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: A bumper system includes a tubular reinforcement beam and a pair of crush towers for mounting the beam to frame rails of a vehicle frame. The illustrated crush towers are formed from top and bottom stamped halves to form a pocket for receiving the ends of the beam, and further to form a crush tower for controlling impact energy communicated to the vehicle frame rails. Still further, the crush towers include an outboard portion forming a structural corner of the bumper system, the structural corner being constructed with crush initiators to provide optimal tuned corner impact characteristics. The combination of the beam 11 and towers 12 forms a bumper system taking advantage of roll forming (or extruding) of a rigid structural beam and a stamped mounting system.

Abstract: A running board system is provided for the light truck market, where a beam of the running board is removable to double as a ramp. For example, a single one of these beams can be used to guide a motorcycle onto a truck bed, or alternatively a pair of these removable beams can be used to provide a ramp for guiding a two wheel cart (e.g., hand truck), four wheel vehicle, or snowmobile onto the truck bed. Optionally, the beam includes lockable storage and/or includes brackets for securement of the beam(s) to the truck's tailgate when used as a ramp.

Abstract: A bumper system includes a rollformed tubular beam with bracket mounts welded to a rear surface for mounting to vehicle frame rails. The illustrated beam has a continuous tubular cross section for its entire length, and includes a center section, corner-forming end sections, and mounting sections connecting ends of the center section to the end sections. The center, end and mounting sections can be linear or similarly curved or differently curved. The center, end and mounting sections can be similarly or differently locally annealed as part of being tuned to specific impact loading criteria, including annealing all or part of cross-sectional areas. The annealing can be done in-line with a rollforming process, such as to assist with forming tight radii in the beam for meeting packaging/space-related requirements, or can be part of a secondary process for advantageously affecting impact strengths in selected localized areas.

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: A bumper system includes a rectangular tubular beam made of high strength material. A center section of the beam is deformed downward and rearward so that a hitch tube receiver welded to a bottom of the center section is secured at a lowered and rearward position relative to the vehicle. At the same time, the ends of the beam are maintained in alignment and in a higher/forward position to support fascia and in particular to support step-forming portions of the fascia on ends of the bumper system.

Abstract: A bumper system includes a rollformed tubular beam with bracket mounts welded to a rear surface for mounting to vehicle frame rails. The illustrated beam has a continuous tubular cross section for its entire length, and includes a center section, corner-forming end sections, and mounting sections connecting ends of the center section to the end sections. The center, end and mounting sections can be linear or similarly curved or differently curved. The center, end and mounting sections can be similarly or differently locally annealed as part of being tuned to specific impact loading criteria, including annealing all or part of cross-sectional areas. The annealing can be done in-line with a rollforming process, such as to assist with forming tight radii in the beam for meeting packaging/space-related requirements, or can be part of a secondary process for advantageously affecting impact strengths in selected localized areas.

Abstract: A bumper system includes a tubular reinforcement beam and a pair of crush towers for mounting the beam to frame rails of a vehicle frame. The illustrated crush towers are formed from top and bottom stamped halves to form a pocket for receiving the ends of the beam, and further to form a crush tower for controlling impact energy communicated to the vehicle frame rails. Still further, the crush towers include an outboard portion forming a structural corner of the bumper system, the structural corner being constructed with crush initiators to provide optimal tuned corner impact characteristics. The combination of the beam 11 and towers 12 forms a bumper system taking advantage of roll forming (or extruding) of a rigid structural beam and a stamped mounting system.

Abstract: A method of manufacturing an improved doorbeam having increased impact strength and reduced weight. The doorbeam is formed from a continuous metal web having opposing lateral edges and a varying thickness therebetween. The stock is rolled into a tubular configuration, and the lateral edges are welded together. The resultant beam provides extra reinforcing material where needed to provide a balance between weight and strength.

Abstract: A method of manufacturing an improved doorbeam having increased impact strength and reduced weight. The doorbeam is formed from a continuous metal web having opposing lateral edges and a varying thickness therebetween. The stock is rolled into a tubular configuration, and the lateral edges are welded together. The resultant beam provides extra reinforcing material where needed to provide a balance between weight and strength.

