Abstract:
A spring-biased mudflap bracket assembly includes a hollow tube with a mounting plate at a proximate end and a frame seat mating to the mounting plate and yieldably biased into contact with the mounting plate by a spring mounted at one end within the hollow tube and to the frame seat at another end. A vibration-absorbing gasket can be mounted on an outer surface of the frame seat to abut the vehicle frame. A double-headed bolt mounts the spring to the hollow tube. The frame seat has three apertures in alignment, a central one of the apertures having a spacing to an upper aperture different than a spacing to a lower aperture, and a pair of mounting fasteners are received in two of the three apertures for mounting the frame seat to a vehicle frame. A concave perimetrical channel in the frame seat mates with a complementary convex annular projection on the mounting plate to form a pivot socket for the mounting plate with respect to the frame seat. The hollow tube has at least one sidewall including a longitudinal recess in an exterior surface thereof a conspicuity reflector is mounted in the longitudinal recess. The mounting plate has a tube-engaging wall which extends into the hollow tube and supports the proximate end of the hollow tube.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. provisional patent application Serial No. 60/173,589, filed Dec. 29, 1999. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to spring-biased brackets for resiliently mounting mudflaps to a vehicle frame. In one of its aspects, the invention relates to a mudflap mounting bracket formed of a hollow tube from sheet metal and including a mounting plate, a frame seat mating with the mounting plate and yieldably biased to the mounting plate through a spring mounted at one end within the hollow tube and at the other end to the frame seat. In another of its aspects, the invention relates to a mudflap mounting bracket with a vibration absorbing gasket for mounting between the frame seat and the vehicle frame. In another of its aspects, the invention relates to a mudflap mounting bracket which is adapted to mount to several different hole configurations in a vehicle frame. In another of its aspects, the invention relates to a mudflap mounting bracket in which a mudflap bracket is mounted in a frame bracket socket for pivotal movement. In another of its aspects, the invention relates to a mudflap mounting bracket which has a protected conspicuity reflector mounted thereto. In another of its aspects, the invention relates to a mudflap mounting bracket which has the same appearance on each side so that the bracket can be mounted to either side of the vehicle. In another of its aspects, the invention relates to a mudflap mounting bracket in which the tube wall, formed from sheet material, is reinforced at the inner end by the mounting plate. 
     2. Description of the Related Art 
     Mudflap brackets having a horizontal tube with a longitudinal mudflap mounting flange on its underside are known. Such brackets comprise a vehicle frame-mounted plate having bolts or studs of a predetermined, fixed separation, often selected to match existing manufacturer provided apertures in the vehicle frame. A proximate end of the horizontal tube is held against the frame-mounted plate, generally in an abutting relationship, by the bias of an elongate spring residing in the tube, the spring connected at one end to the frame-mounted plate and at the other end to the tube, at a location on the tube distal from the vehicle frame. Other prior art embodiments include a mounting plate fastened to the proximate end of the tube, such as by brazing or welding, the tube abutting the flat mounting plate. The mounting plate will generally include a central aperture to allow passage of the spring from the interior of the tube to the frame-mounted plate. 
     The abutting relationship of the horizontal tube and mounting plate to the frame-mounted plate often results in misalignment of the tube, which occurs when the tube is struck or subjected to the forces experienced by the vehicle travelling down the road. The bias of the elongate spring often cannot overcome the misalignment by itself. Comers or edges between the mounting plate, or tube, and the frame-mounted plate catch or hang up on each other, preventing realignment of the tube. 
     The advent of regulations requiring the addition of conspicuity markers to over-the-road trucks has prompted truck owners and manufacturers to devise ways to provide the required markers on their truck. These solutions include modifying the mudflap brackets to provide additional room for conspicuity markers, providing adapters to attach to the mudflap brackets and carry the conspicuity markers, and taking self-adhesive conspicuity tape such as a retroreflective tape and plastering it over the existing mudflap bracket. These installations can look sloppy, and usually provide minimal protection to the conspicuity markers, resulting in a loss of effectiveness and useful life, thereby increasing cost and maintenance time. 
     It would be advantageous to provide a mudflap bracket that can overcome the disadvantages of the prior art brackets in the alignment of the mudflap bracket when subjected to a displacing load. It would further be advantageous to provide mudflap brackets properly configured to provide conspicuity markers that are properly located and protected to help truck owners comply with the law while increasing the effective life of those markers by properly protecting them from damage. 
