A method of manufacturing an energy-absorbing structure according to various aspects of the present disclosure via a two-step molding process includes molding first and second portion precursors including thermoset polymers (e.g., thermoset polymer composites) to a first degree of cure (DOC) less than one so that the portion precursors are in a gelled glass state. The method further includes joining the first and second portion precursors by applying heat and pressure in a joining region such that the thermoset polymers have a second DOC greater than the first DOC and are cross-linked in the joining region. The energy-absorbing component therefore has a unitary structure. The method may further include coupling the energy-absorbing structure to a housing. In certain aspects, energy-absorbing structures may have tailored stiffness and/or tailored crush initiation.

A method and system of curved crease foldcores as energy absorbers with rule lines can that lie parallel in the flat state. Corrugated sheet is bonded to the foldcore material such that the corrugations align with the ruling. The curved creases are then cut from the corrugated layer. The image of the corrugation lines under the folding motion remains a line, and the corrugated structure survives and reinforces the folding mechanism. The corrugation significantly increases the second area moment of inertia about the crushing direction, while leaving the second area moment of inertia about the perpendicular direction largely unchanged. Under compressive failure, the corrugated foldcore fails progressively, rather than catastrophically. Also, the corrugations enforce the curved crease pattern, allowing the required curved panels to be bent while disallowing other deformations. This limiting of extraneous deformation aids in manufacturing, and as a global boundary condition readily enforces local folding directions.

An energy absorbing beam comprises a top plate and a bottom plate, a plurality of upper pillars extending from the top plate toward the bottom plate, a plurality of lower pillars extending from the bottom plate toward the top plate, and a first beam extending laterally between the top plate and the bottom plate and attached to the upper and lower pillars, wherein energy from an impact onto the top or bottom plate is transferred through the upper and lower pillars and absorbed by the first beam.

An instrument panel assembly includes a support beam and an exterior panel. The instrument panel assembly includes an energy absorbing device between the support beam and the exterior panel and having a variable crush resistance based on a temperature of the energy absorbing device. The instrument panel assembly includes a heater operatively coupled to the energy absorbing device.

Support structure adapted to form a collision object for use when testing a subject vehicle to simulate a real traffic environment, the support structure comprising a plurality of panels having a bending stiffness according to ISO 5628:2012 of 20 Nm to 60 Nm, such as 30 Nm to 50 Nm, such as 35 Nm to 45 Nm. A support structure adapted to form a collision object for use when testing a subject vehicle to simulate a real traffic environment, the support structure comprising a plurality of panels made from cardboard, is also provided. A collision object for use when testing a subject vehicle to simulate a real traffic environment is also provided.

A flexible energy absorbing system comprising a material coated, impregnated and/or combined with a strain rate sensitive substance is disclosed. It is formed so as to define repeating adjacent cells, each cell having a re-entrant geometry such that, upon impact, the material locally densifies at the impact site.

An instrument panel assembly includes a support beam and an exterior panel. The instrument panel assembly includes an energy absorbing device between the support beam and the exterior panel and having a variable crush resistance based on a temperature of the energy absorbing device. The instrument panel assembly includes a heater operatively coupled to the energy absorbing device.

A flexible energy absorbing system comprising a material coated, impregnated and/or combined with a strain rate sensitive substance is disclosed. It is formed so as to define repeating adjacent cells, each cell having a re-entrant geometry such that, upon impact, the material locally densifies at the impact site.

A lateral energy absorption system includes a first carbon structure. The first carbon structure includes a first plurality of carbon tubes. The first plurality of carbon tubes have a first end with a first width and a second end with a second width. The first plurality of carbon tubes define a first taper between the second end and the first end that facilitates crumpling of the first plurality of carbon tubes during an impact. A first plurality of carbon flanges connects the carbon tubes together.

A reinforcement member is provided and includes a reinforcement unit that has a pair of reinforcement unit bodies. Each of the reinforcement unit bodies has a protruding surface protruding from a middle part of the reinforcement unit body relative to a longitudinal direction of the reinforcement unit body. The protruding surfaces of the reinforcement unit bodies are in contact with each other while opposing each other, and opposite end parts of the reinforcement unit have rectangular cross sections when cutting the reinforcement unit perpendicularly to a longitudinal direction of the reinforcement unit. A plurality of reinforcement units are arranged and the cross sections of the opposite end parts of the reinforcement units form columns and rows of the reinforcement member.