An energy absorbing assembly for attachment to a vehicle, comprising: a beam, wherein the beam comprises a curved portion contiguous with and oriented between a first end portion and a second end portion, wherein the curved portion comprises a front side and a back side; a first crash can extending from the first end portion of the beam, the first crash can including cavity formed by sides extending from a first attachment face, with a first protrusion projecting forward from the attachment face toward the front side of the beam, and the first crash can extending behind the back side of the beam at the first end portion; wherein the first protrusion extend from the first attachment face by an amount that is greater than or equal to 110% of a distance that the first sides extend from the first attachment face.

A front-end carrier for a passenger vehicle is disclosed. The front-end carrier has at least one cross member element and at least two lateral strut elements which are connected to one another via the cross member element and extend downward in the vertical direction of the vehicle away from the cross member element. Via the strut elements, the front-end carrier can be supported on a main longitudinal support plane of the passenger vehicle. At least one further load plane is above the main longitudinal support plane and below the cross member element.

A pressure sensitive adhesive article of the present invention includes a pressure sensitive adhesive layer comprising a pressure sensitive acrylic polymer and inorganic fine particles; and a fibrous sheet formed by a plurality of mutually intersected fibers that are arranged in the pressure sensitive adhesive layer.

A method of making a hybrid energy absorbing beam, comprises: forming a polymer member comprising a first portion, wherein the first portion includes a first ledge and a connecting ledge connected by a first portion wall; and a rib extending from the first portion wall, wherein a cross-section of the rib taken along a line, A-A, comprises a first channel formed from an opening between a channel wall and a first traverse wall of a lobe, wherein the lobe comprises the first traverse wall and a second traverse wall with a connecting wall disposed between the first traverse wall and the second traverse wall; wherein the first channel extends along a portion of a length, L.sub.p, of the polymer member; and forming a metal/composite member; and attaching the polymer member to the metal/composite member on an opposite side of the polymer member as the connecting wall.

A resin structure having an impact absorbing property includes a resin member including a resin material and having an uneven thickness structure. The resin member includes a thick-walled portion having an average thickness of a first value in an impact absorbing direction and two thin-walled portions having an average thickness of less than the first value in the impact absorbing direction. The thick-walled portion is disposed between the two thin-walled portions. The Expressions (I) and (II) are satisfied.

1<t1/t2<1.545(L/d).sup.0.107 (I)

L/d>0 (II)

In Expressions (I) and (II), t1 represents an average thickness (mm) of the thick-walled portion. t2 represents an average thickness (mm) of the thin-walled portions. L represents an inter-connection-point distance (mm) between connection points formed on the two thin-walled portions, respectively, and connected to other structures. d represents a maximum height (mm) in the impact absorbing direction in a range between the connection points of the resin member.

A bumper assembly is provided having a flange that overlies the body of the vehicle. The flange may be a body flange extending from an elongate bumper beam or a cladding flange extending from an external cladding that covers at least a portion of the bumper beam. The flange may protect the body from wear or corrosion, and/or bridge a gap between the frame and the body of the vehicle. The assembly may also include a contact structure for contacting at least a portion of the vehicle frame, such as the hitch beam. The contact structure may resist rotation of the bumper assembly, prevent vibration of the bumper assembly against the frame, and/or support a vertical load on the bumper. In some embodiments, the assembly may be primarily mounted to the body of the vehicle, such that the bumper beam hangs from the body of the vehicle.

A deformation structure has at least a first layer and a second layer, which are spaced apart from each other and are mounted to be movable relative to each other in the deformation direction or load direction. The first layer and the second layer have complementary protrusions and recesses, which are designed such that the protrusions of the first layer can dip into the recesses of the second layer and vice versa. The first layer and the second layer are connected to each other by deformable connecting pieces such that, in the event of a high impulse in the deformation direction, the protrusions of the first layer dip into the recesses of the second layer and the protrusions of the second layer dip into the recesses of the first layer such that the deformation structure is deformed in the deformation direction at a relatively low level of force and, in the event of a low impulse in the deformation direction, the protrusions of the first layer hit the protrusions of the second layer such that the deformation structure is deformed further in the deformation direction at a relatively high level of force. The deformation control device is formed or produced separately from the first and the second layer and is removably or non-removably connected to the first layer and the second layer.

A method of making a hybrid energy absorbing beam, comprises: forming a polymer member comprising a first portion, wherein the first portion includes a first ledge and a connecting ledge connected by a first portion wall; and a rib extending from the first portion wall, wherein a cross-section of the rib taken along a line, A-A, comprises a first channel formed from an opening between a channel wall and a first traverse wall of a lobe, wherein the lobe comprises the first traverse wall and a second traverse wall with a connecting wall disposed between the first traverse wall and the second traverse wall; wherein the first channel extends along a portion of a length, Lp, of the polymer member; and forming a metal/composite member; and attaching the polymer member to the metal/composite member on an opposite side of the polymer member as the connecting wall.

A manufacturing method for a joined body, includes: bringing a first member and a second member into contact with each other, at least one of the first member and the second member being made of thermoplastic resin, and the second member having a recessed portion on a joining surface to be joined to the first member; and welding the first member and the second member together, including welding a contact portion of the first member and the second member by melting the thermoplastic resin by frictional heat generated in the contact portion by relative movement of the first member and the second member, in a state in which the first member and the second member are in contact with each other.

An approach to designing lightweight metal-polymer composite structures in a manner that decomposes the structure into at least two parts. In one specific embodiment, the approach is a manufacturing process for a vehicle that includes attaching an impact beam to a vehicle structure. The process includes providing a vehicle structure including a back plate of the impact beam being made of a suitable material, such as a metal, that can withstand high temperature processes. A front part of the impact beam including a front plate and a polymer core is attached to the back plate. The back plate is designed to provide structural integrity that allows the vehicle structure to go through the high temperature processes and/or the vehicle structure provides structural integrity that allows the back plate to go through the one or more processes. The back plate is also designed to provide desired functional characteristics of the beam.