     SUMMARY OF THE INVENTION 
     According to the invention, a spring-biased mudflap bracket assembly includes a hollow tube with a mounting plate at a proximate end and a frame seat mating to the mounting plate and yieldably biased into contact with the mounting plate by a spring mounted at one end within the hollow tube and to the frame seat at another end. Optionally, a vibration-absorbing gasket is mounted on an outer surface of the frame seat and adapted to abut the vehicle frame when the bracket assembly is mounted to a vehicle frame. 
     In one embodiment, the outer surface of the frame seat has a recess and the vibration-absorbing gasket is positioned in the recess. The vibration-absorbing gasket is preferably annular. Further, at least one fastener is mounted to the frame seat and projects through the open central portion of the annular gasket. 
     In another embodiment, the frame seat has three apertures in vertical alignment. A central one of the apertures has a spacing to an upper aperture different than a spacing to a lower aperture. A pair of mounting fasteners are received in two of the three apertures for mounting the frame seat to a vehicle frame. Preferably, the three apertures are threaded and the mounting fasteners are threadably received in two of the three apertures. The fasteners can be studs or bolts. 
     In yet another embodiment, a concave perimetrical channel in the frame seat mates with a complementary convex annular projection on the mounting plate. The concave perimetrical channel is preferably arcuate in cross section and forms a socket for the mounting plate when the mounting plate rotates with respect to the frame seat. The frame seat has a central portion that extends axially of the concave perimetrical channel and into the mounting plate, and the central portion includes an eye which extends into the hollow tube. 
     In a preferred embodiment, the hollow tube has at least one sidewall including a longitudinal recess in an exterior surface thereof and a conspicuity reflector mounted in the longitudinal recess. In one embodiment, the vertical face of the hollow tube tapers in height from the proximate end to a distal end. In another embodiment, the vertical face of the hollow tube is substantially uniform in height from the proximate end to the distal end. In another embodiment, a distal portion of the tube is displaced downwardly at an angle from the generally horizontal proximate portion of the tube. 
     In a further embodiment, the hollow tube has opposing vertical faces, each face having a longitudinal recess and a conspicuity reflector mounted in the longitudinal recess, the recess being defined by an overhanging brow and an underlying sill. 
     In another embodiment, a double-headed bolt mounts the spring to the hollow tube. The hollow tube comprises opposing sidewalls, the double-headed bolt passing through aligned apertures in the opposing sidewalls. The double-headed bolt comprises heads presenting a substantially identical appearance on outer surfaces of the sidewalls of the hollow tube. 
     In still another embodiment, the mounting plate has a tube-engaging wall which extends into the hollow tube and supports the proximate end of the hollow tube. The tube-engaging wall bears against an inner surface of the hollow tube and the mounting plate is secured to the hollow tube by welding or embossing. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     In the drawings: 
     FIG. 1 is an exploded perspective partial view of a spring-biased mudflap bracket according to the invention and its relationship to a vehicle frame; 
     FIG. 2 is an exploded perspective view of the spring biased mudflap bracket according to the invention; 
     FIG. 3 is a plan view of a frame seat according to the invention; 
     FIG. 4 is a cross-sectional view taken through line  4 — 4  of FIG. 3; 
     FIG. 5 is a cross-sectional view taken through line  5 — 5  of FIG. 3; 
     FIG. 6 is a plan view of a mounting plate according to the invention; 
     FIG. 7 is a cross-sectional view taken through line  7 — 7  of FIG. 6; 
     FIG. 8 is a side view of an elongate mudflap bracket tube according to the invention; 
     FIG. 9 is a cross-sectional view taken through line  9 — 9  of FIG. 8; 
     FIG. 10 is a further embodiment of a spring-biased mudflap bracket according to the invention; and 
     FIG. 11 is a further embodiment of a spring-biased mudflap bracket according to the invention. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to FIG. 1, a spring-biased mudflap bracket according to the invention is adapted to be mounted to a vehicle frame  100  having a vertical face  104 , the face  104  having a plurality of apertures  102  passing therethrough. While typical vehicle frames  100  have apertures  102  predrilled in a vertical orientation, it is anticipated that the mudflap bracket according to the invention can be adapted to other orientations of apertures  102  in vehicle frame  100 . 
