Hybrid bumper beams and methods for making and using the same
A method of making a hybrid energy absorbing beam, comprises: forming a polymer member comprising a first portion, wherein the first portion includes a first ledge and a connecting ledge connected by a first portion wall; and a rib extending from the first portion wall, wherein a cross-section of the rib taken along a line, A-A, comprises a first channel formed from an opening between a channel wall and a first traverse wall of a lobe, wherein the lobe comprises the first traverse wall and a second traverse wall with a connecting wall disposed between the first traverse wall and the second traverse wall; wherein the first channel extends along a portion of a length, L p , of the polymer member; and forming a metal/composite member; and attaching the polymer member to the metal/composite member on an opposite side of the polymer member as the connecting wall.
1. A hybrid energy absorbing beam for attachment to a vehicle, comprising:
a polymer member, wherein the polymer member comprises
a first portion, wherein the first portion includes a first ledge and a connecting ledge connected by a first portion wall; and
a rib extending from the first portion wall, wherein a cross-section of the rib taken along a line, A-A comprises
a first channel formed from an opening between a channel wall and a first traverse wall of a lobe, wherein the lobe comprises the first traverse wall and a second traverse wall with a connecting wall disposed between the first traverse wall and the second traverse wall; wherein the first channel extends along a portion of a length, L p , of the polymer member; and
a metal and/or composite member coupled to the polymer member on an opposite side of the polymer member from the connecting wall.
2. The hybrid energy absorbing beam of claim 1 , wherein the polymer member further comprises
a second portion, wherein the second portion includes a second ledge and the connecting ledge connected by a second portion wall; and
a rib extending from the second portion wall, wherein a cross-section of the rib taken along a line, A-A comprises
a second channel formed from an opening between a channel wall and a lobe, wherein the lobe comprises a first traverse wall and a second traverse wall with a connecting wall disposed between the first traverse wall and the second traverse wall.
3. The hybrid energy absorbing beam of claim 2 , wherein the ribs extend between the channel wall and the second traverse wall of the lobe.
4. The hybrid energy absorbing beam of claim 2 , further comprising a middle base portion extending between the second traverse wall of the lobe and the first traverse wall of lobe, forming a third channel located between the first channel and the second channel.
5. The hybrid energy absorbing beam of claim 2 , wherein the ribs disposed in the first channel and ribs disposed in the second channel are substantially parallel.
6. The hybrid energy absorbing beam of claim 2 , wherein the lobe has a C-shaped cross-section.
7. The hybrid energy absorbing beam of claim 1 , wherein the polymer member is curved along its length.
8. The hybrid energy absorbing beam of claim 1 , wherein the metal and/or composite member is inserted into the polymer member.
9. The hybrid energy absorbing beam of claim 2 , wherein the polymer member further comprises
a first base portion and a second base portion wherein the first base portion and the second base portion are connected by the middle base portion wherein a first curved portion extends from a side of the middle portion to reach the first base portion and wherein a second curved portion extends from a side of the middle portion to reach the second base portion; and
wherein the first base portion and the second base portion are in mechanical communication with the metal and/or composite member.
10. The hybrid energy absorbing beam of claim 1 , wherein the polymer member further comprises stiffening elements extending from the first base portion and/or extending from the second base portion.
11. The hybrid energy absorbing beam of claim 1 , wherein the polymer member comprises a thermoplastic material.
12. The hybrid energy absorbing beam of claim 1 , wherein the polymer member is injection molded.
13. The hybrid energy absorbing beam of claim 1 , wherein the metal and/or composite member has a substantially I-shaped cross-section or a substantially rectangular cross-section.
14. The hybrid energy absorbing beam of claim 1 , wherein the metal and/or composite member comprises a steel alloy.
15. The hybrid energy absorbing beam of claim 1 , wherein the metal and/or composite member is formed by bending, rolling, or hydroforming.
16. The hybrid energy absorbing beam of claim 1 , wherein the polymer member and the metal and/or composite member form an over-molded unitary structure.
17. A bumper assembly, comprising:
a hybrid energy absorbing beam of claim 1 ; and
a fascia covering a portion of the beam.
18. The bumper assembly of claim 17 , wherein the hybrid energy absorbing beam is configured for attachment to a vehicle front end module and/or a vehicle rear end module.
19. A method of making a hybrid energy absorbing beam, comprising:
forming a polymer member comprising a first portion, wherein the first portion includes a first ledge and a connecting ledge connected by a first portion wall; and a rib extending from the first portion wall, wherein a cross-section of the rib taken along a line, A-A, comprises a first channel formed from an opening between a channel wall and a first traverse wall of a lobe, wherein the lobe comprises the first traverse wall and a second traverse wall with a connecting wall disposed between the first traverse wall and the second traverse wall; wherein the first channel extends along a portion of a length, L p , of the polymer member; and
forming a metal and/or composite member; and
attaching the polymer member to the metal and/or composite member on an opposite side of the polymer member as the connecting wall.
20. The method of claim 19 , wherein the polymer member is over-molded the metal and/or composite member.