Abstract: A bumper reinforcement beam includes a beam having a length and mounts at ends of the beam and cross sectional shapes at various locations along the length, including a first cross sectional shape near ends of the beam providing a first bending moment and a second cross sectional shape at a center of the beam providing a second bending moment different than the first bending moment, and further including intermediate cross sectional shapes between the ends and center having intermediate bending moments between the first and second bending moments. The cross sections may define open C-shapes or may include a tubular shape.

Abstract: A hybrid impact beam, suitable for use as a reinforced impact beam in vehicle bumpers, includes an extruded aluminum section, a fiber reinforced polymeric (FRP) section, and a structural adhesive bonding them together. The components are arranged so that during an impact, the aluminum section experiences compression and receives the direct impact, the FRP section experiences tension, and the adhesive experiences minimal stress by being on a neutral plane of the beam's bending moment. The extruded aluminum beam is preferably extruded as an open section, but becomes a closed section when the polymeric section is attached. The FRP section is preferably a continuous carbon fiber reinforced polymeric section, although different reinforcements can be used. A related method includes bonding an extruded aluminum and fiber-reinforced polymeric section together to form a closed bumper impact beam.

Abstract: A bumper reinforcement beam includes a beam having a length and mounts at ends of the beam and cross sectional shapes at various locations along the length, including a first cross sectional shape near ends of the beam providing a first bending moment and a second cross sectional shape at a center of the beam providing a second bending moment different than the first bending moment, and further including intermediate cross sectional shapes between the ends and center having intermediate bending moments between the first and second bending moments. The cross sections may define open C-shapes or may include a tubular shape.

Abstract: A structural beam includes a reinforcement beam having a length and mounts at ends of the beam and cross sectional shapes at various locations along the length, including a first cross sectional shape near ends of the beam providing a first bending moment and a second cross sectional shape at a center of the beam providing a second bending moment different than the first bending moment, and further including intermediate cross sectional shapes between the ends and center having intermediate bending moments between the first and second bending moments. The cross sections may define open C-shapes or may include a tubular shape.

Abstract: A structural beam includes a reinforcement beam having a length and mounts at ends of the beam and cross sectional shapes at various locations along the length, including a first cross sectional shape near ends of the beam providing a first bending moment and a second cross sectional shape at a center of the beam providing a second bending moment different than the first bending moment, and further including intermediate cross sectional shapes between the ends and center having intermediate bending moments between the first and second bending moments. The cross sections may define open C-shapes or may include a tubular shape.