Bumper system with integrated energy absorber underbar
View Patent ↗A bumper system for an automobile vehicle includes, in an exemplary embodiment, a beam configured to attach to the vehicle, and a thermoplastic energy absorber coupled to the beam. The energy absorber includes an upper portion including a frame portion and a body having a plurality of tunable crush lobes extending from the frame portion. The energy absorber also includes an underbar spaced apart from the upper portion and a plurality of connecting towers extending between the upper portion and the underbar and connecting the underbar to the upper portion.
1. A bumper system for an automobile vehicle, said bumper system comprising:
a beam configured to attach to the vehicle; and
a thermoplastic energy absorber coupled to said beam, said energy absorber comprising:
an upper portion comprising a frame portion and a body comprising a plurality of tunable crush lobes extending from said frame portion;
an underbar spaced apart from said upper portion and positioned below said beam; and
a plurality of connecting towers extending between said upper portion and said underbar and connecting said underbar to said upper portion;
said upper portion of said energy absorber comprising a first thermoplastic material and said underbar and plurality of connecting towers comprising a second thermoplastic material.
2. A bumper system in accordance with claim 1 wherein said plurality of connecting towers comprise at least one of a C-shape, a W-shape, and a ribbed C-shape.
3. A bumper system in accordance with claim 2 wherein at least one of said plurality of connecting towers further comprises a molded-in metal backbone.
4. A bumper system in accordance with claim 1 wherein said second thermoplastic material has a stiffness characteristic that is stiffer than the stiffness characteristic of said first thermoplastic material.
5. A bumper system in accordance with claim 1 wherein said second thermoplastic material is more brittle than said first thermoplastic material.
6. A bumper system in accordance with claim 1 wherein said beam comprises at least one of steel, aluminum, thermoplastic, and glass mat thermoplastic.
7. A bumper system in accordance with claim 1 further comprising a fascia positioned and sized to envelop said beam and said energy absorber.
8. A bumper system for an automobile vehicle, said bumper system comprising:
a beam configured to attach to the vehicle;
a thermoplastic energy absorber coupled to said beam, said energy absorber being tunable for meeting predetermined criteria for both low speed and pedestrian impacts; and
a fascia positioned and sized to envelop said beam and said energy absorber;
said energy absorber comprising:
an upper portion comprising a frame portion and a body, said body comprising a plurality of tunable crush lobes extending from said frame portion, each said crush lobe longitudinally spaced apart from an adjacent crush lobe;
an underbar spaced apart from said upper portion and positioned below said beam; and
a plurality of connecting towers extending between said upper portion and said underbar and connecting said underbar to said upper portion;
said upper portion of said energy absorber comprising a first thermoplastic material and said underbar and plurality of connecting towers comprising a second thermoplastic material.
9. A bumper system in accordance with claim 8 wherein said plurality of connecting towers comprise at least one of a C-shape, a W-shape, and a ribbed C-shape.
10. A bumper system in accordance with claim 9 wherein at least one of said plurality of connecting towers further comprises a molded-in metal backbone.
11. A bumper system in accordance with claim 8 wherein said second thermoplastic material has a stiffness characteristic that is stiffer than the stiffness characteristic of said first thermoplastic material.
12. A bumper system in accordance with claim 8 wherein said second thermoplastic material is more brittle than said first thermoplastic material.
13. A bumper system in accordance with claim 8 wherein said beam comprises at least one of steel, aluminum, thermoplastic, and glass mat thermoplastic.
14. An energy absorber attachable to a beam in a vehicle bumper system, said energy absorber being tunable for meeting predetermined criteria for both low speed and pedestrian impacts and comprising:
an upper portion comprising a frame portion and a body, said body comprising a plurality of tunable crush lobes extending from said frame portion, each said crush lobe longitudinally spaced apart from an adjacent crush lobe;
an underbar spaced apart from said upper portion so that said underbar is positioned below the beam when said energy absorber is attached to the beam; and
a plurality of connecting towers extending between said upper portion and said underbar and connecting said underbar to said upper portion;
said upper portion of said energy absorber comprising a first thermoplastic material and said underbar and plurality of connecting towers comprising a second thermoplastic material.
15. A bumper system in accordance with claim 14 wherein said plurality of connecting towers comprise at least one of a C-shape, a W-shape, and a ribbed C-shape.
16. A bumper system in accordance with claim 15 wherein at least one of said plurality of connecting towers further comprises a molded-in metal backbone.
17. A bumper system in accordance with claim 14 wherein said second thermoplastic material has a stiffness characteristic that is stiffer than the stiffness characteristic of said first thermoplastic material, and wherein said second thermoplastic material is more brittle than said first thermoplastic material.