Fascia energy absorber, bumper system and process

Abstract

The present invention provides for various embodiments of a unitary fascia energy absorber including an aesthetic appearance while also providing improved energy management. In an embodiment a process for producing a fascia energy absorber includes heating and forming a polymer sheets to form an outer member and heating and forming a second polymer sheet to form an inner member. The inner member and the outer member are then joined to form a fascia energy absorber.

1 . A process for making fascia energy absorber, comprising the steps of:
 heating and forming a first polymer sheet to produce inner member;   heating and forming a second polymer sheet about a tool to produce an outer member; and   joining the inner member and the outer member to form a unitary fascia energy absorber.   
     
     
         2 . The process of  claim 1 , wherein forming the first polymer sheet and the second polymer sheet comprises applying gas pressure to the first polymer sheet and the second polymer sheet during forming. 
     
     
         3 . The process of  claim 1 , wherein forming the first polymer sheet and the second polymer sheet comprises applying a vacuum to the first polymer sheet and the second polymer sheet during forming. 
     
     
         4 . The process of  claim 1 , further comprising the step of stretching at least one of the first and the second polymer sheet prior to forming. 
     
     
         5 . The process of  claim 4 , wherein the step of stretching comprises articulating the polymer sheet to move edges of sheet to a predetermined contour pattern so the polymer sheet more closely conforms to the selected pattern of at least one of the outer member and inner member of the fascia energy absorber. 
     
     
         6 . The process of  claim 1 , wherein the process further comprises ejecting at least one of the inner member, the outer member, and the joined fascia energy absorber away from a tool after forming. 
     
     
         7 . The process of  claim 6 , wherein the process further comprises pulling edges of at least one of the polymer sheets during ejection. 
     
     
         8 . The process of  claim 1 , wherein at least one of the polymer sheets is multi-layer sheet of at least two different material compositions. 
     
     
         9 . The process of  claim 1 , wherein:
 the first polymer sheet is formed onto a male core portion of the tool to produce an inner member having an external surface; and   the second polymer sheet is formed onto a female core portion of the tool to produce an outer member having an internal surface; and   the external surface of the inner member is joined to the internal surface of the outer member to produce a fascia energy absorber.   
     
     
         10 . The process of  claim 1 , wherein a polymer sheet is formed onto a male core portion of the tool to produce an outer member having an external surface and internal surface, and further comprising: placing the outer member into a female fixture which contacts the external surface prior to joining the inner surface of the outer member to the inner member. 
     
     
         11 . The process of  claim 1 , wherein the process further comprises the step of loading at least one of the polymer sheets in contact with clamps and wherein the loading, heating and forming steps are performed on an apparatus at a first station, a second station, and a third station, respectively. 
     
     
         12 . The process of  claim 11 , wherein the joining step is performed at the third station after forming. 
     
     
         13 . The process of  claim 11 , wherein the joining step is performed at a fourth station. 
     
     
         14 . The process of  claim 11 , wherein the process is continuous and at least a portion of each step is carried out simultaneously for a different polymer sheet. 
     
     
         15 . The process of  claim 14 , wherein the process comprises:
 moving at least a first polymer sheet to a position previously occupied by at least a second polymer sheet at the second station after heating the at least second polymer sheet;   moving the at least second polymer sheet from the second station to a position previously occupied by at least a third polymer sheet at the third station after forming the at least third polymer sheet to produce a formed polymer unit which is at least one of an outer member, an inner member, and a fascia energy absorber.   
     
     
         16 . The process of  claim 15 , further comprising:
 moving the formed polymer unit from the third station to a position previously occupied by the at least first polymer sheet at the first station; and   ejecting the formed polymer unit from the apparatus.   
     
     
         17 . The process of  claim 16 , further comprising loading a new polymer sheet at the first station after ejecting a formed polymer unit. 
     
     
         18 . A process for making fascia energy absorber, comprising:
 forming an inner member comprising a plurality of crush lobes;   joining the inner member and a fascia to form a unitary fascia energy absorber.   
     
     
         19 . The process of  claim 18 , wherein at least one of the plurality of crush lobes comprises a projected wall spaced a distance from the base, and at least one sidewall which extends from the base to the projected wall of the crush lobe.