Abstract: An energy absorbing unit for use as a vehicle bumper having an upper zone and a lower zone wherein the upper zone comprises an inner relatively high density foam material for protecting a structural part of the vehicle by absorbing energy in a direction generally longitudinal of the vehicle and an outer relatively low density foam material for providing protection against impact for a body by absorbing energy during impact. The lower zone includes a foam material having a density intermediate that of the foam materials in the inner and outer areas of the upper zone.

Abstract: A deployable cellular structure providing impact energy absorption capability is disclosed. The structure may be packed when not in use and deployed automatically or manually to provide impact protection. The structure is useful in a variety of situations including vehicular protection of occupants, deployable highway safety barriers, and aviation emergency safety devices.

Abstract: A vehicular bumper system includes a tubular beam and an energy absorber press-fit within the tubular beam. In particularly, the energy absorber includes front and rear wall sections, planar stiffening wall sections that extend horizontally continuously and completely between the front and rear wall sections, and stabilizing wall sections that extend between the planar stiffening wall sections. Pairs of stubby protrusions are formed on the rear wall sections that are aligned with the planar stiffening wall sections and that combine with the front and rear wall sections to define an arrangement where, when the energy absorber is forcibly pressed into the cavity of the tubular beam, the protrusions are deformed and stressed and/or are shaved off such that they friction-fit into the tubular beam.

Abstract: A method for making an automobile assembly having a moulded plastics structural member and a reinforcing member in which a polymerizable adhesive is employed to bond the two members together and an automobile assembly having a bonded structural member and a reinforcing member. The assembly is suitably used as a “front end carrier” or a bumper system in an automobile.

Abstract: A hybrid bumper system includes a hollow reinforcing metallic beam and a molded engineering thermoplastic resin energy absorber. The energy absorber further includes at least one crushable portion. The hollow metallic beam is secured in a physically stable combination with the energy absorber, thereby resulting in a solitary hybrid bumper system.

Abstract: A bumper assembly, alone and in combination with a vehicle, comprising an integral fascia and energy absorber. The integral fascia preferably being thermoformed with the energy absorber. The energy absorber preferably is made from expanded foam beads.

Abstract: An elongated carrier for receiving a bumper member. In one illustrative embodiment, the elongated carrier includes one or more walls with one or more inner surfaces that define at least part of a cavity, and further includes a slot into the cavity. The slot is preferably defined by at least two terminating ends of the one or more walls, wherein the two terminating ends are defined by terminating end surfaces that are separate from the one or more inner surface of the one or more walls. Preferably, at least one of the inner surfaces of the one or more walls has an inwardly extending nub.

Abstract: A bumper system includes a bumper beam having a face and ends, and an energy absorber mounted on the face. The energy absorber has a one-piece injection-molded non-foam piece with box sections and interconnecting straps, and a one-piece or multi-piece foam component securely insert-molded onto the injection-molded non-foam piece. Different foam molds can be used to form differently shaped front surfaces on the foam component. By this arrangement, different energy absorbing systems are provided for vehicles, such as to satisfy the need for different styling and shapes, while still using the same non-foam piece. By this arrangement, the energy absorber is a single unit that can be handled and attached to the bumper beam. At the same time, capital investment in molding dies and tooling is reduced.

Abstract: A bumper reinforcement attached to a front or a rear side of a vehicle frame as a strength member comprising: a bumper beam to be supported on the vehicle frame, and a reinforcement member attached to the bumper beam on a forward surface thereof which is upstream with respect to an impact exertion direction, wherein: the reinforcement member has a concave portion of a substantially C-shaped cross section projecting in a downstream direction reverse to the impact exertion direction, the bumper beam has a groove portion extending longitudinally of the reinforcement member on the forward surface to which the reinforcement member is attached, and the reinforcement member and the bumper beam are engaged by joining a bottom surface of the concave portion and a surface of the groove portion.

Abstract: A bumper assembly (20) for an automotive vehicle. The bumper assembly includes comprises a beam (24) and an energy absorber (22). In one example embodiment, the energy absorber is tunable for meeting predetermined criteria for both low speed and pedestrian impacts.

