Abstract: A bumper beam for mounting to a frame assembly of a motor vehicle at one end of the motor vehicle includes opposing end portions adapted to be mounted to the frame assembly of the motor vehicle and a centrally disposed intermediate portion extending between the end portions. The end portions and the intermediate portion define an upper wall, a lower wall, and a central wall between the upper and lower walls. The upper and lower walls each have an elongated arcuate flange that extends from a free end of a respective upper and lower wall along a length of the bumper beam. The arcuate flange of each of the upper and lower walls defines an outwardly facing concave surface and an inwardly facing convex surface.

Abstract: A bumper beam for mounting to a frame assembly of a motor vehicle at one end of the motor vehicle includes opposing end portions adapted to be mounted to the frame assembly of the motor vehicle and a centrally disposed intermediate portion extending between the end portions. The end portions and the intermediate portion define an upper wall, a lower wall, and a central wall between the upper and lower walls. The upper and lower walls each have an elongated arcuate flange that extends from a free end of a respective upper and lower wall along a length of the bumper beam. The arcuate flange of each of the upper and lower walls defines an outwardly facing concave surface and an inwardly facing convex surface.

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: 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: A method of hydroforming a reinforced tube comprising providing a metal tubular blank having an interior defined by an inner surface and an exterior defined by an outer surface. A metal reinforcing member is provided and inserted into the interior of the tubular blank. The reinforcing member is engaged with the inner surface of the tubular blank and is attached to the inner surface of the tubular blank. The tubular blank and reinforcing member welded thereto are placed into a hydroforming die having die surfaces defining a die cavity, and pressurized fluid is provided within the tubular blank so as to conform the tubular blank with the die surfaces of the die cavity.