Abstract: An in-vehicle component protection structure includes a first in-vehicle component, a second in-vehicle component that is an object to be protected from collision with the first in-vehicle component, and a protector disposed between the first in-vehicle component and the second in-vehicle component so as to face the first in-vehicle component. When the first in-vehicle component collides with the protector, the protector allows the first in-vehicle component to slide on the protector such that a moving direction of the first in-vehicle component deflects from the second in-vehicle component.

Abstract: An impact energy absorbing member includes an energy absorbing portion and an attachment portion. The attachment portion is fastened to the bumper reinforcement using a fastener, the fastener extending through the attachment portion and a wall of the bumper reinforcement and including an axis that extends in a direction intersecting an axial direction of the energy absorbing portion. The attachment portion and the energy absorbing portion are in a positional relationship in which the energy absorbing portion does not overlap the fastener when the impact energy absorbing member is viewed in a direction from the bumper reinforcement toward the energy absorbing portion in a vehicle front-rear direction.

Abstract: A vehicle body includes: a rear side member that is extended in the front-rear direction at the rear portion of the vehicle body; a back panel that is in contact with a rear end of the rear side member; and a crash box that is disposed between the back panel and a rear bumper and is positioned behind the rear side member. The crash box is fixed to the back panel with a bolt passed through a bolt hole that is extended through the back panel and that is positioned above the rear end of the rear side member. The rear side member is a hollow beam having a pair of side plates, an upper plate, and a lower plate, and a rear portion of the upper plate configures a flange that is bent upward along a lower back panel. The flange covers the bolt and the bolt hole.

Abstract: A device for fastening a first motor vehicle component to a second motor vehicle component. The device includes a first connection piece and a second connection piece. The first connection piece has a first component fastening surface for fastening to the first motor vehicle component, a first connection piece fastening surface which is perpendicular to the first component fastening surface, and first reinforcing surfaces which each connect a lateral end edge of the first component fastening surface to a lateral end edge of the first connection piece fastening surface. The second connection piece includes a second component fastening surface for fastening to the second motor vehicle component, a second connection piece fastening surface which is perpendicular to the second component fastening surface, and second reinforcing surfaces which each connect a lateral end edge of the second component fastening surface to a lateral end edge of the second connection piece fastening surface.

Abstract: The invention relates to a bumper (10) for a motor vehicle, with a cross beam element (30) exhibiting a back side (22) designed to be fastened to the motor vehicle with at least one fastening device (25), preferably in the form of a crash box, and a front side (21) lying opposite the back side (22), wherein the cross beam element (30) has at least one hollow chamber (36, 37) with a closed cross section, and with a reinforcing element (40; 40a), which extends over part of the length of the cross beam element (30) and is joined with the cross beam element (30). The invention provides that the cross beam element (30) be designed together with the reinforcing element (40; 40a) as a single-piece extruded part.

Abstract: A vehicle longitudinal member arrangement having two longitudinal members that are spaced apart from one another in the z direction and are designed to absorb energy in the case of an impact, and having a connection component which connects the longitudinal members to one another. The connection component has its main extension in one plane and has an upper attachment section and a lower attachment section. The connection component is arranged with its main extension plane parallel to the longitudinal extension of the longitudinal members connected by said component. Each of the two attachment sections has two attachment points arranged spaced apart from one another in the longitudinal extension of the longitudinal members, at which points the connection component is connected to the respective longitudinal member, while the section of the connection component located between the attachment points is not connected to the respective longitudinal member.

Abstract: A vehicle-body structure comprises a pair of right-and-left crash cans provided at an end portion of a vehicle body, being spaced apart from each other in a vehicle width direction, a bumper reinforcement extending in the vehicle width direction and connecting respective tip portions of the crash cans, set plates interposed between each of the crash cans and a vehicle-body side frame, wherein each of the crash cans is fixed to the vehicle-body side frame via the set plates, and a brace extending obliquely, in a plan view, from an inward side, in the vehicle width direction, of the crash can or the set plate to the bumper reinforcement such that a space is formed, in the vehicle with direction, between the brace and the crash can. The brace is fixedly joined to a lower face of the bumper reinforcement.

Abstract: A vehicle body front structure is provided that can control an amount of absorption of collision load for each portion of a cowl side member while deforming the cowl side member more reliably.

