Intermittent side rail energy absorbing elements and methods of making the same

1. A vehicle energy absorbing system for a high-speed, small-overlap impact, comprising:

lobes spaced intermittently along a vehicle rail, wherein the lobes include an impact arm, a reactionary arm, and a base, wherein a shape of the base is complimentary to a shape of the vehicle rail and wherein the impact arm and the reactionary arm protrude outwardly from the base and the vehicle rail, wherein a channel is formed in the space between the base, the impact arm, and the reactionary arm, wherein the channel extends through the lobe from end to end;

wherein the lobes have a geometrical configuration and comprise a material designed to

absorb energy upon collision with an impactor; or

deflect the vehicle away from an impactor; or

transfer energy to the vehicle rails; or

absorb energy upon collision with an impactor and deflect the vehicle away from an impactor; or

absorb energy upon collision with an impactor and transfer energy to the vehicle rails;

wherein the impact arm and the reactionary arm converge from the base at an angle and wherein the angle is 0° to 45°.

2. The vehicle energy absorbing system of claim 1 , wherein the lobe further comprises a cover over the channel on one end of the lobe or wherein the lobe further comprises a cover over each end of the lobe.

3. The vehicle energy absorbing system of claim 1 , wherein the lobes are spaced intermittently along an A pillar of the vehicle and along the vehicle rails.

4. The vehicle energy absorbing system of claim 1 , wherein the lobes comprise a material selected from a metallic material, a polymeric material, a composite material, or a combination comprising at least one of the foregoing.

5. The vehicle energy absorbing system of claim 1 , wherein the lobes have a geometrical shape selected from a triangle, a cone, a pyramid, a cylinder, a square, a rectangle, a parallelogram, trapezium, elliptical, hexagonal, or a combination comprising at least one of the foregoing.

6. The vehicle energy absorbing system of claim 1 , wherein the impact arm or the reactionary arm or the impact arm and the reactionary arm includes a corrugated shape.

7. The vehicle energy absorbing system of claim 1 , further comprising greater than or equal to 2 impact arms or further comprising greater than or equal to 2 reactionary arms.

8. The vehicle energy absorbing system of claim 1 , wherein the impact arm and the reactionary arm converge toward an interface disposed between the arms.

9. The vehicle energy absorbing system of claim 1 , wherein the impact arm has a length, l 1 , and the reactionary arm has a length, l 2 , wherein l 1 is equal to l 2 or wherein l 1 is not equal to l 2 .

10. The vehicle energy absorbing system of claim 1 , wherein the lobes comprise a multilayer structure in the channel.

11. The vehicle energy absorbing system of claim 1 , wherein the base is attached to the vehicle rail with a mechanism selected from hooks, snap-fit, mechanical fastener, structural adhesive, or a combination comprising at least one of the foregoing.

12. A vehicle comprising the vehicle energy absorbing system of claim 1 .

13. A vehicle energy absorbing system for a high-speed, small-overlap impact, comprising:

lobes spaced intermittently along a vehicle rail, wherein the lobes include a honeycomb structure protruding outwardly from the vehicle rail at an angle thereto;

wherein the lobes comprise a material designed to

absorb energy upon collision with an impactor; or

deflect the vehicle away from an impactor; or

absorb energy upon collision with an impactor and deflect the vehicle away from an impactor; wherein the honeycomb structure extends from the base at an angle of 0° to 45°.

14. The vehicle energy absorbing system of claim 13 , wherein the honeycomb structure is crushed axially along a length, l h , after collision with an impactor.

15. A method of making a vehicle energy absorbing system, comprising:

forming lobes comprising an impact arm, a reactionary arm, and a base, wherein a shape of the base is complimentary to a shape of a vehicle rail to which the lobe is attached and wherein the impact arm and the reactionary arm protrude outwardly from the base and the vehicle rail, wherein a channel is formed in the space between the base, the impact arm, and the reaction arm, wherein the channel extends through the lobe from end to end; and

attaching the base of the lobes intermittently to the vehicle rail;

wherein the impact arm and the reactionary arm converge from the base at an angle and wherein the angle is 0° to 45°.