A hybrid bumper assembly for a vehicle includes a steel reinforcement beam and aluminum crush cans attached to end portions of the steel reinforcement beam. The reinforcement beam has a multi-tubular shape that is formed by a high-strength steel sheet that is roll formed to provide at least two tubular portions. A crush can has an interfacing portion that is coupled to an end portion of the reinforcement beam. The end portions of the reinforcement beam and the interfacing portion of the crush cans may be configured to attach together using a select joining technology in a manner that minimizes or eliminates bimetallic or galvanic corrosion between the reinforcement beam and the crush cans.

A vehicle beam assembly includes a hollow tubular member configured to be formed with steel tube air forming. The tubular member includes a varied cross section along a length of the tubular member. For example, the hollow tubular member includes a center portion having a first cross-sectional shape, a pair of end portions that extend past corresponding crush cans in a direction away from the center portion, where the pair of end portions extend at an angle of 40-70 degrees, and at least one transition portion disposed between the center portion and one of the pair of end portions. A cross-sectional shape of the center portion, a cross sectional shape of one of the end portions, and a cross-sectional shape of the transition portion are all different cross-sectional shapes.

There is provided a reinforcement member for a vehicle which includes a cylindrical body section having a continuously closed cross section intersecting with a longitudinal direction. The cylindrical body section has a first surface, a second surface, and a third surface. The third surface has a fourth surface extending away from the second surface, and a fifth surface connecting the fourth surface and the first surface to each other. In a sectional view when viewed in the longitudinal direction, in a case where a virtual line connecting a first intersection portion where the first surface and the third surface intersect with each other and a second intersection portion where the second surface and the third surface intersect with each other is set, a third intersection portion where the fourth surface and the fifth surface intersect with each other protrudes outward with respect to the virtual line.

A motor vehicle bumper that has a transverse carrier which can be secured transversely relative to the longitudinal carriers of the motor vehicle by crash boxes. The transverse carrier has a shell member which is open toward the front side and which has a rear wall and two outer members which are both adjoined at the end side by an outwardly directed longitudinal flange. The shell member has a central longitudinal portion which is adjoined in the direction toward the two ends of the transverse carrier by a transition portion, an intermediate portion, a crash box connection portion and an end portion. The shell member is closed at least over the majority of the length thereof by a closure plate which forms the front side. In the transition portions, the shell member has a minimum depth which is less than the maximum depth in the central longitudinal 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 beam article for a vehicle includes a plurality of separate elongated metal sheets attached together to form generally planar walls of an elongated tubular structure. At least one of the plurality of separate elongated metal sheets has a shear wall that is disposed along a hollow interior of the elongated tubular structure and is attached at opposing walls of the elongated tubular structure. At least one of the plurality of separate elongated metal sheets comprises an edge that abuts a side surface of an adjacent one of the plurality of separate elongated metal sheets to define a non-radiused perpendicular weld corner along the elongated tubular structure.

A hybrid bumper assembly for a vehicle includes a steel reinforcement beam and aluminum crush cans attached to end portions of the steel reinforcement beam. The reinforcement beam has a multi-tubular shape that is formed by a high-strength steel sheet that is roll formed to provide at least two tubular portions. A crush can has an interfacing portion that is coupled to an end portion of the reinforcement beam. The end portions of the reinforcement beam and the interfacing portion of the crush cans may be configured to attach together using a select joining technology in a manner that minimizes or eliminates bimetallic or galvanic corrosion between the reinforcement beam and the crush cans.

A bumper-reinforcing system (1) intended for a motor vehicle includes: a bumper beam (2) with a single-piece elongated profile with a closed cross section and including a center zone (21) extending at least over part of the entire width of the bumper beam and an end zone (22) at each extremity of the bumper beam, two bumper fasteners (3) connected to the rear side of the bumper beam (2) at the intersection between the center zone (21) and the end zone (22) of the bumper beam (2), two reinforcing tubes (4) connected by their first end to the rear side of the end zone (22) of the bumper beam (2), extending from the bumper beam (2) so as to form an angle α below 45° with the vertical plane of symmetry of the bumper beam and suited to be connected by their other end on the front rail of the vehicle for which the bumper-reinforcing system (1) is provided, and two covers (5) with a single-piece elongated profile with an open cross section, in contact with the rear side of the end zone (22) of the bumper beam (2) and extending at least from the first end of one of the reinforcing tubes (4) to one of the bumper fasteners (3).

A galvanized reinforcement beam is continuously formed by uncoiling a roll of galvanized sheet stock in a generally horizontal plane. Protrusions are formed at an upper surface of the sheet stock, which is then roll formed to form a tubular shape with the protrusions abutting a surface of the sheet stock to form venting gaps. The sheet stock is laser welded at the protrusions to continuously form a weld joint, where zinc oxide gas generated from the welding is permitted to escape an interior of the tubular shape through the venting gaps.

A structure of an underrun protection bound to a plurality of brackets disposed at the front or rear portion of a frame of a vehicle is disclosed. A hollow having a closed section is defined by a distal face of a longitudinal direction of the vehicle, a proximal face of the longitudinal direction, an upper face, and a lower face. Lightening holes are formed on at least one of the upper face and the lower face of the underrun protection.