Abstract: A front bumper arrangement support structure for a motor vehicle includes a crossmember having a front end region that extends substantially transversely to the vehicle longitudinal direction, a fastening plate located to the rear of the crossmember and at least one deformation element that extends between the front end region of the crossmember and the fastening plate. Here, an integrated bumper element is provided. The bumper element extends in an arcuate manner between the front end region of the crossmember and the fastening plate and protrudes to the front or forward relative to the crossmember. The integrated bumper element, the deformation element and the fastening plate form an approximately triangular structure.

Abstract: [Object] To achieve a weight reduction of a car body structure while maintaining collision safety to impacts from the rear side of the vehicle. [Solution] Provided is a vehicle rear portion structure 1 including a pair of rear frames 4 provided in the vehicle length direction and a rear floor panel 2 joined to the pair of rear frames 4, in which the rear floor panel 2 has a concave section 3 provided from the rear side of the vehicle toward the front side of the vehicle of the rear floor panel 2, and the concave section 3 is formed of a metal sheet having a tensile strength more than or equal to the tensile strength of the pair of rear frames 4. By this configuration, when an impact load from the rear side of the vehicle acts on the concave section 3 of the rear floor panel 2, the rear floor panel 2 can absorb collision energy in a principal way.

Abstract: There is provided a vehicle front section structure including: a pair of front side members that extend in a vehicle front-rear direction; a cross member extending between the front side members; outriggers that are provided running in the vehicle front-rear direction at a vehicle upper side of the front side members, with each of the outriggers extending toward a corresponding front side member at a vehicle front side; joining members that are each joined to a corresponding front side member, the cross member, and a corresponding outrigger; and a suspension member that is fixed to a fixing portion provided at each joining member.

Abstract: A structural member made of metal, formed so as to extend long in a predetermined direction, and having a gutter bottom, two ridges continuing to both ends in a width direction of the gutter bottom, and two vertical walls continuing to the two ridges, includes an outward continuous flange continuously formed at least along the gutter bottom, the ridges, and the vertical walls at an end in the predetermined direction, in which a width of the gutter bottom is reduced as a distance from the end having the outward continuous flange becomes larger.

Abstract: A trailer includes front and rear ends spaced in a longitudinal direction to define a cargo area. A frame includes a rear bolster extending in a transverse direction across the rear end below a bottom rear edge of the cargo area. Spaced rear frame posts extend upwardly from respective distal ends of the rear bolster. A rear impact guard includes a bumper extending transversely and spaced below the rear bolster, a pair of outboard posts extending between the bumper and the rear bolster adjacent the respective distal ends of the rear bolster, and at least one inboard post. Each of the outboard posts has a rearward-extending horizontal first flange and an upward-extending vertical second flange spaced forwardly of the first flange, these flanges including multiple apertures aligned with apertures in the trailer frame, each of the apertures accommodating a removable fastener securing the rear impact guard to the trailer frame.

Abstract: A motor vehicle rear includes two longitudinal members, a trunk floor supported by the longitudinal members, a rear wall which adjoins the ends of the longitudinal members and which delimits a trunk opening at the bottom and D pillars which laterally delimit the trunk opening. Lower end sections of the D pillars extend at the height of the longitudinal members beyond outer sides of the two longitudinal members facing away from one another and are anchored on the longitudinal members.

Abstract: An adjustment mechanism for a fascia of a vehicle includes a riser having an upper end defining a hole and a fascia retainer defining a first threaded bore in a center portion thereof. The adjustment mechanism further includes an externally threaded sleeve received in the first threaded bore, the sleeve defining a lower end configured to engage the upper end of the riser, and a bolt extending through a sleeve bore defined in the sleeve and into the hole in the upper end of the riser. The bolt is threadably coupled to the upper end of the riser.

Abstract: The invention concerns a bumper unit for a motor vehicle, with a bumper cross-member which is connected to a vehicle structure via a crumple element. To provide a bumper unit which has optimal crash behavior on frontal impacts both with small overlap and with larger overlap, according to the invention it is provided that a deformation element is arranged on the bumper cross-member outside of the crumple element with a deformation portion running obliquely relative to a vehicle longitudinal axis X, towards and spaced from the vehicle structure. It is proposed that the deformation element has a rearward running connecting portion which is connected to the bumper cross-member and a center portion running towards the outside from the connecting portion and adjoining the deformation portion.

Abstract: An apparatus is provided for the alignment of an attachment relative to at least one adjacent structural part on the body side on a vehicle. For the improvement of a tolerance compensation between the attachment and the structural part during assembly, it is proposed that the apparatus is part of the structural part, while the attachment comprises at least one first reference point for the alignment of the attachment, wherein the first reference point is incorporated in the attachment by means of a gauge before the installation of the attachment.

