In a crash box, a first extending portion extends from a front end of a first body upper portion in a vehicle front-rear direction of a first body portion, and a second extending portion extends from a front end of a second body lower portion in a vehicle front-rear direction of a second body portion. When an impact load is transmitted to the front ends of the first body portion and the second body portion in the vehicle front-rear direction, a rotation moment toward the lower side of the vehicle acts on the first extending portion and a rotation moment toward the upper side of the vehicle acts on the second extending portion. This can suppress peeling between first and second left side bonded portions and between first and second right side bonded portions of the first body portion and the second body portion.

The present invention relates to a motor vehicle crash box with a working direction in vehicle's longitudinal axis manufactured out of a tube which is expanded into different zones, wherein the zones are different in strength and diameter by using steel after forming a homogenous austenitic microstructure with a strain hardening effect. The present invention further relates to the manufacturing method of such a component.

The present invention relates to a motor vehicle crash box with a working direction in vehicle's longitudinal axis manufactured out of a tube which is expanded into different zones, wherein the zones are different in strength and diameter by using steel after forming a homogenous austenitic microstructure with a strain hardening effect. The present invention further relates to the manufacturing method of such a component.

A reinforcement beam for an automotive component is continuously formed with a metal sheet that is roll formed to have at least one tubular portion that extends along a length of the reinforcement beam. A solid state forge weld is formed between an edge of the metal sheet and an intermediate portion of the metal sheet to close a seam that extends along the tubular portion of the reinforcement beam. Prior to forming the solid state forge weld, select portions of the metal sheet are heated to a desirable welding temperature with a high frequency current delivered by electrical contacts to opposing sides of the weld seam. The desired welding temperature may burn off a galvanized coating on the metal sheet at the select portions prior to forming the solid state forge weld that is generally void of zinc inclusions.

A reinforcement beam for an automotive component is continuously formed with a metal sheet that is roll formed to have at least one tubular portion that extends along a length of the reinforcement beam. A solid state forge weld is formed between an edge of the metal sheet and an intermediate portion of the metal sheet to close a seam that extends along the tubular portion of the reinforcement beam. Prior to forming the solid state forge weld, select portions of the metal sheet are heated to a desirable welding temperature with a high frequency current delivered by electrical contacts to opposing sides of the weld seam. The desired welding temperature may burn off a galvanized coating on the metal sheet at the select portions prior to forming the solid state forge weld that is generally void of zinc inclusions.

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.

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.

A protective device structure for a vehicle is provided that includes an outer surface or shell attached to or otherwise disposed upon a vehicle that covers a top edge of a vehicle to absorb impact. The protective device can include a compressible portion disposed in a cavity defined between the outer shell and the vehicle proximate to the top front wall of the vehicle.

A protective device structure for a vehicle is provided that includes an outer surface or shell attached to or otherwise disposed upon a vehicle that covers a top edge of a vehicle to absorb impact. The protective device can include a compressible portion disposed in a cavity defined between the outer shell and the vehicle proximate to the top front wall of the vehicle.

Systems and methods for forming 3D plastic parts that are cost effective in low volume, have excellent fit and finish, and use many components from 2D construction are disclosed. The systems and methods involve selecting a design and modelling the design. The design comprises 2D and 3D components of plastic parts. A 3D forming buck corresponding to the 3D component is manufactured. At least one of a 2D part and the 3D forming buck may be heated. The 2D part may be loaded onto the 3D forming buck for a predefined period of time. The 3D part formed after the loading may be separated from the 3D forming buck. The 3D part is the 2D part generally having taken the shape of the 3D forming buck. The 3D part may be cooled to obtain an end product.