A system for managing lateral loads in a vehicle includes a crossmember and one or more structures that may be deformable. The crossmember is arranged laterally spanning a first longitudinal frame member, arranged on a first side of the vehicle, and a second longitudinal frame member of the vehicle, arranged on a second side of the vehicle. The structure is affixed to one lateral side of the vehicle, arranged longitudinally forward of the crossmember, arranged laterally outside of the first frame member, and is configured to deform during a small overlap collision. The structure, when under load, is configured to apply a lateral force on an end of the crossmember to cause lateral displacement of the vehicle. A vehicle may include a structure on each side of the vehicle to generate lateral displacement of the vehicle away from a colliding rigid barrier.

A shock absorbing component (a vehicular component having a shock absorbing structure) formed from an aluminum alloy hollow extrusion in an elongated shape includes a collision wall, a non-collision wall, an upper wall, a lower wall, and an inner rib. The collision wall forms a collision surface. The non-collision wall forms a non-collision surface 1B. The upper wall and the lower wall 40 connect the collision wall to the non-collision wall. The shock absorbing component is mounted to a vehicle with a stay (a mounting member) on the non-collision surface. The collision wall and the non-collision wall include joint portions joined to the inner rib. The joint portions of the collision wall and the non-collision wall include a collision wall-side recess formed by recessing the collision wall toward the inner rib in the longitudinal direction of the shock absorbing component and a non-collision wall-side recess formed by recessing the non-collision wall toward the inner rib in the longitudinal direction.

A shock absorbing component (a vehicular component having a shock absorbing structure) formed from an aluminum alloy hollow extrusion in an elongated shape includes a collision wall, a non-collision wall, an upper wall, a lower wall, and an inner rib. The collision wall forms a collision surface. The non-collision wall forms a non-collision surface 1B. The upper wall and the lower wall 40 connect the collision wall to the non-collision wall. The shock absorbing component is mounted to a vehicle with a stay (a mounting member) on the non-collision surface. The collision wall and the non-collision wall include joint portions joined to the inner rib. The joint portions of the collision wall and the non-collision wall include a collision wall-side recess formed by recessing the collision wall toward the inner rib in the longitudinal direction of the shock absorbing component and a non-collision wall-side recess formed by recessing the non-collision wall toward the inner rib in the longitudinal direction.

A vehicle includes a body. The vehicle includes a front bumper reinforcement that is attached to a front end of the body, and extends along a vehicle width direction. The vehicle includes a lower bumper reinforcement that is attached to the front end of the body, is located under the front bumper reinforcement, and extends along the vehicle width direction. The vehicle includes at least one specific member that is fixed to a partial section of the lower bumper reinforcement along an extending direction of the lower bumper reinforcement. Each of the at least one specific member includes a first portion that covers a front face of the lower bumper reinforcement, and a second portion that protrudes more upward than an upper face of the lower bumper reinforcement.

A joining method of a structure includes preparing a first member including a first portion provided with a first hole and a second portion provided with a second hole, a second member, a die, and an elastic member, inserting the second member into the first hole, inserting the elastic member into the second member, in a state where one end of the second member in an axial direction is located between the first portion and the second portion, compressing and expanding the elastic member in the axial direction, thereby expanding and deforming the second member at a portion passing through the first hole to be swaged and joined to the first portion. The die includes a support surface for applying a compressive force from the die to the elastic member through the second hole. The support surface is perpendicular to an axial direction of the elastic member.

A joining method of a structure includes preparing a first member including a first portion provided with a first hole and a second portion provided with a second hole, a second member, a die, and an elastic member, inserting the second member into the first hole, inserting the elastic member into the second member, in a state where one end of the second member in an axial direction is located between the first portion and the second portion, compressing and expanding the elastic member in the axial direction, thereby expanding and deforming the second member at a portion passing through the first hole to be swaged and joined to the first portion. The die includes a support surface for applying a compressive force from the die to the elastic member through the second hole. The support surface is perpendicular to an axial direction of the elastic member.

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.

An under-protector fastening structure includes a bumper assembly coupled to a chassis frame, wherein the bumper assembly includes a bumper inner member and a bumper cover coupled to an outer side of the bumper inner member, and an under-protector coupled to the bumper inner member of the bumper assembly in a direction vertical to a length direction of a vehicle body, wherein the under-protector includes an under-protector mounting assembly coupled to the bumper inner member and an under-protector panel coupled to the under-protector mounting assembly, and wherein the under-protector mounting assembly includes a pipe member extending in the direction vertical to the length direction of the vehicle body, a mounting bracket coupled to the pipe member and the bumper inner member, and an under-protector fixing bracket having a first side coupled to the mounting bracket and a second side coupled to the under-protector panel.

An under-protector fastening structure includes a bumper assembly coupled to a chassis frame, wherein the bumper assembly includes a bumper inner member and a bumper cover coupled to an outer side of the bumper inner member, and an under-protector coupled to the bumper inner member of the bumper assembly in a direction vertical to a length direction of a vehicle body, wherein the under-protector includes an under-protector mounting assembly coupled to the bumper inner member and an under-protector panel coupled to the under-protector mounting assembly, and wherein the under-protector mounting assembly includes a pipe member extending in the direction vertical to the length direction of the vehicle body, a mounting bracket coupled to the pipe member and the bumper inner member, and an under-protector fixing bracket having a first side coupled to the mounting bracket and a second side coupled to the under-protector panel.