Abstract: A cladding tie for providing a support connection between cladding and a vertical backup wall is disclosed. The tie has a base and a retainer assembly. The base has a shaft extending from a back plate. The retainer assembly has a retainer member, and a cladding connection member. The retainer member has a cladding connection member recess. The cladding connection member is movable relative to the retainer to permit differential movement between the cladding connection member and the retainer when the cladding connection member is connected to the retainer.

Abstract: A joining structure of a vehicle frame that includes: a vehicle frame including a tubular first frame and a second frame, the first frame being formed in a closed cross section shape by extrusion molding of a lightweight metal, the second frame being formed in an open cross section shape of which one side is open by die-casting of a lightweight metal, and the second frame being superposed with the first frame in a state of contact therewith; a slit portion formed in the second frame, the slit portion extending along a marginal edge portion at an opening direction side of the second frame; a first welded portion structured by welding the marginal edge portion of the second frame to the first frame; and a second welded portion structured by welding a periphery edge portion of the slit portion to the first frame.

Abstract: A front end module of a vehicle, including a first side member having a first impact portion and a first other portion, a second side member having a second impact portion and a second other portion, and a lower cross member connecting the first side member with the second side member, is disclosed. The first side member and the second side member are each bent towards a front end of the vehicle, and each of the first side member and the second side member is J-shaped.

Abstract: A vehicle front fascia includes a vehicle panel, a bumper assembly positioned below the vehicle panel in a vehicle vertical direction, and a seal member coupled to the vehicle panel and extending between the vehicle panel and the bumper assembly in the vehicle vertical direction. The seal member includes a seal portion that extends downward from the vehicle panel in the vehicle vertical direction, and a bulb portion spaced apart from the seal portion in a vehicle longitudinal direction, the bulb portion comprising a bulb wall that defines a cavity within the bulb wall.

Abstract: A bumper beam assembly includes a reinforcement beam, the reinforcement beam including a front side, a top side, and a bottom side that is positioned opposite of the top side of the reinforcement beam, and a reinforcement patch coupled to the reinforcement beam, where the reinforcement patch extends across the top side and the bottom side of the reinforcement beam and the reinforcement patch includes a longitudinal deformation feature that is detached and spaced apart from at least one of the top side and the bottom side of the reinforcement beam.

Abstract: A vehicle bumper system, comprises a first bracket fixedly mounted to a bumper. A second bracket is fixedly mounted to a vehicle frame horn, the second bracket including at least one vertical slot. At least one bolt is inserted through an opening in the first bracket and the at least one slot.

Abstract: A vehicle body structure includes a bumper reinforcement, a front side member, and a bumper stay. The front side member is formed with a closed section portion, and a protruding portion that protrudes from this closed section portion toward a vehicle front side. The bumper stay, together with a protruding portion, forms an open section portion. Also, a notch is formed on the vehicle width direction inside of the closed section portion, and a cutout is formed on the vehicle width direction outside of the open section portion. Opposing wall portions that are fixed to protruding opposing portions and opposing wall portions that connect the cutout and the notch are formed on the bumper stay. These opposing wall portions are formed with extending edge portions that extend from the cutout side toward the notch side.

Abstract: A mold structure used to form a molded object having an undercut portion includes a fixed mold as a first mold having a first molding surface for molding an obverse surface of the molded object; a slide core having an undercut molding surface used to mold the undercut portion as part of the obverse surface of the molded object; and a movable mold as a second mold having a second molding surface used to mold the reverse surface of the molded object. The first molding surface and the undercut molding surface form a cavity surface. A step is formed between the first molding surface and the second molding surface at a parting position between the fixed mold and the slide core on the cavity surface.

Abstract: A fender front-side step portion has first and second fender front-side fixing portions that engage with and fasten a bumper spacer. The bumper spacer is provided with: a spacer body; a bumper-spacer reinforcing portion that extends toward a fender lower-end portion of a fender panel from the bottom end of the spacer body; and a bumper-spacer rear-side fixing portion which is disposed on the bumper-spacer reinforcing portion, and which overlaps with and fastens the front of the fender lower-end portion. The bumper-spacer rear-side fixing portion is disposed in a position further to the rear than the fender front-side step portion in the longitudinal direction of a vehicle.