Abstract: A bumper system comprising a metal tubular beam, an energy absorber and mounts. The metal tubular beam has a center section having front, rear, top, and bottom walls. The energy absorber includes a rail having a rear surface with a rearwardly-facing C-shaped recess mateably receiving the tubular beam therein, with the energy absorber being configured to crush and absorb impact energy prior to collapse of the tubular beam. The mounts engage a rear of the metal tubular beam.

Abstract: A bumper system for an automobile vehicle includes a beam configured to attached to vehicle rails and an energy absorber coupled to the beam. The energy absorber is tunable for meeting predetermined criteria for both low speed and pedestrian impacts, and includes a flanged frame for attachment to the beam, a body that includes a plurality of lobes extending from the flanged frame and spaced apart from each other. Each lobe includes first and second side walls, having a concave shape.

Abstract: An extruded bumper for a vehicle includes a top face, a bottom face generally opposing the top face, a front face, and a rear face generally opposing the front face. A bumper interior cavity is generally bounded by and defined between the top face, the bottom face, the front face, and the rear face. The bumper interior cavity has at least one partition located therein which is aligned in a longitudinal plane defined by a vehicle rail. The bumper can be extruded along either the x-axis or the z-axis.

Abstract: An elongated bumper core of a polyolefin-based resin-containing foam having a density of 0.045-0.2 g/cm3 and showing a compressive load of F20 at 20% strain, a compressive load of F40 at 40% strain and a compressive load of F60 at 60% strain when compressed by a rigid pipe having an outer diameter of 70 mm at a compression speed of 500 mm/minute, wherein the ratio F20/F40 is in the range of 0.6-1.3 and the ratio F60/F40 is in the range of 0.75-1.3.

Abstract: A bumper system includes a tubular bumper beam, and a hitch-supporting bracket. The bracket has an inverted U-shaped section that fits downwardly onto the tubular bumper beam, and further has a laterally-extending planar section with a hole therein that is shaped to support a ball hitch for hauling a trailer. The beam has offset end sections that extend parallel a center section of the beam, but that are offset horizontally. An energy absorber is supported by the beam, and is sufficiently structural to form steps outboard of ends of the beam, and a fascia substantially covers the beam and energy absorber for aesthetics.

Abstract: A fender structure of a motor vehicle. A fender includes a vertical wall portion, a mounting portion adapted to be mounted on an apron upper member of the vehicle, and an inclined portion formed between the vertical wall and the mounting portion, the inclined portion extending downward and inward as viewed in a width direction of the vehicle. The fender structure also includes first ribs formed on a lower surface of the inclined portion of the fender such that the first ribs face the apron upper member, fragile portions formed at a boundary between the vertical wall portion and the inclined portion, and second ribs formed on a portion of the vertical wall portion of the fender which is located above the apron upper member so as to extend in the vertical direction of the vehicle.

Abstract: An energy absorber that incorporates pedestrian protection and vehicle protection into a front bumper system on automotive vehicles comprises a unitary molded glass mat of thermoplastic material having a plurality of outwardly extending crushable lobes. The energy absorber is combined with a fascia and a reinforcing beam with the energy absorber interdisposed to form a bumper system for automotive vehicles.

Abstract: A resilient bumper assembly for a vehicle having an elongate horizontal beam mounted transversely to an end of the vehicle. Exterior flexible sheet cladding mounted on the beam defines an elongate internal chamber between its inner surface and the outer surface of the beam. An elongate resilient impact absorber is mounted to the beam and housed within the internal chamber, with top, bottom, inner and outer surfaces. Vertically extending cavities within the impact absorber, each opening to at least one of the top and bottom surfaces of the impact absorber provide resilient collapsing and rebound of the impact absorber on impact. The absorber may include variations in the size and shape of cavities, thickness of walls between cavities, and variations in the characteristics of material of which it is molded in order to modify the resilient characteristics of the absorber to suit different design needs.

