Fascia energy absorber, bumper system and process

1. A fascia energy absorber comprising:

an outer polymer member having at least a portion which is curved; and

an inner member comprising a base and a plurality of crush lobes, and

wherein at least one of the plurality of crush lobes comprises a projected wall spaced a distance from the base, and at least one sidewall which extends from the base to the projected wall of the crush lobe; and

wherein the inner member has an external surface located between an internal surface of the inner member and the outer polymer member;

wherein the outer polymer member has an inner surface located between an outer surface of the outer polymer member and the inner member;

wherein the inner member external surface is joined to the outer polymer member inner surface;

wherein at least a first of the plurality of crush lobes is spaced apart from a second of the plurality of crush lobes and separated by a portion of the base; and

wherein at least one of the inner member and the outer polymer member has a thickness that is 0.1 millimeters to 2 millimeters.

2. The fascia energy absorber of claim 1 , wherein the outer polymer member and the inner member are thermoformed components of the fascia energy absorber.

3. The fascia energy absorber of claim 1 , wherein the base of the inner member contacts the outer member and the projected wall of the inner member is spaced a distance from the outer polymer member.

4. The fascia energy absorber of claim 1 , wherein the projected wall of the inner member contacts the outer polymer member.

5. The fascia energy absorber of claim 1 , wherein the outer polymer member substantially envelops the inner member.

6. The fascia energy absorber of claim 1 , wherein at least one of the plurality of crush lobes is corrugated.

7. The fascia energy absorber of claim 1 , wherein at least one of the plurality of crush lobes has a transverse width and a height, and the height of the crush lobe varies along the transverse width.

8. The fascia energy absorber of claim 1 , wherein the projected walls of at least two of the plurality of crush lobes extends substantially along the same plane.

9. The fascia energy absorber of claim 1 , wherein the projected wall of each of the plurality of crush lobes extends substantially along the same plane.

10. The fascia energy absorber of claim 1 , wherein the at least one sidewall of the at least one crush lobe is oriented at an angle relative to the projected wall, wherein the angle ranges from 90 degrees to 145 degrees.

11. The fascia energy absorber of claim 1 , wherein the wall thickness of the at least one sidewall of at least one of the plurality of the crush lobes is at least as great as 50% of the thickness of the base.

12. The fascia energy absorber of claim 1 , wherein the wall thickness of the at least one sidewall of at least one of the plurality of the crush lobes is at least as great as 80% of the thickness of the base.

13. The fascia energy absorber of claim 1 , wherein the distance between the projected wall and the base of at least one of the plurality of the crush lobes ranges from 25 to 75 millimeters.

14. The fascia energy absorber of claim 1 , wherein the outer polymer member has at least one lip proximate to an edge of the outer polymer member.

15. The fascia energy absorber of claim 1 , wherein at least a portion of the base of the inner member has a contoured surface that extends in at least two different directions.

16. The fascia energy absorber of claim 1 , wherein at least one of the inner member and outer polymer member comprises a multi-layer of at least two different material compositions.

17. The fascia energy absorber of claim 1 , wherein the inner member and outer polymer member comprises different material composition.

18. The fascia energy absorber of claim 1 , wherein the inner member and the outer polymer member comprise a thermoplastic material.

19. The fascia energy absorber of claim 1 , wherein the inner member and the outer polymer member each comprise a thermoplastic material selected from polyester, polycarbonate, polyolefin or blends thereof.

20. The fascia energy absorber of claim 1 , wherein the inner member is joined to the outer member by an element selected from the group consisting of an adhesive, a solder joint, a fastener, and a screw.

21. The fascia energy absorber of claim 1 , wherein the inner member is joined to the outer member without fasteners.

22. The fascia energy absorber of claim 1 , wherein the outer member is the outermost member of the fascia energy absorber.

23. The fascia energy absorber of claim 1 , wherein the inner member is directly joined to the outer member to form a unitary structure.

24. The fascia energy absorber of claim 1 , wherein the inner member and outer member form a closed box-like cross-section.