Abstract: A bumper fixing clip includes a leg portion engaging with a vehicle body panel; engagement claws engaging with a plurality of engagement holes formed on a bumper side; and an engagement member including a second engagement claw engageable with or retractable from one of the engagement holes formed on the bumper side by operating an operation portion, and fixing the bumper to the vehicle body panel. The engagement member is integrally formed with a fixing clip main body, and includes an approximately rod-like operation portion; the second engagement claw formed in a vicinity of a turning center of the operation portion; and an abutment piece formed on a side opposite to the second engagement claw.

Abstract: Vehicle structures for dissipating energy associated with a collision are described herein. In one embodiment, a vehicle includes a side support extending in a vehicle longitudinal direction, a bumper assembly coupled to the side support and extending in a vehicle lateral direction that is transverse to the vehicle longitudinal direction, and a repositionable joint assembly extending between and pivotally coupled to the side support and the bumper assembly, the repositionable joint assembly including an outboard linking member pivotally coupled to the bumper assembly at a bumper securement location, an inboard linking member pivotally coupled to the side support at a side support securement location, and a fulcrum portion, where the outboard linking member is pivotally coupled to the inboard linking member at the fulcrum portion.

Abstract: A bumper attachment structure includes a flange of a bumper fascia provided with a guide portion protruding therefrom and a flange of a fender panel having an insertion hole into which the guide portion can be inserted. The bumper attachment structure also includes an attachment bracket having a groove in which the guide portion can be housed and an insertion fitting portion in which a tip portion of the attachment bracket can fit.

Abstract: A material handling vehicle includes a laminated bumper that provides both durability and reduced energy transmissibility. The laminated bumper includes at least a first bumper layer and a second bumper layer, such that at least one of the first bumper layer and second bumper layer of the laminate bumper are allowed to translate upon bumper contact with an object.

Abstract: A vehicle bumper beam including: a resin beam having an elongate body extending along a vehicle-width direction, two tubular shock-absorbing portions disposed at the beam body's opposite longitudinal end portions extending in front-rear direction, the beam body and shock-absorbing portions being formed with each other; a metal beam disposed outside the resin beam in the front-rear direction, fixedly fitted to the resin beam. Further, flat attachment portions, formed with inner end portions of the shock-absorbing portions in front-rear direction; bent portions bent in a crank extending from attachment portions outward in front-rear direction, the beam body being to attachment portions via bent portions, the metal beam fixedly fitted to an outer surface of the beam body's intermediate portion; metal beam's opposite end portions extending beyond bent portions covering the right and left sides, fixedly fitted to distal end portions; each space defined by shock-absorbing portion, metal beam and bent portion.

Abstract: A countermeasure assembly for an automotive vehicle includes a front side rail extending in a generally longitudinal direction; a bumper having a main bumper member and a bumper extension forming an end portion of the bumper; and a pivot link having front and rear mounting portions. The front mounting portion is pivotably engaged with the bumper extension member to define a front pivot joint, and the rear mounting portion is pivotably engaged with the front side rail to define a rear pivot joint. The rear pivot joint is located rearward and inward from the front pivot joint. The bumper extension is bolted to the forward end of the front side rail. The bumper extension has a front member and a rear member, of which the rear member is bolted to the front side rail. The front member and the rear member of the bumper extension define a hollow box structure.

Abstract: A bumper reinforcement structure capable of achieving a weight reduction while still securing required bending strength in a bumper reinforcement structure with closed cross-section structure configured by joining together an inside member and an outside member. A bumper reinforcement is formed with two closed cross-sections configured by joining together three top-to-bottom flanges of an inner panel to three top-to-bottom flanges of an outer panel. The flanges of the inner panel are disposed in the same front-rear direction position as that of the wall portions that configure the closed cross-sections.

Abstract: A bumper fixing clip includes a leg portion engaging with a vehicle body panel; engagement claws engaging with a plurality of engagement holes formed on a bumper side; and an engagement member including a second engagement claw engageable with or retractable from one of the engagement holes formed on the bumper side by operating an operation portion, and fixing the bumper to the vehicle body panel. The engagement member is integrally formed with a fixing clip main body, and includes an approximately rod-like operation portion; the second engagement claw formed in a vicinity of a turning center of the operation portion; and an abutment piece formed on a side opposite to the second engagement claw.

