Metal working – Method of mechanical manufacture – Structural member making
Reexamination Certificate
2006-12-19
2008-03-11
Bryant, David P. (Department: 3726)
Metal working
Method of mechanical manufacture
Structural member making
C029S527100, C293S120000, C293S132000
Reexamination Certificate
active
07340833
ABSTRACT:
A bumper system includes a bumper beam having a face and ends, and an energy absorber mounted on the face. The energy absorber has a one-piece injection-molded non-foam piece with box sections and interconnecting straps, and a one-piece or multi-piece foam component securely insert-molded onto the injection-molded non-foam piece. Different foam molds can be used to form differently shaped front surfaces on the foam component. By this arrangement, different energy absorbing systems are provided for vehicles, such as to satisfy the need for different styling and shapes, while still using the same non-foam piece. By this arrangement, the energy absorber is a single unit that can be handled and attached to the bumper beam. At the same time, capital investment in molding dies and tooling is reduced.
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Exhibit A (2001) includes four pictures of a prior art vehicle bumper system on a Ford Focus model vehicle, which includes a steel beam and an energy absorber that wraps around ends of the beam. The energy absorber includes a lower-density black foam body and has several higher-density white foam blocks inset into an inner surface of the black foam. (Note: Photo 1 shows an “extra” energy absorber loosely setting on a rear bumper system of a Ford Focus, the “extra” energy absorber being reversed to show its inner surface with the white foam blocks exposed.).
Evans Darin
Powell David
Weissenborn Mark
Weykamp Robert
Bryant David P.
Koehler Christopher M
Netshape Energy Management LLC
Price Heneveld Cooper DeWitt & Litton LLP
LandOfFree
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