Abstract: An energy absorbing structure 10 for protecting an impacted body, such as a pedestrian 12. The structure has an incident surface that meets the pedestrian and has at least some expanded metallic structure 18. A pair of wall support surfaces 20, 22 lie substantially in-plane with respect to a normal component of the impacting force. They extend from the incident surface in a direction opposite to the direction of the impact. The substantially in-plane surfaces also have at least some expanded metallic structure. A pair of basal surfaces 26, 28 support the in-plane surfaces, and also have at least some expanded metallic structure.

Abstract: A forward structure of a motor vehicle, particularly of a passenger car, includes a bumper cross member and an energy absorption element, particularly a foam-type impact absorbing element, disposed in front of the bumper cross member in the driving direction. A plurality of recesses are shaped into the forward-side outer contour of the energy absorption element. To ensure optimal energy reduction while the mounting space is reduced, and thereby a best-possible protective function with respect to a leg impact, at least several of the recesses completely penetrate the energy absorption element along its entire depth, whereby a plurality of breakthroughs are arranged in the energy absorption element.

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 bumper system includes primary and secondary structural cross beams, at least one having an S-shaped cross section with forwardly-facing (or outwardly-facing) top concavity. The beams include different arrangements of stiffening ribs in concavities formed by the S-shaped cross section for impact and bending strength. In one form, the beams are made of polymeric material. The beams may include integrally formed crush cans for attachment to the vehicle frame, or alternatively can be attached to vehicle frame rail tips by separate metal crush cans and brackets.

Abstract: An impact limiting system of a vehicle is provided with a cladding element and bumper substructure. The bumper substructure is spaced apart from the cladding element, and is covered by the cladding element. The bumper substructure is arranged on the vehicle body, and exhibits impact energy absorbing elements. The impact limiting system exhibits an impact force conveying element between the cladding element and bumper substructure.

Abstract: An automobile bumper system including an isolator disposed adjacent a cross beam of an automobile frame, and a bumper edge guard strip mounted adjacent upper and/or lower edges of the cross beam. The bumper edge guard strip may include an upper extension fixedly engaged with an upper surface of the cross beam and a lower extension fixedly engaged with a frontal surface of the cross beam, with the upper extension having a length greater than the lower extension for distributing impact energy in a predetermined manner.

Abstract: A front shock absorbing structure of a vehicle includes a bumper reinforcement member that is disposed in a vehicle width direction in a front portion of a vehicle body and is formed as a rigid elongated member, and a shock absorbing member that is positioned on a front surface of the bumper reinforcement member. The shock absorbing member is vertically divided into a first shock absorbing portion and a second shock absorbing portion. The first and second shock absorbing portions are integrally coupled to each other at a forward side, so as to define a space therebetween at a rearward side. The coupling can be broken when an impact is applied by an impactor from ahead. The second shock absorbing portion has a protruding portion that is projected toward the space.

Abstract: This assembly is of the type comprising at least two pairs of front longitudinal members (12, 16) and supporting and attachment plates (20) positioned at the front ends of the longitudinal members (12, 16), a front bumper shield (8) comprising a one-piece frame (22) in plastic material formed with an upper bumper beam (24) and a lower bumper beam (26) and two uprights (28) connecting the upper (24) and lower (26) bumper beams, the shield (8) further comprising an additional beam (40) made with the frame (22) in the same material, said additional beam (40) comprising means for attaching at least one piece of auxiliary equipment of the motor vehicle.

Abstract: A bumper apparatus with a multistage energy absorbing structure mounted to the front and rear ends of a vehicle. The bumper apparatus includes a back beam, a rear shock absorber, a front shock absorber, and a bumper cover. The back beam is mounted to a car body. The rear shock absorber is mounted to the front surface of the back beam and has a plurality of rear shock absorbing units on a middle portion thereof. The front shock absorber is mounted to the front surface of the rear shock absorber and has an arcuate cross-sectional structure. The bumper cover is mounted to the front surface of the front shock absorber.

Abstract: A bumper beam for a vehicle has a hat shaped profile with the crown (12-14) facing the vehicle and has a cover (17) that gives the bumper beam a closed profile. The bumper beam has two mountings (20, 21) that usually are adapted to be fitted to the side rails of the vehicle. The cover is extended on both sides past the mountings, but leaves the outer portions of the hat beam open. The crown of the open portions of the hat beam have a longitudinal indentation (32) and a profile height that decreases towards the ends.