Abstract: A bumper assembly includes a bumper beam having a bumper beam surface extending along a bumper plane X and a crash box including a crash box surface extending along a crash box plane Y. One of the bumper beam and the crash box includes an alignment joint to mate the bumper beam and the crash box and dispose the surfaces in abutting and aligned relationship relative to one another for establishing a linear load path extending linearly along the planes X, Y. A method of assembling a bumper assembly includes the steps of mating the bumper beam and the crash box about the alignment joint and connecting the bumper beam and the crash box together along the alignment joint. The step of connecting the bumper beam and the crash box includes friction stir welding the bumper box and the crash box together along the alignment joint.

Abstract: The present invention relates to a vehicle that includes a hood and a bumper. The hood is provided with open position and a closed position. The bumper is provided with an intermediate bumper portion, a first end cap, and a second end cap. The first and second bumper end caps are supported by the hood and are moveable with the hood as the hood transitions between the open and closed positions.

Abstract: A bumper cover fixing bracket mounted between a fender panel and a bumper cover includes a main supporting member having an upper end attached to an upper member, an auxiliary supporting member having a lower end connected to the main supporting member so as to form a Y-shape and an upper end attached to a wheel house front member, and a fastening member coupled to a lower end of the main supporting member and having one side and the other side mounted on the fender panel and the bumper cover, respectively.

Abstract: A bumper-stay mounting structure includes a rear side member, a bumper stay and a load transmission member, in the bumper-stay mounting structure, a load being transmitted intensively to a lower side of a rear end portion of the rear side member, the bumper-stay mounting structure, the load transmission member having, on an inner peripheral side of a fastened portion, a protruding portion in a box shape, which protrudes toward the rear portion of the bumper stay in the vehicle longitudinal direction so as to be inserted into an opening of the bumper stay; and a side wall of the protruding portion having a substantially U-shaped cross section that is perpendicular to the vehicle longitudinal direction, is opened on a vehicle upper side, and is provided with, at a front end edge of the side wall, a flange extending outward from a side wall as the fastened portion.

Abstract: A method of molding a clip mount on a baseboard includes: forming a clip mount forming space with a die set including at least first slide die and second slide die; injecting molten resin into the space; forming a first wall; forming a connecting wall so as to extend from a distal end of the first wall such that a distance between the connecting wall and a surface of the baseboard increases as a distance from the first wall increases; forming a second wall; forming a mount wall so as to extend from an end of the second wall such that a distance between the mount wall and the connecting wall increases as a distance from the second wall increases; sliding the first slide die for removal; and sliding the second slide die in a different direction from a direction in which the first slide die is slid for removal.

Abstract: Provided is a crash box to be installed to a bumper reinforcement including an outer-wall section, an upper-wall section and a lower-wall section, an upper inner-wall section, a lower inner-wall section, and a clearance between the upper inner-wall section and the lower inner-wall section. The crash box includes a body section provided between a member of a vehicle body side and the bumper reinforcement, an upper support section provided to protrude from the body section to a bumper reinforcement side, a lower support section provided to protrude from the body section to the bumper reinforcement side, and an insertion section provided to protrude from the body section to the bumper reinforcement side, inserted from the clearance into the bumper reinforcement and contacting a lower end portion of the upper inner-wall section and an upper end portion of the lower inner-wall section.

Abstract: A vehicle bumper apparatus includes a bumper reinforcement member formed to have a hollow cross section and including a vehicle interior portion formed to have an open cross section including an opening, and a crush box supporting the bumper reinforcement member to mount the bumper reinforcement member to a side member of a vehicle body, the crush box including a connecting portion arranged at a vehicle exterior portion, the connecting portion closing the opening of the bumper reinforcement member to restrict the opening from being expanded, and a retaining portion protruding from the connecting portion toward an exterior side of a vehicle to retain the bumper reinforcement member.

Abstract: The invention relates to a decorative element, to a dashboard of a motor vehicle, and to a method for manufacturing said decorative element, wherein the decorative element includes a first portion and a second portion, the first portion of the decorative element being made of a first non-transparent material, wherein said first material has a decoration layer, and the second portion of the decorative element being made of a second transparent material, the first portion and the second portion of the decorative member being unitary.

Abstract: An example gusset for attaching a rear bumper assembly to a vehicle has a first attachment portion configured to attach to the bumper reinforcement bracket and the lower back panel of the vehicle, a second attachment portion configured to attach to the rear side member of the vehicle, and an angled portion presenting an oblique surface to a rear impactor to the vehicle. A pair of side portions are interconnected and spaced apart by the second attachment portion, and each side portion has an angled edge adjacent the angled portion.

