Hybrid bumper beams and methods for making and using the same

Patent metadata

Field	Value
Publication number	US-9902351-B2
Application number	US-201515300441-A
Country	US
Kind code	B2
Filing date	Mar 31, 2015
Priority date	Mar 31, 2014
Publication date	Feb 27, 2018
Grant date	Feb 27, 2018

Abstract

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.

First claim

What is claimed is:

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.

Assignees

• Sabic Global Technologies Bv
• Sabic Global Technologies Bv

Inventors

• Bobba Somasekhar Venkat
• Marks Matthew D
• Nagwanshi Dhanendra Kumar

Classifications

• B60R19/18 Primary

  {characterised by the cross-section;} Means within the bumper to absorb impact · CPC title

• F16F7/12

  using plastic deformation of members {(F16F9/30 takes precedence; yieldable means for mounting bumpers on vehicles B60R19/26; yieldable or collapsible steering columns B62D1/192)} · CPC title

• B60R2019/1833

  made of plastic material · CPC title

• F16F7/121 Primary

  the members having a cellular, e.g. honeycomb, structure · CPC title

• B60R2019/186

  Additional energy absorbing means supported on bumber beams, e.g. cellular structures or material · CPC title