Abstract: The present invention provides a blow-molded vehicle part and a blow-molding process for generating a one-piece vehicle part with improved strength, aesthetic appearance and reduced weight and cost. The blow-molded vehicle part includes a front vehicle part portion and a back vehicle part portion, wherein the front vehicle part and the back vehicle part have at least an outer unreinforced layer of a thermoplastic that forms a smooth outer surface of the vehicle part and a reinforced inner layer.

Abstract: A vehicle bumper system includes a beam, and an energy absorber with top and bottom horizontal sections and a mid-horizontal section. The horizontal sections form top and bottom nose portions that are semi-rigid but initially collapsible with a parallelogram motion that shifts the top and bottom portions vertically up (or down) upon impact. Horizontal impact forces are converted in part to vertical forces during an initial stroke of a frontal impact, “catching” an impacted human being. Then during a further continuing impact stroke, the top and bottom horizontal sections provide a “throwing” action. End sections of the energy absorber extend around ends of a bumper beam, forming a collapsible corner that, during impact, initially absorbs energy at a low rate to “catch” a person, and then develops increasing lateral forces that “throw” the person during a continuing impact stroke.

Abstract: A motor vehicle bumper system comprising an outer shell (10) of an automotive bumper having an inner surface (18) generally oriented toward the vehicle. The outer shell comprises a plurality of energy absorbing protuberances (14) extending inwardly from the inner surface of the outer shell. The energy absorbing protuberances may be formed from an energy absorbing material, such as a polymeric foam, and/or may additionally comprise indentations extending into the body of the protuberance to enhance the energy absorbing characteristics of the protuberance.

Abstract: A bumper system includes a bumper beam having a face and ends, and an energy absorber mounted on the face. The energy absorber has a one-piece injection-molded non-foam piece with box sections and interconnecting straps, and a one-piece or multi-piece foam component securely insert-molded onto the injection-molded non-foam piece. Different foam molds can be used to form differently shaped front surfaces on the foam component. By this arrangement, different energy absorbing systems are provided for vehicles, such as to satisfy the need for different styling and shapes, while still using the same non-foam piece. By this arrangement, the energy absorber is a single unit that can be handled and attached to the bumper beam. At the same time, capital investment in molding dies and tooling is reduced.

Abstract: The invention is a composite foam structure comprising a first segment of an anisotropic thermoplastic foam part and a second foam shaped part comprising an isotropic foam wherein the anisotropic foam block and isotropic foam part intersect along at least one common surface.

Abstract: The invention relates to motor vehicle bumper beam. The beam comprises a longitudinal base element 1 and an additional element 2. The two elements engage one in the other and they comprise snap-fastening elements 9, 10, 11 providing a rigid mechanical connection between their longitudinal edges. The invention also provides a motor vehicle bumper having such a beam.

Abstract: A bumper assembly for an automotive vehicle includes a beam and an energy absorber. The energy absorber includes a flanged frame for attachment to the beam and a body extending from the frame. The body includes a first transverse wall, a second transverse wall spaced from the first wall and a plurality of tunable crush boxes extending therebetween. The bumper assembly has greater than fifty percent efficiency.

Abstract: A bumper system for a vehicle, in particular a car, with a bumper support and a trim component is provided, wherein the bumper support has an attachment element for at least one impact horn projecting past the outer surface of the trim component and the trim component has at least one opening for the impact horn. To reduce the production and storage costs for different bumper systems, a covering component that can be inserted into the opening is provided.

Abstract: A bumper system includes a tubular beam with flattened end sections, and further includes an energy absorber having a rear recess mateably receiving the tubular beam in a nested relationship, with the recess also including flat mating surfaces engaging the flattened end sections. Mounts engage a rear of the flattened end sections, and fasteners secure the tubular beam and energy absorber to the mounts. In one modified bumper system, corner sections on the energy absorber are shaped to slidingly engage a side surface of the mount and simultaneously an end of the beam upon corner impact of the vehicle. In another modified bumper system, offset ends of the tubular beam fit into a recess in an energy absorber, with its center section being between vehicle mounts.

Abstract: A bumper system for a motor vehicle includes an energy absorber and a bumper beam interconnecting the energy absorber and vehicle structure. The bumper system also includes a push bar disposed below and operatively connected to the bumper beam to deflect and rotate during an impact with an object by the bumper system.

