Abstract: A method of making a beam-box crash management system comprises forming a first shell (100a) from a first sheet metal blank by a hot forming process. The first shell has a high tensile strength beam portion (102a) and integrally formed there-with a first low yield strength crash box portion (104a) proximate a first end of the beam portion and second low yield strength crash box portion proximate a second end of the beam portion. The first shell also has an open face extending continuously along the beam portion and each of the first and second crash box portions (104a, 106a). A closing element (100b) is formed from a second sheet metal blank, and is fixedly secured adjacent to the open face of the first shell.

Abstract: A crash box includes a body portion extending from a top edge to a bottom edge along a global z-axis (A) and having a pair of side walls disposed in spaced relationship to one another. At least one x-shaped reinforcing web extends between the side walls along a plane (P) disposed transverse to the axis (A). An extension portion is integral with the body portion and extends outwardly from one of the side walls and is disposed along the plane (P). A flange plate is also integral with the body portion and defines at least one flange plate attachment hole for securing the crash box to a frame of a vehicle.

Abstract: A crash box includes a body portion extending from a top edge to a bottom edge along a global z-axis (A) and having a pair of side walls disposed in spaced relationship to one another. At least one x-shaped reinforcing web extends between the side walls along a plane (P) disposed transverse to the axis (A). An extension portion is integral with the body portion and extends outwardly from one of the side walls and is disposed along the plane (P). A flange plate is also integral with the body portion and defines at least one flange plate attachment hole for securing the crash box to a frame of a vehicle.

Abstract: A method of making a beam-box crash management system comprises forming a first shell (100a) from a first sheet metal blank by a hot forming process. The first shell has a high tensile strength beam portion (102a) and integrally formed there-with a first low yield strength crash box portion (104a) proximate a first end of the beam portion and second low yield strength crash box portion proximate a second end of the beam portion. The first shell also has an open face extending continuously along the beam portion and each of the first and second crash box portions (104a, 106a). A closing element (100b) is formed from a second sheet metal blank, and is fixedly secured adjacent to the open face of the first shell.

Abstract: A method of making a beam-box crash management system comprises forming a first shell (100a) from a fist sheet metal blank by a hot forming process. The first shell has a high tensile strength beam portion (102a) and integrally formed there-with a first low yield strength crash box portion (104a)proximate a first end of the beam portion and second low yield strength crash box portion proximate a second end of the beam portion. The first shell also has an open face extending continuously along the beam portion and each of the first and second crash box portions (104a, 106a). A closing element (100b) is formed from a second sheet metal blank, and is fixedly secured adjacent to the open face of the first shell.

Abstract: A method of making a beam-box crash management system comprises forming a first shell (100a) from a first sheet metal blank by a hot forming process. The first shell has a high tensile strength beam portion (102a) and integrally formed there-with a first low yield strength crash box portion (104a) proximate a first end of the beam portion and second low yield strength crash box portion proximate a second end of the beam portion. The first shell also has an open face extending continuously along the beam portion and each of the first and second crash box portions (104a, 106a). A closing element (100b) is formed from a second sheet metal blank, and is fixedly secured adjacent to the open face of the first shell.