A method of manufacturing a unitary energy absorbing structure for a vehicle includes providing a first mold having a cavity receiving a first mandrel and a second mold having a cavity receiving a second mandrel. At least one mandrel segment is positioned in the first mold cavity and cooperates with the first mandrel. One or more layers of composite material at least partially cover the first mold cavity, first mandrel, at least one mandrel segment and second mold. The unitary structure is formed from the first layer, the second layer and the third layer of composite material with the first mandrel, the at least one mandrel segment and the second mandrel in the first mold and the second mold.

A method of manufacturing a unitary energy absorbing structure for a vehicle includes providing a first mold having a cavity receiving a first mandrel and a second mold having a cavity receiving a second mandrel. At least one mandrel segment is positioned in the first mold cavity and cooperates with the first mandrel. One or more layers of composite material at least partially cover the first mold cavity, first mandrel, at least one mandrel segment and second mold. The unitary structure is formed from the first layer, the second layer and the third layer of composite material with the first mandrel, the at least one mandrel segment and the second mandrel in the first mold and the second mold.

A vehicle front end assembly includes a front portion of a vehicle frame structure. A bumper fascia is attached to the front portion of the vehicle frame structure. Further, a headlamp structure is attached to both the front portion of the vehicle frame structure and the bumper fascia.

A vehicle-body structure of a vehicle of the present invention comprises a bumper support portion provided at a vehicle body of the vehicle to support to bumper, a connection portion connecting the bumper and the bumper support portion and supporting the bumper, and a slide allowance portion configured to allow the bumper to slide in a vehicle longitudinal direction relative to the bumper support portion when a longitudinal load having a specified magnitude or larger is applied to the bumper from a vehicle outside, wherein the connection portion is provided on an upper face of the bumper support portion, and the slide allowance portion is configured to allow the longitudinal sliding of the bumper independently from the supporting of the bumper by the connection portion.

A vehicle-body structure of a vehicle of the present invention comprises a bumper support portion provided at a vehicle body of the vehicle to support to bumper, a connection portion connecting the bumper and the bumper support portion and supporting the bumper, and a slide allowance portion configured to allow the bumper to slide in a vehicle longitudinal direction relative to the bumper support portion when a longitudinal load having a specified magnitude or larger is applied to the bumper from a vehicle outside, wherein the connection portion is provided on an upper face of the bumper support portion, and the slide allowance portion is configured to allow the longitudinal sliding of the bumper independently from the supporting of the bumper by the connection portion.

A multi-tubular beam for a vehicle, such as a vehicle structure or a bumper reinforcement, includes an elongated beam formed with a metal sheet. The metal sheet has a central section and outer sections extending along a length of the metal sheet. The outer sections are disposed in opposing directions from the outer edges of the central section to provide adjacent first and second tubular portions. The central section forms a common center wall between the adjacent first and second tubular portions. A first edge portion of the metal sheet is disposed along and in parallel alignment with the center wall. The first edge portion is attached to the center wall at a first weld joint to form the first tubular portion. The first weld joint includes a weld material that extends through a thickness of the center wall and into a thickness of the first edge portion.

In an embodiment a towing pipe connection structure includes a vehicle body rear member including an aluminum material, a towing pipe at least partially including an aluminum material and a connection bracket including a bumper back beam plate in contact with a back panel of a vehicle body and including an insertion hole into which the towing pipe is inserted, an engage plate having an engage hole to which the towing pipe is connected and a connection plate connecting the bumper back beam plate and the engage plate, wherein the connection bracket is connected to a rear member of the vehicle body, and wherein the connection bracket includes an aluminum material.

A crash box may include one or more layers arranged to absorb crash energy. In some embodiments, the crash box includes a first layer having an outer skin defining a periphery of the first layer and at least one of: 1) a rib and web structure, and 2) an array of tubes disposed within the outer skin for absorbing crash energy, and a second layer adjacent to the first layer, the second layer having an outer skin defining a periphery of the second layer and at least one of: 1) a rib and web structure, and 2) an array of tubes disposed within the outer skin for absorbing crash energy.

A crash box may include one or more layers arranged to absorb crash energy. In some embodiments, the crash box includes a first layer having an outer skin defining a periphery of the first layer and at least one of: 1) a rib and web structure, and 2) an array of tubes disposed within the outer skin for absorbing crash energy, and a second layer adjacent to the first layer, the second layer having an outer skin defining a periphery of the second layer and at least one of: 1) a rib and web structure, and 2) an array of tubes disposed within the outer skin for absorbing crash energy.

A vehicle is provided. The vehicle includes: a chassis including a chassis body and chassis modular units; at least one driving unit arranged in at least one of the chassis modular units, and configured to provide a driving force to at least a pair of wheels; and suspension systems. The chassis body is of an elongate shape in a first direction of the vehicle. A cockpit is arranged in the chassis body. The chassis modular units are connected to the chassis body in series in the first direction, and arranged at first and second ends of the chassis body in the first direction. Each chassis modular unit is connected to a corresponding pair of wheels through a corresponding suspension system.