Abstract: A bumper system includes a tubular beam with flattened end sections, and further includes an energy absorber having a rear recess mateably receiving the tubular beam in a nested relationship, with the recess also including flat mating surfaces engaging the flattened end sections. Mounts engage a rear of the flattened end sections, and fasteners secure the tubular beam and energy absorber to the mounts. In one modified bumper system, corner sections on the energy absorber are shaped to slidingly engage a side surface of the mount and simultaneously an end of the beam upon corner impact of the vehicle. In another modified bumper system, offset ends of the tubular beam fit into a recess in an energy absorber, with its center section being between vehicle mounts.

Abstract: A bumper system includes a bumper beam having a face and ends, and an energy absorber mounted on the face. The energy absorber has a one-piece injection-molded non-foam piece with box sections and interconnecting straps, and a one-piece or multi-piece foam component securely insert-molded onto the injection-molded non-foam piece. Different foam molds can be used to form differently shaped front surfaces on the foam component. By this arrangement, different energy absorbing systems are provided for vehicles, such as to satisfy the need for different styling and shapes, while still using the same non-foam piece. By this arrangement, the energy absorber is a single unit that can be handled and attached to the bumper beam. At the same time, capital investment in molding dies and tooling is reduced.

Abstract: A vehicle bumper assembly (10) comprising a hoop-like support (11) having a central aperture (19) surrounded by an upper beam (15) and lower beam (16) connected by outer portions (17 & 18), a resilient shell (12), and an undertray (13). The shell (12) is shaped to the support (11) and its lower portion (41) is backed by foam material (14) mounted on the lower beam (15) and its upper portion (42) is collapsible onto the upper beam (16). The undertray (13) and foam backed lower portion (41) provide spaced supports for the lower leg of a pedestrian.

Abstract: This invention provides a propylene-based composition for the molded polypropylene resin articles excellent in resistance to scratching and moldability, and well-balanced properties between high rigidity and high impact strength, and also provides a method for molding the above propylene-based composition, thereby providing high-performance industrial parts and automobile parts, in particular automobile interior parts.

Abstract: A bumper cover is fastened onto an automobile having a polymeric bumper. The bumper cover has a generally navicular concave shell made of thin wall steel having a chrome plated outer surface, the bumper cover having a shape that conforms to the exterior of the polymeric bumper so that it mates with and overlaps the polymeric bumper.

Abstract: A molding method and an impact resistant automotive part such as a bumper beam resulting from the molding method are obtained wherein a thermoplastic reinforced fiber structure at least partially forms a pair of attachment portions of the part and continuously extends between the attachment portions to link the attachment portions. The method includes the steps of providing a plurality of blanks, heating the plurality of blanks, and stacking the plurality of blanks to form a stack of blanks. The stack is then stamped to form the part including the pair of attachment portions spaced a predetermined distance apart. The thermoplastic reinforced fiber structure has tows of fibers wetted by a resin material such as polypropylene. Preferably, the fibers are woven glass fibers.

Abstract: In a vehicle with a bumper which is attached to the vehicle transverse to the longitudinal direction of the vehicle via a deformation element, the deformation element exhibits two first side walls that are spaced apart, and are joined to second side walls that are spaced apart. The first and second side walls have first and second grooves that run transverse to the longitudinal direction of the vehicle and are arranged in pairs opposite each other, each in a common plane. The first grooves extend over the whole breadth of the first side walls and the second grooves extend over only a middle part of the second side walls leaving a region free at both edges. The first grooves are arranged in pairs in first planes and the second grooves are arranged in pairs in second planes situated between two subsequent first planes.

Abstract: A protective structure for vehicles (10), designed to be used, in particular, in the event of impact between a vehicle (10) and a pedestrian (so-called pedestrian impact), in which at least one energy absorption element or buffer (16) is used, positioned, at least partially, parallel to the front cross member (17) of the vehicle (10); it is furthermore possible to modify the external style (L) of the vehicle (10), by bringing the profile of the bonnet (11) forward and/or furthermore providing for the insertion of a new buffer (25), designed to work on the front-end structure of the vehicle (10), positioned below the bumper (12), in order to obtain advantages in terms of safety.

