Energy absorbing assembly and methods of making and using the same

1. An energy absorbing assembly, comprising:

a foam stage having a first surface and a second surface, wherein the second surface comprises a recess; and

a thermoplastic stage comprising a frame and crush lobes, wherein the frame has longitudinal side above and below the crush lobes;

wherein the crush lobes extend from the frame of the thermoplastic stage into the recess such that the foam stage extends above the crush lobes, below the crush lobes, or both, and toward at least one of the longitudinal sides, wherein greater than or equal to two crush lobes fit within a single recess.

2. The energy absorbing assembly of claim 1 , wherein the foam stage comprises a foam selected from the group consisting of polystyrene, polyethylene, polyurethane, copolymers of any of the foregoing, and combinations comprising at least one of the foregoing.

3. The energy absorbing assembly of claim 1 , wherein the foam stage comprises a closed-cell foam.

4. The energy absorbing assembly of claim 1 , wherein the foam stage has a variable density.

5. The energy absorbing assembly of claim 4 , wherein the foam stage has an increasing density from the first surface to the second surface or wherein the foam stage has an increasing density from the second surface to the first surface.

6. The energy absorbing assembly of claim 1 , wherein the crush lobes comprise a conical structure that diverges from a surface facing the frame to a surface facing the foam stage.

7. The energy absorbing assembly of claim 1 , wherein the frame of the thermoplastic stage comprises a flanged frame having a projecting rim disposed around an edge of the frame.

8. The energy absorbing assembly of claim 7 , wherein the crush lobes protrude from the flanged frame.

9. The energy absorbing assembly of claim 1 , comprising a gap between the foam of the recess and the crush lobes.

10. The energy absorbing assembly of claim 1 , wherein the recess encases the crush lobes.

11. A method of making an energy absorbing assembly, comprising:

forming a foam stage having a first surface and a second surface, wherein the second surface comprises recesses;

forming a thermoplastic stage having a frame and crush lobes protruding from the frame, wherein the frame has longitudinal side above and below the crush lobes; and

engaging the recesses and the crush lobes to form the energy absorbing assembly;

wherein the crush lobes extend from the frame of the thermoplastic stage into the recess such that the foam stage extends above the crush lobes, below the crush lobes, or both, and toward at least one of the longitudinal sides, and

wherein engaging the recesses and the crush lobes comprises inserting the crush lobes into the recesses.

12. The method of claim 11 , wherein the energy absorbing assembly further comprises, wherein the foam stage comprises a foam selected from the group consisting of polystyrene, polyethylene, polyurethane, copolymers of any of the foregoing, and combinations comprising at least one of the foregoing.

13. The method of claim 11 , wherein the foam stage of the energy absorbing assembly comprises a closed-cell foam.

14. The method of claim 11 , wherein the foam stage of the energy absorbing assembly has a variable density.

15. The method of claim 14 , wherein the foam stage of the energy absorbing assembly has an increasing density from the first surface to the second surface or wherein the foam stage has an increasing density from the second surface to the first surface.

16. The method of claim 11 , further comprising:

forming the frame comprising traverse ribs disposed between longitudinal sides wherein the crush lobes protrude from the traverse ribs.

17. The method of claim 11 , wherein there is a gap between the recess and the crush lobe.