25. A bumper system comprising:

a bumper beam; and

a fascia energy absorber, comprising

an outer member having at least a portion which is curved; and

an inner member comprising a base and a plurality of crush lobes, and

wherein at least one of the plurality of crush lobes comprises a projected wall spaced a distance from the base, and at least one sidewall which extends from the base to the projected wall of the crush lobe; and

wherein the inner member has an external surface located between an internal surface of the inner member and the outer member;

wherein the outer member has an inner surface located between an outer surface of the outer member and the inner member;

wherein the inner member external surface is joined to the outer member inner surface;

wherein at least a first of the plurality of crush lobes is spaced apart from a second of the plurality of crush lobes and separated by a portion of the base;

wherein at least one of the inner member and the outer member has a thickness that is 0.1 millimeters to 2 millimeters.

26. The bumper system of claim 25 , wherein the base of the inner member contacts the bumper beam and the base comprises a contoured surface that contacts the bumper beam in at least two different directions.

27. A fascia energy absorber comprising:

a thermoformed outer member having at least a portion which is curved; and

a thermoformed inner member joined to the outer member wherein the inner member comprises a base and a plurality of crush lobes which extend from the base; and

wherein at least one of the plurality of crush lobes comprises a projected wall spaced a distance from the base and at least one sidewall which extends from the base to the projected wall of the crush lobe, and wherein the at least one sidewall has a thickness which is at least as great as 60% of the thickness of the base; and

wherein the inner member has an external surface located between an internal surface of the inner member and the outer member;

wherein the outer member has an inner surface located between an outer surface of the outer member and the inner member;

wherein the inner member external surface is joined to the outer member inner surface in at least one location without the use of a fastener;

wherein at least one of the inner member and the outer member has a thickness that is 0.1 millimeters to 2 millimeters.

28. The fascia energy absorber of claim 27 , wherein at least a first one of the plurality of crush lobes is spaced apart from a second one of the plurality of crush lobes and separated by a portion of the base.

29. The fascia energy absorber of claim 27 , wherein the inner member and outer member form a closed box-like cross-section.

30. A bumper system comprising:

a bumper beam; and

the fascia energy absorber of claim 27 .

31. A fascia energy absorber comprising:

an outer member having at least a portion which is curved; and

an inner member joined to the outer member wherein the inner member comprises a base and a plurality of crush lobes, and

wherein the inner member can slide along a bumper beam; and

wherein at least one of the plurality of crush lobes comprises a projected wall spaced a distance from the base, and at least one sidewall which extends from the base to the projected wall of the crush lobe;

wherein the fascia energy absorber is a unitary structure that is designed to only abut the bumper beam; and

wherein at least one of the inner member and the outer member has a thickness that is 0.1 millimeters to 2 millimeters.

32. A bumper system comprising:

a bumper beam; and

a fascia energy absorber comprising

an outer member having at least a portion which is curved; and

an inner member joined to the outer member forming a unitary structure;

wherein the inner member comprises a base and a plurality of crush lobes, and

wherein at least one of the plurality of crush lobes comprises a projected wall spaced a distance from the base, and at least one sidewall which extends from the base to the projected wall of the crush lobe; and

wherein at least one of the inner member and the outer member has a thickness that is 0.1 millimeters to 2 millimeters; and

wherein the unitary structure only abuts the bumper beam.

33. A fascia energy absorber comprising:

an outer member having at least a portion which is curved; and

an inner member having a base and a plurality of crush lobes, and

wherein at least one of the plurality of crush lobes comprises a projected wall spaced a distance from the base, and at least one sidewall which extends from the base to the projected wall of the crush lobe;

wherein the inner member has an inner member external surface located between an inner member internal surface and the outer member;

wherein the outer member has an outer member inner surface located between an outer member outer surface and the inner member;

wherein the inner member external surface is joined to the outer member inner surface and wherein the inner member can slide along a bumper beam;

wherein the fascia energy absorber forms a unitary structure that is attachable to a vehicle component located adjacent to a bumper beam; and

wherein at least one of the inner member and the outer member has a thickness that is 0.1 millimeters to 2 millimeters.

34. The bumper system of claim 32 , wherein the unitary structure is adjacent but not attached to the bumper beam.