Abstract: A vehicle bumper includes a hollow tubular wall structure adapted to span the front or rear end of an automotive vehicle so as to absorb crash forces when the vehicle is involved in a crash situation at vehicle speeds above some predetermined speed level, e.g., five miles per hour. The hollow tubular wall structure includes an outer wall disposed to receive the crash force, an inner wall connectable to the vehicle, and four connector walls joining the outer wall to the inner wall. The four connector walls bend at a controlled rate to absorb crash energy. The outer and inner walls have aligned air openings adapted to conduct ram air to the vehicle radiator.

Abstract: A one-piece blow molded bumper end cap is provided for use in combination with a vehicle bumper assembly. The bumper end cap functions as an end plug to enhance air flow into the engine compartment when used in combination with a flow-through bumper. The bumper end cap also includes structural features which improve the crashworthiness of the bumper system in lower speed corner impacts, as well as, higher speed frontal impacts.

Abstract: An elongated tubular bumper beam for an automotive vehicle is of box-like cross-section. The bumper beam has upper and lower walls connected by outer and inner walls. A reinforcing web of generally S-shaped configuration interconnects the outer and inner walls. The bumper beam is preferably made of a lightweight material such as aluminum, magnesium or plastic.

Abstract: A bumper structure includes an elongated rollformed tubular vehicle bumper beam. The bumper beam is fabricated of ultra-high strength steel and has a plan view sweep value of more than 10. A relatively thick layer of energy absorbing foam material covered by a facia overlies the bumper beam. The foam material is thickest at the center portion and decreases in thickness towards the longitudinal ends of the bumper beam.

Abstract: A rollformed tubular vehicle bumper beam is fabricated of ultra-high strength steel and has a plan view sweep value of more than 10. The bumper beam has a cross-sectional configuration comprising an upper wall, a lower wall, an outer wall, and an inner wall. Inner portions of the upper and lower walls are angled, respectively, downwardly and upwardly. This configuration permits fabrication of the bumper beam by rollforming without stretching the outer wall to a point where it would be damaged.

Abstract: A rollformed tubular vehicle bumper beam is mounted on a vehicle. The bumper beam is fabricated of ultra-high strength steel and has a plan view sweep value of more than 10. The bumper beam has a cross-sectional configuration comprising an upper wall, a lower wall, an outer wall, and an inner wall. Inner portions of the upper and lower walls are angled, respectively, downwardly and upwardly. This configuration permits fabrication of the bumper beam by rollforming without stretching the outer wall to a point where it would be damaged. The position of the bumper beam on the vehicle is adjustable vertically, transversely, and longitudinally with respect to the vehicle.