Abstract: A method of manufacturing an improved doorbeam having increased impact strength and reduced weight. The doorbeam is formed from a continuous metal web having opposing lateral edges and a varying thickness therebetween. The stock is rolled into a tubular configuration, and the lateral edges are welded together. The resultant beam provides extra reinforcing material where needed to provide a balance between weight and strength.

Abstract: An energy-absorbing crush tower for a vehicle bumper system includes a tube made of a continuous contiguous material, such as a heat-treatable steel. The tube has first and second ring sections connected by an interconnecting section. The first ring section is heat-treated to a high material strength, such as about 120 KSI tensile strength, which is substantially higher than the second ring section, which is kept at about 60 KSI tensile strength. The interconnecting section has a frustoconically-shaped portion forming a ramp. By this arrangement, upon the bumper system receiving an end impact parallel a length of the tube, the first and second ring sections telescopingly collapse with a predictable and consistent multi-phase deformation sequence where a third ring section forms between the first and second ring sections. A method related to the above is also disclosed and claimed.

Abstract: A method of rollforming one-piece tubular doorbeams. The method includes the steps of drawing a continuous metal strip, creating cut-outs in the edges of the strip at spaced locations, rollforming the strip into a tube so that the unindented edges engage one another, welding the engaged edges together, cutting the tube in the areas of the cut-outs to create pre-forms, and opening the ends of the pre-forms to create end brackets. Additional optional steps provide customization of the end brackets.

Abstract: A two-piece doorbeam including a relatively low-cost, low-strength body and a relatively high-cost, high-strength insert. The insert is hat-shaped and crimped within the body. The insert provides improved impact strength where needed, providing the doorbeam the desired strength at relatively low weight and low cost.

Abstract: A method of manufacturing an improved doorbeam having increased impact strength and reduced weight. The doorbeam is formed from a continuous metal web having opposing lateral edges and a varying thickness therebetween. The stock is rolled into a tubular configuration, and the lateral edges are welded together. The resultant beam provides extra reinforcing material where needed to provide a balance between weight and strength.

Abstract: An energy-absorbing crush tower for a vehicle bumper system includes a tube made of a continuous contiguous material, such as a heat-treatable steel. The tube has first and second ring sections connected by an interconnecting section. The first ring section is heat-treated to a high material strength, such as about 120 KSI tensile strength, which is substantially higher than the second ring section, which is kept at about 60 KSI tensile strength. The interconnecting section has a frustoconically-shaped portion forming a ramp. By this arrangement, upon the bumper system receiving an end impact parallel a length of the tube, the first and second ring sections telescopingly collapse with a predictable and consistent multi-phase deformation sequence where a third ring section forms between the first and second ring sections. A method related to the above is also disclosed and claimed.

Abstract: A method of rollforming one-piece tubular doorbeams. The method includes the steps of drawing a continuous metal strip, creating cut-outs in the edges of the strip at spaced locations, rollforming the strip into a tube so that the unindented edges engage one another, welding the engaged edges together, cutting the tube in the areas of the cut-outs to create pre-forms, and opening the ends of the pre-forms to create end brackets. Additional optional steps provide customization of the end brackets.

Abstract: A two-piece doorbeam including a relatively low-cost, low-strength body and a relatively high-cost, high-strength insert. The insert is hat-shaped and crimped within the body. The insert provides improved impact strength where needed, providing the doorbeam the desired strength at relatively low weight and low cost.

Abstract: A vehicle door intrusion beam having a hollow cross-sectional configuration with less weight, greater flexibility and improved impact resistance. The beam body is formed of a single piece of material by roll forming a tubular blank to the desired cross-sectional configuration. End brackets secured to or integrally formed with the beam body mount the beam to the door assembly while also facilitating absorption of impacts. Corrugations may be added to the end brackets for additional impact absorption. Various hollow cross-sectional configurations are contemplated for the beam body including a single-piece with a closed I-beam configuration.