The present bumper impact beam includes pultruding polymer (e.g. thermoset polymer, preferably polyurethane) into continuous reinforcement (preferably carbon fibers or glass fibers), the reinforcement including fabrics selectively positioned and extending around corners for improved impact strength. The beam preferably has a 50%-70% fiber volume fraction that is relatively uniform throughout the part. A curved cooling support and/or beam design may be used to cause the cooled beam to have a sweep.

A method is disclosed for manufacturing a bumper structure. A blank made out of fiber-reinforced composite material is deep drawn in a molding tool to form a bumper cross member having a first groove. A first rib structure is molded in the first groove onto the bumper cross member in the molding tool.

An energy-absorbing member has a structure in which a plurality of fiber reinforced resin layers are layered in a thickness direction of said member and includes as the plurality of fiber reinforced resin layers, at least a plurality of unidirectional materials each including unidirectionally aligned reinforcing fibers and a resin and a plurality of cross materials each including a reinforcing fiber woven fabric and a resin, wherein lengths of the plurality of unidirectional materials in an external-loading direction are sequentially changed.

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.

A bumper back-beam for a vehicle is provided. The bumper back beam includes a glass fiber mat reinforced plastic composite and a carbon fiber reinforced plastic composite disposed within the glass fiber reinforced plastic composite. The glass fiber mat reinforced plastic composite includes polypropylene at about 45 to 60 wt. %, glass fiber at about 35 to 45 wt. %, a crosslink agent at about 0.1 to 10 wt. %, peroxide at 0.1 to 4 wt. %, and an antioxidant at about 0.1 to 4 wt. %. The carbon fiber reinforced plastic composite includes a thermoplastic resin at about 40 to 60 wt. % and a carbon reinforced fiber at about 40 to 60 wt. % arranged in a predetermined direction.

A method of manufacturing a crash-resistant structural part for an automobile, the crash-resistant structural part including a beam element for receiving an impact force during a crash of the automobile is provided. The method comprises a step of arranging at least one layer of fibers having a length of 100 mm or more, and a step of mixing components required to form a thermoplastic polymer resin, the components including a reactive monomer, thereby forming a liquid precursor mixture of the thermoplastic polymer resin. At least one layer of fibers is impregnated with the liquid precursor mixture, and the beam element is formed by an in-situ polymerization reaction of the liquid precursor mixture having impregnated the at least one layer of fibers.

A bumper cross member for a motor vehicle includes an insert of fiber-reinforced composite material and reinforcing structures molded onto the insert. A first groove is formed onto the insert, and the reinforcing structures include ribs formed in the first groove. The ribs extend inclined in relation to a longitudinal direction of the groove from one lateral wall of the groove to the other. The insert is further formed into a second groove, which are open toward opposing sides of the insert. The first and second grooves share a lateral wall. An outer bumper skin is supported by the bumper cross member.

A vehicle body rail for a motor vehicle, which is constructed of fiber-reinforced plastic and is designed as a vehicle body rail which absorbs energy in the event of a collision of the motor vehicle, includes a wall. The wall is provided with indentations and/or elevations such that, in the event of an application of a predetermined collision threshold load in a longitudinal direction of the vehicle body rail, a failure of the wall by fragmentation takes place in the area of the indentations and/or elevations.

A front structure constitutes a front portion of a vehicle body and has a main body including a pair of side portions, an upper portion, and a pair of stay portions. The side portions are provided at an interval in a width direction, and extend in an upper-lower direction. The upper portion extends in the width direction, and couples end portions on an upper side of the side portions. The stay portions extend from respective end portions on a lower side of the side portions in respective directions intersecting both the width direction and the upper-lower direction, and are connected to the upper portion. An end edge on the lower side of the stay portions constitutes a part of an outer peripheral edge of the front structure. The side portions, the upper portion, and the stay portions have an uneven portion extending along directions in which these portions extend.

An energy-absorbing device for a vehicle is disclosed. The energy-absorbing device includes a main direction of elongation, an external face intended to receive an impact, a core made of an energy-absorbing material, and a plastic structure that forms a one-piece entity with the core. The core is of a corrugated shape with a succession of crests in a direction of extension parallel to the main direction of elongation. The plastic structure includes means of attaching the energy-absorbing device to an element of a vehicle which is to be protected. The external face is formed at least in part by crests of the corrugated shape of the core.