     The bracket comprises a frame seat  10  for mounting to the vehicle frame  100 . Frame seat  10  is secured to vehicle frame  100  by a pair of mechanical fasteners passed through apertures  102 . In the preferred embodiment depicted, the mechanical fasteners comprise a pair of threaded studs  23  attached to frame seat  10  and spaced and adapted to align with the apertures  102  in the vehicle frame  100 . Frame seat  10  is then secured to vehicle frame  100  by a pair of lock washers  106  and nuts  108  threadably received on studs  23 . 
     The mudflap bracket further comprises a mudflap bracket tube  40  and an associated mounting plate  30  that serves as an interface between the tube  40  and the frame seat  10 . The tube  40  comprises a mudflap mounting flange  60  to which a mudflap  90  can be mounted by the securing of mudflap mounting bolts  64  through mudflap mounting flange slots  62  and mudflap apertures  92 . The tube  40  further has at least one conspicuity reflector such as reflex reflector  110  mounted along the length thereof. 
     Referring now to FIG. 2, the mudflap bracket further comprises an intervening gasket  18 , which would be mounted between the frame seat  10  and the vehicle frame  100 . The mudflap bracket tube  40  further comprises a spring retaining bolt  70  and an elongate tension spring  72 , and an end cap  80 . 
     The assembly comprising the tube  40  and mounting plate  30  is retained against the frame seat  10  by the elongate tension spring  72  that extends longitudinally within the tube  40 . The spring  72  has at each of its ends first and second hook-like members  74 ,  76 . The first hook-like member  74  is retained inside the tube  40  by the spring retaining bolt  70  that passes through apertures  49  in side faces  48  of the tube  40 . The second hook-like member  76  is retained by an integral eye  26  of the frame seat  10 . Tension force in the elongate spring  72  draws the tube  40  with its attached mounting plate  30  against the frame seat  10  such that a convex annular perimeter  32  (see FIG. 7) of the mounting plate  30  nests in a concave perimetrical channel  28  of the frame seat  10 . 
     Referring to FIGS. 3-5, starting with the plan view of FIG. 3, the frame seat  10  is generally oval. As further shown in the cross-sectional views of FIGS. 4 and 5, the frame seat comprises a first side  12  that is generally flat to mate with the vehicle frame  100 , the first side  12  having an annular recess  16  for receiving the gasket  18 . The gasket  18  serves as a moisture seal and vibration reducer between the frame seat  10  and the vehicle frame  100 . 
     The first side  12  of the frame seat  10  also carries three aligned threaded apertures  20 ,  21 ,  22 , each adapted to receive one threaded stud  23 . The three threaded apertures  20 ,  21 ,  22  are spaced such that two of the three apertures  20 ,  21 ,  22  will align with the various common aperture spacings found in vehicle frames  100 . 
     The second side  14  of the frame seat  10  has a central raised portion  24  that comprises an integral eye  26 . In the illustrated embodiment, the threaded aperture  21  is aligned with the integral eye  26 , while the threaded apertures  20 ,  22  align with the raised portion  24  outside the area defining the integral eye. A concave perimetrical channel  28  surrounds the central raised portion  24 . 
     The mounting plate  30 , shown in detail in FIGS. 6 and 7, is generally annular in plan view and is generally oval to match the frame seat  10 . The mounting plate  30  comprises a first side  31  and a second side  35 . The first side  31  comprises a convex annular perimeter  32  adapted to flushly mate with the concave perimetrical channel  28  of the frame seat  10 . A second side  35  includes an upstanding tube-engaging wall  36 . In the preferred embodiment shown, the perimeter of the wall  36 , as shown in plan view in FIG. 6, is adapted to match with the inner cross section of the tube  40  (see FIG.  9 ), so that the wall  36  fully supports the tube  40  at proximate end  42 . It is anticipated that the mounting plate  30  can be further adapted to engage the outer surface of the tube  40 . The mounting plate  30  further comprises a central aperture  34  sized to receive the central raised portion  24  of the frame seat  10 , including the integral eye  26  of the frame seat  10 , when the convex annular perimeter  32  is received in the concave perimetrical channel  28  of the frame seat  10 . 