Abstract: In a vehicle rear body structure in which a muffler is disposed below a rear cross member disposed to extend transversely below a rear part of the body of a vehicle, a lower end portion 10 of the rear cross member 7 extends downwardly to substantially the same height of that of a lower end portion 4c of a rear bumper face 4a disposed rearward of the rear cross member. Accordingly, it is possible to prevent the generation of heat deformation by protecting from heat related effects from a muffler a lower end portion of a rear bumper which tends to easily heat deform.

Abstract: A bumper system includes a bumper beam having a face and ends, and an energy absorber mounted on the face. The energy absorber has a foam piece engaging the face and an injection-molded end piece securely attached to each end of the foam piece and also engaging the face. By this arrangement, the energy absorber is a single unit that can be handled and attached to the bumper beam, and also can include different end pieces while still using the same foam piece. In one form, the energy absorber also includes a center injection-molded piece and, in another form, includes a long injection-molded piece having foam sections molded onto it.

Abstract: The invention relates to a front end module for a motor vehicle with a front end assembly support (2) between the bumper seats (3) and with a bumper transverse support (5) connecting the longitudinal supports (4) of the motor vehicle. In order to reduce the individual parts and the weight, it is proposed that the bumper transverse support (5) and the assembly support (2) are integrally manufactured in a plastics material injection moulding process as a hybrid component with sheet metal parts (6, 7) placed into the casting mould.

Abstract: A bumper system includes a tubular beam having front and rear walls, and a plurality of horizontally-extending walls that interconnect the front and rear walls. An energy absorber has a rear surface with a recess shaped to mateably receive and support the beam, and includes end sections that extend to be coplanar with the rear wall of the beam. The end sections cover the front wall and also at least partially cover a top, bottom and ends of the beam, and are constructed to flex and absorb energy to reduce a likelihood of vehicle damage. In one form, the end sections include honeycomb sections that engage beam mounts to transfer impact energy directly to the mounts. In another form, the end sections include cantilevered flanges that extend outwardly from ends of the energy absorber for impact absorption at the vehicle corners.

Abstract: A bumper includes a beam and an energy absorber supported thereon. The energy absorber includes horizontal walls, each having a front portion, a rear portion, and an interconnecting mid-portion that offsets and misaligns the front and rear portions. Upon impact, the front and rear portions collapse with the offset mid portion wrapping back upon itself with a predictable energy-absorbing collapse. The energy absorber further includes flanges and friction pads that frictionally engage the top and bottom of the beam to temporarily retain the energy absorber to the beam. In one embodiment, the front beam wall includes at least one aperture, and the energy absorber includes a tubular column extending from its front wall through the aperture in the front beam wall to the rear beam wall. By this arrangement, the front wall of the energy absorber receives support from the front beam wall via the structural column.

Abstract: An impact beam having a polymer matrix and a metal reinforcing structure, the metal reinforcing structure including metal cords that can be made from metal elements having a diameter of 100 &mgr;m or more. The polymer matrix can include a thermoplastic material and/or a fiber material, and the metal can be steel, and the metal cords can be parallel to each other. The polymer matrix can include two or more layers that can be made from the same or different material, one of which can be positioned around the surface of the metal cords and can have a mechanical bond with the cord. The invention also includes a method of making the impact beam.

Abstract: A pedestrian protection assembly for an automotive vehicle includes a bumper support beam rigidly secured to the frame of the vehicle. A bumper is supported on the support beam and spaced forwardly thereof by a resilient foam pad. The bumper includes a ramped rib engaged with the support beam for moving the bumper from a normal position to an impact position. A grill portion extends downwardly from the bumper and supports a facia chin below the bumper. A lower tubular support beam further supports the facia chin on the frame of the vehicle. The bumper moves rearwardly against the bumper support beam in response to front impact of the vehicle and the ramped rib forces the bumper downwardly to force the facia chin and lower tubular support beam downward and forward of the bumper.