Abstract: A support structure for an exhaust pipe includes left and right side frames disposed on a lower side of a rear floor and a back panel extending downward from the rear floor joined to rear end portions of the side frames. Reinforcing plates join the back panel on a vehicle rear side in positions facing the rear of the side frames. Stays extending in a rearward direction mount to the respective reinforcing plates and support a bumper member. A muffler disposed below the rear floor and on a front side of the back panel or an exhaust pipe connected thereto, is supported on a vehicle body by a hanger rubber. A flange portion that is formed with a reinforcing plate extends rearwardly and perpendicularly therefrom. A hanger rubber mounts to the flange portion to support the muffler or exhaust pipe.

Abstract: An injection molded foam article including a structure and a projection projecting from the structure. The thickness of the projection is greater than 40% of the thickness of the structure and the front surface of the structure opposite the projection is free of sink marks.

Abstract: An energy-absorbing device in the form of a safety device against shock loads for a track-borne vehicle includes an energy-absorbing member and a mating member. The mating member co-operates with the energy-absorbing member in such a way that, if a critical shock force applied to the energy-absorbing device is exceeded, the mating member and the energy-absorbing member move relative to one another, towards one another, while at the same time absorbing at least some of the shock energy which is applied to the energy-absorbing device. To enable the overall energy which can be dissipated by the energy-absorbing device to be increased in a way which is easy to implement, provision is made for the energy-absorbing member to have at least one energy-absorbing region made of fibrous composite material which, in the course of the movement of the mating member relative to the energy-absorbing member, is at least partly reduced to fibres non-ductilely.

Abstract: A bumper beam (10) e.g. for an SUV, has its flange portions (18, 19) positioned high and extends asymmetrically downwards relative to them. It has an outwardly convex profile which has in its lower portion a longitudinal concavity (16) which, near to the lower edge of the profile, ends with a forward-pointing profile portion (21). The result is less risk that the bumper will climb up over a lower-positioned bumper (30) which it collides with.

Abstract: A bumper panel assembly for use in a vehicle including an upper bumper panel and a lower bumper panel attached to the upper bumper panel. The bumper panel assembly is formed without cut outs and walls so as to eliminate the need of using lifters to form the bumper panel assembly, and thus reducing manufacturing costs. The upper bumper panel includes a groove extending along the width of the panel, and the lower bumper has a first edge seated along the groove so as to define a styling line. The lower panel further includes a second edge spaced apart from the first edge. A seal is disposed on the second edge and interconnects the lower bumper panel to the vehicle body when the vehicle bumper is assembled onto the vehicle so as to enhance the aerodynamic characteristics of the bumper panel assembly.

Abstract: The bumper stay includes a cylindrical shaft member fit in to a hole of a bumper reinforce, a cylindrical reinforcing member fit in to the outer periphery of the shaft member in the rear side of the bumper reinforce, and a mounting flange member fit in to the outer periphery of the shaft member in its rear end. The shaft member is enlarged by electromagnetic forming and is tightly adhered to the inner peripheral surface of the hole formed in the bumper reinforce, the inner peripheral surface of the reinforcing member, and the inner peripheral surface of the hole flange formed in the mounting flange member, thereby these are joined with each other. Thin aluminum alloy extruded material can be used for the shaft member.

Abstract: Thickness T in a vehicle longitudinal direction of a first energy-absorbing member 18, which is disposed at a front portion of a vehicle 10, tapers from a middle portion of a vehicle lateral direction (thickness Tc) toward an end portion (thickness Ts). For at least one (preferably both) of the first energy-absorbing member 18 and a second energy-absorbing member, rigidity in the vehicle longitudinal direction is made smaller from the vehicle lateral direction end portion toward the middle. Hence, loads acting on an impact body 102 when the vehicle 10 impacts with the impact body 102 are equalized in the vehicle lateral direction.

Abstract: An object struck discrimination system for a vehicle is provided which is effective in increasing the discrimination accuracy for discriminating an object struck by the vehicle. In one form, an object struck discrimination system to be installed in a vehicle includes an impact receiving member for receiving an impact from an object struck which extends lengthwise along the width of the vehicle, a detection sensor for detecting the moving speed or the acceleration of the impact receiving member during a vehicle collision, and a control unit for discriminating the object struck based on the rate of change in the moving speed per unit time or the acceleration introduced from information detected by the detection sensor.