     Referring now to FIGS. 8 and 9, the tube  40  of the mudflap bracket is constructed of a stamped sheet metal and has a proximate end  42  with a cross section adapted to closely correspond to the tube-engaging wall  36  of the mounting plate  30 . The wall  36  provides strength to the tube  40  at proximate end  42 . The tube  40  can be permanently mounted to the mounting plate  30 , such as by welding, embossing, or other well known bonding or mechanical methods. 
     In the cross-sectional view of FIG. 9, the tube  40  is symmetrical about a vertical centerline and can thus be mounted to either side of the vehicle and have the same appearance. The tube includes an arched top  46  and two downwardly projecting side faces  48 . Each of the side faces  48  includes a recess  50  and a mudflap mounting flange  60 . Each of the side faces  48  is bent inwardly at approximately one third the distance from the arched top  46  to form a brow  52 , the brow  52  marking the upper boundary of the recess  50 . The lower boundary of the recess  50  is defined by a sill  54  formed by an outward bending of the side face  48 . The side face  48  is finally bent inwardly and then downwardly to terminate in the mudflap mounting flange  60 . A reflector  110  is shown installed in one of the recesses  50 , for installation on the left side of a vehicle with the reflector  110  facing to the rear of the vehicle. In the alternative, reflector  110  would be installed in the opposite recess  50  for installation on the right side of a vehicle. 
     As shown in FIG. 8, the tube  40  tapers in height from the proximate end  42  to a distal end  44 , the tapering being accomplished by a reduction in the height of the side faces  48  above the recess  50 . The recesses  50  and mudflap mounting flanges  60  remain substantially uniform in height. The mudflap mounting tube  40  remains symmetrical in cross section as it decreases in overall height from the proximate end  42  to the distal end  44 . 
     Each of the side faces  48  has an aperture  49 , the aperture  49  of each side face  48  aligned with the aperture  49  in the opposing side face  48 . The apertures  49  are for receiving the spring retaining bolt  70  therethrough. Referring back to FIG. 2, the bolt  70  has a double-headed bolt having opposing identical heads and telescoping shafts which are threadably joined together through the apertures  49  for a flush mounting against each of the side faces  48 . The bracket can thus be mounted to either side of the vehicle and maintain the same appearance. 
     The mudflap mounting flanges  60  comprise a series of aligned mudflap mounting flange slots  62 . The separation between the mudflap mounting flanges  60  is such that a mudflap  90  can be closely inserted between the mounting flanges  60 , with mudflap apertures  92  in the mudflap  90  aligned with the mudflap mounting flange slots  62 . 
     The recess  50  of each side face  48  has a slot  58  proximate the distal end  44  of the tube  40 . An end cap  80  for covering the distal end  44  of tube  40  comprises two flanges  82  adapted to pass to the interior of the tube  40 . Each of the flanges  82  includes a detent  88  protruding therefrom such that when the flanges  82  are inserted to the inside of the tube  40  at distal end  44 , the detents  88  project outwardly. The flanges resiliently direct the detents  88  into the slots  58  to hold the end cap  80  in place on the distal end  44  of tube  40 . 
     Alternative embodiments of the spring-biased mudflap bracket according to the invention are depicted in FIGS. 10 and 11. Each embodiment is substantially similar to the first embodiment of the invention, in that they each comprise a frame seat  10  and mounting plate  30  as disclosed in FIGS. 3-7. The mounting plate  30  of the first embodiment is modified in that the profile of the tube-engaging wall  36  is modified to match the cross section of the alternative embodiment of the mudflap bracket tubes  140 ,  240  of FIGS. 10 and 11, respectively. In particular, the depending portion of the side faces  48  of the first embodiment have been eliminated, so that the arched top  46  of the tubes  140 ,  240  transitions directly into the brow  52  defining the upper limit of the recess  50 . The cross section of the tubes  140 ,  240  is therefore substantially uniform throughout the length of the tubes  140 ,  240 , rather than the tapered cross section of the tube  40  of the first embodiment. 
     The embodiments of FIGS. 10 and 11 use tubes  140 ,  240 , having substantially the same cross section. The tube of FIG. 10 is substantially straight, having a uniform cross section, while the embodiment of FIG. 11 utilizes a tube  240  having the outer approximate one-third of the tube  240  bent downwardly at an angle to provide clearance where a straight tube would interfere with other parts of the structure of the vehicle. 
