Polymer, energy absorber rail extension, methods of making and vehicles using the same

1. A rail extension, comprising

an energy absorber comprising a polymer body, wherein the energy absorber comprises cells formed by cell walls extending a length of the energy absorber and forming cavities therethrough;

each side of the energy absorber comprises an open channel, wherein the channel is defined by walls of adjacent cells; and

a vehicle attachment tab extending from at least one of the cell walls at one end of the energy absorber and configured to attach to a vehicle rail, and a bumper attachment tab extending from at least one of the cell walls at another end of the energy absorber and configured to attach to a bumper beam; and

a first vehicle attachment tab gusset extending between the vehicle attachment tab and the cell wall on one side of an opening in the vehicle attachment tab and a second vehicle attachment tab gusset extending between the vehicle attachment tab and the cell wall on an opposite side of the opening in the vehicle attachment tab from the first vehicle attachment tab gusset;

a first bumper attachment tab gusset extending between the bumper attachment tab and the cell wall on one side of an opening in the bumper attachment tab and a second bumper attachment tab gusset extending between the bumper attachment tab and the cell wall on an opposite side of the opening in the bumper attachment tab from the first bumper attachment tab gusset;

wherein the energy absorber the vehicle attachment tab and the bumper attachment tab the first vehicle attachment tab gusset, the second vehicle attachment tab gusset, first bumper attachment tab gusset, and the second bumper attachment tab gusset were formed as one-piece.

2. The rail extension of claim 1 , wherein the energy absorber consists of a polymer body.

3. The rail extension of claim 1 , wherein cells adjacent to channels on two opposing sides of the energy absorber have a beveled surface.

4. The rail extension of claim 3 , wherein the beveled surface has a chamfer angle θ of greater than 0 to up to an angle θ of 45°.

5. The rail extension of claim 4 , wherein the chamfer angle θ is 15° to 35°.

6. The rail extension of claim 1 , wherein the energy absorber has a length, l, a width, w, and a height, h, and wherein the length, l, is less than or equal to 300 mm, the width, w, of less than or equal to 200 mm, and the height, h, of less than or equal to 300 mm, wherein the length is greater than or equal to the height which is greater than or equal to the width.

7. The rail extension of claim 6 , wherein the length, l, is 50 mm to 250 mm, the width, w, is 20 mm to 150 mm, and the height, h, is 60 mm to 200 mm.

8. The rail extension of claim 1 , wherein a thickness of the cell walls is up to 5.0 mm.

9. The rail extension of claim 1 , wherein the rail extension has a force during crushing of 0.60x to 1.05x, wherein “x” is the maximum force of the vehicle rail before it will begin crushing.

10. The rail extension of claim 9 , wherein the force during crushing is 0.75x to 1.03x.

11. The rail extension of claim 1 , wherein the cavities comprise foam.

12. The rail extension of claim 1 , wherein, during an impact, the rail extensions begin crushing upon an impact of greater than or equal to 60 kN.

13. The rail extension of claim 1 , wherein, during an impact, the rail extensions have a first peak force of less than or equal to 110% of a force limit of a rail to which the rail extension is attached.

14. A vehicle, comprising,

a bumper beam;

a vehicle rail;

a rail extension comprising

an energy absorber comprising a polymer body, wherein the energy absorber comprises cells formed by cell walls extending a length of the energy absorber and forming cavities therethrough;

each side of the energy absorber comprises an open channel, wherein the channels are defined by walls of adjacent cells; and

a vehicle attachment tab extending from one of the cell walls at a rail end of the energy absorber and attached to the vehicle rail, and a bumper attachment tab extending from one of the cell walls at another end of the energy absorber and attached to the bumper beam;

a first vehicle attachment tab gusset extending between the vehicle attachment tab and the cell wall on one side of an opening in the vehicle attachment tab and a second vehicle attachment tab gusset extending between the vehicle attachment tab and the cell wall on an opposite side of the opening in the vehicle attachment tab from the first vehicle attachment tab gusset; and

a first bumper attachment tab gusset extending between the bumper attachment tab and the cell wall on one side of an opening in the bumper attachment tab and a second bumper attachment tab gusset tab gusset extending between the bumper attachment tab and the cell wall on an opposite side of the opening in the bumper attachment tab from the first bumper attachment tab gusset;

wherein the energy absorber, the vehicle attachment tab and the bumper attachment tab, the first vehicle attachment tab gusset, the second vehicle attachment tab gusset, first bumper attachment tab gusset, and the second bumper attachment tab gusset were formed as one-piece.

15. A method of controlling a crushing of a vehicle extension, comprising:

determining an initial force peak during crushing of the energy absorber;

beveling a surface of some cells based upon the initial force peak; and

changing the angle of the bevel until the initial force peak is less than a desired maximum force;

forming a one-piece rail extension, the rail extension comprising

an energy absorber comprising a polymer body, wherein the energy absorber comprises cells formed by cell walls extending a length of the energy absorber and forming cavities therethrough, wherein some of the cells comprise the bevel;

a vehicle attachment tab extending from one of the cell walls at one end of the energy absorber;

a bumper attachment tab extending from one of the cell walls at another end of the energy absorber; and

open channels along the outside of the rail extension;

a first vehicle attachment tab gusset extending between the vehicle attachment tab and the cell wall on one side of an opening in the vehicle attachment tab and a second vehicle attachment tab gusset extending between the vehicle attachment tab and the cell wall on an opposite side of the opening in the vehicle attachment tab from the first vehicle attachment tab gusset;

a first bumper attachment tab gusset extending between the bumper attachment tab and the cell wall on one side of an opening in the bumper attachment tab and a second bumper attachment tab gusset tab gusset extending between the bumper attachment tab and the cell wall on an opposite side of the opening in the bumper attachment tab from the first bumper attachment tab gusset; and

wherein the energy absorber, the vehicle attachment tab, and the bumper attachment tab, the first vehicle attachment tab gusset, the second vehicle attachment tab gusset, first bumper attachment tab gusset, and the second bumper attachment tab gusset were formed as one-piece.

16. The method of claim 15 , further comprising filling some of the cavities with foam.

17. The method of claim 15 , further comprising filling all of the cavities with foam.

18. The rail extension of claim 1 ,

wherein the rail extension consists of polymer material; or

wherein the rail extension consists of metal attachment inserts in the vehicle attachment tab and the bumper attachment tab, and a remainder of the rail extension consists of polymer material.