Abstract: A method of forming metal castings, including positioning a first end of a structural member in a first mold cavity and a second end of the structural member in a second mold cavity. The first and second mold cavities being fluidly coupled to a reservoir of molten metal. Applying a main pressure to the molten metal in the reservoir to force the molten metal into the first mold cavity and the second mold cavity. Then, applying a first auxiliary pressure to the first mold cavity and a second auxiliary pressure to the second mold cavity to densify the casting formed in the first mold cavity and the second mold cavity. Also, a method for casting including maintaining a main pressure at or less than an initial, mold-filling pressure after first and second mold cavities have been filled. Additionally, a method for detecting whether a first mold cavity is sufficiently filled with molten metal by monitoring a moveable element.

Abstract: An energy absorber for a vehicle bumper system includes a plurality of crush boxes that are configured to absorb impact energy. Each of the plurality of crush boxes are generally hollow and have a front wall and a plurality of side walls integrally formed with and extending from the front wall to a rear of the energy absorber. A first crush box is separated from a second crush box by a distance such that an open space is defined between a side wall of the first crush box and a side wall of the second crush box. At least one rib extends between the side wall of the first crush box and the side wall of the second crush box in the open space to couple the first crush box to the second crush box. The at least one rib is integrally formed with the first crush box and the second crush box, and extends at least partially between the rear of the energy absorber and the front walls of the first and second crush boxes.

Abstract: A vehicle bumper assembly is provided with a bumper cover attachable to a body of a vehicle, the bumper cover having an inner surface defining a groove portion. The vehicle bumper assembly further provides an energy absorbing member with a base to be fixedly secured to a bumper of a vehicle and a bracket coupled to the body of the vehicle, the bracket defining a protrusion portion to engage with the groove of the bumper cover.

Abstract: The present invention relates to a pedestrian safety structure for a motor vehicle body having a soft-nose outer skin panel and a bonnet providing an overlying structure for a grille opening reinforcing front cross member. The grille opening reinforcing front cross member carries a plurality of brackets. The brackets are designed to support loads distributed thereupon by the overlying structure, vertical (Z) loads in the range of 1.0-1.5 kN and longitudinal (X) loads in the range of 0.4-0.6 kN. The brackets are further designed for energy absorbing deformation when subjected to longitudinal (X) loads distributed thereupon by the overlying structure above 0.6 kN, such that the plurality of brackets provide an energy absorbing upper leg impact zone for the protection of pedestrians in the event of a collision with the motor vehicle.

Abstract: An automobile bumper system including an isolator disposed adjacent a cross beam of an automobile frame, and a bumper edge guard strip mounted adjacent upper and/or lower edges of the cross beam. The bumper edge guard strip may include an upper extension fixedly engaged with an upper surface of the cross beam and a lower extension fixedly engaged with a frontal surface of the cross beam, with the upper extension having a length greater than the lower extension for distributing impact energy in a predetermined manner.

Abstract: A protector assembly for attachment to a vehicle such as a truck. The assembly includes a base member which is permanently attached to the truck and a cushion member which is retained adjacent the base member by retainer. The cushion member is slidable relative to the base member between the retention position and a release position whereby in the release position the cushion member is no longer retained by the retainer. The cushion member includes a mounting portion formed from a relatively hard material which engages the retainer, and a working portion formed from a relatively soft resilient elastomeric material.

Abstract: A vehicle bumper system includes a beam configured to attach to a vehicle and a thermoformed energy absorber positioned on the beam. The energy absorber comprises a frame and a crush lobe extending from the frame. The crush lobe comprises a lobe wall extending between the frame and an outer wall. The change in lobe wall thickness may be constant. The outer wall is curved away from the frame.

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 bumper for a motor vehicle includes a cross member which is disposed transversely to a side rail of a motor vehicle frame. A crash box is incorporated between the cross member and the side rail, with set bolts being provided to join the crash box to the cross member in the absence of prepunching.

Abstract: A bumper panel assembly for use in a vehicle including an upper bumper panel and a lower bumper panel attached to the upper bumper panel. The bumper panel assembly is formed without cut outs and walls so as to eliminate the need of using lifters to form the bumper panel assembly, and thus reducing manufacturing costs. The upper bumper panel includes a groove extending along the width of the panel, and the lower bumper has a first edge seated along the groove so as to define a styling line. The lower panel further includes a second edge spaced apart from the first edge. A seal is disposed on the second edge and interconnects the lower bumper panel to the vehicle body when the vehicle bumper is assembled onto the vehicle so as to enhance the aerodynamic characteristics of the bumper panel assembly.

