Abstract: An energy-absorbing system includes two formed and sealed components bonded together to form crush boxes that entrap air for controlled distribution during an impact, and an activator system adapted to extend the crush boxes in the event of a vehicle crash. Channels interconnect the crush boxes for optimal control of lateral flow of air for lateral energy distribution. The components can be thermoformed, injection molded, or otherwise formed. By this arrangement, the crush boxes provide a first level of static energy absorption when impacted in an undeployed state such that energy is absorbed at a first rate and stroke. Also, the crush boxes can be extended to provide a second level of static energy absorption when impacted in a vehicle crash (i.e., the activator system is energized and the crush boxes extended or “deployed”) such that energy is absorbed at a one or more different rates and strokes.

Abstract: An energy absorber includes a base flange and elongated crush boxes that to form a substantially continuously face surface on the energy absorber. Back straps are attached across a back of the crush boxes to prevent unacceptable spreading of the side walls of the crush boxes during an impact. The back straps can be integrally formed when the energy absorber is molded, and can include a living hinge at one end and a free end that can be bent over and snap attached during post-molding assembly without additional secondary operations. Alternatively, a separate wall-stabilizing thermoformed component is sandwiched between the energy absorber and beam.

Abstract: A hybrid bumper system includes a polymeric reinforcement beam with end sections and structural covers attached to the end sections to considerably strengthen the end sections. Bracketry stably supports the reinforcement beam on a vehicle frame. A fascia covers at least part of the reinforcement beam but leaves a portion of the structural covers in a visible position. The structural covers are treated for aesthetics, such as by painting, chroming, or other surface treatment. In one aspect, the beam includes a molded polymeric beam component, structural L-shaped covers attached to its end sections, and a tie bar along its rear side that stiffens and rigidifies a center of the polymeric beam component. In another aspect, a tow bar or rail-to-rail metal reinforcement beam front system (or rear with tow bar) is incorporated.

Abstract: A bumper system includes a tubular beam (21) and a thermoformed energy absorber with crush boxes (23) formed into a base flange, such as by vacuum or thermal forming processes. The crush boxes have planar energy-absorbing sidewalls a depth of about 10 mm to 35 mm, wall thickness of about 1 mm to 3 mm, and are formed from polyethylene or other thermoform materials having a memory. The base flange can include thermoformed features engaging recesses in the beam, and is combinable with injection-molded or foam energy absorbers for design flexibility. In one form, the energy absorber includes a thermoformed first sheet forming crush boxes and a second sheet bonded to the first sheet to define apertured air pockets. Related methods of manufacture and impacting are also disclosed.

Abstract: A bumper system includes a bumper beam having a face and ends, and an energy absorber mounted on the face. The energy absorber has a one-piece injection-molded non-foam piece with box sections and interconnecting straps, and a one-piece or multi-piece foam component securely insert-molded onto the injection-molded non-foam piece. Different foam molds can be used to form differently shaped front surfaces on the foam component. By this arrangement, different energy absorbing systems are provided for vehicles, such as to satisfy the need for different styling and shapes, while still using the same non-foam piece. By this arrangement, the energy absorber is a single unit that can be handled and attached to the bumper beam. At the same time, capital investment in molding dies and tooling is reduced.

Abstract: Standardized bumper testing includes a barrier adapted for testing vehicle bumper impact strength and engagement. The present improvement includes first and/or second thermoformed components attached to the barrier to replicate a profile and crush characteristics of a “generic” vehicle bumper. The first face component is an energy absorbing component with crush boxes for impact absorption, and replicates an energy absorber. The second component covers the first component and replicates a fascia.

Abstract: A bumper system includes a tubular beam and a thermoformed energy absorber with crush boxes formed into a base flange, such as by vacuum or thermoforming processes. The crush boxes have planar energy-absorbing sidewalls a depth of about 10 mm to 35 mm, wall thicknesses of about 1 mm to 3 mm, and are formed from polyethylene or other thermoform materials having a memory. The base flange can include thermoformed features engaging recesses in the beam, and is combinable with injection-molded or foam energy absorbers for design flexibility. In one form, the energy absorber includes a thermoformed first sheet forming crush boxes and a second sheet bonded to the first sheet to define apertured air pockets. A method of manufacture includes providing a plurality of separately usable thermoformed energy absorbers which can be used in conjunction with a common vehicle structure to vary the absorption characteristics of a vehicle bumper.

Abstract: A bumper system includes a beam having mounts adapted for mounting the beam to a vehicle, and a thermoformed energy absorber positioned on a face of the beam for distributing impact energy prior to deformation of the beam. The bumper system further includes a fascia support having a first section with a rear concave surface matably engaging a front surface of the energy absorber and a second section with fascia attachment structure adapted for securing a fascia to the fascia support in a supported position. By constructing different fascia supports, different fascia can be supported on the same beam and energy absorber combination, thus saving tooling costs and reducing the number of different parts that must be inventoried.