Abstract: A bumper system for vehicles includes a B-shaped tubular bumper beam with top and bottom mid-walls defining a channel in its front surface. A polymeric energy absorber has multiple box-shaped sections that abut the front surface of the bumper beam and further includes rearwardly-extending nose sections that extend into the channel. The nose sections include collapse-controlling kick walls that lie along the top and bottom mid-walls and that are connected to the box-shaped sections. Upon impact by an object against the bumper system, the kick walls press into the top and bottom mid-walls, resulting in a consistent and controlled collapse of the energy absorber and tubes of the bumper beam. In another form, an energy absorber having box-shaped sections is positioned on a face of the bumper beam and integral box-shaped end sections designed for a consistent and controlled collapse on impact.

Abstract: A modular shock isolator and method of isolation of components of a system with multiple modular shock isolators arranged to provide different damping and vibration characteristics than an individual modular shock isolator. In one mode, a modular shock isolator having a base with legs extending from each side of the base with each of the legs having a foot that extends outward from the legs with the modular shock isolator either individually mounted to isolate a component or a plurality of modular shock isolators are be ganged, or stacked together to change the shock isolation characteristics of the shock mount formed from the multiple modular shock isolators. A layer of damping material can be sandwiched between layers of elastomers to dampen the natural spring-back of the materials.

Abstract: A bumper system includes a bumper beam having a face and ends, and an energy absorber mounted on the face. The energy absorber has a foam piece engaging the face and an injection-molded end piece securely attached to each end of the foam piece and also engaging the face. By this arrangement, the energy absorber is a single unit that can be handled and attached to the bumper beam, and also can include different end pieces while still using the same foam piece. In one form, the energy absorber also includes a center injection-molded piece and, in another form, includes a long injection-molded piece having foam sections molded onto it.

Abstract: In a method of making a steel crossbeam for use as component of a bumper for motor vehicles, a composite element is formed by attaching sheet metal strips in parallel disposition onto a broadside of a steel sheet strand across an entire length thereof, whereby the sheet metal strips have a width which is narrower than a width of the steel sheet strand. The composite element is then shaped through roll-forming in a direction transverse to the longitudinal extent of the composite element into a crossbeam.

Abstract: A vehicle bumper system includes a bumper beam and a polymeric energy absorber positioned on a front of the bumper beam. The energy absorber has multiple box-shaped sections and also has interconnecting sections positioned along the length that interconnect adjacent ones of the box-shaped sections. The box-shaped sections of the energy absorber, when cross-sectioned by a transverse plane, include top and bottom U-shaped sections formed by top parallel legs and a top vertical leg and by bottom parallel legs and a bottom vertical leg, respectively. End walls close ends of the box-shaped sections and stabilize the top and bottom U-shaped sections. The interconnecting sections include a tying wall that connects the end walls together. By this arrangement, the box-shaped sections provide a stable and reliable energy absorbing mechanism.

Abstract: A structurally enhanced attachment for use in reinforcing automotive rocker assemblies. An expandable material, such as a polymer-based foam, is disposed on a surface of an aluminum extrusion prior to integration of the extrusion into the vehicle and final assembly of the vehicle by the vehicle manufacturer. The system is activated as the vehicle undergoes the final vehicle assembly process, which activates and transforms the expandable material, preferably during an automobile paint operation, to expand, bond and fill the rocker assembly structure thereby structural adhering the extrusion with the rocker assembly and facilitating enhanced structural reinforcement.

Abstract: A pedestrian safety device for mounting to an automotive vehicle has a relatively low-resistance mechanical response when struck by an object having the approximate width of a human leg, and relatively high-resistance response when struck by an object wider than a human leg. The impact energy management device comprises a backplate attachable the vehicle and a plurality of seesaw elements attached to the backplate for pivoting movement relative to the backplate. Each element has a first and a second contact end spaced forwardly from the beam. When a narrow object like a pedestrian's leg strikes the device, only one end of each seesaw element is urged toward the backplate and the element pivots with respect to the backplate to absorb energy and offer a relatively low resistance. When a wider object strikes the device, both contact ends of a seesaw element are engaged so that the element bends toward the backplate. The strain caused by the bending offering a higher resistance to intrusion by the object.