Abstract: A roll forming apparatus and a method thereof form a composite panel by simultaneously roll forming upper and lower plates with different thicknesses and a zigzag-shaped core panel, and welding them together. A bumper beam is manufactured by using the composite panel.

Abstract: A bumper of a motor vehicle includes a cross member which is disposed transversely to a side rail of a motor vehicle frame and has a U-shaped cross section formed by a wall and two legs extending from opposite ends of the wall Extending longitudinally in a direction of the cross member is a reinforcement member which has a T-shaped cross section and closes off a front end of the cross member.

Abstract: A vehicle bumper assembly is provided with a bumper cover attachable to a body of a vehicle, the bumper cover having an inner surface defining a groove portion. The vehicle bumper assembly further provides an energy absorbing member with a base to be fixedly secured to a bumper of a vehicle and a bracket coupled to the body of the vehicle, the bracket defining a protrusion portion to engage with the groove of the bumper cover.

Abstract: The invention relates to a rear crash element for the rear bumper of a motor vehicle in the area of the number plate recess (3), having an impact element (7) seated on the crossbeam (4) of the motor vehicle, behind which, with respect to the driving direction of the motor vehicle, an impact-receiving element (8) is arranged. The element (8) is arranged behind the bumper cladding (1) and is covered by a plastic covering, such as a shell cladding (2) or the like.

Abstract: A steel rope safety system includes at least one steel rope having at least one strand, and the at least one rope or at least one strand is compacted. Further, a method is provided for making a steel rope safety system comprising the step of providing at least two wires, the step of stranding the wires thereby forming a strand for a rope and the step of compacting the strand. There is likewise provided the use of compacted steel ropes as impact reducing material.

Abstract: Vehicle fascia assembly includes a plastic fascia panel and a grille frame. The fascia panel has a grille opening defined by a flange extending rearward from the show surface toward the back side of the fascia panel. The flange has a plurality of flexure fingers at spaced intervals along the flange. The grille frame has a forward facing show surface and has a C-shaped channel molded around the outer edge of the show surface. Upon the assembly of the grille frame onto the backside of the fascia panel, the spaced apart channel legs fit onto the flange and the flexure fingers are biased and then engage with an abutment face on the grille frame, thereby attaching the grille frame onto the back side of the fascia panel without exposing the show surface of the fascia panel to injury by the grille frame during the assembly operation.

Abstract: An object struck discrimination system for a vehicle is provided which is effective in increasing the discrimination accuracy for discriminating an object struck by the vehicle. In one form, an object struck discrimination system to be installed in a vehicle includes an impact receiving member for receiving an impact from an object struck which extends lengthwise along the width of the vehicle, a detection sensor for detecting the moving speed and/or the acceleration of the impact receiving member during a vehicle collision, and a control unit for deriving the maximum moving speed and the maximum acceleration based on the information detected by the detection sensor and discriminating the object struck based on the correlation between the maximum moving speed and the maximum acceleration.

Abstract: A bumper for a motor vehicle includes a lightweight cross member attachable transversely to the longitudinal rails of the motor vehicle frame. The cross member includes two longitudinal profiles which are displaceable relative to each other and support each other during the displacement. The bumper provides improved functionality and increased energy absorption capability.

Abstract: A carrier support arrangement that attaches to a vehicle between a rear bumper crash bar and mounting pads that are provided at the rear of the body of the vehicle. The carrier support is formed of a transverse support bar that has a modified hollow tubular beam construction, with attachment lands its ends. Tubular socket members receive attachment rods of the associated carrier. The tubular beam construction if formed of an upper member and lower member welded together. The web portions of the beam have a series of triangular cutouts, leaving a series of diagonal struts. This construction achieves a weight savings without sacrifice of strength or torsion resistance.

Abstract: A vehicle bumper structure includes a pipe member that extends along the vehicle-width direction. A bumper shock absorbing member extends along the vehicle-width direction, and has a loading space in which the pipe member is placed. A fixing member has a first end portion which is fixed to a vehicle body and a second end portion to which the bumper shock absorbing member is fixed. A bumper cover may be provided on the outer side of the bumper shock absorbing member, and cover the bumper shock absorbing member, the pipe member, and the fixing member.

