Method of making bumper system using thermoformed component

Details Method of making bumper system using thermoformed component Method of making bumper system using thermoformed component

2003-12-15

2009-02-24

Morrow, Jason S (Department: 3612)

Vehicle fenders

Buffer or bumper type

C293S121000, C029S897200

Reexamination Certificate

active

07494165

ABSTRACT:
A bumper system includes a tubular beam (21) and a thermoformed energy absorber with crush boxes (23) formed into a base flange, such as by vacuum or thermal forming processes. The crush boxes have planar energy-absorbing sidewalls a depth of about 10 mm to 35 mm, wall thickness of about 1 mm to 3 mm, and are formed from polyethylene or other thermoform materials having a memory. The base flange can include thermoformed features engaging recesses in the beam, and is combinable with injection-molded or foam energy absorbers for design flexibility. In one form, the energy absorber includes a thermoformed first sheet forming crush boxes and a second sheet bonded to the first sheet to define apertured air pockets. Related methods of manufacture and impacting are also disclosed.

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