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.

The invention relates to a front underrun protection device for a heavy vehicle comprising a beam configured to extend from side to side of the vehicle at a lower front position thereof and to absorb collision energy. The beam is at least partly made of a plastic or polymeric material. The beam comprises a housing beam member having at least one channel extending along the housing beam member, and at least one reinforcement beam member adapted to fit into the channel of the housing beam member. The reinforcement beam member is arranged in the channel and arranged to extend along the housing beam member. The reinforcement beam member is provided with a plurality of wall elements comprising transversal wall elements distributed along and extending across the reinforcement beam member and longitudinal wall elements extending in a longitudinal direction of the reinforcement beam member between the transversal wall elements.

The invention relates to a front underrun protection device for a heavy vehicle comprising a beam configured to extend from side to side of the vehicle at a lower front position thereof and to absorb collision energy. The beam is at least partly made of a plastic or polymeric material. The beam comprises a housing beam member having at least one channel extending along the housing beam member, and at least one reinforcement beam member adapted to fit into the channel of the housing beam member. The reinforcement beam member is arranged in the channel and arranged to extend along the housing beam member. The reinforcement beam member is provided with a plurality of wall elements comprising transversal wall elements distributed along and extending across the reinforcement beam member and longitudinal wall elements extending in a longitudinal direction of the reinforcement beam member between the transversal wall elements.

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 vehicle includes a vehicle frame, a vehicle bumper and a load transfer assembly. The vehicle bumper is coupled to a front end of the vehicle frame and includes a center beam and a bumper beam extension that extends laterally from an end of the center beam. The load transfer assembly includes first and second pivot pins and a load beam. The first pivot pin is fixed to the bumper beam extension and the second pivot pin is fixed to the vehicle frame. The load beam has a first end pivotably coupled to the first pivot pin and a second end pivotably coupled to the second pivot pin. The load beam is configured to load the vehicle frame in a lateral direction upon a vehicle impact event.

A vehicle includes a vehicle frame, a vehicle bumper and a load transfer assembly. The vehicle bumper is coupled to a front end of the vehicle frame and includes a center beam and a bumper beam extension that extends laterally from an end of the center beam. The load transfer assembly includes first and second pivot pins and a load beam. The first pivot pin is fixed to the bumper beam extension and the second pivot pin is fixed to the vehicle frame. The load beam has a first end pivotably coupled to the first pivot pin and a second end pivotably coupled to the second pivot pin. The load beam is configured to load the vehicle frame in a lateral direction upon a vehicle impact event.

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 vehicle body front structure includes front frames, first and second bumper beams, sub-frames, gussets, and load transmission members. The front frames extend in a front-rear direction. The first bumper beam is disposed in front of the front frames. The first bumper beam extends in a vehicle width direction. The sub-frames are disposed below the front frames. The sub-frames extend in the front-rear direction. The second bumper beam is coupled to front ends of the sub-frames. Ends of the second bumper beam protrude further outward than the first bumper beam. Each gusset is coupled to a corresponding one of ends of the second bumper beam and a corresponding one of intermediate portions of the sub-frames. The gussets transmit an impact load to the intermediate portions. The load transmission members are coupled to the sub-frames. The load transmission members are disposed on outer side surfaces of the front frame.