Cast Bumper System And Method Of Manufacturing Same

• US 20170106822A1
• Filed: 12/21/2016
• Published: 04/20/2017
• Est. Priority Date: 07/09/2014
• Status: Active Grant

• Current Assignee: Magna International Incorporated
• Original Assignee: Magna International Incorporated
• Inventors: Brady, Jeremiah John, Winfree, Richard Lee, Steinebach, Edward K., Mellis, Jeffrey Jay
• Granted Patent: US 10,202,091 B2
• Time in Patent Office: Days
• CPC Class Codes: B22D 25/02 by its peculiarity of shape; of works of art cylinders, pistons B22D15/02
• CPC Class Codes: B23K 2101/006 Vehicles
• CPC Class Codes: B23K 2101/28 Beams
• CPC Class Codes: B23K 2103/04 Steel or steel alloys
• CPC Class Codes: B23K 31/02 relating to soldering or welding dip or wave soldering in the manufacture of printed circuits H05K3/34
• CPC Class Codes: B60R 19/03 characterised by material, e.g. composite B60R19/18 takes precedence
• CPC Class Codes: B60R 19/18 characterised by the cross-section; Means within the bumper to absorb impact
• CPC Class Codes: B60R 19/34 destroyed upon impact, e.g. one-shot type
• CPC Class Codes: B60R 2019/1813 made of metal

Abstract

A bumper beam system is provided that includes a bumper beam that is cast from metal and has at least a first portion comprised of a first alloy and a second portion comprised of a second alloy that is different than the first alloy. Furthermore, a crash box is provided that comprises a first portion comprised of a first alloy and a second portion comprised of a second alloy that is different than the first alloy. Additionally, a bumper beam system is provided that has a bumper beam and a crash box. The bumper beam includes at least a first bumper beam portion that is comprised of a first bumper beam alloy, and the crash box includes at least a first crash box portion that is comprised of a first crash box alloy. Methods of manufacturing the bumper beam system and crash boxes are also provided.

Claims

1. A bumper system comprising:

a bumper beam cast from metal;

said metal cast bumper beam including at least a first portion comprised of a first alloy and a second portion comprised of a second alloy being different than said first alloy.

2. A bumper system as set forth in claim 1 further including a crash box mechanically connected to said metal cast bumper beam.

3. A bumper system as set forth in claim 1 wherein said crash box is cast from metal and integrally formed with said metal cast bumper beam.

4. A bumper system as set forth in claim 1, wherein said metal cast bumper beam includes a third portion comprised of a third alloy being different than said first and second alloys.

5. A bumper system as set forth in claim 1 wherein said first portion includes a central portion of said metal cast bumper beam, and said second portion includes a pair of outer portions of said metal cast bumper beam disposed on opposing sides of said central portion.

6. A crash box comprising:

at least a first portion and a second portion each being integrally cast from metal; and

said first portion comprised of a first alloy and said second portion comprised of a second alloy being different than said first alloy.

7. The crash box as set forth in claim 6 wherein said first portion includes a rearward portion of the crash box and said second portion includes a forward portion of said crash box positioned adjacent to and forward of said rearward portion.

8. A bumper system comprising:

a bumper beam;

a crash box;

said crash box and said bumper beam being integrally cast from metal;

said bumper beam including at least a first bumper beam portion comprised of a first bumper beam alloy; and

said crash box including at least a first crash box portion comprised of a first crash box alloy being different than said first bumper beam alloy.

9. A bumper system as set forth in claim 8 wherein said bumper beam further includes a second bumper beam portion comprised of a second bumper beam alloy being different than said first bumper beam alloy and said first crash box alloy.

10. A bumper system as set forth in claim 9 wherein said crash box further includes a second crash box portion comprised of a second crash box alloy being different than said first bumper beam alloy, said first crash box alloy and said second bumper beam alloy.

11. A bumper system as set forth in claim 8 wherein said crash box further includes a second crash box portion comprised of a second crash box alloy being different than said first bumper beam alloy and said first crash box alloy.

12. A method of manufacturing a bumper system comprising:

metal casting a bumper beam having at least a first portion comprised of a first alloy and a second portion comprised of a second alloy being different than the first alloy.

13. A method as set forth in claim 12 further including mechanically connecting a crash box to the metal cast bumper beam.

14. A method as set forth in claim 12 further including metal casting a crash box integral to the metal cast bumper beam, the metal cast crash box having a third portion comprised of a third alloy being different than the first and second alloys.

15. A method as set forth in claim 12 wherein the first portion includes a central portion of the metal cast bumper beam and the second portion includes a pair of outer portions of the metal cast bumper beam disposed on opposing sides of the central portion.

16. A method of manufacturing a crash box comprising:

metal casting a first portion and a second portion integrally with one another, wherein the first portion is comprised of a first alloy and the second portion is comprised of a second alloy that is different than the first alloy.

17. A method of manufacturing a crash box as set forth in claim 16 wherein the first portion is a rearward portion of the crash box and wherein the second portion is a forward portion of the crash box being positioned adjacent to and forward of the rearward portion.

18. A method of manufacturing a bumper system comprising:

metal casting a bumper beam and a crash box integrally with one another, wherein the metal cast bumper includes at least a first bumper beam portion comprised of a first bumper beam alloy and the metal cast crash box includes at least a first crash box portion comprised of a first crash box alloy being different than the first bumper beam alloy.

19. A method of manufacturing a bumper system as set forth in claim 18 wherein the metal cast bumper beam further includes a second bumper beam portion comprised of a second bumper beam alloy being different than the first bumper beam alloy and the first crash box alloy.

20. A method of manufacturing a bumper system as set forth in claim 18 wherein the metal cast crash box further includes a second crash box portion comprised of a second crash box alloy being different than the first bumper beam alloy and the first crash box alloy.