Abstract: A bumper beam of the present invention is provided with a tubular bumper reinforcement member (1) and a tubular crush box (2). A reinforcement member hole (15) is provided in an outer peripheral wall (11) of the bumper reinforcement member (1) in a penetrated manner. A partition wall (22) is provided so as to bridge opposed inner wall surfaces of an outer peripheral wall (21) of the crush box (2). The tip end portion of the crush box (2) is arranged so as to penetrate the reinforcement hole (15). In this state, ridge portions (25a, 25b) are formed, by means of a tube expansion process using a tube expansion die, on the crush box (2) so as to extend in a circumferential direction thereof at a front side and a rear side of the reinforcement hole (15). With this, the crush box (2) is secured to the bumper reinforcement member (1). According to the present invention, the bumper beam can be reduced in size and weight.

Abstract: A frontal impact countermeasure assembly for an automotive vehicle, the countermeasure assembly comprising: a front side rail extending in a generally longitudinal direction and having a forward end; a bumper extending generally laterally to the longitudinal direction of the front side rail and having an outboard end; and a pivot link having outer and inner mounting portions, the outer mounting portion being pivotably engaged with the bumper in a region of the outboard end to define a front pivot joint, the inner mounting portion being pivotably engaged with the front side rail to define a rear pivot joint, the rear pivot joint being located rearward and inward relative to the front pivot joint.

Abstract: An impact absorbing device for a vehicle may include a bumper beam having a hollow cross section which extends in a traverse direction of the vehicle, and crash boxes interposed between the bumper beam and a vehicle body in a longitudinal direction of the vehicle at both distal portions of the bumper beam, wherein rear surfaces of the both distal portions in the bumper beam include an opening formed so as to communicate with the hollow cross section of the bumper beam, wherein a rib may be formed at the opening of the bumper beam in a traverse direction of the opening, and wherein the crash box includes a front tip end inserted through the opening while being fitted to the rib to extend up to an inside of the hollow cross section, and a rear tip end mounted to the vehicle body in the longitudinal direction of the vehicle.

Abstract: A structure of the front section of a vehicle body is disposed on the front end portion of a front side frame on the same position as the rear surface of a side stay in the front-rear direction of the vehicle body, and includes a first extending portion extending downward along the rear surface of the side stay. A lower stay is provided with a second extending portion extending outward in the vehicle width direction beyond the side stay to a position below the first extending portion. A joining section is formed so as to join the front surface of the first extending portion, the upper surface of the second extending portion, and outside surface of the side stay. The joining section defines an arrangement region for inner and outer shock absorbing members having a lower rigidity than the front side frame.

Abstract: A crush box arranged between a side member of a vehicle body and a bumper reinforcement member, the crush box including: a main body portion arranged in a longitudinal direction of a vehicle and formed in a tubular shape, the main body portion having first and second portions; a vehicle body attaching portion arranged at a first end of the main body portion; and a bumper attaching portion arranged at a second end of the main body portion, wherein vertical cross-sections of both the first portion adjacent to the vehicle body attaching portion and the second portion adjacent to the bumper attaching portion are polygonal shapes, and the number of vertices of the polygonal shape of the vertical cross-section of the second portion is greater than the number of vertices of the polygonal shape of the vertical cross-section of the first portion.

Abstract: A multistage energy absorber device is provided that includes at least two generally tubular members. Each of the generally tubular members has a first end and a second end. The second generally tubular member is independent of the first generally tubular member and fits within the first generally tubular member. The first ends of the generally tubular members are substantially flush with each other, but the second end of the second generally tubular member protrudes sufficiently beyond the second end of the first generally tubular member to form a first deformation stage. The first and second generally tubular members extend coextensively sufficiently from the first ends of the first and second generally tubular members to the second end of the first generally tubular member to form a second deformation stage.

Abstract: A roll former for forming a sheet into a continuous multi-tubular reinforcement beam. The roll former includes a first set of rollers that are configured to bend the sheet to form a common center wall in generally perpendicular orientation relative to first and second lateral portions of the sheet that extend in opposing directions from respective first and second radiused ends of the common center wall. The first set of rollers also form radiused edges on the first and second lateral portions. A second set of rollers is configured to form a channel rib longitudinally along each of the first and second lateral portions. A third set of rollers is configured to bend the first and second lateral portions simultaneously and equally to abut the first and second radiused edges with the respective first and second radiused ends of the common center wall to define adjacent tubes of the beam.