Method of constructing bumper incorporating thermoformed energy absorber
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United States of America Patent
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May 29, 2007
Issued Date -
N/A
app pub date -
Aug 29, 2006
filing date -
Jul 3, 2003
priority date (Note) -
Expired
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Abstract
A bumper system includes a tubular beam and a thermoformed energy absorber with crush boxes formed into a base flange, such as by vacuum or thermoforming processes. The crush boxes have planar energy-absorbing sidewalls a depth of about 10 mm to 35 mm, wall thicknesses of about 1 mm to 3 mm, and are formed from polyethylene or other thermoform materials having a memory. The base flange can include thermoformed features engaging recesses in the beam, and is combinable with injection-molded or foam energy absorbers for design flexibility. In one form, the energy absorber includes a thermoformed first sheet forming crush boxes and a second sheet bonded to the first sheet to define apertured air pockets. A method of manufacture includes providing a plurality of separately usable thermoformed energy absorbers which can be used in conjunction with a common vehicle structure to vary the absorption characteristics of a vehicle bumper.
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