A bumper beam includes an outer portion and an inner portion each extending between a top end and a bottom end. At least one of the outer portion or the inner portion includes a pair of geometrical features each of which are disposed in spaced relationship to one another and adjacent a respective one of the top or bottom ends. A top wall and a bottom wall each extend from one of the geometrical features to the other of the outer portion or the inner portion to interconnect the outer and inner portions of the bumper beam. The geometrical features can be varied in size and shape to change and tune the energy absorption properties of the bumper beam and ultimately provide for a bumper beam that is adaptable and flexible over a range of vehicle applications.

A method to prepare a composite laminate object containing an extrusion grade 7xxx Al substrate and a fiber-reinforced polypropylene layer adhesively laminated to the substrate; is provided. The process includes shaping and cutting an extruded 7xxx aluminum to a profile, assembling a layered arrangement of the 7xxx Al profile as substrate, an adhesive film and a fiber reinforced polypropylene preform, heating the layered arrangement to a temperature of 160-175 C. to melt the polypropylene and activate the adhesive film, applying pressure to at least a surface of the fiber reinforced polypropylene preform to mold the preform to the shape of the extruded 7xxxAl substrate and obtain a semi-finished laminate object, cooling the semi-finished laminate object to 90 C., optionally, cooling the semi-finished laminate object to room temperature for inventory storage; heat treating the semi-finished laminate object at 90 C. for 2 to 8 hours; and then heat treating the semi-finished laminate object at 130 C. to 150 C. for 8 to 16 hours; and cooling the heat treated object to obtain the composite laminate object.

A vehicle body structure includes a reinforcing material layer formed of a fiber reinforced resin and a vehicle skeleton member having a closed sectional structure formed of metal. The reinforcing material layer is bonded to a surface of the vehicle skeleton member having a recessed portion recessed toward an inside of the closed sectional structure. An adhesive is disposed at least between the recessed portion and the reinforcing material layer.

A method for joining a first part formed of an aluminum material to a second part formed of a steel material by metal inert gas welding and cold metal transfer is provided. An aluminum filler material forms a fillet joint between the parts and provides a structure for automotive body applications, such an aluminum bumper extrusion joined to a steel crush box connection. The first part includes a notch for hiding the start and end of the joint. A transition plate formed of a mixture of aluminum material and steel material can be disposed between the first part and the second part to provide the notch. The second part can include a mechanical fastener further joining the parts together. In another embodiment, the second part includes a plurality of dimples and is welded to the first part along the dimples.

A beam configured to couple to a vehicle includes end areas comprising end midpoints that are equidistant from a top face and a bottom face on a vertical axis when the beam is positioned on a vehicle, and a central area positioned between the end areas, the central area having a central area midpoint that is equidistant from the top face and the bottom face on the vertical axis when the beam is positioned on a vehicle and that is positioned in the center of the beam along the longitudinal axis. The longitudinal axis of the beam passes through the end area, wherein the central area is capable of rotating about the longitudinal axis when the beam is impacted by an applied force.

An energy absorbing member (20) is formed of an aluminum alloy extruded material having a substantially quadrangular outer shape. Straight portions of a pair of long sides of a quadrangular shape are each segmented into three side walls (21a, 21b, 21c) by two arcuate internal projections (26) that project inward. Vertices of opposing internal projections (26) are joined by a rib (25). Accordingly, the energy absorbing member (20) is configured to have a shape in which three cylindrical portions having hollow portions (24a, 24b, 24c) are joined. Arc-shaped internal projections (23) that each project inward are provided in four corners of the quadrangular shape.

An energy-absorbing structure includes first and second components. The first component includes a polymer and a plurality of reinforcing fibers disposed therein. The first component includes first bumper and crush member portions respectively defined by first and second walls. The second wall projects from and is integrally formed with the second wall. At least some of the fibers continuously extend between the first and second walls. The second component includes the polymer and a plurality of reinforcing fibers. The second component includes second bumper and crush member portions respectively defined by third and fourth walls. The fourth wall projects from and is integrally formed with the third wall. At least some of the fibers continuously extend between the third and fourth walls. The first and second components are joined. The first and third walls cooperate to define a bumper. The second and fourth walls cooperate to define a crush member.

A bumper assembly is provided. The bumper assembly includes a back beam that is disposed within a bumper to absorb an external impact and a collision box that has a hollow tube shape. A first end portion of the collision box is coupled to the back surface of the back beam to receive an impact applied to the back beam and a plate is coupled to a second end portion of the collision box. In particular, the collision box is bonded with the back beam and the plate by an electro magnetic pulse technology method.

A bumper reinforcement includes an aluminum alloy extrusion body having a pair of flanges to be positioned on a vehicle body side and on a collision side and a pair of webs to be positioned in a vehicle vertical direction. The pair of webs connect the pair of flanges at joint portions such that the pair of webs and the pair of flanges form a closed cross section, and the pair of webs do not have a welded portion.

The present invention relates to a front bumper system for a vehicle. A pair of front side members is arranged along a front-rear direction of the vehicle and arranged on opposite sides of the vehicle and on opposite sides of a cross member structure of the vehicle. Pair of crash box units are mechanically fixated to the front side members. A front bumper is laterally disposed and mechanically fixated to each of the crash box units. A lateral push element is mechanically fixed to one of the crash box units and being arranged to provide a load transfer path via the cross member structure towards the opposing front side member such that at least the front side member on the side of the lateral push element is moved towards the opposing front side member in the event of a crash.