Reinforced plastic energy absorber system and methods of making the same

1. A corner energy absorber, comprising:

a plurality of layers with a plurality of ribs connecting the layers, wherein the layers and ribs comprise a first thermoplastic material;

a composite insert comprising a second plastic material and reinforcement, wherein the second plastic material is different than the first thermoplastic material, and wherein the composite insert is disposed in the layers, the ribs, or both;

an extension configured to extend into the end of a bumper beam.

2. The energy absorber of claim 1 , wherein the reinforcement comprises continuous fibers.

3. The energy absorber of claim 1 , wherein the reinforcement is selected from the group consisting of glass, carbon, titanium, aluminum, stainless steel, talc, mica, and combinations comprising at least one of the foregoing.

4. The energy absorber of claim 3 , wherein the reinforcement comprises carbon fibers.

5. The energy absorber of claim 1 , wherein the insert has a density of 1,450 kg/m3 to 1,650 kg/m 3 .

6. The energy absorber of claim 5 , wherein the insert has a density of 1,200 kg/m 3 to 1,700 kg/m 3 .

7. A vehicle, comprising:

a bumper beam; and

an energy absorber extending from an end of the bumper beam;

wherein the energy absorber comprises a number of horizontal layers connected by a number of vertically extending ribs, and a composite insert disposed at the layers and/or the ribs;

wherein the insert comprises a thermoplastic material and a reinforcement.

8. The vehicle of claim 7 , further comprising a second energy absorber extending from another end of the bumper beam.

9. The vehicle of claim 8 , further comprising crush lobes extending across the bumper beam between the energy absorber and the second energy absorber.

10. The vehicle of claim 7 , wherein the energy absorber further comprises an extension that extends into the end of the bumper beam.

11. The vehicle of claim 7 , wherein the energy absorber has an extension that is located within an end of the bumper beam, and wherein the insert is located at a rib external and adjacent to the bumper beam.

12. The vehicle of claim 7 , wherein the reinforcement comprises fibers, flakes, beads, particles, or a combination comprising at least one of the foregoing.

13. The vehicle of claim 7 , further comprising an underbar comprising a second extension configured to connect the underbar to the bumper beam and/or to the energy absorber assembly.

14. The vehicle of claim 13 , wherein the underbar further comprises an insert located on the underbar.

15. The vehicle of claim 7 , wherein the horizontal layers and vertically extending ribs are formed from a thermoplastic material.

16. The vehicle of claim 7 , further comprising a fascia covering the energy absorber.

17. The energy absorber of claim 1 , wherein the second plastic material comprises a thermoset.

18. The energy absorber of claim 17 , wherein the thermoset is epoxy.

19. The energy absorber of claim 1 , wherein the insert comprises polybutylene terephthalate and fibers.

20. The energy absorber of claim 1 , wherein the insert comprises polycarbonate and ceramic filler.

21. The energy absorber of claim 1 , wherein the composite insert comprises at least one of polypropylene, polybutylene terephthalate, and polyamide.

22. The energy absorber of claim 21 , wherein the composite insert comprises continuous fibers.

23. The energy absorber of claim 2 , wherein the composite insert comprises polypropylene.

24. The energy absorber of claim 1 , wherein the first material comprises at least one of polypropylene, polybutylene terephthalate, and polyamide.

25. The energy absorber of claim 1 , wherein the first material comprises polypropylene.