Abstract: A bumper system includes a structural polymeric reinforcement beam and one or more trim components covering visible portions of the beam. The beam has a center section forming a step, and end sections that form corners of the vehicle. The trim component(s) is a thin, lightweight component surface finished for aesthetics. The beam includes functional features, such as a storage pocket with lockable cover, lighting and accessory mounts, electrical connectors for connection to trailer wiring, remote vehicle electrical power, and/or a hidden tow hook. The bumper system is configured to provide a class II hitch, but via add-on components, can be made to be Class III or IV.

Abstract: A bumper system includes primary and secondary structural cross beams, at least one having an S-shaped cross section with forwardly-facing (or outwardly-facing) top concavity. The beams include different arrangements of stiffening ribs in concavities formed by the S-shaped cross section for impact and bending strength. In one form, the beams are made of polymeric material. The beams may include integrally formed crush cans for attachment to the vehicle frame, or alternatively can be attached to vehicle frame rail tips by separate metal crush cans and brackets.

Abstract: A computer controlled roll-forming apparatus is adapted to provide a repeating pattern of different longitudinal shapes to a continuous beam “on the fly” during the roll-forming process. A sweep station of the apparatus includes a primary bending roller tangentially engaging the continuous beam along the line level and an armature for biasing the continuous beam against the primary bending roller for a distance partially around a downstream side of the primary bending roller to form a sweep. Actuators adjustably move the armature partially around the downstream side of the primary bending roller between multiple positions for imparting a series of different longitudinal shapes. Internal and external mandrels control wall stability to allow even sharper sweeps. In one form, the apparatus also includes a coordinated cut-off, so that when separated into bumper beam segments, the ends of the individual beam segments have a greater sweep than their center sections.

Abstract: An energy management structure includes an elongated polygonal tube with at least four walls, the tube having a larger first end and a smaller second end, at least two of the walls including a longitudinally-extending channel-shaped tapered rib starting at the smaller second end and extending toward the larger first end. The ribs become shallower near the larger first end. The walls include crush initiators so that the ribs do not provide undesired strength to the tube during a longitudinal impact. A related method includes roll-forming a polygonal tubular shape with at least four walls, at least two of the walls including longitudinally-extending channel-shaped ribs, and reforming the tubular shape into a tapered polygonal shape with a larger end and a smaller end, the ribs becoming shallower as the ribs extend closer to the larger end.

Abstract: A bumper system includes a tubular reinforcement beam and a pair of crush towers for mounting the beam to frame rails of a vehicle frame. The illustrated crush towers are formed from top and bottom stamped halves to form a pocket for receiving the ends of the beam, and further to form a crush tower for controlling impact energy communicated to the vehicle frame rails. Still further, the crush towers include an outboard portion forming a structural corner of the bumper system, the structural corner being constructed with crush initiators to provide optimal tuned corner impact characteristics. The combination of the beam 11 and towers 12 forms a bumper system taking advantage of roll forming (or extruding) of a rigid structural beam and a stamped mounting system.

Abstract: A computer controlled roll-forming apparatus is adapted to provide a repeating pattern of different longitudinal shapes to a continuous beam “on the fly” during the roll-forming process. A sweep station on the apparatus includes a primary bending roller tangentially engaging the continuous beam along the line level and an armature for biasing the continuous beam against the primary bending roller for a distance partially around a downstream side of the primary bending roller to form a sweep. Further, actuators adjustably move the armature at least partially around the downstream side of the primary bending roller between at least first and second positions for imparting multiple different longitudinal shapes into the continuous beam. In one form, the apparatus also includes a coordinated cut-off, so that when separated into bumper beam segments, the ends of the individual beam segments have a greater sweep than their center sections.

Abstract: A B-shaped tubular reinforcement beam for vehicle bumper systems has a constant B section and longitudinal sweep. The tubular beam has a vertical cross section defining at least first and second tubes connected by a center web, and a front wall that extends across the tubes and the center web to define a channel. The channel has a depth dimension (D1) to the center web of about 15-30 mm, and preferably about 20 mm depth. The first and second tubes on their channel-side portion each include a section of wall defining a radius (R1) that is between about 15-30 mm, and preferably 25 mm.

Abstract: A one-piece dunnage bar for a dunnage rack of the type used to store and transport parts within an automotive factory. The dunnage bar includes integral inner and outer C-shaped portions roll-formed from a single piece of structural metal. The inner and outer portions each include overlying wall segments that cooperate to define the mouth of the C shape. The thickness of each of these wall segments is one-half of the thickness of the remainder of the walls so that the pancaked wall segments have a combined thickness approximately the same as that of the remaining walls.

Abstract: Specification discloses a dunnage bar for a dunnage rack of the type used to store and transport parts within an automotive factory. The dunnage bar includes an outer C-shaped bar and an inner T-shaped bar both roll-formed from structural metal. The inner bar is closely received within and spot-welded to the outer bar. The stem of the inner bar engages the outer bar opposite the mouth and includes spaced webs permitting a welding fixture to be inserted through the mouth and between the webs. The cross arms of the inner bar also engage the outer bar and include spacer webs at their terminal edges to space the inner bar from the mouth of the outer bar.

Abstract: A bumper beam includes an open front section made from a high-strength material such as ultra-high-strength steel (UHSS) material, and further includes a mating back section made of lower-strength material attached to a rear side of the front section along abutting flanges. The front and back sections combine to define different tubular cross sections. The front section can be roll-formed, and the back section can be stamped, thus taking advantage of roll-forming processes' ability to form high-strength materials, while allowing the back section to have a more complicated shape and be stamped. The abutting flanges telescopingly overlap in a fore-aft direction of the vehicle and are welded together at locations that potentially experience shear upon impact, but the flanges of the front section are captured within the flanges of the backs section, thus providing impact strength even if the attachment locations shear off.