Abstract: The present invention relates to a mechanism for reinforcing a fascia including at least one reinforcement structure and at least one strengthening feature. The reinforcement structure is attached to the fascia so that at least a portion of the fascia is covered by the reinforcement structure. The strengthening feature is on at least one side of the reinforcement structure.

Abstract: A bumper reinforcement member 1 includes a small groove 2 and a large groove 3. The large groove 3 is arranged to encompass the small groove 2 inside the groove. When the bumper reinforcement member 1 is deformed, directions of the deformation of the lateral face of the small groove and the deformation of the lateral face of the large groove are oppose to each other, and thus the peak load and the energy absorption amount of the bumper reinforcement member 1 can be increased with a simple configuration.

Abstract: A vehicle bumper system includes a beam configured to attach to a vehicle and a thermoformed energy absorber positioned on the beam. The energy absorber comprises a frame and a crush lobe extending from the frame. The crush lobe comprises a lobe wall extending between the frame and an outer wall. The change in lobe wall thickness may be constant. The outer wall is curved away from the frame.

Abstract: A bumper system includes primary and secondary structural cross beams, at least one having an S-shaped cross section with forwardly-facing (or outwardly-facing) top concavity. The beams include different arrangements of stiffening ribs in concavities formed by the S-shaped cross section for impact and bending strength. In one form, the beams are made of polymeric material. The beams may include integrally formed crush cans for attachment to the vehicle frame, or alternatively can be attached to vehicle frame rail tips by separate metal crush cans and brackets.

Abstract: The use of a bumper faceplate with ports provides for the easy assembly, increased structural strength, and dramatically improved aesthetic appearance of an assembled bumper containing bumper components.

Abstract: An energy absorber includes a base flange and elongated crush boxes that to form a substantially continuously face surface on the energy absorber. Back straps are attached across a back of the crush boxes to prevent unacceptable spreading of the side walls of the crush boxes during an impact. The back straps can be integrally formed when the energy absorber is molded, and can include a living hinge at one end and a free end that can be bent over and snap attached during post-molding assembly without additional secondary operations. Alternatively, a separate wall-stabilizing thermoformed component is sandwiched between the energy absorber and beam.

Abstract: An impact-absorbing device that absorbs impact force when a collision has occurred with an object having relatively low rigidity. The impact-absorbing device is provided with a guide piece that extends in a horizontal direction substantially horizontal to the input direction of the impact, and a movable piece that is movably supported along the guide piece. The guide piece and movable piece deform to absorb impact force when the impact force has acted on the guide piece.

Abstract: The energy absorber system is adapted to a motor vehicle having side rails. The system comprises a top absorber beam positioning in front of the side rails of the motor vehicle, a bottom absorber beam for being positioned beneath the top absorber beam, and at least two uprights providing a rigid connection between the top and bottom beams. The system also includes a rigid cross-member extending between the side rails and being secured directly to the side rails, the top beam being secured to bear against the cross-member.

Abstract: A vehicular metal absorber for efficiently absorbing by a short stroke the impact energy received from legs of a pedestrian at the time of a collision between a pedestrian and an automobile, reducing the residual crush, and protecting the legs of the pedestrian, that is, a long vehicular metal absorber comprising a center flange, a top web and bottom web connected to the two sides of the center flange, a top flange connected to the top web, and a bottom flange connected to the bottom web and formed overall into a hat shaped cross-section, wherein an internal angle ?1 formed by the top web with a flange plane including the top flange and bottom flange and an internal angle ?2 formed by the bottom web with the flange plane are respectively over 0 degree to less than 90 degrees, and in that one or both of the top web and bottom web are provided with a recessed or projecting bead substantially parallel to a front-back direction of a vehicle.

Abstract: A bumper beam structure is provided. The bumper beam structure has a plurality of vertically long weak parts formed in a front surface of the bumper beam. These weak parts are formed having a predetermined interval along the lengthwise direction of the bumper beam.

Abstract: A vehicle bumper and a method for making a vehicle bumper formed of first and second members. Each of the first and second members are formed of substantially similar first and second U-shaped members positioned such that the respective sidewalls of the first and second U-shaped members are positioned adjacent one another. The bumper including a plurality of apertures therein formed by cutouts extending inward from the peripheral edge of each of the first and second U-shaped members.

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.