Abstract: An energy absorber includes a base sheet and a plurality of recovering crush lobes extending from the base sheet. The crush lobes protect an adjacent object by cushioning the blow following repeated impacts in both vehicular and non-vehicular (e.g. helmets) environments. Each crush lobe includes a side wall that is oriented to buckle or bend and then spring back after absorbing energy when impacted. At least one of the base sheet and an end wall of at least one crush lobe optionally includes a number (X) of integrally-formed protruding countermeasures where 0<=X<1000 of lower standing strength than the crush lobes. Methods related to the above are also described.

Abstract: An energy absorber includes a base sheet and a plurality of recovering crush lobes extending from the base sheet. The crush lobes protect an adjacent object by cushioning the blow following repeated impacts in both vehicular and non-vehicular (e.g. helmets) environments. Each crush lobe includes a side wall that is oriented to buckle or bend and then spring back after absorbing energy when impacted. At least one of the base sheet and an end wall of at least one crush lobe optionally includes a number (X) of integrally-formed protruding countermeasures where 0<=X<1000 of lower standing strength than the crush lobes. Methods related to the above are also described.

Abstract: An energy absorber includes a base sheet and a plurality of crush lobes extending from the base sheet. Each crush lobe includes a side wall oriented to crush and collapse to absorb energy when impacted in a first direction and includes an end wall. At least one of the base sheet and the end wall of at least one crush lobe includes an integrally-formed protruding countermeasure of lower standing strength than the crush lobes so that the protruding countermeasure acts to dampen movement causing buzzes, squeaks and/or rattles between the end wall and an adjacent structure. The countermeasure can be integrally formed or an insert, such as a magnet or other insert. Methods related to the above are also described.

Abstract: A display sign for use with a display system includes a thermoplastic sheet having a first region having a first thickness, a second region having a second thickness less than the first thickness, and at least one fastener. The second region is adjacent to the fastener. A volume of material in the fastener plus a volume of material in the second region is generally equivalent to a volume of material in an area of the first region, the area of the first region being equivalent to the area of the second region. A method of forming a display sheet includes providing a thermoplastic sheet, and drawing at least one fastener from the thermoplastic sheet while in a plastic state. The material drawn from the sheet to form the at least one fastener results in a region of reduced thickness of the sheet adjacent to the respective fastener.

Abstract: A thermoformed product formed during a thermoforming process includes a thermoformed sheet of polymeric material having front and rear surfaces defining a thickness, and having a first section thermoformed to include a non-planar three-dimensional useful structure and at least one second section. Each of the at least one second sections have a first area of reduced thickness and have a second area including attachment structure, with the attachment structure being formed in part by material extruded from the first area into the attachment structure while the polymeric material of the sheet is hot during the thermoforming process.

Abstract: A thermoforming process capable of coining and flowing material is provided, such as for making a thermoformed energy absorber for self-attachment to a vehicle bumper beam. The energy absorber includes a thermoplastic sheet with first thickness shaped by a thermoforming process to include a base and lobes configured to absorb energy. The sheet further has integrally formed attachments with solid heads formed from material flowed from adjacent areas into the attachment during the thermoforming process. Many other structures can be formed, such as ringed ridges, thinned regions, snap-attachments, hooks, living hinges, bosses, and the like. The present invention further includes an apparatus and a method for accomplishing the above, such as a heater for heating the sheet, and a die for stretching and shaping the sheet, where heated material is flowed by opposing coining die components to form selectively-shaped 3D structures.

Abstract: An energy absorber includes a base sheet and a plurality of crush lobes extending from the base sheet. Each crush lobe includes a side wall oriented to crush and collapse to absorb energy when impacted in a first direction and includes an end wall. At least one of the base sheet and the end wall of at least one crush lobe includes an integrally-formed protruding countermeasure of lower standing strength than the crush lobes so that the protruding countermeasure acts to dampen movement causing buzzes, squeaks and/or rattles between the end wall and an adjacent structure. The countermeasure can be integrally formed or an insert, such as a magnet or other insert. Methods related to the above are also described.

Abstract: A thermoformed product formed during a thermoforming process includes a thermoformed sheet of polymeric material having front and rear surfaces defining a thickness, and having a first section thermoformed to include a non-planar three-dimensional useful structure and at least one second section. Each of the at least one second sections have a first area of reduced thickness and have a second area including attachment structure, with the attachment structure being formed in part by material extruded from the first area into the attachment structure while the polymeric material of the sheet is hot during the thermoforming process.

Abstract: A thermoforming process capable of coining and flowing material is provided, such as for making a thermoformed energy absorber for self-attachment to a vehicle bumper beam. The energy absorber includes a thermoplastic sheet with first thickness shaped by a thermoforming process to include a base and lobes configured to absorb energy. The sheet further has integrally formed attachments with solid heads formed from material flowed from adjacent areas into the attachment during the thermoforming process. Many other structures can be formed, such as ringed ridges, thinned regions, snap-attachments, hooks, living hinges, bosses, and the like. The present invention further includes an apparatus and a method for accomplishing the above, such as a heater for heating the sheet, and a die for stretching and shaping the sheet, where heated material is flowed by opposing coining die components to form selectively-shaped 3D structures.