Abstract: A storage unit is anchored in a truck bed with an attachment system incorporating side modules forming a track for easy pull-out and yet security when moved to a storage position within the truck bed. The storage unit and/or the side modules have recesses and components shaped for function and utility, as well as security and yet easy access. For example, the side modules can include a stationary light, a pull-out spot light, an electrical plug, a storage recess with a lockable cover, and/or a tool-holding recess. The storage unit includes functionally-shaped walls, pull-out containers and drawers, repositionable dividers for the storage recess, a lockable cover, handles to facilitate carriage, wheels for rolling transport, walls with external cable anchors for tying down items, and/or an air deflector/spoiler. The side modules can be releasable for use as a suitcase-like separate unit.

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 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: 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: An energy-absorbing system includes a tube made of a continuous polymeric material. The tube has first and second tube sections connected by an intermediate tube section. By this arrangement, upon the bumper system receiving a longitudinal impact, the first and second tube sections telescopingly collapse with a predictable and consistent rolling collapse.

Abstract: An integrated, single piece upper fascia support member and bumper energy absorber, wherein the upper fascia support member is structured to provide attachments for various attached parts of a motor vehicle, and wherein the upper fascia support member is integrally connected to the bumper energy absorber of the motor vehicle via a load isolator. The load isolator connects the upper fascia support member to the bumper energy absorber in a fixed position relative to each other (assuming relative loading is below a predetermined threshold) and manages a load applied, relatively, to one of the upper fascia support member and the bumper energy absorber such as to cause relative movement, from adversely affecting the other, as, for example, keeping vehicle damage to a minimum in the event of an untoward impact event.

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 for a vehicle comprising a stamped metal component and a second polymeric component fixedly attached to form a beam with particular localized energy absorber characteristics. The metal component is formed from a sheet and has a thickness in a width direction along a majority of the length when in a vehicle-mounted position. The second polymeric component engages a face of the first component and is rigidly attached to the first component in at least several locations along the length to form a structural beam with the first component. The second polymeric component has sufficient structure to form an integral part of the structural beam and interconnected walls extending in the width direction to form energy-absorbing cells at centered and corner locations configured to crush and absorb energy upon a vehicle impact.

Abstract: A tube comprising an outer tube section with a stepped outer surface and an inner tube section, with the inner tube section being located within the outer tube section. The tube also comprises a spanning section connecting an end of the outer tube section to an end of the inner tube section. The outer tube section is longer than the inner tube section, whereby, upon undergoing a longitudinal impact, the outer tube section crushes predictably and sooner than the inner tube section upon the energy management tube receiving forces from the longitudinal impact, to thereby create a first energy absorption level during crushing of the outer tube section alone and a second energy absorption level during crushing of the outer tube section and the inner tube section.

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 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.

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: 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: 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: An integrated, single piece upper fascia support member and bumper energy absorber, wherein the upper fascia support member is structured to provide attachments for various attached parts of a motor vehicle, and wherein the upper fascia support member is integrally connected to the bumper energy absorber of the motor vehicle via a load isolator. The load isolator connects the upper fascia support member to the bumper energy absorber in a fixed position relative to each other (assuming relative loading is below a predetermined threshold) and manages a load applied, relatively, to one of the upper fascia support member and the bumper energy absorber such as to cause relative movement, from adversely affecting the other, as, for example, keeping vehicle damage to a minimum in the event of an untoward impact event.

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 vehicle bumper system includes a beam and a thermoformed energy absorber positioned on a face of the beam. The thermoformed energy absorber has a plurality of elongated crush boxes thermoformed from a base flange. Crush boxes near a center of the beam are up to about three inches deep, and as a result have side walls that are stretched when thermoformed, while crush boxes near ends of the beam are much shorter and hence not as thin. As a result, the center area has a softer impact intended to reduce pedestrian injury during impact.

Abstract: A bumper system for a vehicle comprises a beam having a face and having mounts adapted for mounting to a vehicle frame, and an energy absorber engaging the face and having end sections located outboard of ends of the beam, the energy absorber being made of a structural engineering polymeric material and the end sections having flat top surfaces for forming steps outboard of the ends of the beam.

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. Related methods of manufacture and impacting are also disclosed.