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: A bumper system includes a tubular beam with flattened end sections, and further includes an energy absorber having a rear recess mateably receiving the tubular beam in a nested relationship, with the recess also including flat mating surfaces engaging the flattened end sections. Mounts engage a rear of the flattened end sections, and fasteners secure the tubular beam and energy absorber to the mounts. In one modified bumper system, corner sections on the energy absorber are shaped to slidingly engage a side surface of the mount and simultaneously an end of the beam upon corner impact of the vehicle. In another modified bumper system, offset ends of the tubular beam fit into a recess in an energy absorber, with its center section being between vehicle mounts.

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: A bumper system includes a tubular beam with flattened end sections, and further includes an energy absorber having a rear recess mateably receiving the tubular beam in a nested relationship, with the recess also including flat mating surfaces engaging the flattened end sections. Mounts engage a rear of the flattened end sections, and fasteners secure the tubular beam and energy absorber to the mounts. In one modified bumper system, corner sections on the energy absorber are shaped to slidingly engage a side surface of the mount and simultaneously an end of the beam upon corner impact of the vehicle. In another modified bumper system, offset ends of the tubular beam fit into a recess in an energy absorber, with its center section being between vehicle mounts.

Abstract: A bumper system includes a tubular beam having front and rear walls, and a plurality of horizontally-extending walls that interconnect the front and rear walls. An energy absorber has a rear surface with a recess shaped to mateably receive and support the beam, and includes end sections that extend to be coplanar with the rear wall of the beam. The end sections cover the front wall and also at least partially cover a top, bottom and ends of the beam, and are constructed to flex and absorb energy to reduce a likelihood of vehicle damage. In one form, the end sections include honeycomb sections that engage beam mounts to transfer impact energy directly to the mounts. In another form, the end sections include cantilevered flanges that extend outwardly from ends of the energy absorber for impact absorption at the vehicle corners.

Abstract: A bumper includes a beam and an energy absorber supported thereon. The energy absorber includes horizontal walls, each having a front portion, a rear portion, and an interconnecting mid-portion that offsets and misaligns the front and rear portions. Upon impact, the front and rear portions collapse with the offset mid portion wrapping back upon itself with a predictable energy-absorbing collapse. The energy absorber further includes flanges and friction pads that frictionally engage the top and bottom of the beam to temporarily retain the energy absorber to the beam. In one embodiment, the front beam wall includes at least one aperture, and the energy absorber includes a tubular column extending from its front wall through the aperture in the front beam wall to the rear beam wall. By this arrangement, the front wall of the energy absorber receives support from the front beam wall via the structural column.

Abstract: A bumper system for vehicles includes a B-shaped tubular bumper beam with top and bottom mid-walls defining a channel in its front surface. A polymeric energy absorber has multiple box-shaped sections that abut the front surface of the bumper beam and further includes rearwardly-extending nose sections that extend into the channel. The nose sections include collapse-controlling kick walls that lie along the top and bottom mid-walls and that are connected to the box-shaped sections. Upon impact by an object against the bumper system, the kick walls press into the top and bottom mid-walls, resulting in a consistent and controlled collapse of the energy absorber and tubes of the bumper beam. In another form, an energy absorber having box-shaped sections is positioned on a face of the bumper beam and integral box-shaped end sections designed for a consistent and controlled collapse on impact.

Abstract: A bumper system for vehicles includes a B-shaped tubular bumper beam with top and bottom mid-walls defining a channel in its front surface. A polymeric energy absorber has multiple box-shaped sections that abut the front surface of the bumper beam and further includes rearwardly-extending nose sections that extend into the channel. The nose sections include collapse-controlling kick walls that lie along the top and bottom mid-walls and that are connected to the box-shaped sections. Upon impact by an object against the bumper system, the kick walls press into the top and bottom mid-walls, resulting in a consistent and controlled collapse of the energy absorber and tubes of the bumper beam. In another form, an energy absorber having box-shaped sections is positioned on a face of the bumper beam and integral box-shaped end sections designed for a consistent and controlled collapse on impact.