     Installation 
     An installer is provided with a substantially assembled mudflap bracket according to the invention. The tube  40  and mounting plate  30  are held to the frame seat  10  by the elongate tension spring  72 , the spring  72  in tension between the spring retaining bolt  70  and the integral eye  26  of the frame seat  10 . At least one reflector  110  can come preinstalled in a recess  50  of a side face  48  of the tube  40 , corresponding to a right or left side installation on the vehicle. In the alternative, the reflector  110  can be placed by the on-site installer into the proper recess  50  to correspond to the side of the vehicle. In a further alternative, reflectors  110  can be preinstalled in both recesses  50  for universal installation of a mudflap bracket according to the invention on either side of a vehicle. 
     Upon receipt of the assembly, the installer will insert threaded studs  23  into the appropriate threaded apertures  20 ,  21 ,  22  on the first side  12  of the frame seat  10 , to match the apertures  102  available in the vehicle frame  100 . The studs  23  will have an interference relationship with the threaded apertures  20 ,  21 ,  22  of the frame seat  10 , such that the threads of the stud  23  will bind in the selected apertures  20 ,  21 ,  22 . In the alternative, the installer will pass bolts (not shown) through the apertures  102  of the vehicle frame  100  so that they extend from the frame face  104 . 
     The installer will then place the frame seat gasket  18  in the annular recess  16  on the first side  12  of the frame seat  10 , and place the frame seat  10  against the vehicle frame  100  so that the studs  23  pass through apertures  102  in the vehicle frame  100 . The vehicle frame  100 , in this preferred embodiment, has a substantially vertical face  104  available for mounting the mudflap bracket. The installer will then secure the mudflap bracket with a lock washer  106  and nut  108 . The mudflap bracket, being symmetrical about the vertical centerline, is universal in application to either the right or the left side of the vehicle frame  100 . 
     Once in place, the mudflap bracket can receive a mudflap  90  between the mudflap mounting flanges  60 , as described above. A mudflap mounting bolt  64  can then be inserted through the mudflap mounting flange slots  62  and the apertures  92  in the mudflap  90  to retain the mudflap  90  between the mudflap mounting flanges  60 . End cap  80  is usually then installed at the distal end  44  of the tube  40 . 
     Operation 
     In use, the mudflap bracket will maintain a generally horizontal orientation. The elongate tension spring  72  is of sufficient strength to maintain the horizontal orientation under the combined weight of the mudflap  90  and mudflap bracket. When the mounting plate  30  is displaced from its generally aligned orientation with the frame seat  10 , such as when the mudflap  90  or mudflap bracket is struck, or when the mudflap bracket bounces out of alignment due to irregularities in the road surface transferred to the vehicle frame  100 , the elongate spring  72  will return the mounting plate  30  to its aligned orientation with the frame seat  10 . The spring  72  is assisted in reaching this objective by the self aligning properties of the mounting plate  30  and the frame seat  10 , specifically the convex annular perimeter  32  of the mounting plate being urged by the elongate tension spring  72  back into the concave perimetrical channel  28  of the frame seat  10 . The absence of sharp edges or corners in the interface between the frame seat  10  and the mounting plate  30  helps to ensure that the mounting plate  30  readily aligns itself with the frame seat  10 . 
     Each of the recesses  50  in the side faces  48  of the tube  40  provides a flat, uninterrupted mounting surface, with the minor exception of the slot  58  proximate the distal end  44 , as described above. This flat mounting surface is sized to receive a reflex reflector  110  of a specified length and width. Reflex reflector  110  is necessary to provide extra conspicuity for the vehicle, and is provided by such reflex reflector products as those produced by STATE-LITE. Reflex reflector  110  installed in recess  50  is advantageously protected along its upper and lower edges by the brow  52  and sill  54  respectively, resulting in a neat installation that will require a minimum of maintenance of the conspicuity reflector. 
     While the invention has been specifically described in connection with certain specific embodiments thereof, it is to be understood that this is by way of illustration and not of limitation. Reasonable variation and modification are possible within the scope of the forgoing disclosure and drawings without departing from the spirit of the invention which is described in the appended claims.