Shape Corporation

James Lupone

David W Heatherington

Les Lewis

A bumper construction for vehicles includes an elongated high-strength metal beam roll-formed from sheet steel, and at least one structural molded piece made of polymeric material attached to opposing end sections of the beam. Each structural piece has a rearwardly swept front surface that forms aerodynamically stylized corners at the ends of the beam. Each structural piece further provides attachment structure for attaching the beam to a vehicle, with the attachment structure being configured to transmit front impact forces compressively through the structural pieces to the vehicle frame, while minimizing the torsional and tensile forces on the attachment structure. The structural pieces further include a recess for closely receiving and supporting an impact-resisting flange on the beam to stabilize the beam during impact. The mateable engagement simplifies assembly, and further provides for high-energy absorption upon front impact of a vehicle.

Composite bumper construction

A bumper beam construction including an elongated tubular beam of high strength but characteristically flexible to absorb substantial energy on impact having a mounting bracket attached at each end of the center section and at least one stiffening bracket attached to each mounting bracket. The mounting brackets extend from the rear wall of the tubular beam and facilitate attachment to a vehicle frame. The stiffening brackets are attached to the mounting brackets and the end sections of the tubular beam outboard of the center section. The stiffening brackets improve the comer impact strength of the tubular beam without adversely affecting the flexibility of the center section. This comer construction arrangement provides for optimal distribution of stress during corner impacts.

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Fruitport, MI, United States of America

James Lupone