In-situ foam core structural energy management system

Abstract

An energy management system for use with a vehicle having an interior includes an elongated plastic member having a wall defining a cavity. Disposed within the cavity is an elongated first in-situ foam core member, which has a first thermal bond to the wall. The wall having a first portion facing towards the vehicle interior and a second portion opposed to the first portion. A second in-situ foam core member is connected to at least a portion of the elongated plastic member forming the energy management system. The energy management system is capable of passing a 5-mph crash test passing Federal Motor Vehicle Safety Standard 215 (FMVSS 215) Phase II.

I claim: 
     
         1 . An energy management system for use with a vehicle having an interior, the system comprising:
 an elongated plastic member having a wall defining a cavity and an elongated first in-situ foam core member disposed within the cavity and having a first thermal bond to the wall, the wall having a first portion facing towards the vehicle interior and a second portion opposed to the first portion; and   a second in-situ foam core member connected to at least a portion of the elongated plastic member, wherein the energy management system is capable of passing a 5-mph crash test passing Federal Motor Vehicle Safety Standard 215 (FMVSS 215) Phase II.   
     
     
         2 . The system of  claim 1 , wherein the energy management system has weight and weighs less than 50 lbs. 
     
     
         3 . The system of  claim 1 , wherein the first in-situ foam core member density ranges from 1 lb/ft 3  to 25 lb/ft 3 . 
     
     
         4 . The system of  claim 1 , wherein the first in-situ foam core member density ranges from 2 lb/ft 3  to 9 lb/ft 3 . 
     
     
         5 . The system of  claim 1 , wherein at one of the first and second in-situ foam core member compositions include a polyolefin composition, an alkenyl aromatic polymer composition, a polystyrene composition, a polyvinyl chloride composition, or a biopolymer composition. 
     
     
         6 . The system of  claim 1 , wherein the second in-situ foam core member is disposed adjacent to the second portion of the wall. 
     
     
         7 . The system of  claim 1 , further comprising a vehicle frame member connected to the vehicle and to the first portion of the wall. 
     
     
         8 . The system of  claim 1 , further comprising a bumper fascia disposed proximate to the second in-situ foam core and opposed to the elongated plastic member. 
     
     
         9 . The system of  claim 1 , wherein the wall composition includes a thermoplastic polymer composition or a natural polymer resin composition. 
     
     
         10 . The system of  claim 1 , wherein the thermal bond includes a cooled connection of a molten or softened portion of the wall, a molten or softened portion of the first in-situ foam core, and a co-mingled layer including portions of both the wall and the first in-situ foam core. 
     
     
         11 . The system of  claim 1 , wherein the second in-situ foam core and the second portion of the wall include a second thermal bond therebetween. 
     
     
         12 . An energy management system for use with a vehicle having an interior, the system comprising:
 an elongated plastic member having a wall defining a cavity and a first in-situ foam core member disposed within the cavity and having a first thermal bond to the wall, the thermal bond including a cooled connection of a molten or a softened portion the wall, a molten or a softened portion of the first in-situ foam core, and a layer including portions of the wall and the first in-situ foam core, the wall having a first portion facing towards the vehicle interior and a second portion opposed to the first portion of the wall; and   a second in-situ foam core member connected to at least a portion of the elongated plastic member by a second thermal bond disposed between the wall and the second in-situ foam core, wherein the energy management system is capable of meeting the requirements of 49 CFR Part 581.5 when measured according to 49 CFR Part 581.6 and 581.7.   
     
     
         13 . The system of  claim 12 , wherein the first in-situ foam core is comprised of expanded polypropylene (EPP) having a density ranging from 1.5 lbs/ft 3  to 10 lbs/ft 3 . 
     
     
         14 . The system of  claim 12 , wherein the second in-situ foam core is comprised of expanded polypropylene (EPP) having a density ranging from 1.5 lbs/ft 3  to 10 lbs/ft 3 . 
     
     
         15 . The system of  claim 12 , wherein the wall is comprised of a metallocene polypropylene composition or a homopolymer polypropylene composition.