Abstract: A bumper system for mounting to a frame assembly of a motor vehicle at one end of the motor vehicle includes a bumper beam and an energy absorber. The bumper beam includes an upper beam wall, a lower beam wall, and a central beam wall between the upper and lower beam walls. The energy absorber is mounted to the bumper beam and includes an upper absorber wall, a lower absorber wall, and a central absorber wall between the upper and lower absorber walls. The energy absorber has a height that is greater than a height of the bumper beam such that the upper absorber wall is spaced upwardly above the upper beam wall and the lower absorber wall is spaced downwardly below the lower beam wall.

Abstract: The present invention relates to improved methods for manufacturing bumper beam assemblies and bumper beam assemblies made by such methods. One method of the invention allows bumper beams of different longitudinal configurations to be made by selecting open cross-sectioned, roll-formed bumper beam members from different sets of beam members and fixing them to bumper beam mounting structures. The mounting structures close off the open cross-section of the bumper beam members. Another method of the invention allows bumper beams for varying applications to be made by selecting bumper beam members from inventory and fixing them to a bumper beam mounting structure.