or airflow. Side sections  80   b  of vertical section  80  provide for mounting holes  74  for attachment of mounting brackets  62  and accessory components. The vertical section  80  mates to a second section, substantially horizontal bottom section  90 , best shown in  FIG. 3 . Frontal section  80  and bottom section  90  are best joined by welding along the interface  94  of the two components. The top surface of bottom section  90  is defined as mounting surface  96 . The opposite side surface is defined as underside mounting surface  98 . Mounting surface  96  is comprised of features such as grille guard mounting holes  102 , accessory mounting holes  104 , and cutouts  105  for weigh reduction, airflow, and water drainage. Vertical section  80  also mates to a pair of third sections, substantially horizontal upper sections  110 . Sections  110  can be joined to form a single upper section without substantially changing functionality. Frontal section  80  and upper sections  110  are best joined by welding at the interface  112  of the components. Upper sections  110  provide for through-holes  114  to be used for mounting accessory components. 
         [0030]    The winch mounting system  76  serves as an extension of the vehicle frame  16 , upon which additional accessories may mount. One such accessory is a grille guard  120 , as shown in  FIG. 2B . The grille guard  120  of the present disclosure is a round tubular member but can have other shapes as desired. Grille guard  120  is comprised of a substantially horizontal section  120   a , two substantially vertical sections  120   b , and two inserts  122  that serve to mount the grille guard  120  to the winch carrier  70 . 
         [0031]    A grille guard  120  mounts to winch carrier  70  by attaching to mounting surface  96 , as best shown in  FIG. 3 . In one embodiment of the disclosure, the grille guard  120  removably attaches to mounting surface  96  using threaded fasteners  124 . Fasteners  124  pass through holes  102  in mounting surface  96  and into threaded holes  126  of inserts  122 , which are fixedly attached to the grille guard  120 . In another embodiment of the disclosure, the grille guard  120  permanently attaches to mounting surface  96  by means including welding. Grommets  130  are disposed in holes  114  of winch carrier  70 , such that vertical sections  120   b  of grille guard  120  pass through grommets  130 . Grommets  130  aid the stability of the installed grille guard  120  and limit degradation of a protective coating on the grille guard  120 . Grommets  130  also limit noise generated by the grille guard  120  during vibration against upper sections  110 . 
         [0032]    With reference to  FIGS. 4 and 5 , the installation of the winch mounting and grille guard system  60  on the front of a vehicle  140  with additional accessories mounted thereon will now be described. Mounting brackets  62  attach to a frame  16  of a vehicle  140  as previously described (illustrated in  FIG. 2A ). The mounting brackets  62  are configured such that modification of an original equipment bumper  142  may be avoided. Forward mounting flanges  68  of mounting brackets  62  may protrude through existing openings  144  in the bumper  142  or alternatively may protrude from underneath the bumper  142 . Winch carrier  70  attaches to forward mounting flanges  68  of mounting brackets  62  as previously described to complete a winch mounting system  76 . 
         [0033]    Using the winch mounting system  76  as a foundation, additional accessory components may be added. One such accessory component is a grille guard  120 . One function of an installed grille guard  120  is to protect a vehicle grille  146  from damage caused by objects in the path of the vehicle  140 . The grille guard  120  mounted to the winch mounting system  76  together form the winch mounting and grille guard system  60 , previously described. Other accessory components may mount to either the winch mounting system  76  or the winch mounting and grille guard system  60 . 
         [0034]    A winch  150  is another example of an accessory component. Winch  150  attaches to mounting surface  96  of winch carrier  70  (shown in  FIG. 3 ) and secures using threaded fasteners in accessory mounting holes  104 . A fairlead  152  is an accessory component that is often used with a winch. A fairlead guides a winch cable during winch use. Fairlead  152  attaches to surface  82  of frontal section  80   a  of winch carrier  70  using threaded fasteners in accessory mounting holes  84 . 
         [0035]    The present disclosure also includes a light bar  156  adapted to mount to grille guard  120 . Light bar  156  provides a location to securely attach auxiliary lights  158 . Mounting flanges  156   a  of light bar  156  conform to the shape of vertical sections  120   b  of grille guard  120  and include through-holes such that threaded fasteners may secure light bar  156  to grille guard  120 . Light bar  156  removably attaches to grille guard  120  using threaded fasteners or permanently attaches by welding. Auxiliary lights  158  mount to light bar  156  and secure with threaded fasteners. In another embodiment of the disclosure, auxiliary lights may mount directly to winch carrier  70  or may mount to light mounting brackets that attach to mounting surface  96  of winch carrier  70  using accessory mounting holes  84 . More than one accessory component may simultaneously attach to winch carrier  70  using accessory mounting holes  84 . 
         [0036]    Headlamp guards  162  are further examples of accessory components. Headlamp guards  162  serve to protect vehicle headlamps  164  and the surrounding vehicle area from damage by objects in the vehicle path. Headlamp guards  162  removably attach to grille guard  120  and winch carrier  70  using threaded fasteners or permanently attach by welding. Mounting flanges  162   a  of headlamp guards  162  conform to the shape of vertical sections  120   b  of grille guard  120  and include through-holes such that threaded fasteners may secure headlamp guard  162  to grille guard  120 . Mounting flanges  162   b  of headlamp guards  162  conform to the shape of side sections  80   b  of winch carrier  70  and include through-holes such that threaded fasteners may secure headlamp guard  162  to winch carrier  70 . However, the present disclosure also contemplates replacing mounting flanges  162   b  of headlamp guard  162  with a second pair of mounting flanges  162   a  such that headlamp guards  162  attach only to grille guard  120 . 
         [0037]    A front receiver  170  is a further example of an accessory component. Front receiver  170  serves primarily to temporarily mount accessory components. Examples of temporary accessory components are trailer hitch inserts and bicycle racks. Front receiver  170  removably attaches to underside mounting surface  98  of winch carrier  70  using threaded fasteners or permanently attaches by welding. Front receiver  170  is secured using threaded fasteners in accessory mounting holes  84 . 
         [0038]    The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the invention, and all such modifications are intended to be included within the scope of the invention.